Service Manual

Transfer Switch
1200−4000 Amperes

WBTPCE (Spec A)
WBTPCF (Spec A)
WBTPCG (Spec A)
WBTPCH (Spec A)
WBTPCJ (Spec A)

English − Original Instructions 3-2010 A030R453 (Issue 1)

Table of Contents

SECTION TITLE PAGE

SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII

1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Transfer Switch Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Bypass Switch Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Drawout Isolation Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Utility-to-Genset Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Utility-to-Utility Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Control Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Removing and Replacing Electronic Control Components . . . . . . . . . . . . . . . . . . . 1-3
Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
How to Obtain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

2. COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Bar Graph Meter Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Pushbuttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Bypass Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Contact Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bypass Switch Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Drawout-Isolation Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Drawout Cranking Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Automatic Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Contact Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Linear Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Motor Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Auxiliary Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Electronic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Electronic Control Circuit Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Digital Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Time Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
System Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Two-Wire Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

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Transfer Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Testing With or Without Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Generator Exercise Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Real-Time Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Relay Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Load Monitoring Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Remote Test Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Auxiliary Relays Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Load Shed Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Security Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
PowerCommand Network Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

3. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Automatic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Bypassing the Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Bypassing Load to Normal (Source 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Bypassing Load to Emergency (Source 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Isolating the Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Reconnecting the Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Manual Transfer to Source 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Manual Transfer to Source 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Generator Set Start Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
With Load Standby Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Non-Load Break Transfer Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Generator Set Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

4. DIGITAL DISPLAY MENU SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Main Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Setup Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Main Menu Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Using the Previous Menu Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Main Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Source 1 and Source 2 Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Load Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Starting with Software Version 1.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Events Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

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Setup Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Setup Menu Navigation and Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Starting with Software Version 1.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Starting with Software Version 1.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Sync Check Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Starting with Software Version 1.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Test Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Starting with Software Version 1.5.190 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Exercise Exceptions Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Starting with Software Version 1.5.190 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Starting with Software Version 1.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Starting with Software Version 1.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Starting with Software Version 1.13.244 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Starting with Software Version 1.13.244 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Starting with Software Version 1.20.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Clock Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Sequencer Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Starting with Software Version 1.20.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
System Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Starting with Software Version 1.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34

5. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
InPower Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
About Network Applications and Customer Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Digital Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Control LED Indicators and Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Exerciser Enable/Disable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Sequence of Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Transfer from Source 1 to Source 2 in Programmed Transition . . . . . . . . . . . 5-3
Transfer from Source 2 to Source 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Troubleshooting Using Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Fault Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Fault Flash-Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Fault Event Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Controller Checksum Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Low Controller Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
ATS Fail to Close: Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
ATS Fail to Close: Re-Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Network Communications Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

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Troubleshooting with Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Troubleshooting Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

6. AUTOMATIC TRANSFER SWITCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Membrane Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Power Module Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Digital Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Initial Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Setup with a Capture File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Setup Without a Capture File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
After the Setup is Completed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Removing the Automatic Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Bypass, Isolate, and Remove the Automatic Transfer Switch . . . . . . . . . . . . . . . . 6-6
To Bypass and Isolate the Automatic Transfer Switch . . . . . . . . . . . . . . . . . . . 6-6
To Remove the Automatic Transfer Switch (1200-Amp Bypass) . . . . . . . . . . 6-10
To Remove the Automatic Transfer Switch (1600- to 4000-Amp Bypass) . . 6-13
Install and Reconnect the Automatic Transfer Switch (When Finished) . . . . . . . . 6-13
To install the Automatic Transfer Switch (1200-Amp Bypass) . . . . . . . . . . . . . 6-13
To Install the Automatic Transfer Switch (1600- to 4000-Amp Bypass) . . . . 6-13
To Reconnect the Automatic Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Linear Actuator Solenoid Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-16
Removing Actuator Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Replacing Actuator Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Contact Assembly Removal and Replacement (1200 Amperes) . . . . . . . . . . . . . . 6-17
Removing the Contact Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Replacing the Contact Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Movable Contact Assembly Removal and Replacement (1600 − 2000 Amperes) 6-22
Removing the Contact Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Replacing the Contact Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Movable Contact Assembly Removal and Replacement (3000 Amperes) . . . . . . 6-25
Removing the Contact Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Replacing the Contact Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Auxiliary Switch Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Removing and Replacing an Auxiliary Switch Assembly. . . . . . . . . . . . . . . . . 6-29
Mis-Wired Current Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

iv
Table of Contents (Continued)

SECTION TITLE PAGE

7. BYPASS SWITCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Disconnect AC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Reconnecting AC Power (When Finished) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Contact Assembly Removal and Replacement (1200 Amperes) . . . . . . . . . . . . . 7-1
Removing the Contact Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Replacing the Contact Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Movable Contact Assembly Removable and Replacement
(1600 − 2000 Amperes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Removing the Contact Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Replacing the Contact Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Movable Contact Assembly Removal and Replacement (3000 Amperes) . . . . . . 7-9
Removing the Contact Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Replacing the Contact Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

8. SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

v
THIS PAGE LEFT INTENTIONALLY BLANK

vi
Safety Precautions
This manual includes the following symbols to indi- UTILITY-TO-GENSET OR GENSET-TO-
cate potentially dangerous conditions. Read the GENSET APPLICATIONS
manual carefully and know when these conditions
exist. Then take the necessary steps to protect per- If the cabinet must be opened for any reason:
sonnel and the equipment.
1. Move the operation selector switch on the gen-
DANGER This symbol warns of immediate erator set to Stop.
hazards that will result in severe personal inju- 2. Disconnect the starting batteries of the gener-
ry or death. ator set or sets (remove the ground [−] lead
WARNING This symbol refers to a hazard or first).
unsafe practice that can result in severe per- 3. Remove AC power to the automatic transfer
sonal injury or death. switch. If the instructions require otherwise,
CAUTION This symbol refers to a hazard or
use extreme caution due to the danger of
shock hazard.
unsafe practice that can result in personal inju-
ry or product or property damage. UTILITY-TO-UTILITY APPLICATIONS
ELECTRICAL SHOCK CAN CAUSE If the cabinet must be opened for any reason, re-
SEVERE PERSONAL INJURY OR DEATH move AC power to the automatic transfer switch. If
High voltage in transfer switch components pres- the instructions require otherwise, use extreme
ents serious shock hazards that can result in se- caution due to the danger of shock hazard.
vere personal injury or death. Read and follow
these suggestions. GENERAL PRECAUTIONS

Keep the transfer switch cabinet closed and Place rubber insulative mats on dry wood platforms
locked. Make sure only authorized personnel have over metal or concrete floors when working on any
the cabinet and operational keys. electrical equipment. Do not wear damp clothing
(particularly wet shoes) or allow skin surfaces to be
Due to the serious shock hazard from high voltages damp when handling any electrical equipment.
within the cabinet, all service and adjustments to
the transfer switch must be performed only by an Jewelry is a good conductor of electricity and
electrician or authorized service representative. should be removed when working on the electrical
equipment.
Whenever the bypass switch is in the Emergency
position, an auxiliary switch closes a set of normally Wear safety glasses whenever servicing the trans-
open contacts to provide a constant generator set fer switch and and do not smoke near the batteries.
start/run signal. The transfer switch, the emer-
gency bus, and the load bus are energized by Do not work on this equipment when mentally or
the output of the generator set and present a physically fatigued, or after consuming alcohol or
serious shock hazard whenever the bypass any drug that makes the operation of equipment
switch is in the Emergency position. unsafe.
WARNING
INCORRECT SERVICE OR REPLACEMENT OF PARTS CAN RESULT IN DEATH, SEVERE
PERSONAL INJURY, AND/OR EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST BE
TRAINED AND EXPERIENCED TO PERFORM ELECTRICAL AND/OR MECHANICAL SER-
VICE.
WBTPC-2

vii
THIS PAGE LEFT INTENTIONALLY BLANK

viii
 1. Introduction
ABOUT THIS MANUAL TRANSFER SWITCH APPLICATION

This manual contains service procedures for By- The WBTPC transfer switch combines an auto-
pass Transfer Switch PowerCommand (WBTPC) matic transfer switch, a manual bypass switch and
automatic transfer switches (ATS) rated at a drawout isolation mechanism into one unit.
1200−4000 amperes. This is a bypass transition
Transfer switches are an essential part of a build-
(BT) transfer switch equipped with PowerCom-
ing’s standby or emergency power system. Power
mand Control (PC) and it is capable of executing
Source 1 (Normal), commonly the utility line, is
Open Transition with Sync Check, Programmed
backed up by Power Source 2 (Emergency), often
Transition, and Closed Transition transfer modes.
a generator set. The transfer switch automatically
An Open Transition with Sync Check Transfer switches the electrical load from one source to the
Mode executes an open transition when both other.
sources of power are within specified tolerances of
frequency, voltage, and relative phase difference. The load is connected to the common of the ATS
If both sources meet the tolerances, a fast transfer (Figure 1-1). Under normal conditions, the load is
occurs. supplied with power from Source 1 (illustrated as
Normal). If Source 1 is interrupted, the load is
A Programmed Transition Transfer Mode exe- transferred to Source 2 (Emergency). When
cutes an open transition by disconnecting the load Source 1 returns, the load is retransferred to
from the source of power, pausing in the neutral Source 1. The transfer and retransfer of the load
position of the transfer switch (between switched are the two most basic functions of the ATS.
positions) to allow transient currents from the load
to diminish, and then the load is switched to the Automatic transfer switches, capable of automatic
other source. operation without operator intervention, perform
the basic function of transferring the load to the
A Closed Transition Transfer Mode executes a available source. The controller monitors each
load transfer by momentarily paralleling both source for suitable voltage and frequency range.
sources (a maximum of 100ms) before switching
sources. SOURCE 1 SOURCE 2
(NORMAL) (EMERGENCY)
Refer to the schematic and wiring diagram pack-
age that was shipped with the ATS for specific in- ISOLATING
CONTACTS
formation about its configuration.

Use normal and necessary safety precautions be-

fore starting any service procedure. Identify all
hazards by referring to the Safety Precautions and
observe all warnings and cautions within the
manual. Whenever you are troubleshooting, re-
member that the generator set, ATS, and utility
power source are all interdependent.
ES1968

BYPASS
TRANSFER AUTOMATIC
SWITCH TRANSFER
LOAD SWITCH

FIGURE 1-1. WBTPC TRANSFER SWITCH

PowerCommand is a registered trademark of Onan Corporation.
(TYPICAL FUNCTION)
Onan and Cummins are registered trademarks of Cummins Inc.

1-1
Bypass Switch Function preferred source. The control automatically trans-
fers the load between the two utilities and detects
The bypass switch allows the operator to manually alarm conditions. The exercise routine is not avail-
connect the load to the available power source, by- able with this configuration.
passing the automatic transfer switch (Figure 1-1).
When bypassed, the automatic transfer switch can The operator can select either source as the pre-
be isolated for service or removal without causing ferred source (see Figure 1-2). The Preferred
a power interruption. Source menu is included in the Test submenus
(see Figure 4-13). The PC service tool can also be
Drawout Isolation Mechanism used to designate either source as the preferred
source.
The drawout isolation mechanism allows the auto-
matic transfer switch to be withdrawn for testing or
service. The transfer switch is mounted on rails
and is connected to the load, power sources, and  Preferred Source
controls through isolation contacts. Turning a Source 1/Source 2 
drawout cranking handle moves the automatic
transfer switch either along a rail or on rollers then
engages and disengages the isolation contacts
without disconnecting power or control cables. FIGURE 1-2 . PREFERRED SOURCE SUBMENU

UTILITY-TO-GENSET OPERATION CONTROL LEVEL

In utility-to-genset applications, the transfer switch Only a Level 2 control is used with WBTPC transfer
performs the following functions: switches.

1. Senses the interruption of the Source 1 pow- The control board level can be viewed using the
er. digital display (see Figure 1-3). This menu is in-
cluded in the About submenus (see Figure 4-23,
2. Sends a start signal to the generator set depending upon software version).
(Source 2).

3. Transfers the load to the Source 2.

 ATS Board Level
4. Senses the return of Source1.  2

5. Retransfers the load to Source 1.

6. Sends a stop signal to the generator set. FIGURE 1-3 . CONTROL LEVEL SUBMENU

UTILITY-TO-UTILITY OPERATION The following configuration types are available

with WBTPC transfer switches.
In utility-to-utility applications, the transfer switch
performs the following functions: • Utility-to-Genset

1. Senses the interruption of the Source 1 pow- • Utility-to-Utility

er.
The following transition types are available with
2. Transfers the load to the Source 2. WBTPC transfer switches.
3. Senses the return of Source 1.
• Open Transition with Sync-check
4. Retransfers the load to Source 1.
• Programmed Transition
The controller can control a two-utility configura-
tion for prime power. One utility is designated the • Closed Transition

1-2
 REMOVING AND REPLACING Refer to page 1-4 for a list of feature/option codes.
ELECTRONIC CONTROL COMPONENTS
The model number is made up of code segments
WARNING AC power within the cabinet and that designate various features or options:
the rear side of the cabinet door presents a
shock hazard that can cause severe personal W _ PC _ _ _ _ _
injury or death. Disconnect connector J10/P10 | | | | | | | |
before working on the electronic control sys- 1 2 3 4 5 6 7 8
tem.
1. Schnider Wingoal (Tian Jing) electric equip-
Disconnecting J10/P10 removes all power to the ment co, LTD
door.
2. Switch type
Be sure to remove all power before replacing elec- OT − Open transition
tronic control modules and components. This in- BT − Bypass
cludes removing one of the lithium batteries from
the Digital Module. Reinstall the lithium battery af- 3. PC − PC (Type)
ter performing service parts replacement.
4. Amperage (A) : 40, 70, 125, 150, 225, 260,
No special tools are required to remove and re- 300, 400, 600, 800, 1000, 1200, 1600, 2000,
place control system components. Be sure to use 3000, 4000
all of the hardware when remounting components.
5. Poles − 3, 4
If possible, use the InPower service tool to
6. Transfer type:
create a capture file of the calibration and adjust-
S − Sync check
ment settings in the Digital Module. Use the cap-
D − Delay
ture file to write these settings to a replacement
Digital Module. 7. Controller type:
1 − Level 1 control
MODEL IDENTIFICATION
2 − Level 2 control
Identify your model by referring to the Model and
8. Feature
Specification number as shown on the nameplate.
Electrical characteristics and application informa- HOW TO OBTAIN SERVICE
tion are shown on the lower portion of the name-
plate. The nameplate is located on the cabinet When the transfer switch requires servicing, con-
door. tact Schneider Electric at +8622 8371 2900
Ext − 875. Factory−trained Parts and Service rep-
If it’s necessary to contact a dealer or distributor re- resentatives are ready to handle all your service
garding the transfer switch, always give the com- needs.
plete Model, Specification, and Serial number as
listed on the nameplate. This information is neces- When contacting Schneider Electric, always sup-
sary to properly identify your unit among the many ply the complete Model, Specification and Serial
types manufactured. Number as shown on the nameplate.

InPower is a trademark of Cummins, Inc. 1-3

 FEATURE FEATURE
FEATURE DESCRIPTION FEATURE DESCRIPTION
OPTION OPTION
Poles: Phase:
3 Poles A028 1 Phase, 2-W or 3-W A041
4 Poles A029 3 Phase, 3-W or 4-W A042
Application: Meters:
Utility to Genset A035 Digital Bar Graph Meters D009
Utility to Utility A036
Auxiliary Relays:
Agency Approvals: 24 VDC Coil L101
IEC Listing A046 Emergency Position L102
Normal Position L103
Frequency: Generator Start L104
60 Hertz A044 12 VDC Coil L201
50 Hertz A045 Emergency Position L202
Normal Position L203
Voltage: Generator Start L204
190 VAC R038
208 VAC R021 Miscellaneous:
220 VAC R022 Terminal Block − 30 Position M003
240 VAC R023 Load Shed − From Emergency M007
380 VAC R024 Cable Terminal Lugs N008
416 VAC R025
440 VAC R035 Cabinet:
480 VAC R026 Type 30 − General use, Indoor B001
600 VAC R027 Type 34 − Outdoor use B002
Type 65 − Indoor or Outdoor use B003
Controls: Open Construction − No Enclosure B004
Level 2 Switch Control C024 Type 61 − Indoor, dust- and waterproof B010
Type 65 − Stainless Steel B025
Control Options:
Front Panel Security Key M017
Digital Display M018
LONWORKS Network Com. Module M020
Load Monitoring M022
Relay Module M023

1-4
 2. Component Description
This section describes the standard and optional types are designated as general-purpose, indoor
control features as well as the control cabinet and or outdoor cabinets.
bypass transfer switch.
CONTROL PANEL
CABINET The panel features are divided into three groups:

• Bar Graph Meter Panel (optional)

The standard cabinet meets the requirements of
IEC for a IP Type 30 cabinet. Cabinets are avail- • Switch Panel
able in IEC types 30, 34, 65 and 61. The various • Digital Display

P OWER COMMAND

BAR GRAPH
METER PANEL
(OPTIONAL)

SWITCH PANEL
KEY SWITCH
(OPTIONAL)

DIGITAL DISPLAY

FIGURE 2-1. Portion of CABINET WITH OPTIONS

2-1
 BAR GRAPH METER PANEL  Motor Disconnect Switch is Off
 Transfer Inhibit
The Bar Graph Meter Panel (optional) includes a
three phase AC ammeter, a power meter, a power  Retransfer Inhibit
factor meter, a frequency meter, and a three phase  Load Shed
AC voltmeter.
 Bypass switch is connected
AC Ammeter: The ammeter displays the percent-
Test/Exercise Active: The Test/Exercise Active
age of full load current in amperes (1−125%).
indicator is lit when the transfer switch test or exer-
Power Meter: The power meter displays the real cise operation is active.
power in percentage of full load in kilowatts
(0−125%). Pushbuttons

Power Factor Meter: The power factor meter dis- Pressing any pushbutton will “wake up” the display
plays real power delivered to the load (1.0−0.6 lag- panel if it is in a sleep mode.
ging) and (1.0−0.9 leading).
Test Switch: For utility-to-genset applications, the
Frequency Meter: This meter displays the output Test switch sends a start signal to the generator set
frequency (percentage of nominal frequency), of designated Source 2 and flashes the Test/Exer-
the power source connected to the load cise Active indicator. After the start and transfer
(70−110%). time delays, Source 2 starts and assumes the load
provided the With Load option is enabled. Press
AC Voltmeter: The voltmeter displays the per- the Test switch again to end the test; the Test/Exer-
centage of line to neutral voltages of either power cise Active indicator goes out and Source 1 re-
source connected to the load (70−110%). sumes as the source of power.

SWITCH PANEL Override Switch: The Override switch terminates

most system time delays. Program Transition, Ele-
The switch panel (Figure 2-1) contains six indica- vator signal and Engine Cool Down are not af-
tor lamps and three membrane pushbuttons. fected by this switch. Pressing this switch while the
Transfer or Retransfer Inhibit inputs are active, im-
Indicators
mediately transfers or retransfers the load.
Source 1 and Source 2 Available: These indica-
tors are lit when the corresponding sources have Reset/Lamp Test Switch: The Reset/Lamp Test
acceptable output voltage and/or frequency. switch turns on all control panel indicators. This
These indicators can be lit simultaneously. switch also acknowledges events.

Source 1 Connected: This indicator is lit when the DIGITAL DISPLAY

transfer switch is in the normal position and Source
1 is supplying power to the load. The Digital Display contains a 2-line by 20-charac-
ter Digital Display Module and 6 momentary con-
Source 2 Connected: This indicator is lit when the tact membrane buttons. The module displays the
transfer switch is in the emergency position and menu system. The buttons are used to navigate
Source 2 is supplying power to the load. through the menu system.

Not in Auto: This indicator lights when the transfer Each menu indicates the function of the four but-
switch is not in the Automatic mode of operation tons at the sides of the Display Module. Not all but-
and when any of the following signals are active: tons are active for each menu.

2-2
 BYPASS SWITCH BYPASS SWITCH CONTROLS

The bypass switch, located above the automatic Indicators

transfer switch, is used to open and close the con- There are five indicator lamps for the bypass
tacts connecting the load to the Normal or Emer- switch (see Figure 2-3).
gency power source. The manually operated by-
pass switch is mechanically interlocked to prevent NOTE: Bypass mechanism and indicators on
simultaneous closing to a dead source or to both 1600−4000 amp switches in IEC 30, 65 or
power sources at the same time. Operation of the 61 cabinets are not visible from the outer
bypass switch is accomplished with the Bypass door.
Switch Handle and the Source Select switch (see • Bypass to Normal (Source 1)
Figure 2-2). • Bypass to Emergency (Source 2)
• ATS in Test
• ATS Isolated
• ATS Inhibit

Bypass Bypass

Source 1 Source 2
MANUAL BYPASS
HANDLE IN CLOSED
POSITION
ATS Inhibit ATS Test
ATS Isolated
SELECTOR
SWITCH IN
NORMAL
POSITION
FIGURE 2-3. 1200−4000 AMP INDICATORS
(CURRENT PRODUCTION)
TRANSFER The Bypass Normal (Source 1) lamp is lit whenever
SWITCH IS
BYPASSED TO
the bypass switch is connecting (bypassing)
SOURCE 1 Source 1 (Normal) to the load.
(NORMAL)
The Bypass Emergency (Source 2) lamp is lit
whenever the bypass switch is connecting (by-
FIGURE 2-2. MANUAL BYPASS OPERATION passing) Source 2 (Emergency) to the load.

Contact Assemblies The ATS in Test lamp is lit whenever the automatic
transfer switch is in the Test position.
Like the automatic transfer switch, the bypass
The ATS Isolated lamp is lit whenever the transfer
switch has either three or four poles. Three pole switch is Isolated from either source and the by-
transfer switches are provided with a neutral bar. pass switch is connected.
The contact assemblies are manually actuated to
connect the load to one of the two power sources, The ATS Inhibit lamp is lit whenever the automatic
bypassing the automatic transfer switch. When transfer switch is disabled by the limit switches and
closed to either the Normal or the Emergency pow- interlocks that respond to the operation of the by-
er source, the contacts are mechanically held. pass switch and the drawout/isolation mechanism.

2-3
 DRAWOUT-ISOLATION MECHANISM The cranking handle will operate only when
power is available, and when the bypass
The drawout-isolation mechanism allows the auto- switch is connected to one of the sources. The
matic transfer switch to be isolated for testing or operator must activate the drawout lever and push
service. Three sets of primary isolation contacts in on the crank handle to deactivate the cranking
(Normal source, Emergency source, and Load) interlocks.
connect the switching contacts to the terminal
lugs. A set of secondary isolation contacts con- The Drawout Position Indicator shows the position
nects the automatic transfer switch controls to the the automatic transfer switch is in. The drawout
available power source (see Figures 2-4 and 2-5). mechanism can be stopped in one of three posi-
tions: Automatic, Test, and Isolate.

In the Automatic position, both the primary and the

secondary isolation contacts are closed. The auto-
matic transfer switch is in its normal operating posi-
tion.

In the Test position, the primary isolation contacts

are open and the secondary isolation contacts are
closed. The load-supplying contacts of the auto-
matic transfer switch are out of service, but the
controller and linear actuator are powered and ful-
ly operational. In this position, the controller, linear
actuator, and contact mechanisms can be tested.

DRAWOUT HANDLE In the Isolate position, both the primary and the
AND MECHANISM
SC1638s
secondary isolation contacts are open. On
1200−4000 amp switches, connector J10/P10
FIGURE 2-4. 1200 AMP DRAWOUT MECHANISM must be disconnected (see Figure 2-11). The
transfer switch mechanism is completely isolated
from both the power and control circuits and can be
removed for service.
WARNING Improper removal of the automatic
transfer switch can cause severe personal in-
jury or death. Removal of the automatic trans-
fer switch must only be performed by trained
and experienced personnel, following the pro-
cedures provided in the service manual.
AUTOMATIC TRANSFER SWITCH
The automatic transfer switch (Figure 2-6) opens
and closes the contacts that transfer the load be-
tween the two power sources (1 and 2). The switch
DRAWOUT HANDLE
AND MECHANISM
is mechanically interlocked to prevent simulta-
neous closing to both power sources. The main
FIGURE 2-5. 1600−4000 DRAWOUT MECHANISM parts of the transfer switch discussed here are:

Drawout Cranking Handle • Contact Assemblies

The drawout cranking handle is used to isolate and • Linear Actuator

reconnect the automatic transfer switch. The • Auxiliary Contacts
cranking handle turns a gear drive that moves the
transfer switch along a mechanically guided path. • Motor Disconnect Switch

2-4
 BYPASS
SWITCH

AUTOMATIC
TRANSFER
SWITCH

FIGURE 2-6. BYPASS TRANSFER SWITCH

Contact Assemblies Linear actuator operation is initiated automatically

with automatic transfer switches.
The automatic transfer switch has either three or
four poles. Three pole transfer switches are pro-
Motor Disconnect Switch
vided with a neutral bar. The contact assemblies The Motor Disconnect toggle switch, on the acces-
make and break the current flow. When closed to sory control plate, enables and disables the linear
either the Normal or the Emergency power source actuator (Figure 2-7).
(1 or 2), the contacts are mechanically held. Elec-
trical and mechanical interlocks prevent them from
closing the load to a dead source or to both power
sources at the same time (unless under a closed
transition configuration).

The power contacts are rated at 600 VAC. They

are made of a long-life silver alloy which resists
burning and pitting, and feature separate arcing
surfaces. FIGURE 2-7. MOTOR DISCONNECT SWITCH
Placing the switch in the Auto position enables the
Linear Actuator linear actuator. Placing the switch in the Off posi-
tion disables the linear actuator. When placed in
The linear actuator is the solenoid that moves the the Off position, the Not In Auto indicator on the
contact assemblies between the Normal (Source front panel will light and the display indicates a Mo-
1) power and the Emergency (Source 2) power. tor Disconnect event.

2-5
Auxiliary Contacts NOTE: When making adjustments, do not operate
the linear motor more then once every two minutes.
Auxiliary contacts are provided on the Normal and
Emergency sides of the transfer switch. They are All calibration and adjustment procedures are de-
actuated by operation of the transfer switch during scribed in the Installation manual (shipped with the
transfer and retransfer. The Normal side (Source transfer switch). The InPower service tool can be
1) auxiliary contact switch is actuated when the used to create a capture file of all the calibration
transfer switch is in the Normal position. The Emer- and adjustment settings in the Digital Module. For
gency side (Source 2) auxiliary contact switch is more information, refer to the InPower User’s
actuated when the transfer switch is in the Emer- Guide.
gency position. The auxiliary contacts have cur- WARNING Accidental actuation of the linear
rent ratings of 10 amperes at 250 VAC. The con- motor could cause severe personal injury. Be-
tacts are wired to terminal block TB1 (Figure 2-8). fore making any adjustments, disable the lin-
ear actuator.
WARNING AC power within the cabinet and
the rear side of the cabinet door presents a
NO shock hazard that can cause severe personal
SOURCE 1 injury or death. Use extreme caution to avoid
(NORMAL) NC
AUXILIARY SWITCH touching electrical contacts whenever the cab-
COM inet door is open. Do not wear long hair, damp
clothing, or jewelry. Use insulated tools, stand
on a dry rubber mat or wood platform and wear
safety glasses.
NO
SOURCE 2 Electronic Control Circuit Modules
(EMERGENCY) NC
AUXILIARY SWITCH The Bypass Transfer Switch PowerCommand
COM
(WBTPC) transfer switch control incorporates a
Digital Module and a Power Module. Power Mod-
ules are available in three different voltage ranges.
TB1
The Digital Module has two 3-volt batteries to pow-
er the real-time clock when no source voltage is
FIGURE 2-8. TERMINAL BLOCK TB1 available. Replace these batteries every two
years.
ELECTRONIC CONTROL SYSTEM
Digital Module
This section describes the standard and optional
components of the electronic control system. The Digital Module (Figure 2-9) contains the logic
and timing circuits that control transfer switch op-
WARNING Improper calibration or adjustment eration. These modules also contain many cus-
of electronic control modules can cause death, tomer interface circuits (including the generator
severe personal injury, and equipment or prop- set start signal and network port), the RS-232 com-
erty damage. Calibration and adjustment of munications port for the InPower service tool, and
these components must be performed by tech- drivers for the control panel indicators, switches,
nically qualified personnel only. and bar graph meter panel.

InPower is a trademark of Onan Corporation.

2-6
 Connect 120 volt switches A:N for 2-wire, and
DIGITAL MODULE
BATTERIES AN:CN for 3 wire single phase systems. The other
BAR GRAPH transformers are used to power the 10 VDC supply
ASSEMBLY on the module. One transformer is connected to
Source 1 and the other to Source 2 (Figure 2-10).

Power Modules contain six pilot relays defined as:

OPTIONAL
NETWORK K12 Neutral to Source 1
COMMUNICATIONS K13 Neutral to Source 2
MODULE K14 Source 2 to Neutral
K15 Source1 to Neutral.

TB13 TB14

T1 T6 T7 T8

K17

K16
K13
K15
K14

K12
TO J24 ON
J11 DIGITAL
BOARD
DIGITAL

DANGER
DISPLAY DIGITAL T2 T3 T4 T5
POWER MODULE
MODULE

TB11 TB12
FIGURE 2-9. INTERIOR CONTROL COMPONENTS
FIGURE 2-10. POWER MODULE

Control Plate
Power Module
The Control Plate contains two transformers (T1
The Power Module supplies power to the Digital and T2); one for Emergency supply and one for
Module, and contains voltage sensing transform- Normal supply (Figure 2-11).
ers, and relays. These modules also hold interface
Three bridge rectifiers (CR1, CR2, and CR3) con-
circuits for the transfer switch including position
trol voltage to the transfer and bypass switch. The
sensing switches and relay drivers. 10 VDC rectifi-
Auto/Test signals are controlled by Relay K5 to the
cation and regulation circuits on this module are
transfer switch. An optional relay, (K6) may be
powered by both sources through transformers T1
added for the Load Shed feature.
and T2 (see Figure 2-10).
The Motor Disconnect switch S1 interrupts signals
The Power Module contains eight transformers. and disables the linear actuator.
Each source (1 and 2) use three transformers.
Source 1 and 2 voltages are sensed by transform- Connectors J1, J10 and J3 are the interface and
ers T1 and T2. Both sources are connected A:N, power sources for the cabinet door, the bypass
B:N and C:N except for 120 volt switches. switch and the transfer switch.

2-7
 Transfer Time Delay (TDNE): This brief time
MOTOR DISCONNECT
SWITCH OPTIONAL delay allows the generator set to stabilize before
LOAD SHED the load is applied. This delay begins when the
Source 2 (typically the generator) voltage and fre-
quency reaches the settings of the control. After
T1 the delay, the transfer switch transfers the load to
Source 2. It has an adjustable range of 0 to 120
K6
seconds in 1 second increments. The default val-
ue is 10 seconds. The value is set with the InPower
T2
service tool or the digital display.

Retransfer Time Delay (TDEN): This delay allows

Source 1 to stabilize before retransfer. The delay
begins the moment Source 1 line voltage and fre-
quency return to specified values. After the delay,
the transfer switch can retransfer the load to
K5 Source 1. It has an adjustable range of 0 to 30 min-
utes in 1 minute increments. The default value is
OPTIONAL 10 minutes. The value is set with the InPower ser-
OPTIONAL CURRENT MODULE vice tool or the digital display.
RELAY MODULE (LOAD MONITORING)
Programmed Transition (TDPT): Program Tran-
FIGURE 2-11. CONTROL PLATE sition introduces a delay during transition of the
switch. Programmed transition stops the switch in
the neutral position for an adjustable interval of
time. In this position, the load is not connected to
Time Delays either Source 1 or 2. This delay allows residual cur-
rent from inductive loads to decay to an acceptable
Start Time Delay (TDES-A): This brief time delay level before transfer is completed.
prevents the generator set from starting during
short power interruptions. The delay is adjustable Parameters are adjustable. The length of time that
from 0 to 120 seconds in 1 second increments. The the transfer switch is in the neutral position can be
default value is 3 seconds. Timing begins at the adjusted from 0 to 60 seconds in 1 second incre-
Source 1 power interruption. If the duration of in- ments. The default value is 0 seconds. The proper
terruption exceeds the delay time, the control sys- adjustment is a function of the load. The values are
tem starts the generator. The value is set with the set with InPower service tool or the digital display.
InPower service tool or the digital display.
Elevator Transfer Time Delay (TDEL): Used in
Stop Time Delay (TDEC-A): This delay is adjust- elevator applications, this delay sets a time to wait
able from 0 to 30 minutes in 1 minute increments. for an elevator pre-transfer signal. This signal al-
The default value is 10 minutes. It begins timing lows the elevator to come to a complete stop be-
when the load is retransferred to Source 1. At the fore the switch transfers. The adjustable range is 0
end of the delay, the stop signal is sent to the gen- to 60 seconds. The time delay begins when a
erator set. During this time delay, the generator set transfer or retransfer signal signal has been sent to
cools down without load before stopping. The val- the relays. The default value is 0. The value can be
ue is set with the InPower service tool or the digital set using the InPower service tool or the digital dis-
display. play.

2-8
System Sensors ling voltage is 95 to 100% of the drop-out setting.
The default value is 95%. The adjustable range for
Under-Voltage Sensing: All controls include the delay time period is 0.5 to 120.0 seconds in 1
3-phase under-voltage sensors for Source 1 and second intervals. The default delay time is 3.0 sec-
Source 2. When a sensor detects a low voltage con- onds. The over-voltage sensing feature is enabled
dition over a specified time period, it initiates a trans- by default. These values are set with the InPower
fer. When the source voltage returns to an accept- service tool or the digital display. See Figure 2-13
able value again, the sensor initiates a retransfer. for an example using the default values. This fea-
ture can also be disabled.
These parameters are adjustable. The under-volt-
age sensing range for a falling voltage (drop-out) is
Example using Default Settings
75 to 98% of the pick-up voltage setting. The de- for Nominal Voltage of 240 VAC
fault value is 90%. The pick-up range for a rising
voltage is 85 to 100% of the nominal voltage set- Nominal Pick-up Drop-out
point. The default value is 90%. The adjustable Setpoint Setting Setting
(240V) (251V) (264V)
range for the time delay period is 0.1 to 1.0 sec-
onds in 0.1 second increments. The default delay
VOLTS
time is 0.5 second. These values are set with the
InPower service tool or the digital display. See Fig-
ure 2-12 for an example using the default values. 95% of 110% of
Drop-out Nominal
Example using Default Settings
for Nominal Voltage of 240 VAC FIGURE 2-13. OVER-VOLTAGE SENSING
Drop-out Pick-up Nominal
Setting Setpoint Frequency Sensing: All controls include frequen-
Setting
(194V) (216V) (240V) cy sensors for Source 1 and Source 2 that can be
disabled and not used. When a sensor detects a
VOLTS high or low frequency condition over a specified
delay time period, it initiates a transfer. When the
frequency returns to an acceptable value again,
90% of 90% of
Pick-up Nominal
the sensor initiates a retransfer.

These parameters are adjustable. The nominal

FIGURE 2-12. UNDER-VOLTAGE SENSING
frequency can be set between 45.0 and 60.0 Hz in
Over-Voltage Sensing: All controls include 0.1 Hz increments. The default frequency is 60 Hz.
3-phase over-voltage sensors for Source 1 and The acceptable frequency bandwidth (pick-up) is
Source 2 that can be disabled and not used. When ±5 to ±20% of the nominal frequency setpoint. The
a sensor detects a high voltage condition over a default value is 10%. The drop-out frequency is 1
specified time period (delay), it initiates a transfer. to 5% beyond the pick-up. The default value is 1%.
When the source voltage falls to an acceptable The range for the delay time period is 0.1 to 15 sec-
value again, the sensor initiates a retransfer. onds. The default delay time is 1.0 second. The
frequency sensing feature is enabled by default.
These parameters are adjustable. The over-volt- See Figure 2-14 for an example using the default
age sensing range (drop-out) for a rising voltage is values. These values are set with the InPower ser-
105 to 135% of the nominal voltage setpoint. The vice tool or the digital display. This feature can also
default value is 110%. The pick-up range for a fal- be disabled.

2-9
 Example using Default Settings tions, after a storm, or when there is generator re-
for Nominal Frequency of 60 Hz wiring.
60 Hz
This feature is enabled by default. It can be dis-
abled using the PC Service tool or the digital dis-
play Setup submenus.

Loss of Single Phase Sensor: Three phase Lev-

el 2 controllers include a loss of single phase sen-
Pick-up Frequencies
sor. This feature initiates a transfer from a source
54 Hz 66 Hz
that has lost a single phase and prevents a transfer
Drop-out Frequencies to a source that has lost a single phase. This is
53.5 Hz 66.7 Hz generally caused by a single phase to line ground
or open. The controller indicates a fault when the
FIGURE 2-14. FREQUENCY SETTING
relative phase angle between any line-to-line
Voltage Imbalance Sensor: Three phase Level 2 phase angle drops to less than 90 degrees. This
controllers include a voltage imbalance sensor for feature is mainly used to protect three phase de-
both Source 1 and Source 2. This feature informs vices, such as motors.
the operator when there is significant voltage im-
The operator can enable this sensor using the PC
balance between the phases of Source 1 or
Service tool or the digital display Setup sub-me-
Source 2. This feature is used for equipment
nus. This sensor is inactive for single phase sys-
protection.
tems and indicates no failures.
A voltage imbalance is typically caused by severe
single phase loading. The sensor indicates a fail- Two-Wire Starting
ure when the maximum deviation from the average The starting circuit is a basic supervisory function
voltage is greater than a user-specified value be-
of the electronic control. Water-cooled generator
tween 2 and 10 % (drop-out) of the average volt-
sets use a two-wire start control.
age in 1% increments. The pickup value is fixed at
10% of the drop-out. The time delay for the imbal- Although the logic is more involved, the two-wire
ance sensor drop-out is adjustable (2−20 sec- starting circuit can be thought of as a single pole,
onds). single throw switch. A closed switch starts the gen-
The operator can enable this sensor using the PC erator set. An open switch stops the generator.
Service tool or the digital display Setup sub-me- NOTE: Three-wire starting is not available on
nus. This sensor is inactive for single phase sys- WBTPC transfer switches.
tems and indicates no failures. To prevent nui-
sance faults, the setting can be increased up to 10 Transfer Times
percent of the nominal voltage.
The controller senses and records the time it takes
Phase Rotation Sensor: Three phase Level 2 for the transfer switch to break from one source
controllers include a phase rotation sensor. This and reconnect to the other source. (Transfer times
feature monitors the phase rotation of the source are not recorded if Programmed Transition delay is
opposite from the connected source. When the al- in use.)
ternate source is out of phase rotation with the
connected source, transfer is inhibited. This gen- Testing With or Without Load
erally occurs on new installations or after storm
damage or generator rewiring. This feature pro- The transfer switch, generator, and power system
tects against equipment damage by preventing can be tested automatically. The operator can acti-
transfer to a source that is out of phase. This fea- vate a test by pressing the Test pushbutton, using
ture is required in fire pump applications. a remote switch, or via software commands (net-
work input).
Both voltage sources have to be applied in order to
check phase rotation. Generally, a power source The Test function can be programmed to test only
may become out of phase rotation in new installa- the generator set start command (default setting)

2-10
or to test with a load transfer. When testing with a NOTE: The clock is not set at the factory. To set the
load, the generator set will warm-up prior to a clock, use the digital display or InPower service
transfer. The load transfers to the generator set tool.
when genset power becomes available (accept-
CONTROL OPTIONS
able).
Relay Module
Generator Exercise Programs
The Relay Module contains 11 Form-C relay con-
Programmable generator exercises and exercise tacts including the Elevator Pre-Transfer Delay
exceptions are generally programmed to be recur- (see Figure 2-15). Additional signal relay contacts
ring. They can be programmed from the PC ser- may be used with other applications.
vice tool or the digital display when it is available.
The Source 1 or Source 2 Connected relays are
Level 2 controllers include eight programmable energized when the respective power source is
generator exercises and eight programmable ex- producing power and connected to the load.
ercise exceptions. While all events can be set us-
The Source 1 or Source 2 Available relays are en-
ing the InPower service tool, only two exercises
ergized when their respective power sources are
and two exercise exceptions can be set with the
available and within the acceptable limits of the
digital display.
voltage sensors.
If Source 1 has an interruption while the generator The Test/Exercise relay is energized when the sys-
set is exercising without load, the ATS transfers tem is in a test or exercise routine.
the load to the generator set.
The Load Shed relay (optional) is energized when
All controllers have a push-button switch on the the transfer switch is signaled to shed load from
digital module that enables and disables the exer- emergency. Connections at J15-15 and J15-16
ciser clock. are input from load shed to the control. This con-
tact is used by the load shed circuit and is not avail-
The Real-Time clock must be set before exercise able for customer use.
programs are entered. See the Digital Display
Menu System section for details on setting the The Elevator Pre-Transfer signal delays transfer
clock. (or retransfer) gives warning to an elevator control
that a transfer (or retransfer) is about to occur.
For utility-to-genset configurations, the exercise The Not-In-Auto relay is energized when any one
clock initiates generator set start and run cycles at of the following is active:
specified intervals for specified durations. This • Motor Disconnect Switch is set to Off
feature is not used in utility-to-utility applications.
• Fail-to-Disconnect event is active
NOTE: Exercise and Test routines are not used in • Control is locked out
Utility-to-Utility configurations. • Wiring harness is disconnected from J12 on
the Power Module
Real-Time Clock • Controller is set to Offline
• The Operator Release key switch is in the
All controllers have a real-time clock that keeps Unlocked (Manual) position − This only ap-
track of the time and date. The controller uses the plies to models that include the optional ex-
real-time clock to time and date stamp all events. ternal manual operation handle.

2-11
 LOCATION OF J15 & J14 WITH
J16
BOARD ORIENTED AS SHOWN

FIGURE 2-15. RELAY MODULE

Load Monitoring Options

TO J23 ON
DIGITAL BOARD
Controllers can include a load current and power
sensor (Current Module) and current transformers
installed on the load lines (see Figure 2-11). The
control senses the all the load currents (including
the neutral current), three load voltages, and three
power factor angles. The control calculates the
real load power and the apparent load power. J41

The load current sensing feature is active when

CT1
CT4

CT3

CT2

the Current Module is installed and connected to

the Digital Module.
J40

The control issues a warning when the neutral cur-

rent exceeds a user specified value between 100
FIGURE 2-16. CURRENT MODULE
and 150% of the rated current during a specified
time period between 10 and 60 seconds. CAUTION To avoid system faults, false
alarms and fault messages, do not remove P40
The warning threshold (100−150%) and time from the Current Module while the CTs are en-
delay (10−60 sec) are set only with the InPower ergized unless the secondaries are shorted.
service tool. For more information, see page 6-30.

2-12
Remote Test Transfer Load Shed Options
The Load Shed Module is used to disconnect the
load from an available Power Source 2 in order to
The transfer switch may be wired with a remote reduce the power consumed from that source.
test switch. Closure of a set of contacts across the When the load shed function is initiated, the trans-
remote test inputs causes the transfer switch to fer switch is moved to the neutral position and the
sense a (simulated) utility power failure and send a Not In Auto indicator lights.
start/run signal to the generator set. The load is
transferred to Source 2 when Source 2 becomes When the load shed feature is active and power on
available. (See Testing With or Without Load on Source 1 returns, the control immediately retran-
page 2-10.) sfers to Source 1.
If the load shed signal is removed before Source 1
returns, the switch transfers back to Source 2.
Auxiliary Relays Options
Load Shed is enabled or disabled using the InPow-
er service tool. The Relay Module must be
installed with a Load Shed Module. Load shed in-
DC auxiliary relays provide contacts for energizing cludes power relay K6, mounted to the control
external alarms, remote indicators, and control plate. Figure 2-11 shows the location of these re-
equipment such as louver motors and water lays.
pumps (Figure 2-17). Relays are 4-pole, 12 or 24
VAC. Security Key Switch
The optional security key switch is located on the
front panel between the handle and the Control
Panel (Figure 2-1). When in the Panel Lock posi-
tion, it disables the front panel input switches, Test
and Override. It also prevents changes being
made to the setup menus using the Digital Display;
however, values can be viewed, but not changed.
Modifications can be made when the switch is in
the Program position.
PowerCommand Network Interface
Module
This option interfaces the transfer switch to the
PowerCommand network. It allows for remote
monitoring of the transfer switch. Some com-
mands can be sent from the remote location. Inter-
facing is accomplished through LONWORKS soft-
ware. Refer to the Network Installation and
Operation Manual (900-0366 for TP-78 networks
or 900−0529 for FT-10 networks) for network de-
tails.
The Network Interface Module is only enabled with
the InPower service tool and is mounted to the digi-
FIGURE 2-17. AUXILIARY RELAYS tal board.

LONWORKS is a registered trademark of Echelon Corp.

2-13
 TO J20 ON
DIGITAL BOARD

FIGURE 2-18. NETWORK MODULE

2-14
 3. Operation
AUTOMATIC OPERATION • Operation selector switch (engine con-
trol): Remote position.
During normal automatic operation the transfer
switch indicators and components will be in the fol-
lowing positions.

• Drawout Position Indicator: On transfer

switch − AUTO position (see Figures 3-5
and 3-6).
BYPASS SWITCH
• Manual Bypass Mechanism: HANDLE IN CLOSED
POSITION
Lower position (OPEN). Neither the Bypass
Normal and the Bypass Emergency indica-
tor lamps are illuminated (see Figures 3-1). BYPASS
SOURCE
SELECTION
Bypass Bypass SWITCH IN
NORMAL
POSITION

Source 1 Source 2 TRANSFER

SWITCH IS
BYPASSED TO
SOURCE 1
(NORMAL)
ATS Inhibit ATS Test
ATS Isolated
FIGURE 3-2. MANUAL BYPASS OPERATION

FIGURE 3-1. 1200−4000 AMP INDICATORS

(CURRENT PRODUCTION)

• Motor Disconnect Toggle Switch: Place in

AUTO position (see Figure 3-4).

• Bypass Selector Switch: Place in OFF

position (see Figure 3-2).

• Front Panel Indicator: The Source 1 or

Source 2 Connected indicator is lit (Figure
3-3). FIGURE 3-3. Switch Panel

3-1
 BYPASSING THE TRANSFER SWITCH front switch panel for 2 seconds (Figure 3-3).
The Test/Exercise LED is on.
NOTE: The load can only be bypassed to the same
source that the automatic transfer switch is con- After the Engine Start time delay, and Source
nected to. Interlocks prevent the operator from by- 2 output is acceptable, the brief Normal to
passing the load to the opposite source or to a dead Emergency time delay begins. The Source 2
source.
Available lamp is lit and the linear motor ener-
Bypassing Load to Normal (Source 1) gizes and drives the transfer switch contact
mechanism to neutral or Source 2.
The transfer switch should be in the Normal posi-
tion and Source 1 power must be available. The Source 2 Connected indicator on the
switch panel will light.
1. Turn the Source Selector Switch to the Normal
NOTE: If the Program Transition feature is ac-
position (Figure 3-2).
tive, additional delays and sensor checks must
occur before a transfer command is issued. If
2. Insert the manual Bypass Handle and move
the ATS is closed to Source 1, this operation
the mechanism up to the Bypass position. will cause a brief power interruption while
The transfer switch is bypassed and the digital switching to Source 2.
display reads “Bypassed to S1.” The Not in
The transfer switch door must be opened if the
Auto LED is on. The Bypass/Normal indicator
cabinet is a IEC 34, 65 or 61.
and the ATS Inhibit indicator, inside the cabi-
net, are lit. WARNING Use extreme caution to avoid
The transfer switch is bypassed. The digital touching electrical contacts when the cabinet
display reads “Bypassed to S1,” and the Not door is open. Do not wear long hair, damp
clothing, or jewelry. Use insulated tools, stand
In Auto LED in on.
on a dry rubber mat or wood platform. 12
Bypassing Load to Emergency (Source 2) 3. Turn the Source Selector Switch to the Emer-
Transfer Load to Source 2 gency position.

The software variable Test−With/Test Without Load 4. Insert the Manual Bypass handle and move
must be set to the With Load value. the mechanism up to the Bypass position.

1. To activate the switch panel, turn the key The transfer switch is bypassed and the digital
switch on the front panel to PROGRAM. display reads “Bypassed to S2.” The Not in
Auto LED is lit. The Bypass/Emergency indi-
2. To transfer to Source 2, first, start the genset cator and the ATS Inhibit indicator, inside the
by pressing and holding the Test button on the cabinet, are lit.

3-2
 ISOLATING THE TRANSFER SWITCH Check that the transfer switch position pointer
is aligned with the word ISOLATE (Figures 3-7
To isolate the automatic transfer switch for servic- and 3-8). Check that the ATS Isolated and
ing, the operator must manually bypass the load to ATS Inhibit lamps are lit.
either the Normal source or to the Emergency
source, and then crank the transfer switch out to
the Isolated position.

NOTE: The load can only be bypassed to the same

source that the automatic transfer switch is con-
nected to. Interlocks prevent the operator from by-
passing the load to the opposite source or to a dead
source.

1. Bypass the transfer switch to either available

Source.

2. To access the transfer switch and handle,

open the cabinet door (IEC 34, 65 and 61 cab-
inets).
DRAWOUT HANDLE
AND MECHANISM
WARNING AC power within the cabinet SC1638s

and the rear side of the cabinet door pres- FIGURE 3-5. 1200 AMP DRAWOUT MECHANISM
ents a shock hazard that can cause severe
personal injury or death. Use extreme cau-
tion to avoid touching electrical contacts
whenever the cabinet door is open. Do not
wear long hair, damp clothing, or jewelry.
Use insulated tools, stand on a dry rubber
mat or wood platform.

3. Move the Motor Disconnect toggle switch

(Figure 3-4) to the Off position to disable the
linear actuator.

DRAWOUT HANDLE
AND MECHANISM

FIGURE 3-6. 1600−4000 DRAWOUT MECHANISM

5. Return the handle to its storage place.

FIGURE 3-4. MOTOR DISCONNECT SWITCH 6. Disconnect connector J10/P10 from the
transfer switch before removing the switch
NOTE: The cranking handle operates only from the enclosure.
when power is available, and when the bypass
switch is connected to one of the sources. WARNING Improper removal of the auto-
matic transfer switch can cause severe
4. Locate the drawout cranking handle and insert personal injury or death. Removal of the
it into cranking mechanism. While pressing in automatic transfer switch must only be
on the cranking handle, rotate the drawout han- performed by trained and experienced ser-
dle (Figures 3-5 and 3-6) counterclockwise to vice personnel, following the procedures
move the transfer switch out. in Section 6.

3-3
 nected to the same position as the ATS, there will
not be a power interruption.

1. Position the transfer switch to the same power

source that the bypass switch is connected to.
See Manual Operation on the next page.

POINTER IN 2. Reconnect harness J10/P10.

TEST POSITION
3. Locate the cranking handle and insert it into
the cranking mechanism. Rotate the handle
clockwise moving the switch to the Test posi-
tion.

4. Check that the automatic transfer switch posi-

SC1640s
tion pointer is aligned with the word TEST
Check that the ATS in Test lamp is lit and the
FIGURE 3-7. 1200 AMP DRAWOUT POSITION
POINTER
ATS Inhibit lamp is not lit (see Figures 3-7 and
3-8).

5. Keep turning the drawout cranking handle

clockwise to move the automatic transfer
switch back to the AUTO position.
POINTER IN
TEST POSITION 6. Make sure the automatic transfer switch posi-
tion pointer is aligned with the word AUTO.
Return the drawout cranking handle to its
stored position.

7. Move the Motor Disconnect toggle switch (lo-

cated on the control plate) to the AUTO posi-
tion to enable the linear actuators.

8. Move the Manual Bypass handle down to the

OPEN position.

9. Make sure the ATS Inhibit, Bypass Source

SC1641
1 and Bypass Source 2 indicator lamps are
not lit. Return the manual bypass handle to its
FIGURE 3-8. 1600−4000 AMP DRAWOUT stored position.
POSITION POINTER
After the automatic transfer switch is returned
RECONNECTING THE TRANSFER to the Auto position, the Motor Disconnect
SWITCH toggle switch is moved to the Auto position,
and the bypass switch is moved to the open
The manual bypass switch must be in the Normal (disconnected) position, the automatic trans-
or Emergency position in order to reconnect the fer switch will respond to transfer/retransfer
transfer switch. If not done already, connect the signals from the controller.
bypass switch using one of the procedures de-
scribed previously. If the bypass switch is con- 10. Close and lock the cabinet door.

3-4
 MANUAL OPERATION WARNING Manual operation of the trans-
fer switch under load presents a shock
The transfer switch has operator handles that are hazard that can cause severe personal in-
intended for maintenance use only. Manual opera- jury or death. Do not attempt to operate
tion must be performed by qualified personnel un- switch manually when it is under load.
der NO-LOAD CONDITIONS ONLY.
4. Then, insert the handle in the slot for the
WARNING Manual operation of the transfer Emergency contacts and close the Emergen-
switch under load presents a shock hazard that cy contacts by pulling the handle downward
can cause severe personal injury or death. Do (Figure 3-9).
not attempt to operate switch manually when it
is under load. Be certain to push the handle all the way to the
LOCK position. A distinct over-center locking
On standard transfer switches, there are two action can be felt.
manual operator slots—one for the Normal
(Source 1) contacts and one for the Emergency 5. Return handle to the storage position.
(Source 2) contacts.
WARNING Automatic transfer switch op-
A manual operating handle is provided with the eration results in rapid movement of the
transfer switch. The handle is a straight steel rod or manual operator mechanism and presents
a hazard of severe personal injury if the op-
tube, with a knob or hand grip on one end.
erator handle is engaged in the mecha-
nism. Remove the handle and place it in its
The transfer switch and the bypass switch must be storage position.
connected to the same source to isolate and re-
connect the transfer switch. 6. Reconnect the transfer switch to the AUTO
position.
Manual Transfer to Source 2
7. Move the Motor Disconnect switch to the
If you determine that Source 2 is available but the
AUTO position, and close the cabinet door.
transfer switch does not automatically transfer (re-
fer to the Troubleshooting section), perform this
procedure to manually transfer to Source 2.

1. Bypass and isolate the automatic transfer

switch to the available source as described
earlier in this section.

2. Make sure the Motor Disconnect switch is in

the OFF position.

WARNING AC power within the cabinet

and the rear side of the cabinet door pres-
ents a shock hazard that can cause severe
personal injury or death. Use extreme cau- NORMAL SIDE
tion to avoid touching electrical contacts
whenever the cabinet door is open. Do not
wear long hair, damp clothing, or jewelry.
Use insulated tools, stand on a dry rubber EMERGENCY
mat or wood platform. SIDE

3. Insert the transfer switch handle in the slot for

the Normal contacts and open the Normal FIGURE 3-9. MANUAL TRANSFER SWITCH
contacts by pulling the handle downward. SLOTS

3-5
Manual Transfer to Source 1 not tested and there is no transfer of load to the
Emergency source (Source 2).
1. Bypass and isolate the automatic transfer
switch as described in this section. 1. Place the key switch in the PROGRAM position.
2. Set the software Test−With/Test Without
2. Make sure the Motor Disconnect switch is in Load variable to the Without Load (default
the OFF position. setting) value.

WARNING AC power within the cabinet 3. Start the genset by pressing and holding the
and the rear side of the cabinet door pres- Test button on the front panel for 2 seconds
ents a shock hazard that can cause severe (Figure 3-3).
personal injury or death. Use extreme cau-
tion to avoid touching electrical contacts 4. After the Engine Start time delay, the genera-
whenever the cabinet door is open. Do not tor starts and the Source 2 Available lamp is
wear long hair, damp clothing, or jewelry. lit.
Use insulated tools, stand on a dry rubber NOTE: Pressing the Override button on the
mat or wood platform. front panel will cancel any time delays except
for Programmed Transition, Engine Cool-down
3. Insert the handle in the slot for the Emergency and Elevator signal.
contacts and open the Emergency contacts
by pulling the handle upward. 5. To end the test routine, press the Test button
again to stop the generator.
4. Insert the handle in the slot for the Normal 6. Reset the Test−With/Without Load variable
contacts and close the Normal contacts by to the desired value for regularly scheduled
pulling the handle upward. exercise routines. Refer to Generator Set Ex-
Be certain to push the handle all the way to the ercise below.
LOCK position. A distinct over-center locking
With Load Standby Test
action can be felt. Return the handle to its stor-
age position. The software variable Test−With/Test Without
Load must be set to the With Load value. This op-
5. Return handle to the storage position. eration causes a brief power interruption while
switching to Source 2.
WARNING Automatic transfer switch op-
eration results in rapid movement of the 1. Activate the switch panel by turning the key
manual operator mechanism and presents switch on the front panel to PROGRAM.
a hazard of severe personal injury if the op- 2. Start the genset by pressing and holding the
erator handle is engaged in the mecha- Test button on the front panel for 2 seconds
nism. Remove the handle and place it in its (Figure 3-3).
storage position.
3. After the Engine Start time delay, and Source
6. Reconnect the transfer switch to the AUTO 2 output is acceptable, the brief Normal to
position. Emergency time delay begins. The Source 2
Available lamp is lit and the linear actuator en-
7. Move the Motor Disconnect switch to the ergizes and drives the transfer switch contact
AUTO position, and close the cabinet door. mechanism to neutral or Source 2.

SYSTEM TESTING NOTE: If the Programmed Transition feature is

active, additional delays and sensor checks
must occur before a transfer command is is-
Generator Set Start Test sued.

This routine tests the start circuits of the Power- 4. To end the test routine, press the Test button
Command control and starts the generator set. again. The controller issues a retransfer time
The linear actuators and contact mechanisms are delay.

3-6
 At the end of the TDEN time delay, the load re- In the Test position, the load-supplying con-
transfers from Source 2 to Source 1. The con- tacts of the automatic transfer switch are out
troller issues a engine cool-down time delay of service, but the PowerCommand control
and turns off the generator. The Test/Exercise and the linear actuators are powered and fully
LED is turned off. operational. In this position, the control, the
linear actuators, and the contact mechanisms
5. Reset the Test−With/Without Load variable can be tested.
to the desired value for regularly scheduled
NOTE: The cranking handle operates only when power is
exercise routines. available. The bypass switch must be connected to one of
the sources.
NOTE: Time delays for Engine Start and Engine
Cool-down are not used in Utility-to-Utility configu- 5. Make sure the Test−With/Without Load vari-
rations. able is set to With Load.

Non-Load Break Transfer Switch Test 6. Move the Motor Disconnect toggle switch (lo-
cated on the control plate) to the AUTO posi-
WARNING AC power within the cabinet and tion to enable the automatic transfer switch
the rear side of the cabinet door presents a linear actuators. Close the cabinet door.
shock hazard that can cause severe personal
injury or death. Use extreme caution to avoid 7. Press and hold the TEST button on the front
touching electrical contacts whenever the cab- panel.
inet door is open. Do not wear long hair, damp The generator set will start and run. After the
clothing, or jewelry. Use insulated tools, stand transfer time delay, the linear actuators will
on a dry rubber mat or wood platform. drive the contact mechanism to the Emergen-
cy side. Because the automatic transfer
The software variable Test−With/Test Without switch is bypassed and isolated from the load,
Load must be set to the With Load value in order to there is NO transfer of load to the Emergency
test the linear actuators and the contact mecha- source and NO interruption of power to the
nisms. Because the automatic transfer switch is load.
bypassed and isolated from the load, there will
NOT be an actual With Load test. 8. At the end of the test routine and time delays,
the linear actuators will drive the contact
1. Insert the Manual Bypass handle into the by- mechanism back to the Normal side.
pass drive mechanism. To avoid any retransfer time delays, press the
Override button. The generator will stop after
2. Turn the Bypass Selector switch to the Normal the stop time delay.
position and move the Manual Bypass handle
up (Figure 3-2). 9. Move the Motor Disconnect toggle switch (lo-
cated on the control plate) to the OFF position
Check that the Bypass Normal and ATS In-
to disable the automatic transfer switch linear
hibit lamps are lit. actuators.
3. Push in and rotate the drawout cranking han- 10. Move the automatic transfer switch back to
dle (Figures 3-5 and 3-6) counterclockwise to the Auto position by rotating the drawout
move the automatic transfer switch to the cranking handle clockwise. The ATS Inhibit
TEST position. lamp will light.
Check that the automatic transfer switch posi- 11. Make sure the position pointer is aligned with
tion pointer is aligned with the word Test (Fig- the word AUTO. Return the drawout cranking
ures 3-7and 3-8). handle to its stored position.
Check that the ATS in Test lamp is lit. and that 12. Move the Motor Disconnect toggle switch to
the ATS Inhibit lamp is not lit. the AUTO position. Close the cabinet door.
4. Return the drawout cranking handle to its 13. Move the Manual Bypass handle down.
stored position. Check that the ATS Inhibit, Bypass Normal

3-7
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