Ats Gtec

Service Manual
Transfer Switch
40−1000 Amps
OTPCA (Spec A)
OTPCB (Spec A)
OTPCC (Spec A)
OTPCD (Spec A)
English
Original Instructions 8-2021 0962−0516 (Issue 15)
Table of Contents
SECTION TITLE PAGE
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Transfer Switch Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Transfer Switch Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Utility-to-Genset Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Utility-to-Utility Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Generator-to-Generator Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Prime Power (Plant to Plant) Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Dual Stand-By Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Control Levels 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
How to Obtain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
2. COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Bargraph Meter Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
AC Ammeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Power Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Power Factor Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Frequency Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
AC Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Membrane Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Security Key Switch Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Electronic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Electronic Control Circuit Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Motor Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Two-Wire Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Auxiliary Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Remote Start-Stop Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Programmed Transition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Transfer Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Test With or Without Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Programmable Generator Exerciser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Remote Test Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Real-Time Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Voltage Imbalance Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
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SECTION TITLE PAGE
Phase Rotation Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Loss of Single Phase Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Generator-to-Generator Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Utility-to-Utility Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Transfer Inhibit Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Retransfer Inhibit Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Electronic Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Auxiliary Relays Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Relay Module Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Load Current and Power Sensor Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Load Shed Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Battery Charger Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Battery Charger Alarm Contacts Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
PowerCommand Network Interface Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Load Shed Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Load Sequencing Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Transfer Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Contact Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Linear Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Auxiliary Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Motor Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Removing and Replacing Electronic Control Components . . . . . . . . . . . . . . . . . . . . . 2-1
3. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Functional Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Programmed Transition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Transfer Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Generator Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Test With or Without Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Transfer/Re-Transfer Inhibits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Real-Time Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Time Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Time Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Time Delay Engine Start (TDESa, and TDESb) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Time Delay Engine Cooldown (TDECa, and TDECb) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Time Delay Normal to Emergency (TDNE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Time Delay Emergency to Normal (TDEN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Time Delay Programmed Transition (TDPT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Elevator Time Delay (TDEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Transfer Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Under-Voltage Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Over-Voltage Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Frequency Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Voltage Imbalance Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Phase Rotation Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Loss of Single Phase Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
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SECTION TITLE PAGE
Sync Check Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Generator Tests, Exercises, and Exercise Exceptions . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Test With or Without Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Generator Set Start Test Without Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Generator Set Start Test With Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Real-Time Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Sleep Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Programmable Generator Set Exercises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Setting Exercise(s) − For Software Versions Prior to 1.5.190 . . . . . . . . . . . . . . . . . . 3-12
Setting Exercise(s) − Starting with Software Version 1.5.190 . . . . . . . . . . . . . . . . . . 3-13
Setting Exercise Exception(s) − Starting with Software Version 1.5.190 . . . . . . . . . 3-14
Setting Exercise(s) − Starting with Software Version 1.13.244 . . . . . . . . . . . . . . . . . 3-15
Setting Exercise Exception(s) − Starting with Software Version 1.13.244 . . . . . . . 3-16
Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Automatic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
With-Load Standby System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Planned Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
4. DIGITAL DISPLAY MENU SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Main Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Password and Setup Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Main Menu Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Main Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Source 1 and Source 2 Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Load Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Statistics Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Statistics Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Events Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Setup Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Setup Menu Navigation and Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Saving or Restoring Setup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Changing Setup Parameters − Software Versions Prior to Version 1.12 . . . . . . . . . 4-11
Changing Setup Parameters − Starting with Software Version1.12 . . . . . . . . . . . . . 4-12
Sensor 1 & Sensor 2 Submenus − Software Versions Prior to Version 1.12 . . . . . 4-13
Sensor 1 & Sensor 2 Submenus − Starting with Software Version 1.12 . . . . . . . . . 4-15
Sync Check Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Time Delay Submenus − Software Versions Prior to Version 1.12 . . . . . . . . . . . . . . 4-18
Time Delay Submenus − Starting with Software Version 1.12 . . . . . . . . . . . . . . . . . 4-20
Test Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Exerciser Submenus − Software Versions Prior to 1.5.190 . . . . . . . . . . . . . . . . . . . . 4-23
Exerciser Submenus − Starting with Software Version 1.5.190 . . . . . . . . . . . . . . . . 4-25
Exercise Exceptions Submenus − Starting with Software Version 1.5.190 . . . . . . . 4-27
Exercise Submenus − Starting with Software Version 1.12 . . . . . . . . . . . . . . . . . . . . 4-29
Exercise Exceptions Submenus − Starting with Software Version 1.12 . . . . . . . . . 4-31
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Exercise Submenus − Starting with Software Version 1.13.244 . . . . . . . . . . . . . . . . 4-33
Exercise Exceptions Submenus − Starting with Software Version 1.13.244 . . . . . 4-35
Mode Submenu − Prior to Software Version 1.20.250 . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Mode Submenu − Starting with Software Version 1.20.250 . . . . . . . . . . . . . . . . . . . . 4-37
Clock Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Sequencer Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
About Submenus − Prior to Software Version 1.20.250 . . . . . . . . . . . . . . . . . . . . . . . 4-40
About Submenus − Starting with Software Version 1.20.250 . . . . . . . . . . . . . . . . . . 4-42
System Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Active TD Submenus − Prior to Software Version 1.12 . . . . . . . . . . . . . . . . . . . . . . . 4-45
Active TD Submenus − Starting with Software Version 1.12 . . . . . . . . . . . . . . . . . . . 4-46
5. EVENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Event Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Event History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Fault Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Control Locked Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Fail to Retransfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Fail to Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
S1 Failed to Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
S1 Failed to Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
S2 Failed to Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
S2 Failed to Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Non-Fault Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
CT Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Emergency Start A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Emergency Start B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Exercise in Progress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Exercise Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Fail to Sync . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Generator A Common Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Generator B Common Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Load Sequencer Outputs (1-8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Network Wink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Neutral Current Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Not in Auto: ATS Motor Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Not in Auto: Common Output (Network Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Not in Auto: Load Shed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Not in Auto: Retransfer Inhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Not in Auto: Transfer Inhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Phase Rotation Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Preferred Source 1 (or 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Service Tool Connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Source 1 Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Source 1 Connected or Bypassed Source 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Source 1 Loss of Phase Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Source 1 Over-Voltage Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Copyright  2021 Cummins Inc. iv

SECTION TITLE PAGE
Source 1 Over/Under Frequency Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Source 1 Under-Voltage Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Source 1 Voltage Imbalance Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Source 2 Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Source 2 Connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Source 2 Loss of Phase Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Source 2 Over-Voltage Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Source 2 Over/Under Frequency Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Source 2 Under-Voltage Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Source 2 Voltage Imbalance Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Speed Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Sync Check Active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Sync Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Test In Progress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Test Start A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Time Delay Engine Cool-Down (TDEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Time Delay Programmed Transition (TDPT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Time Delay Source 1 (N) to Source 2 (E) (TDNE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Time Delay Source 2 (E) to Source 1 (N) (TDEN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Time Delay Start A (TDES-A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Time Delay Start B (TDES-B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Transfer Pending (TDEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
6. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
InPower Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
About Network Applications and Customer Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Digital Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Control LED Indicators and Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Exerciser Enable/Disable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Sequence of Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Transfer from Source 1 to Source 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Transfer from Source 2 to Source 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Troubleshooting Using Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Fault Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Fault Flash-Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Troubleshooting Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Fault Event Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Controller Checksum Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Low Controller Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
ATS Fail to Close: Re-Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
ATS Fail to Close: Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Battery Charger Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Network Battery Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Network Communications Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Controller Loss of Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
v Copyright  2021 Cummins Inc.

SECTION TITLE PAGE
Troubleshooting With Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Troubleshooting Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
7. TRANSFER SWITCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Removing and Replacing Electronic Control Components . . . . . . . . . . . . . . . . . . . . . 7-1
Membrane Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Power Module Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Power Module 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Power Module 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Digital Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Initial Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Setup with a Capture File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Setup Without a Capture File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
After the Setup is Completed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Switch Assembly Removal/Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Disconnect AC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Reconnecting AC Power (When Finished) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Linear Actuator Removal and Replacement (40−125A, 3−Pole ATS Only) . . . . . . . 7-9
Removing Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Replacing Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Block and Cross-Bar Assembly Removal and Replacement
(40 to 125 Amperes, Three Pole Transfer Switches Only) . . . . . . . . . . . . . . . . . . . . . . 7-1
Removing the Block and Cross-Bar Assembly (Normal or Emergency) . . . . . . . . . 7-11
Replacing the Block and Cross-Bar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Aux Switch Removal and Replacement (40−125A, 3−Pole ATS Only) . . . . . . . . . . 7-15
Removing Auxiliary Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Replacing Auxiliary Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Linear Actuator Removal and Replacement (150−260A, 40−125A 4−Pole ATS) . 7-17
Removing Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Replacing Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Block and Cross-Bar Assembly Removal and Replacement
(150−260A, 40−125A, 4−Pole ATS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Removing the Block and Cross-Bar Assembly (Normal or Emergency) . . . . . . . . . 7-20
Replacing Block and Cross-Bar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Aux Switch Removal and Replacement (150−260A,40−125A 4−Pole ATS) . . . . . . 7-24
Linear Actuator Removal and Replacement (300−600A) . . . . . . . . . . . . . . . . . . . . . . 7-26
Block and Cross-Bar Assembly Removal and Replacement (300−600A) . . . . . . . . 7-29
Removing the Block and Cross-bar Assembly (Normal or Emergency) . . . . . . . . . . 7-29
Replacing the Block and Cross-bar Assembly (Normal or Emergency) . . . . . . . . . . 7-32
Auxiliary Switch Removal and Replacement (300−600A) . . . . . . . . . . . . . . . . . . . . . 7-33
Copyright  2021 Cummins Inc. vi

SECTION TITLE PAGE
Linear Actuator Removal and Replacement (800 and 1000A) . . . . . . . . . . . . . . . . . 7-35
Block and Cross-Bar Assembly Removal and Replacement (800 and 1000A) . . . 7-38
Removing the Block and Cross-bar Assembly (Normal or Emergency) . . . . . . . . . . 7-38
Replacing the Block and Cross-bar Assembly (Normal or Emergency) . . . . . . . . . . 7-42
Auxiliary Switch Removal and Replacement (800 and 1000A) . . . . . . . . . . . . . . . . . 7-43
Mis-Wired Current Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45
8. SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
vii Copyright  2021 Cummins Inc.

Safety Precautions
This manual includes the following symbols to indi- 1. Move the operation selector switch on the gen-
cate potentially dangerous conditions. Read the erator set to Stop.
manual carefully and know when these conditions
exist. Then take the necessary steps to protect per- 2. Disconnect the battery charger.
sonnel and the equipment. 3. Disconnect the starting batteries of the genera-
DANGER This symbol warns of immediate tor set or sets (remove the ground [−] lead first).
hazards that will result in severe personal injury 4. Remove AC power to the automatic transfer
or death. switch. If the instructions require otherwise,
WARNING This symbol refers to a hazard or use extreme caution due to the danger of
unsafe practice that can result in severe per- shock hazard.
sonal injury or death.
UTILITY-TO-UTILITY APPLICATIONS
CAUTION This symbol refers to a hazard or If the cabinet must be opened for any reason, re-
unsafe practice that can result in personal inju- move AC power to the automatic transfer switch. If
ry or product or property damage. the instructions require otherwise, use extreme
caution due to the danger of shock hazard.
ELECTRICAL SHOCK CAN CAUSE
SEVERE PERSONAL INJURY OR DEATH GENERAL PRECAUTIONS
High voltage in transfer switch components pres- Place rubber insulative mats on dry wood platforms
ents serious shock hazards that can result in severe over metal or concrete floors when working on any
personal injury or death. Read and follow these electrical equipment. Do not wear damp clothing
suggestions. (particularly wet shoes) or allow skin surfaces to be
Keep the transfer switch cabinet closed and locked. damp when handling any electrical equipment.
Make sure only authorized personnel have the cabi-
net and operational keys. Jewelry is a good conductor of electricity and
should be removed when working on the electrical
Due to the serious shock hazard from high voltages equipment.
within the cabinet, all service and adjustments to
the transfer switch must be performed only by an Wear safety glasses whenever servicing the trans-
electrician or authorized service representative. fer switch and and do not smoke near the batteries.
Do not work on this equipment when mentally or
UTILITY-TO-GENSET OR physically fatigued, or after consuming alcohol or
GENSET-TO-GENSET APPLICATIONS any drug that makes the operation of equipment un-
If the cabinet must be opened for any reason: safe.
WARNING
INCORRECT SERVICE OR REPLACEMENT OF PARTS CAN RESULT IN

DEATH, SEVERE PERSONAL INJURY, AND/OR EQUIPMENT DAMAGE. SER-
VICE PERSONNEL MUST BE QUALIFIED TO PERFORM ELECTRICAL AND/
OR MECHANICAL SERVICE
Copyright  2021 Cummins Inc. viii

1. Introduction
ABOUT THIS MANUAL
NORMAL
This manual contains service procedures for an

OTPC automatic transfer switch (ATS). This is an OVERCURRENT
open transition (OT) transfer switch with Power- PROTECTIVE
Command Control (PC). With an open transition DEVICE
switch there is never a time when both sources are
supplying power to the load.
Refer to the schematic and wiring diagram pack-

age that was shipped with the ATS for specific infor-
mation about its configuration.
Use normal and necessary safety precautions be-

fore starting any service procedure. Identify all haz- LOAD
ards by referring to the Safety Precautions and ob-
serve all warnings and cautions within the manual.
Whenever you are troubleshooting, remember that
the generator set, ATS, and utility power source are
all interdependent.
TRANSFER SWITCH APPLICATIONS
Transfer switches are an essential part of a build-

OVERCURRENT
ing’s standby or emergency power system. Power PROTECTIVE
Source 1 (Normal), commonly the utility line, is DEVICE
backed up by Power Source 2 (Emergency), often
a generator set. The transfer switch automatically
switches the electrical load from one source to the
other. EMERGENCY
The load is connected to the common of the ATS FIGURE 1-1. LOAD TRANSFER SWITCH
(Figure 1-1). Under normal conditions, the load is (TYPICAL FUNCTION)
supplied with power from Source 1 (as illustrated).
If Source 1 is interrupted, the load is transferred to
Source 2. When Source 1 returns, the load is re-
transferred to Source 1. The transfer and retransfer
of the load are the two most basic functions of a
ATS.
1-1 Copyright  2021 Cummins Inc.

TRANSFER SWITCH FUNCTION The operator can select either source as the pre-
ferred source (see Figure 1-2). The Preferred
Automatic transfer switches, capable of automatic Source menu is included in the Test submenus
operation without operator intervention, perform (see Figure 4-17). The PC service tool can also be
the basic function of transferring the load to the used to designate either source as the preferred
available source. The controller monitors each source.
source for allowable voltage and frequency range.
Transfer switches may interact with any of the LON- Note: The exercise routine is not available in this
WORKS devices, such as: configuration.
 Generator Set
 Master Controller Preferred Source

Source 1/Source 2
 Annunciator Panel
 Circuit Breaker Level 2 Controllers Only
The OTPC ATS supports utility-to-generator, utility-

to-utility, and generator-to-generator applications. FIGURE 1-2. PREFERRED SOURCE SUBMENU
UTILITY-TO-GENSET OPERATION GENERATOR-TO-GENERATOR

OPERATION
In utility-to-genset applications, the transfer switch
In genset-to-genset applications, there are two
performs the following functions:
possible configurations, as shown in Figure 1-3.
1. Senses the interruption of the Source 1 power.  Prime Power − Two gensets provide all of
2. Sends a start signal to the generator set the power (utility power is not available)
(Source 2).  Dual Standby − Two gensets are used to
3. Transfers the load to the Source 2. back up utility power
4. Senses the return of Source 1. In Prime Power genset-to-genset applications, the
5. Retransfers the load to Source 1. ATS performs the same as with utility-to-genset ap-
6. Sends a stop signal to the generator set. plications.
UTILITY-TO-UTILITY OPERATION In Dual Standby genset-to-genset applications, the

master and the slave ATSs perform the following
In utility-to-utility applications, the transfer switch functions.
performs the following functions: 1. The slave ATS begins connected to the pre-
1. Senses the interruption of the Source 1 power. ferred source (either genset A or B, but neither
genset is operating yet) and monitors for the
2. Transfers the load to the Source 2. Stand-by Start signal from the master ATS
3. Senses the return of Source 1. (see Figure 1-3).
4. Retransfers the load to Source 1. 2. When the signal is received, the slave ATS
starts the preferred genset.
If the preferred power source fails to operate within
the specified range of voltage and frequency, the 3. If the preferred source voltage is acceptable,
transfer switch automatically connects to the alter- the slave ATS remains there and turns off the
nate power source if within the specified range of non-preferred genset. Otherwise, the slave
voltage and frequency. ATS will transfer to the non-preferred source.
4. When the utility source returns on the master
Level 2 controllers can control a two-utility configu- ATS, then it will transfer back to the utility and
ration for prime power. One utility is designated the disables the Stand-by Start signal.
preferred source. The control automatically trans- 5. When the Stand-by Signal is disabled, the
fers the load between the two utilities and detects slave ATS turns off the operating genset (ei-
alarm conditions. ther genset A or B).
Copyright  2021 Cummins Inc. 1-2

Note: The Test/Exercise function and Load Shed transfer switch transfers the load to the backup
feature are not available in this configuration. genset.
Prime Power (Plant−to−Plant) Operation At any time, the PC service tool or the Test sub-
menu (see Figure 1-2) can be used to designate ei-
In prime power applications, utility power is not ther genset (Source 1 or Source 2) as the preferred
available. The system includes one transfer switch genset. The Preferred Source menu is included in
and two gensets (see Figure 1-3). One genset is al- the Test submenus (see Figure 4-17).
ways running and supplying power to the load while
the other genset is the backup genset. An external If the user manually changes the preferred source
power supply is not needed in this application. setting so that the backup genset becomes the pre-
ferred genset, the transfer switch transfers the load
Preferred Source Selection − Under normal op- to the new preferred genset when it becomes avail-
eration, one genset is designated as the preferred able. The unit that is carrying the load is always
source and supplies power to the load. The second considered the preferred source. The control does
genset is the backup power source. If the preferred not automatically select which source is consid-
genset fails, the backup genset starts and the ered preferred.
GENSET B GENSET B UTILITY
OVERCURRENT OVERCURRENT
PROTECTIVE PROTECTIVE
DEVICE DEVICE
MASTER
ATS
STAND-BY START
SLAVE
LOAD LOAD
ATS
OVERCURRENT
PROTECTIVE
DEVICE
OVERCURRENT OVERCURRENT
PROTECTIVE PROTECTIVE
DEVICE DEVICE
GENSET A GENSET A
GEN-TO-GEN CONFIGURATION IN GEN-TO-GEN CONFIGURATION IN

PRIME POWER MODE DUAL STANDBY MODE
FIGURE 1-3. GENERATOR-TO-GENERATOR CONFIGURATION IN PRIME POWER

AND DUAL STANDBY MODES

Automatic Changeover − The transfer switch can 2. Place the transfer switch in the Source 1 posi-
be set up to change the preferred source automati- tion.
cally by enabling the changeover timer. The Time
Delay sub-menus under Setup (see Figure 4-15 or 3. Place the Off−Manual−Auto selector switch on
4-16, depending upon your software version) or the the Source 1 genset control in the Auto posi-
PC Service tool can be used to enable the change- tion. The genset will start and supply power to
over timer and specify a changeover delay time pe- the load (the load will be energized and TDE-
riod. Ca may be timing).
The automatic changeover timer automatically 4. Use the PC Service tool or the Test sub-menu
changes the preferred source and transfers the to set this genset as the preferred source.
load to the new preferred genset after a TDEN time 5. Wait for TDECa to finish timing.
delay. After the transfer is complete, the control ini-
tiates a cool-down period (TDEC) on the old pre- 6. Place the Off−Manual−Auto selector switch on
ferred genset before shutting it down. The old pre- the backup genset (Source 2) control in the
ferred genset is now the new backup genset. The Auto position.
changeover timer is now timing for the next
changeover and the cycle continues as long as the 7. Place the motor disconnect switch in the Auto
changeover timer is enabled. position.
8. If desired, use the Time Delay sub-menus un-

der Setup or use the PC Service tool to enable
Changeover Enable the changeover timer and specify a change-
Enabled/Disabled over delay time period.
Testing the System by Turning Off the Pre-

CHANGEOVER ENABLE/DISABLE
ferred Source:
Changeover Delay 1. With the preferred source genset running and

24 Hours supplying power to the load, place the genset
control Off−Manual−Auto selector switch in
the Off position. The backup genset should
CHANGEOVER TIME DELAY start and run.
Level 2 Controllers Only
After the voltage and frequency are at accept-
able levels, the transfer switch should transfer
FIGURE 1-4. CHANGEOVER SUBMENUS
the load to the backup genset.
Prime Power Wiring − A permanent start jumper is
2. Place the genset control Off−Manual−Auto se-
installed in the transfer switch and is shipped from
lector switch on the preferred genset back in
the factory in the prime power mode. Verify that the the Auto position. The preferred genset should
jumper (TB3-57 to TB3-59) is installed (see inter- start and run.
connect drawing 630−2108, sheet 3 in Chapter 8).
After the voltage and frequency levels are at
System Startup − To set up a system for prime acceptable levels, the transfer switch should
power operation: transfer the load back to the preferred genset.
1. Place the motor disconnect switch in the Off After the transfer is complete, the control initi-
position, and both generator selector switches ates a cool-down period (TDEC) on the back-
into the OFF position. up genset and it should stop.

Testing the System by Changing the Desig- transfer switch control will not start either genset.
nated Preferred Source: When a Stand-By Start command is received from
a Master ATS (or other device), the preferred gen-
1. With the preferred source genset running and set immediately starts. If the preferred genset does
supplying power to the load, use the PC Ser- not start, a time delay engine start (TDES) is initi-
vice tool or the Test sub-menu to change the ated and the control starts the backup genset. The
preferred source. The new preferred source load is connected to the genset when it becomes
should start and run. available.
able levels, the transfer switch should transfer If the preferred genset becomes available while the
the load to the new preferred source. backup genset is active, a time delay retransfer
(TDEN) period is initiated and the load is retrans-
After the transfer is complete, the control initi- ferred back to the preferred genset. A time delay
ates a cool-down period (TDEC) on the old cool-down (TDEC) period is initiated before turning
preferred source and it should stop. off the backup genset. When the Stand-By Start
becomes deactivated, a TDEC period is initiated
2. Use the PC Service tool or the Test sub-menu
and the active generator is turned off.
to change the preferred source back to the
original genset. The original genset should Preferred Source Selection − Under normal op-
start and run. eration, one genset is designated as the preferred
After the voltage and frequency levels are at source and the second genset is designated as the
acceptable levels, the transfer switch should backup power source. If the both the utility power
transfer the load back to the original genset. and the preferred genset fails, the backup genset
starts and the genset-to-genset transfer switch
After the transfer is complete, the control initi- transfers the load to the backup genset.
ates a cool-down period (TDEC) on the back-
up genset and it should stop. At any time, the PC Service tool or the Test sub–
menu on the genset-to-genset transfer switch can
Dual Stand-By Operation be used to designate either genset (Source 1 or
Source 2) as the preferred genset. If the preferred
In dual stand-by applications, utility power is avail- genset is changed and the backup genset be-
able. The system includes two transfer switches comes the preferred genset, the transfer switch
and two gensets. Utility power supplies power to transfers the load to the new preferred genset if it is
the load and both gensets are backup gensets. needed and when it becomes available.
Under normal operation, the utility is supplying Alternating Preferred Source − In an attempt to
power to the load through the lead transfer switch. keep the running time equally distributed between
The lead transfer switch is a utility-to-genset both gensets, the control can be set to alternate be-
switch. The two gensets are connected to the gen- tween the gensets when utility power fails. The se-
set-to-genset transfer switch. The load side of this lected preferred genset starts with the first power
switch is connected to the genset side of the lead outage. The second power outage starts the back-
transfer switch. up genset, which now becomes the preferred gen-
set. Upon subsequent outages, the preferred gen-
Upon loss of utility power to the lead transfer set alternates.
switch, a signal is sent to the genset-to-genset
transfer switch to start the preferred genset. When Only utility outages and tests or exercises initiated
the lead transfer switch senses generator voltage, at the lead transfer switch result in the gensets be-
it transfers the load to that genset. If the preferred ing alternated. The designated preferred genset
genset fails to start, a signal is sent to the backup will not change if it fails and the backup genset
genset to start. The PC Service tool or the Test sub- takes over the load. This alternating preferred
menu on the genset-to-genset transfer switch can source can only be enabled with the PC Service
be used to set the preferred source. tool. When enabled, a genset can be designated
as the preferred source for a maximum of two
If the Stand-By Start is inactive, upon initial power– weeks. Time adjustments can be made in one-hour
up (or reset), or during software initialization, the increments.

Control Voltage − A dual stand-by configuration 10. Set the time delay engine stop (TDECa) to
requires an external 12−24 VDC power supply to zero on the lead transfer switch.
keep the genset-to-genset control active. An op-
tional Battery Kit is available, or the genset starting 11. If desired, use the PC Service tool to enable
batteries can be used. See drawing 630−2024 for the alternating preferred source.
connection details.
12. Place the motor disconnect switch in the Auto
Dual Stand-By Wiring − For dual stand-by ap- position on both transfer switches.
plications, the jumper (TB3-57 to TB3-59) must be
removed (see interconnect drawing 630−2024 in Testing the System by Removing Utility Power
Chapter 8). and Turning Off the Preferred Genset:
System Startup − To set up a system for dual 1. With the utility supplying power to the load and
stand-by operation: neither genset running, turn off the utility circuit
breaker feeding the load transfer switch. The
1. Place the motor disconnect switch on both preferred genset should start and run.
transfer switches in the Off position.
2. Connect both transfer switches to the Source 1 able levels, the lead transfer switch should
side. transfer the load to the preferred genset.
3. Make sure the Off−Manual−Auto selector
switch on both gensets is in the Off position. 2. Place the Off−Manual−Auto selector of the
preferred genset (running) control in the Off
4. Make sure the genset-to-genset transfer position.
switch is being powered by an external DC
supply. The preferred genset should stop and the
backup genset should start and run.
5. Press the Lamp Test/Reset button on the gen-
set-to-genset transfer switch. If all of the front After the voltage and frequency are at accept-
panel lights come on, the control is running able levels, the genset-to-genset transfer
properly. switch should transfer the load to the backup
genset.
6. Use the PC Service tool or the Test sub-menu
on the genset-to-genset transfer switch to set 3. Place the Off−Manual−Auto selector switch on
the Source 1 genset as the preferred source. the preferred genset back to the Auto position.
The preferred genset should start and run.
7. Energize utility power to the lead transfer
switch. The load is energized and a time delay After the voltage and frequency are at accept-
(TDECa) begins. able levels, the genset-to-genset transfer
8. Wait for TDECa to finish timing. switch should transfer the load to the preferred
genset. The backup genset should stop after
9. Set the time delay engine start (TDESa) to the time delay engine cool-down (TDECa) is
zero on the lead transfer switch. completed.

CONTROL LEVELS 1 AND 2 OTPCA 00000 Spec.A
| | | |
Two controls are available. The type of power 1 2 3 4
source switched and the desired features deter-
mine the control levels available. See the Descrip- 1. OTPC - Open Transition PowerCommand
tion section for details. The table lists the applica- Control.
tions that are available with each control.
2. Ampere Rating:
TABLE 1-1. AVAILABLE CONTROL LEVELS A = 40, 70, 125
B = 150, 225, 260
Power Sources Level 1 Level 2 C = 300, 400, 600
Genset-to-Utility X X D = 800, 1000
Genset-to-Genset X 3. Assigned spec number - issued for each spe-
Utility-to-Utility X cific combination of accessories, voltages, fre-
quency and standards codes. This number is
The control board level can be viewed, using the only repeated for standard product.
digital display (see Figure 1-5). This menu is in-
cluded in the About submenus (see Figure 4-29 or 4. Specification letter - advances with production
4-30, depending upon software version). modification.
HOW TO OBTAIN SERVICE
ATS Board Level When the transfer switch requires servicing, con-
2 tact your nearest Cummins Inc. distributor. Facto-
ry-trained Parts and Service representatives are
ready to handle all your service needs.
FIGURE 1-5. CONTROL LEVEL SUBMENU
To contact your local Cummins Inc. distributor in
MODEL IDENTIFICATION the U.S. or Canada, call 1-800−CUMMINSTM
(1−800−286−6467). (This automated service uti-
Identify your model by referring to the Model and lizes touch-tone phones only.) By selecting Option
Specification number as shown on the nameplate. 1 (press 1), you will be automatically connected to
Electrical characteristics and application informa- the distributor nearest you.
tion are shown on the lower portion of the name-
If you are unable to locate a dealer or distributor,
plate. The nameplate is located on the cabinet
consult the Yellow Pages. Typically, distributors are
door.
listed under:
If it’s necessary to contact a dealer or distributor re- Generators-Electric,
garding the transfer switch, always give the com- Engines-Gasoline or Engines-Diesel, or
plete Model, Specification, and Serial number as Recreational Vehicles-Equipment,
listed on the nameplate. This information is neces- Parts and Service.
sary to properly identify your unit among the many
types manufactured. For outside U.S. and Canada,visit http://www.cum-
mins.com/support for global solution center infor-
Refer to the next section for a list of feature/option mation list.
codes.
When contacting your distributor, always supply
The model number is made up of code segments the complete Model Number and Serial Number as
that designate various features or options: shown on the nameplate.

FEATURE DESCRIPTION FEATURE FEATURE DESCRIPTION FEATURE
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
Utility−to− Utility A036 Digital Bar Graph Meters D009
Genset−to−Genset A037
Battery Charges:
Agency Approvals: 2A, 12/24VDC K001
UL Listing A046 10A, 12VDC K002
NFPA 20 A064 10A, 24VDC K003
15 Amp, 12 VDC KB59
Frequency: 12 Amp, 24 VDC KB60
60 Hertz A044
50 Hertz A045 Auxiliary Relays:
Voltage: 24 VDC Coil L101
Emergency Position L102
120 VAC R020 Normal Position L103
190 VAC R038 Genset Start L104
208 VAC R021 12 VDC Coil L201
220 VAC R022 Emergency Position L202
240 VAC R023 Normal Position L203
380 VAC R024 Genset Start L204
416 VAC R025
440 VAC R035 Miscellaneous:
480 VAC R026
R027 Terminal Block − 30 Position M003
600 VAC
Load Shed − From Emergency M007
Controls: Terminal Block − Battery Chrg Alarms N002
C023 Power Connect − Bus Stubs N009
Level 1 Switch Control
Level 2 Switch Control C024
Cabinet:
Control Options: Type 1 B001
Front Panel Security Key M017 Type 3R B002
Digital Display M018 Type 4 B003
LonWorks Network Com. Module M020 Open Construction B004
Load Monitoring M022 Type 12 B010
Relay Module M023 Type 4X − Stainless Steel B025

2. Component Description
CABINET The front of the cabinet door includes the control
panel, door handle, and the optional key switch.
The standard cabinet meets the requirements of CONTROL PANEL
the National Electrical Manufacturers Association
(NEMA) for a UL Type 1 cabinet. This type is desig- The control panel (See Figure 2-1) includes one or
nated as a general-purpose, indoor cabinet. Cabi- more of the following three panels.
nets are available in NEMA types 1, 3R, 4, 4X, and
12.  Bargraph Meter Panel
 Switch Panel
An example of a cabinet showing interior compo-
nents is shown in Figure 2-5.  Digital Display
BAR GRAPH
METER PANEL
(LEVEL 1 NA,
LEVEL 2 OPTIONAL)
SWITCH PANEL
(STANDARD)
OPTIONAL
KEY SWITCH
DIGITAL DISPLAY
(LEVEL 1 OPTIONAL
LEVEL 2 STANDARD)
FIGURE 2-1. CONTROL PANEL ON CABINET DOOR (INCLUDES OPTIONS)

BARGRAPH METER PANEL SWITCH PANEL
The analog Bargraph Meter Panel is not available The switch panel (Figure 2-3) is a standard feature
with Level 1 control and is optional with Level 2 con- on all OTPC transfer switches. It contains six indi-
trol. Green, red and amber LEDs provide at-a- cator lamps and three membrane buttons.
glance indication of system acceptability. Features
include a three phase AC ammeter, a power meter,
a power factor meter, a frequency meter, and a
three phase AC voltmeter.
AC Ammeter
The ammeter displays percent of full load currents

in amperes (1−125%).
Power Meter
The power meter displays the real power in percent

of full load in kilowatts (0−125%). FIGURE 2-3. SWITCH PANEL
Indicator Lamps
Power Factor Meter
Source 1 Available and Source 2 Available
The power factor meter displays the real power de-
These indicators are lit when the corresponding
livered to the load (1.0 − 0.6 lagging) and (1.0 − 0.9
sources have acceptable output voltage and/or fre-
leading).
quency. These indicators can be lit simultaneously.
Frequency Meter Source 1 Connected
This meter displays the output frequency (percent This indicator is lit when the ATS is in the Source 1
of nominal frequency), of the power source con- position and Source 1 is supplying power to the
nected to the load (70−110%). load.
Source 2 Connected
AC Voltmeter
This indicator is lit when the ATS is in the Source 2
The voltmeter displays percent of line to neutral position and Source 2 is supplying power to the
voltages of the power source connected to the load load.
(70−110%).
Not in Auto
For all configurations, the Not in Auto indicator
lights when the ATS is not in Auto.
The transfer switch is not in auto when any of the

following signals are active:
 Motor Disconnect Switch is set to Off
 Fail-to-Disconnect event is active
 Control is locked out
 Wiring harness is disconnected from J12 on
the Power Module
 Controller is set to Offline
 The Operator Release key switch is in the
Unlocked (Manual) position − This only ap-
plies to models that include the optional ex-
FIGURE 2-2. BARGRAPH METER PANEL ternal manual operation handle.

Test/Exercise Active events and resets active faults (refer to Events on
The Test/Exercise Active indicator is lit when the page 3-17).
ATS has a test or exercise in progress.
DIGITAL DISPLAY
Membrane Buttons The Digital Display is standard on Level 2 controls
Test and optional on Level 1 controls. It contains a 2-line
by 20-character digital display module and 6 mo-
For utility-to-genset applications, the Test switch mentary contact membrane buttons. The display
sends a start signal to the generator set designated provides a method for monitoring load power con-
Source 2 and blinks the Test/Exercise Active indi- dition, adjusting transfer switch parameters, moni-
cator. After the start and transfer time delays or toring PowerCommand Network status, or review-
source synchronization, Source 2 starts and as- ing transfer switch events. It is password protected
sumes the load provided that the With Load option
to limit access to unauthorized adjustments. The
is selected. Press the Test switch again to end the
module displays the software menus and the but-
test; the Test/Exercise Active indicator goes out
tons are used to navigate through the menu sys-
and Source 1 resumes as the source of power.
tem.
For utility-to-utility applications, the Test switch
starts the transfer time delay or source synchro- Each menu indicates the function of the four
nization and the non-preferred Source assumes switches at the sides of the display module. Not all
the load, provided that the With Load option is se- buttons are active for each menu. See Section 4:
lected. Press the Test switch again to end the test; Digital Display Menu System, for details on the
the Test/Exercise Active indicator goes out and the complete digital display menu structure.
preferred Source resumes as the source of power.
For genset-to-genset applications, there is no

test function.
Override
The Override switch terminates most system time
delays. The Program Transition (TDPT), Elevator
signal (TDEL) and Engine Cool Down (TDEC) are
not affected by this button. If you press this switch
FIGURE 2-4. DIGITAL DISPLAY
while the Transfer Inhibit input is active, the switch
immediately transfers the load. If you press this SECURITY KEY SWITCH OPTION
switch while the Retransfer Inhibit input is active,
the switch immediately retransfers the load. For The optional security key switch is located on the
more information on Transfer Inhibit, see page front panel between the handle and the Control
2-10. For information on Retransfer Inhibit, see Panel. When it is in the Panel Lock position, it dis-
page 2-10. ables the front panel input switches, Test and Over-
ride. It also prevents changes to the Digital Display
The Override function is not available unless the
from the setup menus; however, the current values
front panel switch is in the Program position. are displayed. Changes can be made when the
Reset/Lamp Test switch is in the Program position.
The Reset/Lamp Test button turns on all control The key switch can be disabled in PowerCommand
panel indicators. This switch also acknowledges using the PC service tool.

OPTIONAL BATTERY
BAR GRAPH CHARGER
ASSEMBLY AUTOMATIC
CONTROLLER PC SERVICE TRANSFER
NETWORK BATTERIES TOOL CONNECTOR SWITCH
COMMUNICATIONS TB1
MODULE (NCM)
NETWORK
BATTERIES
(SEE NOTE)
DIGITAL
MODULE
P1 POWER
(CONTROL)
DISCONNECT
DIGITAL TRANSFER
RELAY MOTOR DISCONNECT DISPLAY TB2 SWITCH
ASSEMBLY SWITCH (S1) POWER HANDLES
MODULE
NOTE: NCM boards on current production models do not use batteries.
FIGURE 2-5. INTERIOR/COMPONENTS: 40-125 AMP SWITCH

ELECTRONIC CONTROL SYSTEM EARLY PRODUCTION BATTERIES J26
J20 J22
This section describes the standard and optional
components of the electronic control system.
WARNING Improper calibration or adjustment

of electronic control modules can cause death,
severe personal injury, and equipment or prop-
erty damage. Calibration and adjustment of
these components must be performed by tech-
nically qualified personnel only.
Calibration and adjustment procedures are de-

scribed in the Installation manual (which is shipped
with the ATS).
J24 J28 J25
K10 J27
WARNING Accidental actuation of the linear CURRENT PRODUCTION
motor could cause severe personal injury. Be- BATTERY J26
J20 J22
fore making any adjustments, place the Motor
Disconnect Switch (Figure 2-5) in the Off posi-
tion. Return the switch to the Auto position af-
ter adjustments are completed.
WARNING AC power within the cabinet and

the rear side of the cabinet door presents a
shock hazard that can cause severe personal
injury or death. When the cabinet door is open,
use extreme caution to avoid touching electri-
cal contacts with body, tools, jewelry, clothes,
hair, etc.
Electronic Control Circuit Modules J24 J28 K10 J25

J27
The OTPC transfer switch control incorporates a FIGURE 2-6. LEVEL 1 DIGITAL MODULE
Digital and a Power Module. Two versions of each
are available: one for Level 1 controls and one for BATTERIES J26
J20 J29 J26
Level 2 controls. The power modules are available
in four different voltage ranges (240 VAC 1 phase 3
wire, 208−240 VAC 3 phase 4 wire, 380−480 VAC 3
phase 4 wire, and 600 VAC 3 phase 4 wire). The
digital module has two 3-volt batteries to power the
real-time clock when no source voltage is avail-
able. When replacing these batteries, change them
one at a time.
Digital Module: The digital module (see Figures

2-6 and 2-7) contains the logic and timing circuits
that control transfer switch operation. These mod-
ules also contain many of the customer interface
circuits (including the genset start signal and net- J24 J28 J25
work port), the RS-232 communications port for the J27
service tool, and drivers for the control panel indi-
cators, switches, and bar graph meter panel. FIGURE 2-7. LEVEL 2 DIGITAL MODULE

Power Module: The power modules contain a Level 2 power modules contain six pilot relays de-
power supply for the digital modules, voltage sens- fined:
ing transformers, and relays. These modules also
contain the interface circuits for the transfer switch K12 Neutral to Source 1
including the position sensing switches and relay K13 Source 2 to Neutral
drivers.12 VDC rectification and regulation circuits K14 Neutral to Source 2
on this module are powered by both sources K15 Source1 to Neutral
through transformers. K16 Closed Transition Enable
K17 Not Used
The Level 1 power module has three transformers
allowing power from either source (1 or 2) for the TO J24
switch components. The connections for two trans- ON THE J12
DIGITAL J13
formers on Source 1 are A-B and B-C. Source 2 MODULE
transformer is connected at A-C. J11
Level 1 power modules contain four pilot relays de- T8 T5

fined:
K12
TB14
TB12
K12 Neutral to Source 1 K14
K13 Source 2 to Neutral T7 T4
K15
K14 Neutral to Source 2
K15 Source1 to Neutral K13
K16
TO J24 T6 T3
K17
TB13
TB11
ON THE J12
DIGITAL
MODULE
J11 K12
K14 T2 T1
K13
K15
FIGURE 2-9. POWER MODULE 2
Motor Disconnect Switch

T1 T2 T3 The Motor Disconnect toggle switch, on the control
plate, enables and disables the linear actuator mo-
tor (see Figure 2-5). This switch is accessible only
from inside the enclosure. The Not In Auto LED on
the front panel indicates the state of this switch. It is
TB11 lit when the switch is in the Off position. (Other ATS
conditions also light this indicator: See the descrip-
tion of the Not in Auto indicator under Switch Panel
FIGURE 2-8. POWER MODULE 1
on page 2-2.) Place the switch in the Auto position
to enable the linear actuator. Place the switch in the
The Level 2 power module contains eight trans-
Off position to disable the linear actuator.
formers. Each source (1 and 2) use three trans-
formers. Both sets are connected A:N, B:N and C:N Two-Wire Starting
except on 120 volt switches which are connected
A:N only. The other transformers are used to power The starting circuit is a basic supervisory function
the 12 VDC supply on the module. One transformer of the electronic control. Water-cooled generator
is connected to Source 1 and the other source 2. sets use a two-wire start control.

Although the logic is more involved, the two-wire A jumper must be connected between terminals 1
starting circuit can be thought of as a single pole, and 2 for PowerCommand Control systems. A
single throw switch. A closed switch starts the gen- jumper must be connected between terminals 2
erator set. An open switch stops the generator. and 3 for Detector Control systems. A jumper is not
used with all other systems.
NOTE: Three-wire starting is not available on OTPC
transfer switches.
Auxiliary Contacts 1 GND

2 2
Auxiliary contacts, used for external alarm or con-
trol circuitry, are available for the Source 1 (Normal) 3 B+
and Source 2 (Emergency) sides of the transfer
switch. Connections for the auxiliary contacts can 4 RMT
be made on terminal block TB1 (Figure 2-10). The 5 REMOTE TEST
contacts have ratings of 10 amperes at 250 VAC.
6 TRANSFER INHIBIT
Figure 2-10 shows the normally open and normally
closed positions of the auxiliary contacts with the 7 LOAD SHED (OPTIONAL)
transfer switch in the neutral position. Moving the
8 COMMON
transfer switch to Normal or Emergency actuates
the corresponding auxiliary contacts.
TB2
FIGURE 2-11. TB2: START CONNECTIONS,

REMOTE TEST, AND TRANSFER INHIBIT
NO
SOURCE 1
(NORMAL) NC
Programmed Transition
AUXILIARY SWITCH
COM Program Transition introduces a delay (TDPT) dur-
ing transition of the switch. Programmed transition
stops the switch in the neutral position for an ad-
justable interval of time. In this position, the load is
NO
not connected to either Source 1 or 2. This delay al-
SOURCE 2 lows residual current from inductive loads to decay
(EMERGENCY) NC
AUXILIARY SWITCH
to an acceptable level before transfer is completed.
COM
The parameters are adjustable. The length of time
that the ATS is in the neutral position can be ad-
justed from 0 to 60 seconds in 1 second incre-
TB1
ments. The default value is 0 seconds. The proper
adjustment is a function of the load. This feature is
FIGURE 2-10. TERMINAL BLOCK TB1 enabled by default. The values are set with PC ser-
vice tool or the digital display.
Remote Start-Stop Connections
Transfer Times
Remote starting (for Cummins water-cooled gen-
erator sets only) uses terminals B+, GND (ground), The controller senses and records the time it takes
and RMT of terminal block TB2 (Figure 2-12). for the ATS to break from one source and reconnect
These terminals are connected to like terminals on to the other source. (Transfer times are not re-
the generator set. corded if Programmed Transition delay is in use.)

Test With or Without Load set. The load is transferred to Source 2 when
Source 2 becomes available.
The operator can test the ATS, generator, and pow-
er system automatically. The operator can transfer A jumper can be temporarily connected between
the load during the test or to only test the generator. TB2-5 and TB2-8 to test this feature.
Both hardware means (switch input) and software
means (PowerCommand network) input can acti- Opening a set of contacts across the remote test
vate an automatic test sequence. transfer input causes the transfer switch to sense
that utility power has been restored and transfers
the load back to Source 1.
Programmable Generator Exerciser
Programmable generator exercises and exercise

exceptions are generally programmed to be recur-
ring. They can be programmed from the PC service 1 GND
tool or the digital display when it is available. 2 2
Level 1 controllers include two programmable gen- 3 B+

erator exercises and two programmable exercise 4 RMT
exceptions. While all events can be set using the
PC Service tool, only one exercise and one exer- 5 REMOTE TEST
cise exception can be set with the digital display. 6 TRANSFER INHIBIT
7 LOAD SHED (OPTIONAL)

Level 2 controllers include eight programmable
generator exercises and eight programmable exer- 8 COMMON
cise exceptions. While all events can be set using
the PC Service tool, only two exercises and two ex-
ercise exceptions can be set with the digital display. TB2
FIGURE 2-12. TB2 CONNECTIONS FOR REMOTE

All controllers have a push-button switch on the TEST TRANSFER
digital module that enables and disables the exer-
ciser clock. See the Digital Display Menu System For utility-to-utility applications, closure of a set of
section for details on setting the clock. The Real- contacts across the remote test transfer input
Time clock must be set before exercise programs (TB2-5 and TB2-8) causes the transfer switch to
are entered. sense a (simulated) power failure of the primary
source and transfers the load to the backup source.
For utility-to-genset configurations, the exerciser
clock initiates genset start and run cycles at speci- Opening a set of contacts across the remote test
fied intervals for specified durations. The exerciser transfer input causes the transfer switch to sense
is not used in utility-to-utility or genset-to-genset that the primary source has been restored and
configurations (see Generator-to-Generator Con- transfers the load back to the primary source.
trol Mode).
This feature is not available with genset-to-
Remote Test Switch genset applications.
The transfer switch may be wired with a remote test Real-Time Clock
switch.
All controllers have a real-time clock that keeps
track of the time and date. This clock is year 2000
For utility-to-genset applications, closure of a set compliant. The controller uses the real-time clock
of contacts across the remote test transfer input to time and date stamp all events.
(TB2-5 and TB2-8 − see Figure 2-12) causes the
transfer switch to sense a (simulated) utility power The clock is not set at the factory. To set the clock,
failure and sends a start/run signal to the generator use the digital display or PC Service tool.

Voltage Imbalance Sensor Loss of Single Phase Sensor
Three phase Level 2 controllers include a voltage Three phase Level 2 controllers include a loss of
imbalance sensor for both Source 1 and Source 2. single phase sensor. This feature initiates a trans-
This feature informs the operator when there is sig- fer from a source that has lost a single phase and
nificant voltage imbalance between the phases of prevents a transfer to a source that has lost a single
Source 1 or Source 2. This feature is used for phase. This is generally caused by a single phase
equipment protection. to line ground or open. The controller indicates a
fault when the relative phase angle between any
A voltage imbalance is typically caused by severe line-to-line phase angle drops to less than 90. This
single phase loading. The sensor indicates a failure feature is mainly used to protect three phase de-
when the maximum deviation from the average vices, such as motors.
voltage is greater than a user-specified value be-
tween 2% and 10% (drop-out) of the average volt- The operator can enable this sensor. See the Digi-
age in 1% increments. The pickup value is fixed at tal Display Menu System section. This sensor is in-
10% of the drop-out. The time delay for the imbal- active for single phase systems and indicates no
ance sensor drop-out is adjustable (2−20 sec- failures.
onds).
Generator-to-Generator Control Mode
The operator can enable this sensor. See the Digi-
tal Display Menu System section. This sensor is in- Level 2 controllers can control a two-generator
active for single phase systems and indicates no configuration for either dual standby or prime pow-
failures. To prevent nuisance faults, the setting can er. One generator is designated the preferred
be increased up to 10 % of the nominal voltage. source. The control automatically transfers the
load between the two generators and detects gen-
Phase Rotation Sensor
erator alarm conditions. This configuration re-
Three phase Level 2 controllers include a phase quires the optional Battery Kit when used in dual
rotation sensor. This feature monitors the phase standby mode.
rotation of the source opposite from the connected
The operator can select the preferred source
source. When the alternate source is out of phase
(Source 1 or Source 2) in the genset-to-genset
rotation with the connected source, transfer is in-
mode. The preferred source selection is made at
hibited. This generally occurs on new installations
the digital display (under Test).
or after storm damage or generator rewiring. This
feature protects against equipment damage by
A separate changeover timer automatically trans-
preventing transfer to a source that is out of phase.
fers loads between the two generators. The
This feature is required in fire pump applications.
changeover timer is set from the digital display or
CAUTION Level 1 controls do not support the PC Service tool. The exerciser clock is not
three-phase sensing on Source 2. Do not select available in this configuration.
the three-phase option for the Source 2 Sens-
ing adjustment with Level 1 controls, even if the Utility-to-Utility Control Mode
system is three phase. This setting will prevent
Source 2 from becoming available. Level 2 controllers can control a two-utility configu-
ration for prime power. One utility is designated the
Both voltage sources have to be applied in order to preferred source. The control automatically trans-
check phase rotation. Generally, a power source fers the load between the two utilities and detects
may become out of phase rotation in new installa- alarm conditions. The exerciser clock is not avail-
tions, after a storm, or when there is generator re- able in this configuration.
wiring.
The operator can select either source as the pre-
This feature is enabled by default. To disable it, see ferred source. See the Digital Display Menu Sys-
the Digital Display Menu System section. tem section.

Transfer Inhibit Input Retransfer Inhibit Input
This feature is used to control load transfer to gen-
sets. When activated, load transfer will not take
This feature is used to prevent the ATS from auto-
place unless the Override button on the switch pan-
matically transferring the load back to Source 1 (or
el is pressed or the transfer inhibit input is disabled.
the preferred source in genset-to-genset applica-
A transfer inhibit input is set up by connecting a re- tions). When activated, load retransfer will not take
mote contact between TB2-6 and TB2-8 (see Fig- place unless the Override button on the switch pan-
ure 2-13). Closing the contact enables the feature el is pressed, the retransfer inhibit input is disabled,
and opening the contact disables it. When enabled, or Source 2 (or the backup source in genset−to−
the event is displayed on the front panel.
genset applications) fails.
This feature can also be activated through a net-
work or with the PC service tool. A jumper can be NOTE: If Source 2 (or the backup source in gen-
temporarily connected between TB2-6 and TB2-8 set-to-genset applications) fails, the Re-
to test this feature. transfer Inhibit is ignored.
Retransfer Inhibits are set up by connecting a re-

1 GND
mote contact between TB3-53 and TB3-54 (see
Figure 2-14). Closing the contact enables the fea-
2 2
ture and opening the contact disables it. When en-
3 B+ abled, the event is displayed on the front panel. For
4 RMT TB3 location inside the transfer switch cabinet, see
Figure 2-16.
5 REMOTE TEST
6 TRANSFER INHIBIT
7 LOAD SHED (OPTIONAL)

TB3
8 COMMON
TB2
FIGURE 2-13. TB2 CONNECTIONS FOR FIGURE 2-14. TB3 CONNECTIONS FOR
TRANSFER INHIBIT RETRANSFER INHIBIT

ELECTRONIC CONTROL OPTIONS
Auxiliary Relays Option
Optional auxiliary relays provide contacts for ener-

gizing external alarms and remote indicators. They
can also control equipment such as louver motors
and water pumps.
AUXILIARY
RELAYS
Connections to the auxiliary relays are made di-
rectly to the relay terminals. Figure 2-16 shows the
location of the Auxiliary Relays on the options pan-
el. The terminals accept wire sizes from one num-
ber 12 AWG wire to two number 18 AWG wires. For
TB3
connection to the screw terminal, strip the insula-
tion back 3/8 inch (10 mm).
There are two types of auxiliary relay coils (12 VDC

and 24 VDC). Table 2-1 lists the available auxiliary
relay options.
RELA
Y MODULE
All relays have two normally open and two normally
closed contacts that are rated for 6 amperes at 600
VAC (Figure 2-15).
TABLE 2-1. AUXILIARY RELAY OPTIONS
24 VDC COIL INSTALLED, NOT WIRED

FIGURE 2-16. CONTROL WIRING CONNECTIONS
24 VDC COIL EMERGENCY RELAY
24 VDC COIL NORMAL RELAY Relay Module Option
24 VDC COIL GENSET RUN RELAY
The Relay Module provides nine sets of form C
12 VDC COIL INSTALLED, NOT WIRED contacts and two sets of normally open contacts
12 VDC COIL EMERGENCY RELAY that are rated for 2 Amps at 30 VDC or 0.60 Amps at
12 VDC COIL NORMAL RELAY 120 VAC. Two sets of form C contacts and one set
12 VDC COIL GENSET RUN RELAY of normally open contacts is reserved for future
use. Connections to these relays are made at J14
and J15 on the Relay Module. The Relay Module is
located on the left inside wall of the transfer switch
enclosure. See Figure 2-16 for location in the en-
closure and Figure 2-17 for details. See Table 2-2
for relay module signals according to control type.
13 21 31 43 A1
The Source 1 and Source 2 Connected relays are
energized when their respective power sources are
available, ready to produce power, and connected
to the load.
14 22 32 44 A2
The Source 1 and Source 2 Available relays are en-
ergized when their respective power sources are
producing power.
The Test/Exercise relay is energized when the sys-

FIGURE 2-15. AUXILIARY RELAY TERMINALS tem is in test or exercise mode.

FAIL TO
OPEN / CLOSE
FAIL TO
SYNCHRONIZE
FAIL TO
DISCONNECT
LOCATION OF J15 & J14 WITH

J16
BOARD ORIENTED AS SHOWN
FIGURE 2-17. OPTIONAL RELAY MODULE

TABLE 2-2. RELAY SIGNAL MODULE The Fail to Synchronize relay is energized when
the two power sources did not come into synchron-
Relay Signal Control Type icity (frequency, voltage, phase) within a two-min-
ute limit, during a transfer between two live
Source 1 Connected Level 1 and Level 2
sources.
Source 1 Available Level 1 and Level 2
Source 2 Connected Level 1 and Level 2 The Fail to Disconnect fault is used only in
Source 2 Available Level 1 and Level 2
closed transition modes. The relay is energized
whenever the two sources remain parallel lon-
Test/Exercise Active Level 1 and Level 2 ger than a set time limit (100 milliseconds).
Load Shed Active Level 1 and Level 2
Fail to Transfer/Retransfer Level 2 The Elevator Pre-Transfer relay is energized dur-
ing the elevator signal time delay. The relay con-
Fail to Synchronize Level 2
tacts are used to provide a warning that a transfer
Fail to Disconnect Closed Transition or retransfer is about to occur. This time delay
Level 2 (TDEL) is adjustable over a range of 0 to 60 sec-
Elevator Pre-Transfer Level 1 and Level 2 onds. The default value is 0 seconds. The value is
Transfer Switch Not In Auto Level 1 and Level 2 set with the PC service tool or the digital display
when it is available (see Figure 4-15 or 4-16, de-
pending on software version).
The Load Shed relay is active when the transfer
switch has been commanded to disconnect the
load from Source 2. This feature is not available
TDEL
on transfer switches that do not possess a neu-
0.0 Seconds
tral position. For more information, see “Load
Shed Option” on see page 2-20.
FIGURE 2-18. TDEL SUB-MENU

The Fail to Transfer/Retransfer relay is energized
whenever the transfer switch does not open or The ATS Not-In-Auto relay is energized when any
close within a set time interval after the command of the previously listed conditions occur (see page
to transfer or retransfer. 2-2).

The ATS Not-In-Auto relay is energized when any (see Figure 2-19). This menu is included in the
one of the following is active: About submenus (see Figure 4-29 or 4-30).
 Motor Disconnect Switch is set to Off
 Fail-to-Disconnect event is active
 Control is locked out Load Module
OK
 Wiring harness is disconnected from J12 on
the Power Module
 Controller is set to Offline
 The Operator Release key switch is in the FIGURE 2-19. LOAD CURRENT MODULE STATUS
Unlocked (Manual) position − This only ap- SUBMENU
plies to models that include the optional ex-
ternal manual operation handle. Load Shed Option
Use number 22 to number 12 AWG wire. For con- The load shed option removes the load from the
nection to the screw terminal, strip the insulation emergency power source by driving the transfer
back 3/8 inch (10 mm). switch to the neutral position. When the signal con-
tacts open the load is transferred back to the emer-
Load Current and Power Sensor Option gency source. The load immediately transfers to
the preferred source when it is re-established.
Three-phase Level-2 controllers can include a load
current and power sensor (Current Module). The The load shed relay (K4) is mounted on the control
control senses the four load currents (three line plate (see Figure 2-20). Signals to K4 are received
currents and the neutral current), three load volt- from the relay module at J15 and J16.
ages, and three power factor angles. The control
calculates the real load power and the apparent CONTROL PLATE
load power.
The load current sensing feature is active on Level LOAD SHED POWER
2 controllers when the Current Module is installed RELAY K4 (300−1000
AMP TRANSFER
and connected to the Digital Module. Four current SWITCHES)
transformers, connected between Source 1 and 2
monitor the load current for the Current Module.
One current transformer is mounted on the neutral
cable to monitor and display neutral current. This
current can be higher than phase current with a
non-linear or harmonic producing load.
The control issues a warning when the neutral cur-

rent exceeds a user specified value between 100 RELAY
PLATE
and 150% of the rated current during a specified COVER
time period between 10 and 60 seconds.
The warning threshold (100−150%) and time delay LOAD SHED POWER
(10−60 sec) are only set with InPower. RELAY K4 (40−260
AMP TRANSFER
SWITCHES)
The status of the load current module (OK or Not
Installed) can be viewed with the digital display FIGURE 2-20. LOAD SHED RELAY MOUNTING

Battery Charger Options three fault display LEDs, and an ammeter for indi-
cation of charging current.
Originally, either a 2-amp or a 10-amp battery char-
ger was available for use with an OTPC transfer On the 10-ampere charger, three sets of (Form-C)
switch. Those battery chargers have now been re- alarm contacts (corresponding to the three fault
placed with new 2-amp and 15/12-amp battery LEDs) are also available. Using an optional alarm
chargers. Battery chargers are used with utility-to- contact harness, these contacts can be wired by
genset and genset-to-genset applications. the installer to activate other audible or visual
alarms.
When present, the status of the battery charger can
be viewed using the digital display (see Figure
Under normal operating conditions, the Low Bat
2-21). The battery charger status submenu is in-
cluded in the Statistics submenus (see Figure 4-5 and AC Fail relays are energized and the High Bat
or 4-6). relay is de-energized. In response to a Low Bat or
AC Fail condition, the appropriate normally ener-
gized relay (Low Bat or AC Fail) drops out. In re-
Battery Charger
sponse to a High Bat condition, the normally de-en-
ergized High Bat relay is energized.
Ok/Fault
FIGURE 2-21. BATTERY CHARGER STATUS

SUBMENU
When so equipped, a battery charger can be used
for charging genset starting and control batteries.
These chargers are current limiting and supply au-
tomatic constant voltages.
When the battery approaches the full charge preset

voltage, the charging current automatically tapers
to zero amperes or to a steady-state load on the
battery.
Original Float Battery Charger Options

A float-charge battery charger regulates its charge 2-AMP CHARGER 10-AMP CHARGER
voltage to continuously charge without damaging
the battery. As the battery approaches full charge, FIGURE 2-22. ORIGINAL BATTERY CHARGERS
the charging current automatically tapers to zero
amperes or to steady-state load on the battery. The battery charger may be a 10- or 2-amp supply
with an output of 12 or 24 volts. Ten amp chargers
Two battery chargers are available (see Figure contain alarm LEDs that indicate AC Power Fail-
2-22). One battery charger is rated for 10 amperes ure, and Low or High Battery Voltage faults. Option-
at 12 or 24 VDC. The other battery charger is rated al wiring harness brings signals out to the terminal
for 2 amperes at 12 or 24 VDC. block for easy customer connections.
The 2-ampere battery charger has an ammeter to Float Voltage Adjustments for:
indicate charging current and a fuse to protect the
battery charger circuit. 12 volt 24 volt
Lead Acid Batteries 13.2 volts 26.4 volts
The 10-ampere battery charger has three fuses
(two on the AC input and one on the DC output), NiCad Batteries 14 volts 28 volts

Current Float Battery Charger Options Control Panel
A float-charge battery charger regulates its charge The 2-amp charger control panel includes a digital
voltage to continuously charge without damage to display, a RESET button, and an LED status indica-
the battery. As the battery approaches full charge, tor (see Figure 2-25).
the charging current automatically tapers to zero  The 2-line x 16-character digital display dis-
amperes or to steady-state load on the battery. plays menus and faults.
 The RESET button is used to select menu op-
Two battery chargers are available (see Figure tions and to clear fault messages.
2-23). One battery charger is rated for 2 amperes at  The status LED displays the appropriate color
12 or 24 VDC. The other battery charger is rated for for the following conditions.
15 amperes at 12 VDC or 12 amperes at 24 VDC. − Green − On solid indicates unit is charg-
ing
− Red − On solid indicates a fault condition.
The fault number is shown on the digital
display.
2-AMP CHARGER 15-AMP (12 VOLT), 12-AMP

(24 VOLT) CHARGER
FIGURE 2-23. CURRENT BATTERY CHARGERS

FIGURE 2-24. 2-AMP POWERCOMMAND BATTERY
CHARGER
2-Amp Battery Charger
The 2-ampere battery charger (see Figure 2-24)
has a 5 amp DC output circuit breaker switch on the
front of the battery charger. The charger also in-
cludes a 5 amp AC fuse to protect the battery char-
ger circuit.
Under normal operating conditions, the Low Bat

and AC Fail relays are energized and the High Bat RESET DIGITAL LED STATUS
BUTTON DISPLAY INDICATOR
relay is de-energized. In response to a Low Bat or
AC Fail condition, the appropriate normally ener- FIGURE 2-25. 2-AMP CHARGER CONTROL PANEL
gized relay (Low Bat or AC Fail) drops out. In re-
sponse to a High Bat condition, the normally de-en- Battery Charger Configuration
ergized High Bat relay is energized. The RESET button on the control panel (see Figure
2-25) is used to configure the battery charger for
ATTENTION: To avoid a possible battery failure, the correct battery voltage. (More information on
make sure the application does not draw more than Setup menus is included in the Battery Charger
two amps. Operator’s Manual.)

15/12-Amp Battery Charger − Green − On solid indicates unit is charg-
ing
There are two types of 15/12-amp PowerCom-
mand battery chargers (see Figure 2-27). All − Amber − On solid indicates Equalizing
15/12-amp battery chargers have a 20 amp DC cir- − Red − On solid indicates a fault condition.
cuit breaker switch on the front of the battery char- The fault number is shown on the digital
ger. The 120, 208, and 240 VAC battery chargers display.
include two 10 amp AC circuit breaker switches
and a circuit breaker guard, while the 277, 380,
416, and 600 VAC battery chargers include two AC
fuse holders.
Control Panel
The 15/12-amp charger control panel includes a

digital display, a Reset button, and an LED status
indicator (see Figure 2-26).
 The 2-line x 16-character digital display dis-
plays menus and faults.
 The Reset button is used to select menu op- RESET DIGITAL LED STATUS
BUTTON DISPLAY INDICATOR
tions and to clear fault messages.
 The status LED is displays the appropriate col- FIGURE 2-26. 15/12-AMP CHARGER CONTROL
or for the following conditions. PANEL
STATUS
CONTROL LED
PANEL
120, 208, AND 240 VAC

BATTERY CHARGERS
277, 380, 416, 480, AND 600 VAC

BATTERY CHARGERS
CIRCUIT
BREAKER
GUARD
FAULT ALARM
OUTPUT
CONNECTOR 20 AMP DC OUTPUT
CIRCUIT BREAKER SWITCH
(SHOWN IN “ON” POSITION)
FUSE
HOLDERS
OPTIONAL BATTERY
TEMPERATURE
SENSOR CONNECTOR
FIGURE 2-27. 15/12-AMP POWERCOMMAND BATTERY CHARGERS

Optional Battery Temperature Sensor relay is de-energized. In response to a Low Bat or
AC Fail condition, the appropriate normally ener-
A connector for an optional battery temperature gized relay (Low Bat or AC Fail) drops out. In re-
sensor is located on the front of the battery charger. sponse to a High Bat condition, the normally de-en-
When used to monitor battery temperature, the op- ergized High Bat relay is energized.
tional battery temperature sensor is connected
from the battery charger to the positive terminal of
The contacts are rated for 4 amperes at 120 VAC or
the battery. A fault message (fault code 2263) is
30 VDC. Connections to these contacts are made
displayed if the battery temperature is too high
at terminals 41-42-43 (AC failure), 44-45-46 (high
(reaches 131 degrees F (55 degrees C)).
battery voltage), and 47-48-49 (low battery volt-
Battery Charger Configuration age) of TB3. See Figure 2-16 for the location of TB3
on the option panel.
The RESET button on the control panel (see Figure
2-26) is used to configure the battery charger. Use number 22 to number 12 AWG wire. For con-
(More information on Setup menus is included in nection to the screw terminal, strip the insulation
the Battery Charger Operator’s Manual.) back 3/8 inch (10 mm).
 Battery Voltage and Type − The battery
charger must be correctly configured, using The Level 1 and Level 2 Digital Modules have an
the Setup menus, for the correct battery volt- input dedicated to monitor the AC Line failure on
age and type before it is connected to the the battery charger. This input is located at J27-23
battery. The battery voltage can be set for 12 and activated when grounded. (As of this printing,
or 24 VDC (default = 12 VDC). The battery this input is only available at J27-23.)
type can be set for Lead-Acid, Gel, or AGM
batteries (default = Lead-Acid).
TB3
NOTE: A factory installed battery charger is
set up for the proper DC battery volt- AC C
age requested on the production or- LINE NC
der, with the Lead-Acid battery type FAILURE NO
selected as the default.
HIGH C
 Battery Equalization − Battery equalization BATTERY NC
is available for lead-acid batteries that are VOLTAGE NO
completely charged, using the Equalize Bat- LOW C
tery screen in the Setup menus. When bat- BATTERY NC
tery equalization is in process, the LED sta-
VOLTAGE NO
tus indicator turns amber.
NETWORK DATA
Battery Charger Alarm Contacts Option (OPTIONAL) − USE DATA1
TWISTED PAIR
The optional 10-ampere battery charger can in- WIRING DATA2
clude three sets of Form-C relay contacts, as an
additional option.
Under normal operating conditions, the Low Bat FIGURE 2-28. BATTERY CHARGER ALARM
and AC Fail relays are energized and the High Bat CONTACTS AND NETWORK CONNECTIONS

PowerCommand Network Interface Option
The PowerCommand network interface option in-

cludes a PowerCommand Network Communica-
tions Module (NCM) that provides a connection to
the PowerCommand network. The module is Lon-
Works compatible for integration into customer
monitoring strategy. Refer to the Network Installa-
tion and Operator’s Manual (900-0366 for TP-78
networks or 900−0529 for FT-10 networks) for net-
work details.
With a PowerCommand network interface, B+ from

the genset is brought into the transfer switch by a
lead connected from TB2-3 on the power panel as-
sembly of the transfer switch to J27-21 on the digi-
CURRENT
tal module. PRODUCTION
The Network Interface Module is only enabled with EARLY

the PC service tool. PRODUCTION
For installations that include an NCM, stranded FIGURE 2-29. NETWORK COMMUNICATIONS
twisted pair network cable is connected to the left MODULE (NCM)
side of terminals TB3-51 and TB3-52 (see Figures
2-16, 2-28, and 2-30). The NCM is located on the TB3
left side of the digital module (see Figure 2-5).
NOTE: Early production NCMs included two Lithi-

um batteries and a battery hold-down
bracket. Current production NCMs no lon- FIGURE 2-30. NETWORK COMMUNICATIONS
ger use batteries (see Figure 2-29). MODULE CONNECTIONS
RESET BUTTON (S2)

SERVICE BUTTON (S3)
“SVC” LED (DS1)
NODE “OK” LED (DS3)
NETWORK ERROR
LED (DS2) NETWORK
COMMUNICATIONS
NETWORK ACTIVITY MODULE (NCM)
LED (DS5)
FIGURE 2-31. BUTTON AND LED LOCATIONS ON NETWORK COMMUNICATIONS MODULE

The status of the NCM (OK, Not Installed, Not En-
abled, or Not Available) can be viewed with the digi-
Load Sequencer
tal display (see Figure 2-32). This menu is included
Enabled/Disabled
in the About submenus (see Figure 4-29 or 4-30).
LOAD SEQUENCER ENABLE/DISABLE
Network Module Sequence Activation

OK Transfer/Re-transfer/All
SEQUENCE ACTIVATION
FIGURE 2-32. NETWORK MODULE STATUS

SUBMENU Sequence Length
8
Self-Installation − The current Network Commu-

SEQUENCE LENGTH
nications Module being used on OTPC transfer
switches includes a self-installation feature. To
self-install, press and hold the Service button (S3) Output 1 Time Delay
(see Figure 2-31) for at least two seconds until the 5 Second
Node “OK” LED (DS3) begins flashing.
OUTPUT 1 TIME DELAY
Network Sequencer
Output 2 Time Delay
The Sequencer feature allows the user to send a 5 Second
predetermined sequence of network event an-
nouncements. The announcements are sent in a
OUTPUT 2 THROUGH 8 TIME DELAY
timed, sequential order and are used to turn ATS
loads off and on. When used, a few seconds should
be allowed between load steps to allow the genera- FIGURE 2-33. SEQUENCER SUBMENUS
tor voltage and frequency to stabilize.
The Sequencer submenus (see Figure 2-33), avail-

SWEST GEN#1 0kW
able through the digital display, can only be viewed
Warning Lo Batt
if the NCM is installed and enabled. These menus
allow the user to enable/disable the feature, set the
operational mode, activate up to eight relay output GENERATOR STATUS EXAMPLE
signals, and set an output time delay from 0 to 60
seconds for each of the outputs. Additional infor-
mation on how to adjust these values is included in SWEST ATS#1 450kW
Figure 4-28. Auto S1=ON S2=NA
ATS STATUS EXAMPLE

Network System Device Status
If an NCM is installed, the user can view the status Master >###0 kW
of up to 32 LonWorks networked devices through Shutdwn N=On, E=NA
the digital display. The status of networked gen-
sets, additional ATSs, and the Master Control (if
connected) can be viewed. Examples of status me- MASTER CONTROL STATUS EXAMPLE
nus are shown in Figure 2-34. For additional infor-
mation on these menus, see Figure 4-31. FIGURE 2-34. SYSTEM SUBMENUS

Load Shed Option tion. Typically, Open Transition Transfer
Switches with Sync Check do not have a Neu-
The optional Load Shed function is used to discon- tral Position for their contacts and must not be
nect the load from an available Source 2 in order to used to execute Load Shedding.
reduce the power consumed from that source.
When the load shed function is initiated, the trans-
fer switch is moved to the neutral position.
1 GND
When load shedding is active and power Source 1
returns, the control immediately retransfers to pow- 2 2
er Source 1. 3 B+
If the load shed signal is removed before power 4 RMT

Source 1 returns, the switch transfers back to pow- 5 REMOTE TEST
er Source 2.
6 TRANSFER INHIBIT
The load shed relay (K6 − see Figure 2-16) is 7 LOAD SHED
mounted on the relay plate. Signals to K6 are re-
ceived from the relay module at J15 and J16. 8 COMMON
Load shed is set up by connecting a remote contact

between TB2-7 and TB2-8 (see Figure 2-35). The TB2
Load Shed feature can be enabled or disabled with FIGURE 2-35. TB2 CONNECTIONS FOR LOAD
the PC service tool. SHED OPTION
This feature can also be activated through a net- Load Sequencing Option
work or with the PC service tool. A jumper can be
temporarily connected between TB2-7 and TB2-8 Controllers can include up to eight timed network
to test this feature. variables to use for turning on loads in sequence af-
ter a transfer, a retransfer, or both. The Network
WARNING Executing load shedding on trans- Communications Module (NCM) must be installed.
fer switches that are not designed for this op- Each variable can be delayed up to 60 seconds af-
tion can result in severe personal injury, and ter the preceding variable. The network variables
equipment or property damage. Load Shed- are intended to activate relays on the Network Digi-
ding can only be executed in Transfer Switches tal Input/Output Module (DIM). The DIM is located
capable of Programmed Transition or Closed remotely from the transfer switch. See Figure 4-28
Transition because the Source 1 and Source 2 for information on how to set up load sequencing
contacts can be positioned in the Neutral Posi- values using the digital display.

TRANSFER SWITCH ASSEMBLY switch is actuated when the transfer switch is in the
Source 2 position. The contacts are wired to termi-
The ATS (Figure 2-5) opens and closes the con- nal block TB1.
tacts that transfer the load between Source 1 and
Source 2. The switch is mechanically interlocked to The auxiliary contacts have current ratings of 10
prevent simultaneous closing to both power amperes at 250 VAC.
sources. The main parts of the switch discussed
Motor Disconnect Switch
here are:
 Contact assemblies The Motor Disconnect toggle switch, on the Relay
Assembly, enables and disables the linear actua-
 Linear actuator tor. This switch is only accessible from inside the
 Motor Disconnect switch enclosure. The Not In Auto LED on the front panel
indicates the state of this switch. It is lit when the
 Auxiliary contacts switch is in the Off position. (Other ATS conditions
also light this indicator: See the description of the
Contact Assemblies Not in Auto indicator in the Cabinet section.) Place
The switch has either three or four poles. Three the switch in the Auto position to enable the linear
pole ATSs are provided with a neutral bar. The con- actuator. Place the switch in the Off position to dis-
tact assemblies make and break the current flow. able the linear actuator.
When closed to either Source 1 or Source 2, the
REMOVING AND REPLACING
contacts are mechanically held. A mechanical in-
terlock prevents closing to both power sources at ELECTRONIC CONTROL COMPONENTS
the same time. WARNINGAC power within the cabinet and
Linear Actuator the rear side of the cabinet door presents a
shock hazard that can cause severe personal
The linear actuator is a linear induction motor that injury or death. Disconnect connector J1/P1
moves the contact assemblies between the con- before working on the electronic control sys-
tacts of Source 1 and Source 2. Linear actuator op- tem.
eration is initiated automatically by the ATS. Manu-
al operation of the switch is also possible. Refer to Disconnecting J1/P1 removes all power to the
Manual Operation. door.
Auxiliary Contacts Be sure to remove all power before replacing elec-

tronic control modules and components. This in-
Auxiliary contacts are provided on the Source 1 cludes removing one of the two Lithium batteries
and Source 2 sides of the transfer switch. They are from the digital display module. The battery can be
actuated by operation of the switch during transfer replaced after replacing or adding new compo-
and retransfer. The Source 1 auxiliary contact nents. No special tools are required to remove and
switch is actuated when the transfer switch is in the replace control system components. Be sure to use
Source 1 position. The Source 2 auxiliary contact all of the hardware when remounting components.

THIS PAGE LEFT INTENTIONALLY BLANK

3. Operation
FUNCTIONAL PROGRAMS If Source 1 has an interruption while the genset is
exercising without load, the ATS transfers the load
Programmed Transition to the genset.
All controllers have a push-button switch on the
Program Transition introduces a delay (TDPT) dur-
digital module that enables and disables the exer-
ing transition of the switch. Programmed transition
ciser clock (Figure 6-1). The Real-Time clock must
stops the switch in the neutral position for an ad-
be set before exercise programs are entered.
justable interval of time. In this position, the load is
not connected to either Source 1 or 2. This delay al- For utility-to-genset configurations, the exercise
lows residual current from inductive loads to decay routine initiates genset start and run cycles at spe-
to an acceptable level before transfer is completed. cified intervals for specified durations. The exer-
cise routine is not used in utility-to-utility or genset-
The parameters are adjustable. The length of time to-genset configurations (see Control Modes −
that the ATS is in the neutral position can be ad- Generator-to-Generator).
justed from 0 to 60 seconds in 1 second incre-
ments. The default value is 0 seconds. The proper Refer to Section 4: Digital Display Menu System,
adjustment is a function of the load. This feature is for details on setting the clock and programming
enabled by default. The values are set with PC ser- the exercise routines.
vice tool or the digital display.
Test With or Without Load
Transfer Times The operator can test the ATS, generator, and pow-
er system automatically. The operator can either
The controller senses and records the time it takes transfer the load during the test or test the genera-
for the transfer switch to break from one source and tor only. Both hardware means (switch panel) and
reconnect to the other source. (Transfer times are software means (PowerCommand network) input
not recorded if Programmed Transition delay is in can activate an automatic test sequence.
use.)
Testing the system with or without the load is setup
Generator Exercise using PowerCommand or the PC service tool.
Programmable generator exercises and exercise To test using the Test Button:
exceptions are generally programmed to be recur-
1. Press and hold the button for at least 2 sec-
ring. They can be programmed from the PC service
onds. The Test Exercise LED will begin flash-
tool or the digital display when it is available.
ing and the test sequence will begin.
Level 1 controllers include two programmable gen- 2. Press the Test button again to deactivate the
erator exercises and two programmable exercise test. The Test/Exercise LED will flash once and
exceptions. While all events can be set using the the test end sequence will begin.
PC service tool, only one exercise and one exer-
cise exception can be set with the digital display. NOTE: The Test button does not function unless
the Front Panel Security Switch is in the Program
Level 2 controllers include eight programmable position.
generator exercises and eight programmable exer- To Test using PowerCommand or InPower soft-
cise exceptions. While all events can be set using ware, refer to the documentation supplied with
the PC service tool, only two exercises and two ex- those packages.
ercise exceptions can be set with the digital display.
Transfer/Re-Transfer Inhibits
Run the generator set for at least 30 minutes once
each week, with at least 50 percent load (if pos- Transfer Inhibit setup is used to control load trans-
sible). fer to gensets. When activated, load transfer will

not take place unless the Override button is Note: TDESa and TDECa are for the Source 2 gen-
pressed. When Transfer or Re-transfer Inhibit is set and TDESb and TDECb are for the Source 1
enabled, the Not In Auto LED and event displays on genset.
the front panel.
Use the Time Delay sub-menus under Setup or the
Re-transfer inhibit is used to prevent the controller PC Service tool to change the settings.
from automatically re-transferring the load back to
Source 1. Some operators prefer to manually Time Delay Engine Start (TDESa, and
transfer the load, using the Override button, once TDESb)
they are satisfied Source 1 is stable.
This brief time delay prevents the generator set
NOTE: If Source 2 fails, the Re-transfer inhibit is ig- from starting during short power interruptions. Tim-
nored.
ing starts at the Source 1 power interruption. If the
Transfer inhibits are setup using the PC Service duration of interruption exceeds the delay time, the
tool and a remote switch inside the cabinet con- control system starts the generator. This delay is
nected to TB2. adjustable from 0 to 15 seconds in 1 second incre-
ments on Level-1 controls and from 0 to 120 sec-
Real-Time Clock onds in 1 second increments on Level-2 controls.
The default value is 3 seconds for both. The value
All controllers have a real-time clock that keeps is set using the PC service tool or the digital display
track of the time and date. This clock is year 2000 when it is available.
compliant. The controller uses the real-time clock
to time and date stamp all events, and records ac- For genset-to-genset applications, TDESa is the
cumulated Run-time for each power source. start time delay to start Source 2 genset and
TDESb is the start time delay to start Source 1 gen-
NOTE: The clock is not set at the factory. To set the
clock, use the digital display or PC Service tool.
set.
For utility-to-utility applications, TDESa and

If the Lithium batteries on the Digital Board go com-
TDESb are not available.
pletely dead, the clock will need to be reset.
TIME DELAYS
TDESa
Time Delays
3.0 Seconds
All the time delays are factory set and are adjust-
able through the front panel display. The factory
settings are: Used only in Level 2 Genset-to-Genset
applications
TDNE 10 SEC
TDEN 600 SEC TDESb
TDESa 3 SEC 3.0 Seconds
TDECa 600 SEC

TDESb 3 SEC
TDECb 600 SEC FIGURE 3-1. TDESa AND TDESb SUBMENUS

Time Delay Engine Cooldown (TDECa,
and TDECb)
TDNE
10.0 Seconds
This delay maintains availability of the genset for
immediate reconnection in the event the normal
source fails shortly after retransfer. It also allows
gradual genset cool-down by running unloaded. FIGURE 3-3. TDNE SUBMENU
The delay is adjustable from 0 to 30 minutes in 1
minute increments. The default value is 10 min- Time Delay Emergency to Normal (TDEN)
utes. It begins timing when the load has retrans- This delay allows the Source 1 to stabilize before
ferred to Source 1. At the end of the delay, the stop retransfer. Delay begins the moment Source 1 line
signal is sent to the generator set. The value can be voltage and frequency return to specified values.
set using the PC service tool or the digital display After the delay, the ATS retransfers the load to
when it is available. Source 1. It has an adjustable range of 0 to 30 min-
utes in 1 minute increments. The default value is 10
For genset-to-genset applications, TDEC-A is the minutes. The value is set using the PC service tool
stop time delay to stop Source 2 genset and TDEC- or the digital display when it is available.
B is the stop time delay to stop Source 1 genset.
TDEN is the delay from backup source to preferred
For utility-to-utility applications, TDEC-A and source in utility-to-utility applications.
TDEC-B are not available.
TDNE
10.0 Seconds
TDECa
10.0 Minutes
FIGURE 3-4. TDNE SUBMENU

Used only in Level 2 Genset-to-Genset Time Delay Programmed Transition
applications
(TDPT)
TDECb This delay introduces a pause during transfer to al-
10 Minutes low residual voltage from inductive loads to decay
to an acceptable level. The load is not connected to
either source during this time while voltage is trans-
ferred to a neutral position. The adjustable range is
FIGURE 3-2. TDECa AND TDECb SUBMENUS 0 to 60 seconds. The time delay begins before
transfer, when both Sources are available. The de-
Time Delay Normal to Emergency (TDNE) fault value is 0. The value can be set using the PC
service tool or the digital display when it is avail-
This brief time delay allows the generator set to sta- able.
bilize before the load is applied. This delay begins
when Source 2 (typically the generator) voltage
and frequency reach the settings of the control. Af-
TDPT
ter the delay, the ATS transfers the load to Source 0.0 Seconds
2. It has an adjustable range of 0 to 120 seconds in
1 second increments. The default value is 10 sec-
onds. The value is set using the PC service tool or
the digital display when it is available. FIGURE 3-5. TDPT SUBMENU
Elevator Time Delay (TDEL)

TDNE is the delay from preferred source to backup
source in utility-to-utility and genset-to-genset ap- Used in elevator applications, this delay sets a time
plications. to wait for an elevator pre-transfer signal. This sig-

nal allows the elevator to come to a complete stop Sync Check or when a Programmed Transition is
before the switch transfers. The adjustable range is used and the Programmed Transition time delay is
0 to 60 seconds. The time delay begins when a zero.
transfer or retransfer signal signal has been sent to
The controller also keeps track of closed transition
the relays. The default value is 0. The value can be
transfer times.
set using the PC service tool or the digital display
when it is available.
Avg OT Transfer
nnn msec
TDEL
0.0 Seconds
AVERAGE OPEN TRANSITION TRANSFER TIME
Avg CT Transfer
FIGURE 3-6. TDEL SUBMENU
nnn msec
Transfer Times
AVERAGE CLOSED TRANSITION TRANSFER TIME
The controller senses and records the time it takes
for the transfer switch to break from one source and
reconnect to the other source (see pages 4-6 and Number of Transfers
4-7). nnn
The controller keeps track of open transition trans-

fer times and provides an average open transition TOTAL NUMBER OF TRANSFERS
transfer time. The controller records the transfer
time if the transition mode is an open transition with FIGURE 3-7. TRANSFER SUBMENUS

SENSORS
Under-Voltage Sensing S1 UV Dropout
90%
All controls include under-voltage sensors for
Source 1 and Source 2. When a sensor detects a
UNDER-VOLTAGE SENSOR DROP-OUT VOLTAGE
low voltage condition over a specified time period, it
initiates a transfer. When the source voltage re-
turns to an acceptable value again, the sensor initi-
S1 UV Pickup
ates a retransfer.
90%
These parameters are adjustable. The under-volt-

age sensing range for a falling voltage (drop-out) is UNDER-VOLTAGE SENSOR PICKUP
75 to 98% of the pick-up voltage setting. The de-
fault value is 90%. The pick-up range for a rising
voltage is 85 to 100% of the nominal voltage set- S1 UV Time Delay
point. The default value is 90%. The adjustable 0.5 Seconds
range for the time delay period is 0.1 to 1.0 seconds
in 0.1 second increments. The default delay time is
0.5 second. These values are set with the PC ser- UNDER-VOLTAGE DROP-OUT TIME DELAY
vice tool or the digital display (see Figure 3-8). See
Figure 3-9 for an example using the default values. FIGURE 3-8. UNDER-VOLTAGE SENSING
SUBMENUS
NOTE: In utility-to-genset applications, it may be
necessary to increase the under-voltage dropout Example using Default Settings
time delay in order to allow for the genset recovery for Nominal Voltage of 240 VAC
time after load acceptance.
Drop-out Pick-up Nominal
Setting Setting Setpoint
(194V) (216V) (240V)
VOLTS
90% of 90% of
Pick-up Nominal
FIGURE 3-9. UNDER-VOLTAGE SENSING

Over-Voltage Sensing
All controls include over-voltage sensors for S1 OV Dropout
Source 1 and Source 2 that can be disabled and 110%
not used. When a sensor detects a high voltage
condition over a specified time period (delay), it ini-
tiates a transfer. When the source voltage falls to OVER-VOLTAGE DROP-OUT
an acceptable value again, the sensor initiates a re-
transfer.
S1 OV Pickup
These parameters are adjustable. The over-volt- 95%
age sensing range (drop-out) for a rising voltage is
105 to 135% of the nominal voltage setpoint. The
default value is 110%. The pick-up range for a fal- OVER-VOLTAGE SENSOR PICKUP
ling voltage is 95 to 100% of the drop-out setting.
The default value is 95%. The adjustable range for
the delay time period is 0.5 to 120.0 seconds in 1 S1 OV Time Delay
second intervals. The default delay time is 3.0 sec- 3.0 Seconds
onds. The over-voltage sensing feature is enabled
by default. These values are set with the PC ser-
vice tool or the digital display (see Figure 3-11). See OVER-VOLTAGE DROP-OUT TIME DELAY
Figure 3-10 for an example using the default val-
ues. This feature can also be disabled.
S1 OV Enable
Example using Default Settings Enabled/Disabled

for Nominal Voltage of 240 VAC
OVER-VOLTAGE SENSING ENABLE
Nominal Pick-up Drop-out
Setpoint Setting Setting
(240V) (251V) (264V) FIGURE 3-11. OVER-VOLTAGE SENSING
SUBMENUS
VOLTS
95% of 110% of
Drop-out Nominal
FIGURE 3-10. OVER-VOLTAGE SENSING

Frequency Sensing
All controls include frequency sensors for Source 1 Nominal Frequency
and Source 2 that can be disabled and not used. 60.0
When a sensor detects a high or low frequency
condition over a specified delay time period, it initi- NOMINAL FREQUENCY SETTING
ates a transfer. When the frequency returns to an
acceptable value again, the sensor initiates a re-
transfer. Frequency Pickup
10%
These parameters are adjustable. The nominal fre-
quency can be set between 45.0 and 60.0 Hz in
FREQUENCY BANDWIDTH PERCENTAGE
0.1 Hz increments. The default frequency is 60 Hz.
The acceptable frequency bandwidth (pick-up) is
5 to 20% of the nominal frequency setpoint. The
Frequency Dropout
default value is 10%. The drop-out frequency is 1 to
1%
5% beyond the pick-up. The default value is 1%.
The range for the delay time period is 0.1 to 15 sec-
onds. The default delay time is 1.0 second. The fre- DROPOUT FREQUENCY PERCENTAGE
quency sensing feature is enabled by default. See
Figure 3-12 for an example using the default val-
Frequency Delay
ues.. Figure 3-13 shows the frequency submenus
5.0 Seconds
available with the digital display. These values are
set with the PC service tool or the digital display.
This feature can also be disabled. FREQUENCY TIME DELAY
Example using Default Settings S1 Frequency Sensor

for Nominal Frequency of 60 Hz Enabled/Disabled
60 Hz
FREQUENCY SENSING ENABLE
FIGURE 3-13. FREQUENCY SENSING SUBMENUS
Pick-up Frequencies
54 Hz 66 Hz
Drop-out Frequencies
53.5 Hz 66.7 Hz
FIGURE 3-12. FREQUENCY SETTING

Voltage Imbalance Sensor Phase Rotation Sensor
Three phase Level-2 controllers include a voltage Three phase Level 2 controllers include a phase
imbalance sensor for both Source 1 and Source 2. rotation sensor. This feature monitors the phase
This feature informs the operator when there is sig- rotation of the source opposite from the connected
nificant voltage imbalance between the phases of source. When the alternate source is out of phase
Source 1 or Source 2. This feature is used for rotation with the connected source, transfer is in-
equipment protection. hibited. This generally occurs on new installations
or after storm damage or generator rewiring. This
A voltage imbalance is typically caused by severe feature protects against equipment damage by
single phase loading. The sensor indicates a failure preventing transfer to a source that is out of phase.
when the maximum deviation from the average This feature is required in fire pump applications.
voltage is greater than a user-specified value be-
tween 2 and 10% (dropout) of the average voltage CAUTION Level 1 controls do not support
in 1% increments. The pickup value is fixed at 10% three-phase sensing on Source 2. Do not select
of the dropout. The time delay for the imbalance the three-phase option for the Source 2 Sens-
sensor drop-out is adjustable (2−20 seconds). ing adjustment with Level 1 controls, even if the
system is three phase. This setting will prevent
This sensor can be enabled using the the PC ser- Source 2 from becoming available.
vice tool or the digital display Setup submenus.
This sensor is inactive for single phase systems Both voltage sources have to be applied in order to
and indicates no failures. To prevent nuisance check phase rotation. Generally, a power source
faults, the setting can be increased up to 10% of the may become out of phase rotation in new installa-
nominal voltage. Figure 3-14 shows the voltage im- tions, after a storm, or when there is generator re-
balance submenus available with the digital dis- wiring.
play.
This feature is enabled by default. The sensor can
be disabled using the PC service tool or the digital
display Setup submenus. Figure 3-15 shows the
Imbalance Dropout phase rotation sensing submenu available with the
4%
digital display.
IMBALANCE PICKUP PERCENT OF DROPOUT
Phase Rotation
Imbalance Delay Enabled/Disabled
5.0 Seconds
VOLTAGE IMBALANCE TIME DELAY FIGURE 3-15. PHASE ROTATION SENSING

SUBMENU
S1 Imbalance Sensor Loss of Single Phase Sensor

Enabled/Disabled
Three phase Level 2 controllers include a loss of

VOLTAGE IMBALANCE ENABLE single phase sensor. This feature initiates a trans-
fer from a source that has lost a single phase and
FIGURE 3-14. VOLTAGE IMBALANCE SUBMENUS prevents a transfer to a source that has lost a single
phase. This is generally caused by a single phase
to line ground or open. The controller indicates a
fault when the relative phase angle between any
line-to-line phase angle drops to less than 90 de-
grees. This feature is mainly used to protect three
phase devices, such as motors.

This sensor can be enabled using the PC service available. The sync check sensor menus available
tool or the digital display Setup submenus. This with the digital display are shown in Figure 3-17.
sensor is inactive for single phase systems and in-
dicates no failures. Figure 3-16 shows the loss of
phase sensing submenu available with the digital
Frequency Bandwidth
display.
n.n Hz
SYNC CHECK FREQUENCY BANDWIDTH

S1 Loss of Phase
Enabled/Disabled
Voltage Window
nn.n volts
FIGURE 3-16. LOSS OF SINGLE PHASE SENSING

SUBMENU SYNC CHECK VOLTAGE DIFFERENCE
Sync Check Sensor

Manual Offset
If enabled, the Sync Check sensor overrides pro- nn msec
grammed transition whenever transferring be-
tween two live sources. If only one power source is
TRANSFER TIME MANUAL OFFSET
available, programmed transition overrides the
Sync Check sensor.
FIGURE 3-17. SYNCHRONICITY PARAMETER
SUBMENUS
Sync Check is used to determine when both
sources of power are within specified tolerances of Another feature included with controls that have a
frequency, voltage, and relative phase difference. If Sync Check sensor is the Return to Programmed
both sources are within this range, a fast or syn- Transition. If the two sources fail to synchronize
chronized transfer occurs. within two minutes, a Failed to Synchronize event
occurs. If the Return to Programmed Transition
Synchronicity parameters are adjustable. The fre- feature is enabled, the control reverts to transfer-
quency bandwidth range is from 0.1 to 1.0 Hz. The ring the transfer switch to the programmed transi-
default value is 1.0 Hz. The frequency difference tion mode. This feature can be enabled with the PC
between the sources must be equal to or less than service tool or with the digital display.
the set value in order for transfer to occur. The volt-
age window is from 5 to 25 volts. The default value
is 10 volts. The average voltage difference be- Return PT Enable
tween the two sources must be equal to or less than Enabled/Disabled
the set value in order for transfer to occur. The
manual offset range is from −25 to +25 millisec-
onds. The default value is 0 milliseconds. The
FIGURE 3-18. RETURN TO PROGRAMMED
transfer switch controller measures non-pro- TRANSITION SUBMENU
grammed transition transfer times from one source
to another. It takes into account relay coils and so- The transfer switch mode setting can be changed
lenoids energizing. These values can be set with with the PC service tool or with the digital display, if
the PC service tool or with the digital display, if available.

GENERATOR TESTS, EXERCISES, AND Menu System section or the PC service tool for
EXERCISE EXCEPTIONS details).
The Test With/Without Load variable must
Test With or Without Load be set to the With Load value in order to test
with load.
The operator can test the transfer switch, genera-
tor, and power system locally. The operator can 2. Press and hold the Test switch for two sec-
transfer the load during the test or only test the gen- onds. The generator set starts after the start
erator. Both hardware means (switch panel push time delay and assumes the load after the
button) and software means (PowerCommand net- transfer time delay.
work) can activate a test sequence. See Figure
3. At the end of the test period, press the Test
3-19 for information on how to set the Test button
switch again briefly. To bypass the retransfer
on the front panel to test with or without load using
time delay and cause immediate load retran-
the digital display.
sfer, press the Override switch. The generator
stops after the stop engine cooldown time
delay.
Test
With/Without Load
Real-Time Clock
All controllers have a real-time clock that keeps
track of the time and date. The controller uses the
FIGURE 3-19. TEST WITH OR WITHOUT LOAD real-time clock to time and date-stamp all events.
SUBMENU Descriptions of all events are included in Section 5.
NOTE: The Test button does not function unless NOTE: The clock is not set at the factory. To set the
the Front Panel Security Switch is in the clock, use the PC service tool or the digital
Program position. display.
To Test using PowerCommand or InPower soft- The clock menus available with the digital display
ware, refer to the documentation supplied with are shown in Figure 3-20. For information, see Fig-
those packages. ure 4-27.
Generator Set Start Test Without Load

This test is used with utility-to-genset applications Date:
only. Day mo/dd/yyyy
1. Verify that the transfer switch is set to Test DATE

Without Load (see Figure 4-17 in the digital
display Menu System section or the PC ser- Time:
vice tool for details). hh:mm:ss
The Test With/Without Load variable must
TIME
be set to the Without Load value in order to
test without load.
2. Press and hold the Test switch for two sec- Daylight Saving
onds. The generator set starts and runs. Enabled/Disabled

3. At the end of the test period, press the Test DAYLIGHT SAVINGS ENABLE/DISABLE
switch again briefly. The generator stops.
Generator Set Start Test With Load FIGURE 3-20. CLOCK SUBMENUS
This test is used with utility-to-genset applications To set the clock using the digital display:
only.
1. Using the digital display, navigate to the Setup
1. Verify that the transfer switch is set to Test With submenu (see Figure 4-8) and enter the pass-
Load (see Figure 4-17 in the Digital Display word (574).

2. Navigate to the Clock submenu (see pages Programmable Generator Set Exercises
4-10 and 4-38) and program the clock.
Programmable generator exercises and exercise
a. Set the date − Month (January = 1, Decem- exceptions are generally programmed to be recur-
ber = 12), Date (1−31), and Year (1−9999). ring. They can be programmed from the PC service
tool or the digital display.
b. Enter the time − Hours (0−23), Minutes
(0−59, and Seconds (0−59). Generator set exercising and Testing are only
available with utility-to-genset applications. For
utility-to-genset configurations, the exercise rou-
c. Enable/Disable Daylight Savings time. Ad-
tine initiates genset start and run cycles at specified
justs clock setting for daylight savings time.
intervals for specified durations.
The default is “Disabled.”
The real-time clock (see page 3-10) must be set be-
The Daylight Savings Time program is fore exercise programs are entered. The clock can
set for North America. be set using the PC service tool or the digital dis-
− The first Sunday in April moves the play.
time forward one hour.
The control should be set up to exercise the gener-
− The last Sunday in October moves the ator set for at least 30 minutes once every four
time back one hour. weeks with at least 30 percent of rated load (if pos-
sible). If you do not want to use the exerciser, use
If you are anywhere outside of North
the Test switch on the front panel to manually test
America, Daylight Savings Time should
the generator set.
be disabled.
The exerciser can be programmed for specified ex-
NOTE: If the batteries are weak or not in place dur- ercise periods and is used to exercise the genera-
ing a power failure, the clock will need to be
tor set automatically with or without load. If Source
reset.
1 has an interruption while the generator set is ex-
Sleep Mode ercising without load, the automatic transfer switch
transfers the load to the generator set.
After a period of screen inactivity (35 minutes), the All controllers have a push-button switch on the
digital display goes blank. Screen inactivity is when digital module that enables and disables the exer-
there is no user interaction with the menu system
ciser clock (Figure 6-1).
and when there are no events. The digital display is
reactivated when an event occurs or when an oper- For Level 1 controllers:
ator touches one of the menu buttons.
 Early versions of software allowed for setting
In order to conserve controller battery power, the up one exercise period but no exceptions.
loss of utility power also causes the digital display
to go blank. The digital display is reactivated when  Starting with software versions 1.5.190, the
a second power source becomes available. digital display can be used to set one exer-
cise period and one exception.
The status of the controller batteries can be viewed
using the digital display (see Figure 3-21). The con-  Starting with software version 1.13.244, the
troller batteries status submenu is included in the digital display can be used to set a maximum
Statistics submenus (see Figure 4-5 or 4-6). of two exercise periods and two exercise ex-
ceptions on Level 1 controllers.
Control Batteries For Level 2 controllers:

Ok/Low/Fail
 Early versions of software allowed for setting
up two exercise periods but no exceptions.
FIGURE 3-21. CONTROLLER BATTERIES STATUS  Starting with software version 1.5.190, the
SUBMENU digital display can set parameters for a maxi-

mum of two exercise periods and two excep- f. Select whether or not you want the exercise
tions. to run the generator(s) with or without a
load. The default is “Without Load.”
 Starting with software version 1.13.244, the
digital display can be used to set a maximum 3. Exit the Setup submenus and select “Save” to
of eight exercise periods and eight exercise save the changes made to the Exercise sub-
exceptions on Level 2 controllers. menus (see page 4-11).
The PC service tool can set parameters for eight

exercise periods and eight exceptions.
Exercise Enable
Setting Exercise(s) − For Software Versions Enable/Disable
Prior to 1.5.190
Menus needed to set up an exercise using the digi-
tal display are shown in Figure 3-22). A second ex-
Next Exercise
ercise period can also be set up on installations hh:mm:ss
with a Level 2 controller.
To set up an exercise:
Program 1
1. Using the digital display, navigate to the Setup
Enable/Disable
submenu (see pages 4-9 and 4-23) and enter
the password (574).
2. Navigate to the Exercise submenus (see page Start Day 1

4-10) and set exercise(s): day
NOTE: If any exercises are already enabled,

the “Next Exercise In” submenu displays the
time remaining until the next exercise cycle be- Start Time 1
gins. hh:mm
Next Exercise
Duration 1
hh:mm:ss
hh:mm
a. Select “Enable” to enable an exercise.

Program 1 Repeat
nn weeks
b. Select a day between Sunday and Satur-
day.
c. Enter the time of day the exercise cycle is Exercise 1

to begin (hr = 0−23, mn = 0−59). With/Without Load
d. Set the duration the exercise cycle will run

(hr = 0−23, mn = 0−59).
FIGURE 3-22. EXERCISE SUBMENUS
e. Enter the number of weeks (0−52) between
each exercise (interval) (0 = one time only,
1 = once a week, 2 = once every two weeks,
52 = once every 52 weeks).

Setting Exercise(s) − Starting with Software 2. Navigate to the Exercise submenus (see
Version 1.5.190 pages 4-10 and 4-25) and set exercise(s):
Menus needed to set up exercise(s) using the digi-
tal display are shown in Figure 3-23). A second ex- NOTE: If any exercises are already enabled,
ercise period can also be set up on installations the “Next Exercise In” submenu displays the
with a Level 2 controller. time remaining until the next exercise cycle be-
gins. If no exercises are enabled, the message
“No Next Exercise” is displayed.
Exercise 1 Enable
Enabled/Disabled
Next Exercise In
__Day __Hr __Min
Exercise 1 Start
______day
g. Select “Enabled” to enable an exercise.
h. Select a day between Sunday and Satur-

Exercise 1 Start day.
hr:mn
i. Enter the time of day the exercise cycle is

to begin (hr = 0−23, mn = 0−59).
Exercise 1 Duration
hr:mn
j. Set the duration the exercise cycle will run
(hr = 0−23, mn = 0−59).
k. Enter the number of weeks (0−52) between

Exercise 1 Repeat each exercise (interval) (0 = one time only,
nn weeks 1 = once a week, 2 = once every two weeks,
52 = once every 52 weeks).
Exercise 1
l. Select whether or not you want the exercise
With/Without Load
to run the generator(s) with or without a
load. The default is “Without Load.”
FIGURE 3-23. EXERCISE SUBMENUS NOTE: Exercise exceptions are also available
through the digital display menus. See “Setting
Exercise Exception(s)” on page 3-14.
To set up an exercise:
1. Using the digital display, navigate to the Setup 3. Exit the Setup submenus and select “Save” to
submenu (see page 4-9) and enter the pass- save the changes made to the Exercise sub-
word (574). menus (see page 4-11).

Setting Exercise Exception(s) − Starting with 2. Navigate to the Exercise Exceptions subme-
Software Version 1.5.190 nus (see page 4-27) and set exercise excep-
tion(s):
Menus needed to set up exercise exception(s) us-
ing the digital display are shown in Figure 3-24). A NOTE: If any exercise exceptions are en-
second exercise exception can also be set up on abled, the “Exception Remaining” submenu
installations with a Level 2 controller. displays the time remaining for the exception
of the longest duration. If no exercise excep-
tions are enabled, the message “No Excepts
Active” is displayed.
Exception 1 Exception Remaining

Enabled/Disabled __Days __Hr __Min
a. Select “Enabled” to enable an exercise ex-

ception.
Excpt 1 Start Date
mo/dy b. Enter a starting month and day that you do
not want the exercise to run (mo = 1−12, dy
= 1−31).
c. Enter a starting time that you do not want

Excpt 1 Start Time the exercise to run (hr = 0−23, mn = 0−59).
hr:mn
d. Enter the length of time that you want the

exception to override the exercise (days =
1−31, hr = 0−23, mn = 0−59).
Except 1 Duration
e. Select whether or not you want the excep-
__Days__Hr__Min
tion to repeat. Select “Disabled” if you want
the exception to occur only once. Select
“Enabled” if you want the exception to re-
peat once a year.
Exception 1 Repeat
Enabled/Disabled NOTE: Exercise exceptions can be cancelled in
the “Cancl Active Excpts” submenu (change from
“Normal” to “Cancel” to cancel all exceptions).
FIGURE 3-24. EXERCISE EXCEPTIONS

SUBMENUS Cancl Active Excpts
Normal/Cancel
To set up an exercise exception:

3. Exit the Setup submenus and select “Save” to
1. Complete the setup of exercise(s) as de- save the changes made to the Exercise sub-
scribed on page 3-13. menus (see page 4-11).

Setting Exercise(s) − Starting with Software 2. Navigate to the Exercise submenus (see
Version 1.13.244 pages 4-10 and 4-33) and set exercise(s):
Menus needed to set up exercise(s) using the digi- NOTE: If any exercises are already enabled,
tal display are shown in Figure 3-25). the “Next Exercise In” submenu displays the
time remaining until the next exercise cycle be-
NOTE: Level 1 controllers can have up to two exer- gins. If no exercises are enabled, the message
cise periods. Level 2 controllers can have “No Next Exercise” is displayed.
up to eight exercise periods.
Next Exercise In
__Day __Hr __Min
View/Edit Exercise
# (Enabled/Disabled)
NOTE: The exercise program allows for set-

ting either an exercise interval (step f) or an ex-
Exercise # Enable
ercise that will repeat on a specific day of the
month (step g).
Enabled/Disabled
a. Enter a number for an exercise (1 or 2 with
Level 1 controllers or 1 thru 8 with Level 2
controllers). The status (enabled or dis-
Exercise # Start abled) is automatically displayed.
______day
b. Select “Enabled” to enable the exercise se-
lected in the previous step.
c. Select a day between Sunday and Satur-
Exercise # Start day that the exercise is to start.
hr:mn d. Enter the time of day the exercise cycle is
to begin (hr = 0−23, mn = 0−59).
e. Set the duration the exercise cycle will run
Exercise # Duration (hr = 0−23, mn = 0−59).
hr:mn f. To set an exercise interval, enter the num-
ber of weeks (0−100) between each exer-
cise (0 = one time only, 1 = once a week, 2 =
once every two weeks, 52 = once every 52
Exercise # Repeat weeks).
Every __ Weeks OR
OR g. To set an exercise that will repeat on a spe-
cific day of each month, select the value
Exercise # Repeat (1st, 2nd, 3rd, 4th, or 5th) for the day of the
Every ___ ___day week selected in step c.
NOTE: After selecting the button, press
the down or up button ( or ) until the de-
sired 1st thru 5th ____day value is dis-
Exercise # played. The menus required to set a specif-
With/Without Load ic day of the month to exercise are dis-
played when you use the button to go be-
low “0” or the button to go above “100.”
FIGURE 3-25. EXERCISE SUBMENUS h. Select whether or not you want the exercise
to run the generator(s) with or without a
To set up an exercise: load. The default is “Without Load.”
1. Using the digital display, navigate to the Setup 3. Exit the Setup submenus and select “Save
submenu (see page 4-9) and enter the pass- changes” to save the changes made to the Ex-
word (574). ercise submenus (see page 4-12).

Setting Exercise Exception(s) − Starting with 3. Navigate to the Exercise Exceptions subme-
Software Version 1.13.244 nus (see page 4-33) and set exercise excep-
tion(s):
Menus needed to set up exercise exception(s) us-
ing the digital display are shown in Figure 3-26).
NOTE: If any exercise exceptions are en-
NOTE: Level 1 controllers can have up to two exer- abled, the “Exception Remaining” submenu
cise exceptions. Level 2 controllers can displays the time remaining for the exception
have up to eight exercise exceptions. of the longest duration. If no exercise excep-
tions are enabled, the message “No Excepts
Active” is displayed.
View/Edit Exception
Exception Remaining
__Days __Hr __Min
Exception #
a. Select an Exception number. This number
Disabled/Enabled
must match the number of the Exercise se-
lected in step 2.
b. Select “Enabled” to enable an exercise ex-

Excpt 1 Start Date
ception.
mo/dy
c. Enter a starting month and day that you do

not want the exercise to run (mo = 1−12, dy
= 1−31).
Excpt 1 Start Time
hr:mn
d. Enter a starting time that you do not want
the exercise to run (hr = 0−23, mn = 0−59).
e. Enter the length of time that you want the

Except # Duration
exception to override the exercise (days =
__Days __Hr __Min
1−31, hr = 0−23, mn = 0−59).
f. Select whether or not you want the excep-

tion to repeat. Select “Disabled” if you want
Exception # Repeat the exception to occur only once. Select
Enabled/Disabled “Enabled” if you want the exception to re-
peat once a year.
NOTE: Exercise exceptions can be cancelled in

FIGURE 3-26. EXERCISE EXCEPTIONS
SUBMENUS
the “Cancl Active Excpts” submenu (change from
“Normal” to “Cancel” to cancel all exceptions).
To set up an exercise exception:

Cancl Active Excpts
1. Complete the setup of exercise(s) as de- Normal/Cancel
scribed on page 3-15.
2. Select an exercise that you wish to add an ex-

ception to by navigating to the View/Edit Exer- 4. Exit the Setup submenus and select “Save
cise submenu and selecting the desired exer- changes” to save the changes made to the Ex-
cise number. ercise submenus (see page 4-12).

EVENTS 3. Transfer - from Source 1 (Normal) to
Source 2 (Emergency):
Functions and failures of the transfer switch are re-
a. Pull the upper manual operator handle
corded in the software within the Events program.
down.
The program retains up to 50 events and can be
displayed on the digital display or from the PC ser- b. Push the lower manual operator handle
vice tool. Events are displayed in chronological or- down.
der beginning with the most recent first. Controllers Retransfer - from Source 2 to Source 1:
display both a time and date stamp on each event.
c. Pull the lower manual operator handle up.
A description of normal events is included in Sec-
tion 5. Below is a list of events that are stored. d. Push the upper manual operator handle up.
4. Before moving the Motor Disconnect switch
A list of fault codes and corrective actions is in- back to the Auto position, remember the trans-
cluded in Section 6: Troubleshooting. Fault codes fer switch transfers the load to the active power
will remain on the display until the HOME button is source. (If both power sources are available,
pressed. it transfers the load to the Source 1 or to the
preferred source.)
OPERATION
WARNING Automatic transfer switch op-
Automatic Operation eration results in rapid movement of the
manual operator handles and presents a
Place control switches in the positions given below. hazard of severe personal injury. Keep
hands clear of handles when switching
 Motor Disconnect switch: Auto position. back to automatic operation.
 For utility-to-genset and genset-to-genset 5. Move the Motor Disconnect switch to the Auto
configurations, the generator set control position.
must also be set for automatic (Auto) opera-
tion. 6. Close the cabinet door.
TRANSFER
Manual Operation SWITCH HANDLES
The transfer switch has operator handles for manu-

ally transferring the load. Manual operation must
be performed by qualified personnel under NO-
LOAD CONDITIONS ONLY. Use the following pro-
cedure:
WARNING AC power within the cabinet and
the rear side of the cabinet door presents shock
hazards that can cause severe personal injury
or death. Use extreme caution to avoid touch-
ing electrical contacts with body, tools, jewelry,
hair, clothes, etc.
WARNING Manual operation of the transfer
switch under load presents a shock hazard that
can cause severe personal injury or death. Do
not attempt to operate switch manually when it
is under load. Follow the “Safety Related Work
Practices” listed in NFPA 70E. Do not attempt a
closed transition during manual operation.
1. Open the cabinet door of the automatic trans-
fer switch.
2. Move the Motor Disconnect switch to the Off FIGURE 3-27. MANUAL OPERATION, 40−1000 AMP
position. SWITCHES

WITH-LOAD STANDBY SYSTEM TEST ride switch. The generator set starts and as-
sumes the load after the start time delay.
1. Set the Test With/Without Load variable to the
3. At the end of the test period, press the Test
With Load value.
switch again. To bypass the retransfer time
delay and cause a faster load retransfer, press
The Test With/Without Load variable must be the Override switch. The generator stops after
set to the With Load value in order to test with the stop time delay.
load.
4. In anticipation of scheduled or automatic gen-
2. Press and hold the Test switch for two sec- erator set exercise, set the With/Without Load
onds. To bypass the transfer time delay and variable to the desired value. Refer to the Op-
cause a faster load transfer, press the Over- erator’s manual.
PLANNED MAINTENANCE
Performing the annual planned maintenance procedures increases reliability of the transfer switch. The
following procedures must only be done by technically qualified personnel. If repair or component replace-
ment is necessary, call your dealer or distributor.
WARNING AC power within the cabinet and the rear side of the cabinet door presents a shock haz-
ard that can cause severe personal injury or death. Incorrect installation, service, or parts replace-
ment can result in severe personal injury, death, and/or equipment damage. All corrective service
procedures must be done only by technically qualified personnel.
WARNING The transfer switch presents a shock hazard that can cause severe personal injury or
death unless all AC power is removed. Be sure to set the genset operation selector switch to Stop,
disconnect AC line power, disconnect the battery charger from its AC power source, and discon-
nect the starting battery (negative [−] lead first) before servicing.
WARNING Ignition of explosive battery gases can cause severe personal injury. Do not smoke or
cause any spark, arc, or flame while servicing batteries.
1. Disconnect All Sources of AC Power:
A. Disconnect both AC power sources from the transfer switch before continuing. Turn the genera-
tor set operation selector switch to Stop. (The selector switch is located on the generator set con-
trol panel.)
B. If there is an external battery charger, disconnect it from its AC power source. Then dis-
connect the set starting battery (negative [−] lead first).
2. Clean
A. Thoroughly dust and vacuum all controls, meters, switching mechanism components, interior
buswork, and connecting lugs.
B. Close the cabinet door and wash exterior surfaces with a damp sponge (mild detergent and wa-
ter). Do not allow water to enter the cabinet, especially at meters, lamps, and switches.

3. Inspect
A. Check buswork and supporting hardware for carbon tracking, cracks, corrosion, or any other
types of deterioration. If replacement is necessary, call your dealer or distributor.
B. Check stationary and movable contacts. If contact replacement is necessary, see section 5.
C. Check system hardware for loose connections. Tighten as indicated in step 4.
D. Check all control wiring and power cables (especially wiring between or near hinged door) for
signs of wear or deterioration.
E. Check all control wiring and power cables for loose connections. Tighten as indicated in step 4.
F. Check the cabinet interior for loose hardware. Tighten as indicated in step 4.
4. Perform Routine Maintenance
A. Tighten buswork, control wiring, power cables, and system hardware, as necessary. Hardware
torque values are given in section 5. Retorque all cable lug connections. Lug torque require-
ments are listed in Table 3-1.
B. Replace the batteries (3V lithium) in the Digital Module and the Network Module (if applicable.
Replace batteries every two years. See Figure 2-5.
5. Connect AC Power and Check Operation
A. Connect the set starting battery (negative [−] lead last). Connect the normal AC power source,
enable the backup power source. If applicable, connect power to the battery charger.
B. Verify proper operation of the battery charger.
C. Test system operation as described in this section. Close and lock the cabinet door.
TABLE 3-1. LUG TIGHTENING REQUIREMENTS
Set Screw Socket Minimum torque for

Size (Across Flats) Proper Operation
3/16 inch 80 In-lbs (9 N-m)
1/4 inch 200 In-lbs (23 N-m)
5/16 inch 275 In-lbs (31 N-m)
3/8 inch 375 In-lbs (43 N-m)
1/2 inch 500 In-lbs (57 N-m)
9/16 inch 600 In-lbs (68 N-m)


4. Digital Display Menu System
This section describes the Digital Display Menu MAIN MENUS
System and navigation through the menus. The
menus display status information, events, and set- The main menu system consists of three top-level
up menus. Setup menus contained parameters menus that list vertical menus (or submenus). The
with adjustable values. The descriptions in this sec- sub-menus display status information. This infor-
tion include ranges for the parameters and default mation cannot be changed in the main menus. The
values. The Digital Display is an option with Level 1 main menus contain eight submenus including the
controls and is standard with Level 2 controls. The Setup Menus.
system menus can also be accessed with the PC
service tool. PASSWORD AND SETUP MENUS
Before you can navigate and change setup param-
The Digital Display Menu System is a 2-line by eters, you must enter a password; however, you
20-character graphical display screen and six but- can bypass the password and examine but not
tons. The screen or menu displays status informa- change parameters. When parameters are
tion, parameters, events and messages. The but- changed in any setup menu, you are prompted to
tons change screens and parameters. Two buttons either save the changes or restore the old values.
have names: Home and Previous Menu. These Setting and navigating through the password me-
buttons are used for navigation. Messages include nus is described in Figure 4-8 and 4-9.
navigational indicators for the other four buttons
(see Figure 4-1). NAVIGATION
Refer to Figures 4-34 through 4-39 at the end of this
section for an over view of menu navigation. These
illustrations can also be used to locate a submenu
and determine how to access it.

MAIN MENU NAVIGATION
Using the MORE button Using the HOME button
Source1 Load Source1 Load

Source2 More >> Source2 More >>
Home Previous Home Previous

Menu Menu
Statistic Setup Statistic Setup

Events More >> Events More >>

Menu Menu
About Active TD About Active TD

System More >> System More >>

Menu Menu
Using the PREVIOUS MENU button
Source1 Load Statistic Setup About Active TD

Source2 More >> Events More >> System More >>
Home Previous Previous Previous

Home Home
Menu Menu Menu
FIGURE 4-1. NAVIGATION

MAIN MENU DESCRIPTIONS
FIRST MAIN MENU

The LOAD key moves through submenus
to display information on the Load con-
These buttons move between submenus nected source:
that monitor aspects of both power sources:
Line-to-Line Voltage
Frequency  Source1
Source2
Load
More >>
Voltage Output
Amps and Frequency
Power Factor and Output
Source Connected
Running Time
The MORE button advances to the Sec-
Home Previous ond Main Menu (below).
Menu
The HOME key returns to this
display within any of the Source The PREVIOUS MENU key is not
1 or 2 or Load submenus. active at this level.
SECOND MAIN MENU

The SETUP button enters the Pass-
word protected adjustment program:
The STATISTIC button displays information
Adjust Sensors
about either source:
Set Time Delays
Run Time
Test and Exercise
Average Transfer Time
Statistic Setup Exercise Exceptions
Total Number of Transfers
Transition Mode Trim
Total Number of Failures Events More >>
Load Sequencer Enable
Battery and (optional) Charger status
Control On Time
The MORE button advances to the
Home Previous
Third Main Menu (below).
The EVENTS button displays the last 50 Menu
events or fault codes recorded on the
From this display, the PREVIOUS
controller.
MENU button returns to the First
Main Menu.
From this display, the HOME button
returns to the First Main Menu.
THIRD MAIN MENU

The ACTIVE TD button displays
The ABOUT program displays general all active time delays.
information about the transfer switch
and controller. About Active TD
System More >> The MORE button returns the
The SYSTEM program provides access display to the First Main Menu.
to data from surrounding devices com-
municating through a LonWorks net- Home Previous
work. If the optional network card is not Menu The PREVIOUS MENU button
included with the transfer switch, the
returns to the Second Main
SYSTEM program is not displayed.
Menu (above).
From this display, the HOME button
returns to the First Main Menu.
NOTE: The Active TD feature was not available in early versions of software.
FIGURE 4-2. MAIN MENUS

FIRST MAIN MENU − Source 1 and Source 2 Submenus
Press either one of these buttons to obtain

read-only information on the power sources.  Source1
Source2
Load
More >>
Home Previous
Pressing the HOME button in the Menu The PREVIOUS MENU button
submenus below returns the pro-
is not active at this level.
gram to the First Main Menu.
Use the buttons on left to navigate through these screens.
This screen displays Line-to-Line voltages for either Source 1 or

Source 2 for three phase, two phase, or single phase configurations.
Volts L12 L23 L31
If the voltage is measured at 10 volts or less, the display reads 0.
nnn nnn nnn
On Level 1 Controllers, only one voltage will be displayed at L12.
On Level 2 Controllers, if the Source is two phase, the display will
Line-to-Line Voltage
read voltages at L12 and L31.
This screen displays Line-to-Neutral voltage measurements for

Volts L1N L2N L3N three phase, two phase, or single phase configurations. (Num-
nnn nnn nnn bers do not display if the system has no neutral.)
This screen does not display with Level 1 controllers.
Line-to-Neutral Voltage
Frequency
60.0 Hz This screen displays the sensed line frequency for Source 1 or 2.
Sensed line frequency
Source 1 (or 2)
Connected/Open This screen displays the position of contactors for either Source 1 or 2.
Position of contactors
Run Time Source1 (2) This screen displays the total time the transfer switch has been
nnnnnn.n hrs connected to either Source 1 or 2.
Total connection time
FIGURE 4-3. SOURCE 1 AND 2 SUBMENUS

FIRST MAIN MENU − Load Submenus
This subset is not available on Level 1 Controls

and is optional on Level 2 Controls
The LOAD program moves through submenus
to display read-only information about the Load
connected source:
Voltage Output
Source1 Load Power Factor and Output
Source2 More >> Amps and Frequency
The MORE button advances to the Second

Main Menu.
Home Previous
Pressing the HOME button within Menu
the submenus below returns the Pressing the PREVIOUS MENU button
program to the Main Menu. within the submenus will return to this
menu.
Volts L12 L23 L31 Real Power kW

nnn nnn nnn nnnn.n
Line-to-Line Load Voltage

Real Power of the transfer switch
Volts L1N L2N L3N Apparent Power KVA

nnn nnn nnn nnnn.n
Line-to-Neutral Voltage for Load Total Apparent Power of

the transfer switch
Amps L1 L2 L3 Power Factor

nnnn nnnn nnnn nn.n Lead/Lag
Line Currents for Load Average Power Factor of the transfer switch
This will be displayed as lead or lag.
Frequency Neutral Current

60.0 Hz nnnn Amps
Sensed line frequency for

Load connected source Neutral Current of the transfer switch
FIGURE 4-4. LOAD SUBMENUS

SECOND MAIN MENU − Statistics Submenus − Prior to Software Version 1.12
The STATISTICS program displays read-

only information about either source:
Run Time
Avg. Transfer time Statistics Setup
Total Number of transfers Events More >>
Total Number of failures
Battery & (optional) Charger status
Current ON time HOME PREVIOUS
MENU
MENU and HOME buttons return
the program to the First Main
Menu
Use the buttons on left to navigate through these screens
Run Time Source1 Total Source 2 Fail

nnnn.n hrs nnnn
Total time the transfer switch has Total number of Source 2 failures
been connected to Source 1 (includes under-voltage, over-
voltage, over/under frequency)
Run Time Source2

nnnn.n hrs
Control Batteries
Ok/Low/Fail
Total time the transfer switch
has been connected to Source 2
Status of lithium batteries
on controller board
Average Trans Time
nnn msec
Battery Charger
Ok/Fault
Average. transfer time over the last
four transfers. Includes only time that
both sources are disconnected. Sens- Status of optional generator
ing is disabled when Programmed battery charger
Transition is active.
Control on Time
Number of Transfers
nnnnnn.n hrs
nnn
Displays the amount of time the

Total number of switch transfers
controller board has been operat-
in both directions
ing since initialization. Value is
stored permanently.
Total Source 1 Fail

nnn
Total number of Source 1 failures
FIGURE 4-5. STATISTICS SUBMENUS (PRIOR TO SOFTWARE VERSION 1.12)

SECOND MAIN MENU − Statistics Submenus − Starting with Software Version 1.12
The STATISTICS program displays read-

only information about either source:
Run Time
Avg. Transfer time Statistic Setup
Total Number of transfers Events More >>
Total Number of failures
Battery and (optional) Charger status
Current ON time Home Previous
Menu

MENU and HOME buttons return the
program to the First Main Menu.

nnnn.n hrs nnnn
Total time the transfer switch has

Total number of Source 1
been connected to Source 1
failures
nnnn.n hrs nnnn
Total time the transfer switch has Total number of Source 2 failures
been connected to Source 2 (includes under-voltage, over-
voltage, over/under frequency)
Avg OT Transfer
nnn msec
Control Batteries
Ok/Low/Fail
Average time over the last four transfers between
the start of the command to move the switch from
the old source (OT) and the position sensor sens- Status of lithium batteries
ing that the movement was completed. on controller board
Avg CT Transfer Battery Charger

nnn msec Ok/Fault
Average time over the last four transfers be- Status of optional generator
tween the start of the command to close the battery charger
new switch (CT) and the position sensor
sensing that the movement was completed.
Control On Time
Number of Transfers nnnnnn.n hrs
nnn
Displays the amount of time the control-
Total number of switch ler board has been operating since init-
transfers in both directions ialization. Value is stored permanently.
FIGURE 4-6. STATISTICS SUBMENUS (STARTING WITH SOFTWARE VERSION 1.12)

SECOND MAIN MENU − Events Submenus
The EVENTS program displays informa- Statistic Setup

tion about either source. The controller Events More >>
stores and records the last fifty “events” in
chronological order, beginning with the
most recent event. The date and time are
Home Previous
listed with each event.
Menu
The Events program include Fault codes, From this display, the PRE-
active time delays or significant power VIOUS MENU button and HOME
system changes.
button returns program to the
First Main Menu.
Within the submenus, press the
PREVIOUS MENU button any-
time to return to this menu.
Sample Events
Source-1 Connected
01/24/99 08:47
Indicates Event is currently active.
Source-2 Connected
01/23/99 23:48
TD Retransfer
mo/dy/yr hr:mn
TD Retransfer
mo/dy/yr hr:mn
S1 UnderVoltage Failure
mo/dy/yr hr:mn
FIGURE 4-7. EVENTS SUBMENUS

SECOND MAIN MENU − Setup Submenus
Password
The SETUP button enters the Password
protected adjustment programs to:
Statistic Setup Adjust Sensors
Events More >> Set Time Delays
Test and Exercise
Exercise Exceptions
From this display, the PREVIOUS Transition Mode Trim
Home Previous
MENU button and HOME button returns Load Sequencer Enable
Menu
program to the Main Menu.
The MORE button advances to the
Third Main Menu.
Entering the Password Program
Press the Setup button to access the setup password

Enter Password
menu.
* * *
The password is 574.

Use the + and * buttons to select numbers.
Use the button to move the cursor to the
next field. + Enter Password
NOTE: Except for the “View/Edit Exercise” and “View/Edit − _ _
Exception” submenus available starting with software ver-
sion 1.13.244, entering the password is required to change
setup parameters. The remaining setup menus can be
viewed (read-only) by pressing the button three times
without pressing either the + or − buttons to select numbers.
Enter Password
When the password is set, press the button R R R
to enter the setup program.
The Setup program is now accessed. Sensor1 SynchChck

This is the first Setup Menu screen. Sensor2 More >>
FIGURE 4-8. PASSWORD SUBMENUS

Setup Menu Navigation and Description
Sensor1 SynchChck TimeDelay Exercise Mode Sequencer

Sensor2 More >> Test More >> Clock More >>
Back to
Group 1
Setup Group 1 Setup Group 2 Setup Group 3
This group allows programming the The Time Delay submenus allow pro- The Mode submenu allows program-
operational parameters of the gramming time for the: ming the type of transition the switch
switch for Source 1 and Source 2. Engine Start uses. See Figure 4-25 or 4-26.
The Sensor Submenus are used Power Source 1 to Source 2 The Clock submenus program the
for setting the: Power Source 2 to Source 1 time and date, as well as daylight
Phase Type Engine Cooldown savings time. See Figure 4-27.
Nominal Voltage Programmed Transition Load Sequencer is a software fea-
Undervoltage Settings Elevator Pre-Transfer ture, available only with LonWorks
Overvoltage Settings Genset to Genset Engine Controls NetWork Communication Module.
Time Delays Refer to Figure 4-15 or 4-16 for Time This program allows the user to send
Frequency Settings Delay submenus. a predetermined sequence of event
Imbalance Settings Test submenus allow programming announcements in a timed, sequen-
Phase Loss the front panel test switch to test the tial order to turn the load off and on.
Phase Rotation source with or without a load. If the See FIgure 4-28.
See Figures 4-12 or 4-13 for Sen- configuration is genset to genset,
sor Submenus. Source 1 or 2 is selectable. See Fig-
The SynchChck sensor submenus ure 4-17.
allow programming synchronous Exerciser submenus allows program-
conditions for Source 1 and Source ming an exercise routine for Power
2 that must be met before Source 2 and are available only on
transferring from one to the other utility-to-genset controls. The number
source. See Figure 4-14 for Sync of exercise programs that can be set
Check submenus. is dependent upon the software ver-
sion installed and the type of control.
See Figure 4-18, 4-19, 4-21, or 4-23
for Exercise submenus. Exercise sub-
menus also allow for adding and de-
leting exercise exceptions. See Fig-
ure 4-20, 4-22, or 4-24 for Exercise
Exceptions submenus. Up to 8 rou-
tines and exceptions can be pro-
grammed using the PC service tool.
NOTE: Exercise Exceptions subme-
nus were not available on early ver-
sions of software.
FIGURE 4-9. SETUP DESCRIPTION

Changing Setup Parameters − Software Versions Prior to Version 1.12
When this button is pressed within any subme-

nu, a cursor appears in the location of the edit-
Sensing able field. In most cases, there is only one field
1 phase−2 wire to edit.
+
−
Use the + and * buttons to select numerical

values or to toggle through a list of selections.
Default values are shown in parenthesis.
Use the button to move the cursor to the next
field.
When entering numerical values, the * button
lowers the value to it’s lowest range, then begins
again at the top end of the range. The + button
increases the value to its highest range, then
begins again at the low end of the range.
If changes are made, press the button to
enter the new value and return to the previous
menu.
Changing any data within the setup submenus
will invoke a SAVE/RESTORE screen when exiting
the Setup Submenu Groups.
If the PREVIOUS MENU button is pressed during
an editing session, the data will not be changed.
If the HOME button is pressed during an editing
session, the SAVE/RESTORE screen is invoked.
Saving or Restoring Setup Parameters
Changing any parameters within the Setup submenus in-

vokes this screen when exiting the Setup Submenu Groups. Save
Restore
Use the Restore button to delete any setup parameter
changes that were made during the current session. The
program reverts to data from the previous session and does
not save any changes.
FIGURE 4-10. CHANGING SETUP PARAMETERS (SOFTWARE VERSIONS PRIOR TO 1.12)

Changing Setup Parameters − Starting with Software Version 1.12
When this button is pressed within any subme-

nu, a cursor appears in the location of the edit-
Sensing
able field. In most cases, there is only one field
1 phase−2 wire to edit.
+
−
Use the + and * buttons to select numerical val-

ues or to toggle through a list of selections.
Default values are shown in parenthesis.
Use the button to move the cursor to the next
field.
When entering numerical values, the * button
lowers the value to it’s lowest range, then begins
again at the top end of the range. The + button
increases the value to its highest range, then be-
gins again at the low end of the range.
If changes are made, press the button to
enter the new value and return to the previous
menu.
Changing any data within the setup submenus will
invoke a SAVE CHANGES/CANCEL CHANGES
screen when exiting the Setup Submenu Groups.
If the PREVIOUS MENU button is pressed during
an editing session, the data will not be changed.
If the HOME button is pressed during an editing
session, the SAVE CHANGES/CANCEL CHANGES
screen is invoked.
Saving or Canceling Setup Parameters
Changing any data within the setup submenus invoke this

screen when exiting the Setup Submenu Groups. Save changes
Cancel changes
Use the “Cancel changes” button to delete any setup pa-
rameter changes that were made during the current ses-
sion. The program will revert to it’s original data.
FIGURE 4-11. CHANGING SETUP PARAMETERS (STARTING WITH SOFTWARE VERSION 1.12)

Setup − Group 1
Sensor 1 & Sensor 2 Submenus − Software Versions Prior to Version 1.12
Sensor 1 and Sensor 2 submenus

are identical except:

Sensor 1
S1 refers to Source 1 or Sensor 2 More >>
S2 refers to Source 2
For 2-wire system, select:

1 phase−2 wire
For a single phase - 3 wire system, Sensing
select: 1 phase−3 wire 1 Phase−2 wire When this button is pressed in any
For a 3 phase system, select: submenu, a cursor appears in the
3 phase location of the editable field. In most
cases, there is only one field to edit.
System Voltage for Source 1 or 2
Enter the system voltage between S1 Nominal Voltage
110 and 600 VAC nnn
Note: Level 1 Controls are Line-to- +
Line Voltages and Level 2 Controls − __ ________
are Line-to-Neutral Voltages.
Under-Voltage Sensor Pick-Up

S1 UV Pickup Use the + and * buttons to select
Enter a number between 85 and 90 % numerical values or to toggle through
100% of the nominal voltage
a list of selections.
(90%)
Default values are shown in parenthe-
sis)
Under-Voltage Sensor Drop-Out
Voltage When entering numerical values, the
S1 UV Dropout
* button lowers the value to its lowest
Enter a number between 75 and 90 % range, then begins again at the top
98% of the under-voltage pick-up
end of the range. The + button in-
percentage (90%)
creases the value to its highest range,
then begins again at the low end of the
Under-Voltage Drop-Out Time range.
Delay S1 UV Time Delay
Use the button to move the cursor
Enter a time between 0.0 and 1.0 0.5 Seconds to the next field.
seconds (0.5)
If changes are made, press the but-
ton to enter the new value and return
to the previous menu.
Over-Voltage Sensing Enable S1 OV Enable Changing any data within the setup
submenus will invoke a SAVE/RE-
Choose Enabled or Disabled Enabled/Disabled STORE screen when exiting the Setup
(Enabled) Submenu Groups.
If the PREVIOUS MENU button is
Over-Voltage Pick-Up pressed during an editing session, the
This adjusts the over-voltage pick- data will not be changed.
S1 OV Pickup
up as a percentage of the over-volt- If the HOME button is pressed during
age drop-out 95 %
an editing session, the SAVE/RESTORE
Enter a number between 95 and screen is invoked.
99% (95%)
Note: Default values are in

parenthesis. Continued on next page
FIGURE 4-12. SETUP GROUP 1 − SENSOR SUBMENUS (SOFTWARE VERSIONS PRIOR TO 1.12)

Setup − Group 1
Sensor 1 & Sensor 2 Submenus − Software Versions Prior to Version 1.12 (Continued)

are the same except:

Sensor 1
S1 refers to Source 1 or Sensor 2 More >>
Continued from previous page

Frequency Delay
5.0 Seconds
S1 OV Dropout
110 %
Enter a time between 0.1 and
Over-Voltage Dropout 15.0 seconds (5 Seconds)
Enter a percentage between 105 and
135% of the nominal voltage (110%)
S1 OV Time Delay
S1 Imbalance Sensor
3.0 Seconds
Enabled/Disabled
Over-Voltage Time Delay

Detects unbalanced voltages
Enter a range between 0.5 and
on 3-phase sources (Disabled)
120 seconds (3 Seconds)
Imbalance Dropout
S1 Frequency Sensor
5%
Enabled/Disabled
Monitors line frequency on Enter a percentage between

A-Phases of both sources 2 and 10% (5%)
(Enabled)
Nominal Frequency Imbalance Delay

5 Seconds
60 Hz
Enter a time between

Enter a frequency between 45
2 and 20 seconds (5 Seconds)
and 65 Hz (60 Hz)
S1 Loss of Phase
Frequency Pickup
Enabled/Disabled
10 %
Enter a percentage between 5 and The loss of single phase sensing can
20% of the nominal frequency (10%) be enabled or disabled (Disabled)
Phase Rotation
Frequency Dropout
Enabled/Disabled
1%
The phase rotation sensing can

Enter a percentage between 1 and Note: Default values are
be enabled or disabled (Enabled)
5% of the frequency pickup (1%) in parenthesis.
FIGURE 4-12. SETUP GROUP 1 − SENSOR SUBMENUS (SOFTWARE VERSIONS PRIOR TO 1.12)
(Continued)

Setup − Group 1
Sensor 1 & Sensor 2 Submenus − Starting with Software Version 1.12
are identical except:

Sensor1 SynchChck
S1 refers to Source 1 or
Sensor2 More >>
For 2-wire system, select:

1 phase 2 wire.
Sensing
For a single phase - 3 wire system,
select: 1 phase 3 wire. 1 Phase 2 wire When this button is pressed in any
For a 3 phase system, select: submenu, a cursor appears in the
3 phase. location of the editable field. In most
See Note 2. Level 2 Controllers Only cases, there is only one field to edit.
Delta or Wye Configuration. This
Delta or Wye Conn
menu is only displayed with Level 2
Controllers. Delta/Wye
+
Chose Delta or Wye (Wye). − __ ________
System Voltage for Source 1 or 2

Enter the system voltage between S1 Nominal Voltage Use the + and * buttons to select
110 and 600 VAC. numerical values or to toggle through
nnn V L-N
a list of selections.
Note: Level 1 Controllers are Line-to-
Line Voltages and Level 2 Controllers When entering numerical values, the
are Line-to-Neutral Voltages. * button lowers the value to its lowest
range, then begins again at the top
Under-Voltage Sensor Pick-Up end of the range. The + button in-
S1 UV Pickup
Enter a number between 85 and creases the value to its highest range,
90% then begins again at the low end of the
100% of the nominal voltage
(90%). range.
Under-Voltage Sensor Drop-Out to the next field.
Voltage S1 UV Dropout If changes are made, press the but-
Enter a number between 75 and ton to enter the new value and return
90%
98% of the under-voltage pick-up to the previous menu.
percentage (90%). Changing any data within the setup
submenus will invoke a SAVE
Under-Voltage Drop-Out Time CHANGES/CANCEL CHANGES screen
Delay when exiting the Setup Submenu
S1 UV Time Delay
Groups.
Enter an time between 0.0 and 0.5 Seconds
4.0 seconds (0.5 seconds). If the PREVIOUS MENU button is
pressed during an editing session, the
data will not be changed.
If the HOME button is pressed during
Over-Voltage Sensing Enable S1 OV Enable an editing session, the SAVE
CHANGES/CANCEL CHANGES screen is
Choose Enabled or Disabled Enabled/Disabled
invoked.
(Enabled).
Over-Voltage Pick-Up Note 1: Default values are in parenthesis.

This adjusts the over-voltage pick- Note 2: Not all sensing choices are valid for
S1 OV Pickup
up as a percentage of the over-volt- for all combinations of Level 1/Lev-
age drop-out. 95% el 2 and Source 1/Source 2 transfer
Enter a number between 95 and switches. Only the valid choices
99% (95%). are displayed.
Continued on next page
FIGURE 4-13. SETUP GROUP 1 − SENSOR SUBMENUS (STARTING WITH SOFTWARE VERSION 1.12)

Setup − Group 1
Sensor 1 & Sensor 2 Submenus − Starting with Software Version 1.12 (Continued)

are the same except:

Sensor1 SynchChck
S1 refers to Source 1 or Sensor2 More >>
Frequency Delay
5.0 Seconds
S1 OV Dropout
110%
Enter a time between 0.1 and
Over-Voltage Dropout 15.0 seconds (5.0 seconds).
135% of the nominal voltage (110%). Level 2 Controllers Only
S1 Imbalance Sensor
S1 OV Time Delay
Enabled/Disabled
3.0 Seconds
Over-Voltage Time Delay Detects unbalanced voltages

on 3-phase sources (Disabled).
Enter a range between 0 and
120 seconds (3 seconds).
Imbalance Dropout
4%
S1 Frequency Sensor
Enabled/Disabled
Enter a percentage between
Monitors line frequency on 2 and 10% (4%).
A-Phases of both sources (Enabled).
Imbalance Delay
5.0 Seconds
Nominal Frequency
60.0
Enter a time between
2 and 20 seconds (5 seconds).
Enter a frequency between 45
and 65 Hz (60 Hz).
S1 Loss of Phase
Enabled/Disabled
Frequency Pickup
10%
The loss of single phase sensing can
be enabled or disabled (Disabled).
20% of the nominal frequency (10%).
Phase Rotation
Enabled/Disabled
Frequency Dropout
1%
The phase rotation sensing can
be enabled or disabled (Enabled).
5% of the frequency pickup (1%). Note: Default values are in parenthesis.
FIGURE 4-13. SETUP GROUP 1 − SENSOR SUBMENUS (STARTING WITH SOFTWARE VERSION 1.12)
(Continued)

Setup − Group 1
Sync Check Submenus − Starting with Software Version 1.20.250
Sensor1 SynchChck
Sensor2 More
Frequency Bandwidth
Active Sync
n.n Hz
Enabled/Disabled
Frequency Bandwidth
Enter a frequency between Active Sync Enable
0.1 and 1.0 Hz (1.0 Hz) Choose Enabled or Disabled (Disabled)
NOTE: For closed transition transfer
Voltage Window switches, do not enable the Active Sync fea-
ture unless the system has an active paral-
nn.n volts
leling genset. Otherwise, Fail to Synchronize
faults may occur.
Voltage Difference Window
Enter a range between 5
and 25 volts (10.0 volts)
Active Sync Delay
n.n seconds
Manual Offset
nn msec
Active Sync Timer
Transfer Time Manual Offset Enter a range between 0.0 and
5.0 seconds (0.5 seconds)
Enter a range between −25 and
+25 milliseconds (0 milliseconds)
Return PT Enable
Enabled/Disabled
Return to Programmed Transition

Allows a return to Programmed
Transition after a Fail to Sync
event occurs during a transfer/re-
transfer sequence (Enabled). If
disabled, the controller stays in
the Sync Check mode.
Note: Default values are in parenthesis.
FIGURE 4-14. SYNC CHECK SUBMENUS (STARTING WITH SOFTWARE VERSION 1.20.250)

Setup − Group 2
Time Delay Submenus − Software Versions Prior to Version 1.12
Sensor1 TimeDelay Exercise

Sensor2 More >> Test More >>
GROUP 1 GROUP 2
In a Normal to Emergency transfer this

function allows Source 2 to stabilize be-
fore the load is applied. TDNE
Enter a time from 0 to 120 seconds (10 10.0 Seconds When this button is pressed in any
seconds). See Note 2. submenu, a cursor appears in the
location of the editable field. In most
In a Emergency to Normal transfer this

allows Source 1 to stabilize before re- TDEN
transfer. +
10.0 Minutes
− __ __________
Enter a time from 0 to 30 minutes (10
minutes). See Note 2.
Sets the time delay for Engine Start on
genset (a) used in a utility-generator Use the + and * buttons to select
and generator-generator mode. Pre- numerical values or to toggle through
vents nuisance genset starting during a list of selections.
TDESa
brief power interruptions. This menu Default values are shown in parenthe-
3.0 Seconds
does not appear in utility-to-utility sis.
installations. Use the button to move the cursor
Enter a range from 0 to 120 seconds to the next field.
(3.0 seconds). See Note 2. When entering numerical values, the
Sets the time delay for Engine Cool- * button lowers the value to its lowest
down following a re-transfer. This menu range, then begins again at the top
TDECa
does not appear in utility-to-utility end of the range. The + button in-
10.0 Minutes creases the value to its highest range,
installations.
Enter a time from 0 to 30 minutes (10 then begins again at the low end of the
minutes). range.
If changes are made, press the
Sets the time delay for Programmed button to enter the new value and re-
Transition setting of 0.0 disables the TDPT turn to the previous menu.
program.
0.0 Seconds Changing any data within the setup
Enter a time from 0 to 60 seconds submenus will invoke a SAVE/RE-
(0 seconds). STORE screen when exiting the Setup
Submenu Groups.
Sets the time delay to wait for an eleva- If the PREVIOUS MENU button is
tor pre-transfer signal. TDEL pressed during an editing session, the
0.0 Seconds data will not be changed.
Enter a time from 0 to 60 seconds (0
seconds). If the HOME button is pressed during
an editing session, the SAVE/RESTORE
screen is invoked.
Note: Default values are in parenthesis. Continued on next page
Note 2: On early versions of software, the sequence of the first

three menus were as follows: TDESa, TDNE, and TDEN.
FIGURE 4-15. SETUP GROUP 2 − TIME DELAY SUBMENUS (SOFTWARE VERSIONS PRIOR TO 1.12)

Setup − Group 2
Time Delay Submenus − Software Versions Prior to Version 1.12 (Continued)
Time Delay
Test More >>
GROUP 2
This group is used only in Genset to Genset applications
Level 2 Controller Only
Sets the Engine Start time delay to for

genset (b). TDESb
Enter a time from 0 to 120 seconds (3 3.0 Seconds
seconds)
Sets the time delay for Engine Cooldown to

begin. TDECb
Enter a time of 0 to 30 minutes (10 minutes) 10 Minutes
Changeover Enable
Enabled/Disabled
If Changeover Enabled is enabled, this

menu sets the amount of time a single
Changeover Delay
generator can be run before switching to
the other generator. 24 Hours
Enter a time from 1 to 336.0 hours (24 hrs)
FIGURE 4-15. SETUP GROUP 2 − TIME DELAY SUBMENUS (SOFTWARE VERSIONS PRIOR TO 1.12)
(Continued)

Setup − Group 2
Time Delay Submenus − Starting with Software Version 1.12
Sensor1 SynchChck TimeDelay Exercise

GROUP 1 GROUP 2
In a Normal to Emergency transfer this

function allows Source 2 to stabilize be-
fore the load is applied. TDNE
Enter a time from 0 to 120 seconds (10 10.0 Seconds When this button is pressed in any
seconds). See Note 2. submenu, a cursor appears in the
location of the editable field. In most
In a Emergency to Normal transfer this

allows Source 1 to stabilize before re-
TDEN
transfer. +
10.0 Minutes
Enter a time from 0 to 30 minutes (10 − __ __________
minutes).
Sets the time delay for Engine Start on

genset (a) used in a utility-generator Use the + and * buttons to select
and generator-generator mode. Pre- numerical values or to toggle through
vents nuisance genset starting during a list of selections.
brief power interruptions. This menu TDESa Default values are shown in parenthe-
does not appear in utility-to-utility 3.0 Seconds sis.
installations.
Enter a range from 0 to 15 (Level 1 to the next field.
controls or 0 to 120 (Level 2 controls)
seconds (3.0 seconds). See Notes 2 When entering numerical values, the
and 3. * button lowers the value to its lowest
range, then begins again at the top
Sets the time delay for Engine Cool-
end of the range. The + button in-
down following a re-transfer. This menu TDECa
creases the value to its highest range,
does not appear in utility-to-utility 10.0 Minutes then begins again at the low end of the
installations.
range.
Enter a time from 0 to 30 minutes
If changes are made, press the
(10 minutes).
button to enter the new value and re-
Sets the time delay for Programmed turn to the previous menu.
Transition setting of 0.0 disables the pro- TDPT Changing any data within the setup
gram. 0.0 Seconds submenus will invoke a SAVE
Enter a time from 0 to 60 seconds CHANGES/CANCEL CHANGES screen
(0 seconds). See Note 2. when exiting the Setup Submenu
Groups.
Sets the time delay to wait for an eleva- If the PREVIOUS MENU button is
tor pre-transfer signal. TDEL pressed during an editing session, the
0.0 Seconds data will not be changed.
Enter a time from 0 to 60 seconds (0
seconds). See Note 2. If the HOME button is pressed during
an editing session, the SAVE
Continued on next page CHANGES/CANCEL CHANGES screen is
Note 1: Default values are in parenthesis. invoked.
Note 2: TDNE, TDESa, TDESb, TDEL, and TDPT values up to 20 Note 3: For long engine start time delays (over 15
seconds are adjustable in 1 second increments. Values seconds) a remote battery source should be
over 20 seconds are adjustable in 5 second increments. used.
FIGURE 4-16. SETUP GROUP 2 − TIME DELAY SUBMENUS (STARTING WITH SOFTWARE VERSION 1.12)

Setup − Group 2
Time Delay Submenus − Starting with Software Version 1.12 (Continued)
Time Delay
Test More >>
GROUP 2
This group is used only in Genset-to-Genset applications.
Level 2 Controller Only
Sets the Engine Start time delay for genset (b).

Enter a time from 0 to 15 (Level 1 controls) or TDESb
0 to 120 (Level 2 controls) seconds 3.0 Seconds
(3.0 seconds). See Notes 2 and 3.
Sets the time delay for Engine Cooldown to

begin. TDECb
Enter a time of 0 to 30 minutes (10 minutes). 10 Minutes
Changeover Enable
Enabled/Disabled
If Changeover Enabled is enabled, this

menu sets the amount of time a single Changeover Delay
generator can be run before switching to 0 Hours
the other generator.
Enter a time from 0 to 336 hours (24
hours).
Note 1: Default values are in parenthesis.

Note 2: TDNE, TDESa, TDESb, TDEL, and TDPT values up to 20
seconds are adjustable in 1 second increments. Values over
20 seconds are adjustable in 5 second increments.
Note 3: For long engine start time delays (over 15 seconds) a remote
battery source should be used.
FIGURE 4-16. SETUP GROUP 2 − TIME DELAY SUBMENUS (STARTING WITH SOFTWARE VERSION 1.12)
(Continued)

Setup − Group 2
Test Submenus
Sensor 1 SynchChck Time Delay Exercise

Sensor 2 More >> Test More >>
GROUP 1 GROUP 2
This menu is used only in This menu is used only in Genset-to-Genset

Utility-to-Genset applications and Utility-to-Utility applications
Test Preferred Source

With/Without Load Source 1/Source 2
Level 2 Control Only

Allows an operator to automatically
test the transfer switch, generator
and power system. Allows for the selection of the
Preferred Source
Sets the function of the Test (Default = Source 1)
Switch on the front panel
(Default = Test With Load).
FIGURE 4-17. SETUP GROUP 2 − TEST SUBMENUS

Setup − Group 2
Exerciser Submenus − Software Versions Prior to 1.5.190
These submenus are available only in Utility-to-Genset applications.
Sensor 1 Time Delay Exercise

Sensor 2 More >> Test More >>
GROUP 1 GROUP 2
Enables or disables all the functions of Exercise Enable

exercising the generator(s) Enable/Disable
Displays the Time remaining until the

next exercise cycle. This display is Next Exercise
readable only when the exerciser is hh:mm:ss
Enabled (May not be displayed in Soft-
ware Version 1.0)
This screen allows disabling Exercise

Program 1
Program 1 only
Enable/Disable
The first of four programming subme-

nus for the Exerciser cycle. Sets the
day an Exercise cycle will occur Start Day 1
day
Select a day between Sunday=0 and
Saturday=6
Sets a Time for the exercise cycle to

begin Start Time 1
hh:mm
Enter a time within a 24 hour period:
hh = 0 − 23, mm = 0 − 59.
Sets the length of Time the exercise

cycle will run Duration 1
hh:mm
hh = 0 − 23, mm = 0 − 59.
Sets an Interval the exercise cycle will

repeat Program 1 Repeat
Enter a cycle between 0 and 52 weeks nn weeks
Typical values are 1 or 2
Only one program is available
for Level 1 Controllers Continued on next page
FIGURE 4-18. SETUP GROUP 2 − EXERCISER SUBMENUS (SOFTWARE VERSIONS PRIOR TO 1.5.190)

Setup − Group 2
Exerciser Submenus − Software Versions Prior to 1.5.190 (Continued)
Time Delay Exerciser

Test More >>
GROUP 2
Level 2 Controllers allow for two exercise programs

to be setup from the Setup menu screen. Six addi-
tional programs and eight exceptions can be setup Continued from previous page
using the PC service tool.
Enables or disables exercising the gener- Exercise 1

ator(s) with or without a load With/Without Load
This screen allows disabling Exercise Program 2

Program 2 only
Enable/Disable
Sets the day of the second exercise cycle. Start Day 2

Enter a day between Sunday = 0 and Sat- DAY
urday = 6.
Sets the time the second exercise cycle

will begin Start Time 2
Enter a time within a 24 hour period: hh = 0 hh:mm
− 23, mm = 0 − 59.
Sets a time limit the second exercise cycle

will run Duration 2
Enter a time within a 24 hour period: hh = hh:mm
0 − 23, mm = 0 − 59.
Sets an Interval the second exercise cycle

will repeat Program 2 Repeat
Enter a range from 0 to 52 weeks. Typical nn weeks
values are 1 or 2.
Enables or disables the second exercise Exercise 2

program to run the generator(s) with or
With/Without Load
without a load
FIGURE 4-18. SETUP GROUP 2 − EXERCISER SUBMENUS

(SOFTWARE VERSIONS PRIOR TO 1.5.190) (Continued)

Setup − Group 2
Exerciser Submenus − Starting with Software Version 1.5.190
These submenus are available only in Utility-to-Genset applications.
Sensor1 Time Delay Exercise

GROUP 1 GROUP 2
Note: Instead of “Exercise

Feature,” this menu is titled
Enables or disables all the functions of Exercise Feature “Exercise Enable” in some
exercising the generator(s). (Default = Enabled/Disabled early versions of software.
Disabled) This menu is no longer in-
cluded with current software.
Displays the Time remaining until the

next exercise cycle. If no exercises are Next Exercise In
enabled, the message “No Next Exer- __Day __Hr __Min
cise” is displayed.
This screen allows disabling Exercise

Exercise 1 Enable
1 only. (Default = Disabled)
Enabled/Disabled
The first of four programming subme-

nus for the Exercise cycle. Sets the
day an Exercise cycle will occur Exercise 1 Start
______day
Select a day between Sunday and Sat-
urday. (Default = Sunday)
Sets a Time for the exercise cycle to

begin. Exercise 1 Start
hr:mn
hr = 0−23, mn = 0−59. (Default =
00:00)
Sets the length of Time the exercise

cycle will run. Exercise 1 Duration
hr:mn
hr = 0−23, mn = 0−59. (Default =
00:00)
Sets an Interval the exercise cycle will

repeat. Exercise 1 Repeat
Enter a cycle between 0 and 52 weeks. nn weeks
Typical values are 1 or 2. (Default = 0
weeks)
Note: Only one exercise is
available for Level 1 Controllers Continued on next page
FIGURE 4-19. SETUP GROUP 2 − EXERCISE SUBMENUS (STARTING WITH SOFTWARE VERSION 1.5.190)

Setup − Group 2
Exercise Submenus − Starting with Software Version 1.5.190 (Continued)
Time Delay Exercise

Test More >>
GROUP 2
to be setup from the Setup menu screen. Six addi- Continued from previous page
tional programs and eight exceptions can be setup
Enables or disables the first exercise pro- Exercise 1
gram to run the generator(s) with or with- With/Without Load
out a load. (Default = Without Load)
This screen allows disabling Exercise Exercise 2 Enable

2 only. (Default = Disabled)
Enabled/Disabled
Sets the day of the second exercise cycle. Exercise 2 Start

Enter a day between Sunday and Saturday. _______day
(Default = Sunday)
Sets the time the second exercise cycle

will begin. Exercise 2 Start
Enter a time within a 24 hour period: hr = hr:mn
0−23, mn = 0−59. (Default = 00:00)
Sets a time limit the second exercise cycle

will run. Exercise 2 Duration
Enter a time within a 24 hour period: hr = hr:mn
0−23, mn = 0−59. (Default = 00:00)
Sets an Interval the second exercise cycle

will repeat. Exercise 2 Repeat
Enter a range from 0 to 52 weeks. Typical nn weeks
values are 1 or 2. (Default = 0 weeks)
Enables or disables the second exercise Exercise 2

program to run the generator(s) with or
With/Without Load
without a load. (Default = Without Load)
Add and Delete Exceptions

(continued on next page)
FIGURE 4-19. SETUP GROUP 2 − EXERCISE SUBMENUS

(STARTING WITH SOFTWARE VERSION 1.5.190) (Continued)

Setup − Group 2
Exercise Exceptions Submenus − Starting with Software Version 1.5.190
Time Delay Exercise

Test More >>
GROUP 2
Level 2 Controllers allow for adding and deleting

exceptions to the two exercise programs setup from
the Setup menu screen. Continued from previous page
Indicates the number of active exercise __ Exceptions Active

exceptions. If there are no active excep-

tions, the message “No Exceptions Ac-
tive” is displayed.
This screen allows canceling all excep- Cancl Active Excpts

tions. (Default = Normal)
Normal/Cancel
This screen allows enabling/disabling Exception 1

Exception 1 only. (Default = Disabled) Enabled/Disabled
Sets the month and day for Exception 1.

Enter a starting date that the exercise will Excpt 1 Start Date
not run: mo = 1−12, dy = 1−31. mo/dy
Sets a time of day for Exception 1.

Enter a starting time of day that the exer- Excpt 1 Start Time
cise will not run: hr = 0−23, mn = 0−59. hr:mn
Sets the Time period that Exception 1 will

override an Exercise. Except 1 Duration
Enter a time: dy = 1−31, hr = 0−23, mn = __Days __Hr __Min
0−59.
FIGURE 4-20. SETUP GROUP 2 − EXERCISE EXCEPTIONS SUBMENUS

(STARTING WITH SOFTWARE VERSION 1.5.190)

Setup − Group 2
Exercise Exceptions Submenus (Continued)
Time Delay Exercise

Test More >>
GROUP 2
This screen allows enabling/disabling Exception 1 Repeat

Exception 1 repeating. (Default = Disabled) Enabled/Disabled


Excpt 2 Start Date
Enter a starting date that the exercise will
not run: mo = 1−12, dy = 1−31. mo/dy


Enter a time: dy = 1−31, hr = 0−23, mn = __Days __Hr __Min
0−59.



Setup − Group 2
Exercise Submenus − Starting with Software Version 1.12
These submenus are only available in Utility-to-Genset applications.
Sensor1 SynchChck Time Delay Exercise

GROUP 1 GROUP 2
Displays the Time remaining until the next exer-

cise cycle. If no exercises are enabled, the mes- Next Exercise In
sage “No Next Exercise” is displayed. __Day __Hr __Min
This screen allows disabling Exercise 1 only. Exercise 1 Enable

(Default = Disabled) Enabled/Disabled
The first of four programming submenus for the

Exercise cycle. Sets the day an Exercise cycle Exercise 1 Start
will occur
______day
Select a day between Sunday and Saturday.
(Default = Sunday)
Sets a Time for the exercise cycle to begin.

Exercise 1 Start
hr:mn
hr = 0−23, mn = 0−59. (Default = 00:00)
Sets the length of Time the exercise cycle will

run. Exercise 1 Duration
hr:mn
hr = 0−23, mn = 0−59. (Default = 00:00)
Sets an interval the exercise cycle will repeat.

Enter a cycle between 0 and 52 weeks.
Exercise 1 Repeat
(Default = 0 weeks). Typical values are 1 or 2.
nn weeks
Set the value to 0 to exercise one time only.
Set the value to 1 to exercise once a week.
Set the value to 2 to exercise every other week.
Note: Only one exercise is available for Level 1 Controllers
FIGURE 4-21. SETUP GROUP 2 − EXERCISE SUBMENUS (STARTING WITH SOFTWARE VERSION 1.12)

Setup − Group 2
Exercise Submenus − Starting with Software Version 1.12 (Continued)
Time Delay Exercise

Test More >>
GROUP 2
to be setup from the Setup menu screen. Six addi- Continued from previous page
tional programs and eight exceptions can be setup
Enables or disables the first exercise program Exercise 1
to run the generator(s) with or without a load. With/Without Load
(Default = Without Load)
This screen allows disabling Exercise 2 only. Exercise 2 Enable

(Default = Disabled)
Enabled/Disabled
Sets the day of the second exercise cycle. Exercise 2 Start

Enter a day between Sunday and Saturday. _______day
(Default = Sunday)
Sets the time the second exercise cycle will begin.

Exercise 2 Start
hr = 0−23, mn = 0−59. (Default = 00:00) hr:mn
Sets a time limit the second exercise cycle will

run. Exercise 2 Duration
Enter a time within a 24 hour period: hr:mn
hr = 0−23, mn = 0−59. (Default = 00:00)
Sets an interval the second exercise cycle will
repeat. Enter a range from 0 to 52 weeks.
(Default = 0 weeks) Typical values are 1 or 2. Exercise 2 Repeat
Set the value to 0 to exercise one time only. nn weeks
Enables or disables the second exercise pro- Exercise 2

gram to run the generator(s) with or without a With/Without Load
load. (Default = Without Load)
Add and Delete Exceptions

(continued on next page)

(STARTING WITH SOFTWARE VERSION 1.12) (Continued)

Setup − Group 2
Exercise Exceptions Submenus − Starting with Software Version 1.12
Time Delay Exercise

Test More >>
GROUP 2
Level 1 Controllers allow for setting one exception.

Level 2 Controllers allow for adding and deleting
exceptions to the two exercise programs setup from Continued from previous page
the Setup menu screen.
Indicates the time remaining for the ex- Exception Remaining

ception of the longest duration. If there __Days __Hr __Min

are no active exceptions, the message
“No Excepts Active” is displayed on the
first line.
This screen allows canceling all excep- Cancl Active Excpts

tions. (Default = Normal)
Normal/Cancel


Enter a starting date that the exercise will Excpt 1 Start Date
not run: mo = 1−12, dy = 1−31. mo/dy


Enter a time: days = 1−31, hr = 0−23, __Days __Hr __Min
mn = 0−59.

(STARTING WITH SOFTWARE VERSION 1.12)

Setup − Group 2
Exercise Exceptions Submenus − Starting with Software Version 1.12 (Continued)
Time Delay Exercise

Test More >>
GROUP 2



Excpt 2 Start Date
Enter a starting date that the exercise will
not run: mo = 1−12, dy = 1−31. mo/dy


mn = 0−59.


(STARTING WITH SOFTWARE VERSION 1.12) (Continued)

Setup − Group 2
Exercise Submenus − Starting with Software Version 1.13.244
These submenus are only available in Utility-to-Genset applications.
Sensor1 SynchChck Time Delay Exercise

GROUP 1 GROUP 2
Level 1 Controllers allow for setting two exercise

periods and Level 2 Controllers allow for setting eight
exercise periods from the digital display screen.
Displays the Time remaining until the next exer-

cise cycle. If no exercises are enabled, the mes- Next Exercise In
sage “No Next Exercise” is displayed. __Day __Hr __Min
This screen allows for selecting one of the available

exercises and displays its status. *
View/Edit Exercise
Enter a number between 1 and 8 (Default = 1).
NOTE: Only Exercises 1 and 2 are available with
Level 1 controllers. Exercises 1 through 8 are avail-
able with Level 2 controllers.
This menu is used to enable/disable the Exercise Exercise # Enable

selected in the previous menu. (Default = Dis- Enabled/Disabled
abled)
The first of four programming submenus for the

Exercise cycle. Sets the day an Exercise cycle Exercise # Start
will occur
______day
Select a day between Sunday and Saturday.
(Default = Sunday)
Sets a Time for the exercise cycle to begin.

Exercise # Start
hr:mn
hr = 0−23, mn = 0−59. (Default = 00:00)
* If a password (see the Setup Password Submenu in Figure 4-8) is not entered:
− Only the View/Edit Exercise and View/Edit Exception menus can be modified.
− When the View/Edit Exercise or View/Edit Exception menus are modified, the Save Changes/Cancel
Changes submenu is displayed upon exiting the Exercise submenus.


Setup − Group 2
Exercise Submenus − Starting with Software Version 1.13.244 (Continued)
Time Delay Exercise

Test More >>
GROUP 2
Sets the length of Time the exercise cycle will

run. Exercise # Duration
hr:mn
hr = 0−23, mn = 0−59. (Default = 00:00)
Sets an interval the exercise cycle will repeat.

Enter a cycle between 0 and 100 weeks. (Default = 0
weeks). Typical values are 1 or 2. Exercise # Repeat
Set the value to 0 to exercise one time only. Every __ Weeks
Set the value to 52 to exercise once every 52 weeks.
OR
OR
Enter a cycle for a specific day of the month (1st,
2nd, 3rd, 4th, or 5th ____day of the month).
Exercise # Repeat
For example, set the value to 1st Monday to exercise
Every ___ ___day
only on the first Monday of each month.
NOTE: After selecting the button, press the down
or up button ( or ) until the desired 1st thru 5th
____day value is displayed. The menus required to
set a specific day of the month to exercise are dis-
played when you use the button to go below “0” or
the button to go above “100.”
NOTE: The day of the week displayed in this menu
matches the day selected on the first “Exercise #
Start” menu.
Enables or disables the first exercise program

Exercise #
to run the generator(s) with or without a load.
(Default = Without Load) With/Without Load


Setup − Group 2
Exercise Exceptions Submenus − Starting with Software Version 1.13.244
Time Delay Exercise

Test More >>
GROUP 2
Level 1 Controllers allow for setting two exceptions and
Level 2 Controllers allow for setting exceptions to the
eight exercise programs setup from the digital display
screen. Continued from previous page
Indicates the time remaining for the exception Exception Remaining

of the longest duration. If there are no active __Days __Hr __Min

exceptions, the message “No Excepts Active”
is displayed on the first line.
This screen allows canceling all exceptions. Cancl Active Excpts

(Default = Normal)
Normal/Cancel
This screen allows for selecting an Exception

and displaying its status. *
View/Edit Exception
Enter a number between 1 and 8 (Default = 1).
NOTE: The number selected here must match
the Exercise number selected in the “View/Edit
Exercise” menu.
This menu is used to enable/disable the Excep-

tion selected in the previous menu. (Default = Exception #
Disabled) Disabled/Enabled

Enter a starting date that the exercise will not Excpt 1 Start Date
run: mo = 1−12, dy = 1−31. mo/dy
* If a password (see the Setup Password Submenu in Figure 4-8) is not entered:
− Only the View/Edit Exercise and View/Edit Exception menus can be modified.
− When the View/Edit Exercise or View/Edit Exception menus are modified, the Save Changes/Cancel
Changes submenu is displayed upon exiting the Exercise submenus.


Setup − Group 2
Exercise Exceptions Submenus − Starting with Software Version 1.13.244 (Continued)
Time Delay Exercise

Test More >>
GROUP 2

Enter a starting time of day that the exercise will Excpt 1 Start Time
not run: hr = 0−23, mn = 0−59. hr:mn
Sets the Time period that the Exception will

override the same numbered Exercise. Except # Duration
mn = 0−59.
This menu allows for enabling/disabling Exception # Repeat

repeating the Exception. (Default = Dis- Enabled/Disabled
abled)


Setup − Group 3
Mode Submenu − Prior to Software Version 1.20.250
Sensor 1 Time Delay Exerciser Mode Sequencer

Sensor 2 More >> Test More >> Clock More >>
GROUP 1 GROUP 2 GROUP 3
Transfer Mode
Progrm Transition
The transfer mode is preset and cannot

be changed.
FIGURE 4-25. SETUP GROUP 3 − MODE SUBMENU (PRIOR TO SOFTWARE VERSION 1.20.250)
Setup − Group 3
Mode Submenu − Starting with Software Version 1.20.250
Sensor 1 Sync Check Time Delay Exercise Mode Sequencer

Sensor 2 More >> Test More >> Clock More >>
GROUP 1 GROUP 2 GROUP 3
Transfer Mode
Progrm Transition
Program Transition
Open Sync Check
Closed Momentary
(Default = Closed Momentary)
NOTE: Available settings vary from genset to genset
FIGURE 4-26. SETUP GROUP 3 − MODE SUBMENU (STARTING WITH SOFTWARE VERSION 1.20.250)

Setup − Group 3
Clock Submenus
Mode Sequencer
The Clock submenus allow the Clock More >>
user to set the actual date and-
time, as well as select the Daylight
Saving Time option.
Sets the actual day and date.

Date:
Enter a month between Jan = 1 and Dec =
Day mo/dd/yyyy
12, date between 1 and 31, and year be-
tween 1 and 9999.
Sets the actual time of day. Time:

Enter the actual time within a 24 hour period hh:mm:ss
Enter a time within a 24 hour period: hh = 0 −
23, mm = 0 − 59, ss = 0 − 59.
Activates the Daylight Savings time option. Daylight Saving

Selecting Enabled automatically updates the Enabled/Disabled

clock +/− one hour on the appropriate days.
(Default = Disabled)
Note: The Daylight Savings Time program is set for North America. If you are anywhere outside of North America, the
time should be changed manually.
The first Sunday in April − moves the time forward one hour.
The last Sunday in October − moves the time back one hour.
FIGURE 4-27. SETUP GROUP 3 − CLOCK SUBMENUS

Setup − Group 3
Sequencer Submenus
The Sequencer submenus are a
software−only feature allowing the
user to send a predetermined se-
Mode Sequencer quence of network event announce-
ments. The announcements are
Clock More >>
sent in a timed, sequential order
and are used to turn ATS loads off
and on. When used, a few seconds
should be allowed between load
steps to allow the generator voltage
Sequencer is available only with the optional Network and frequency to stabilize.
Communication Module. The module must be installed
and enabled with the PC service tool before these
screens are displayed.
When Enabled, allows event announce-

ments to be sent to the transfer switch. Load Sequencer
Enabled/Disabled
Sets activation for certain operational

modes. Sequence Activation
Transfer/Re-transfer/All
Choose Transfer, Re-transfer, or All
The control can activate a maximum of 8

relay output signals. Sequence Length
8 Second
Enter the number of relay output signals
desired to activate: 1 thru 8.
When Load Sequencer is triggered, the

controller deactivates all remote relay out- Output 1 Time Delay
put signals. Starting with Relay 1, the con- 5 Second
troller counts down the specified time
delay, then activates Relay 1.
Enter a time from 0 to 60 seconds.
If the Sequence Length is greater than 1,

the control counts down the specified Output 2 Time Delay
Relay 2 time delay, then activates the 5 Second
Relay 2 signal.
Enter a time from 0 to 60 seconds.
Menus continue through
Output 8, depending on
The process repeats until all relay signals the number of Sequence
have been sequenced. The maximum time Lengths specified.
delay for all 8 signals is 8 minutes.
FIGURE 4-28. SETUP GROUP 3 − SEQUENCER SUBMENUS

THIRD MAIN MENU − About Submenus − Prior to Software Version 1.20.250
The About submenus contain read-
only information about the transfer
switch and controller. About Active TD
System More >>
HOME PREVIOUS
MENU
Displays the name of the switch as de- Name of Switch

fined in the Event Handling Requirement.

Displays the current firmware version of Software Version

the controller.
n.nn
Displays the manufacturing date of the Build Date

controller.
mo/dy/yr
Data
Test Mode
Displays the configuration of the control-
ler. Changes are made by service per-
sonnel using the PC service tool.

ATS Configuration
Data  Util−Gen
Utility−Utility
Genset−Genset
Unknown
Data
Displays the mode of operation the con-
trol is using. Adjustments can be made
by service personnel using the PC ser-

ATS Type
Data  OT = Open Transition
BT = Bypass Transition
vice tool. Unknown
Displays the ATS board level (1 or 2). ATS Board Level

NOTE: This menu was not included in 2
early versions of software.
FIGURE 4-29. THIRD MAIN MENU − ABOUT SUBMENUS (SOFTWARE VERSIONS PRIOR TO 1.20.250)

THIRD MAIN MENU − About Submenus − Prior to Software Version 1.20.250 (continued)
About Active TD
System More >>
HOME PREVIOUS
MENU
Hardware Software
Detected Enabled Data
This screen indicates if a Network Com- Network Module True True OK

munications Module is installed and en- OK False True Not Installed
abled. True False Not Enabled
False False Not Available
This screen indicates if the Relay Module Relay Module

hardware is installed. OK
Data
OK
Not Installed
This screen indicates if the Load Current Load Module
Module hardware is installed. OK
This feature is not available on Level 1
controllers
FIGURE 4-29. THIRD MAIN MENU − ABOUT SUBMENUS (SOFTWARE VERSIONS PRIOR TO 1.20.250)
(Continued)

THIRD MAIN MENU − About Submenus − Starting with Software Version 1.20.250
The About submenus contain read-

only information about the transfer
switch and controller. About Active TD
System More >>
Home Previous
Menu
Displays the name of the switch as de- Name Tag

fined in the Event Handling Requirement.
Onan ATS
Displays the current firmware version of Software Version

the controller.
n.nn
Displays the current bootcode version of Bootcode Version

the controller.
n.nn.nnn
Displays the manufacturing date of the Build Date

controller.
mm/dd/yy
Data
OHPC/CHPC
Displays the switch mechanism of the Zenith
controller.

Switch Mechanism
Data  Zenith2
OTPC/BTPC
PLT
Data
Displays the configuration of the control- Offline
ler. Changes are made by service per-
sonnel using the PC service tool.

ATS Configuration
Data  Util−Gen
Util−Util
Gen−Gen
FIGURE 4-30. THIRD MAIN MENU − ABOUT SUBMENUS (STARTING WITH SOFTWARE VERSION 1.20.250)

THIRD MAIN MENU − About Submenus− Starting with Software Version 1.20.250 (continued)
About Active TD
System More >>
Home Previous
Menu
Data
Displays the mode of operation the con-
trol is using. Adjustments can be made
by service personnel using the PC ser-

ATS Type
Data  OT = Open Transition
BT = Bypass Transition
vice tool. CT = Closed Transition
Displays the ATS board level (1 or 2). ATS Board Level

2
Hardware Software
Detected Enabled Data
This screen indicates if a Network Com- Network Module True True OK

munications Module is installed and en- OK False True Not Installed
abled. True False Not Enabled
False False Not Available
This screen indicates if the Relay Module Relay Module

hardware is installed. OK
Data
OK
Not Installed
This screen indicates if the Load Current Load Module
Module hardware is installed. OK
This feature is not available on Level 1
controllers.
FIGURE 4-30. THIRD MAIN MENU − ABOUT SUBMENUS (STARTING WITH SOFTWARE VERSION 1.20.250)
(Continued)

THIRD MAIN MENU − System Submenus
These submenus are available only with the optional Network Communication Module.
The status of up to 32 devices can be viewed at the ATS.
About Active TD
System More >>
The System submenus give the user
Returns to First Top Level Menu
access to data from surrounding Lon-
Works network devices. HOME PREVIOUS
MENU
Available only with networked transfer switches
ATS Master ATS Master

Generator Generator
Load (kW)
EXAMPLES EXAMPLES
Name Tag (12 Char)
SWEST ATS#1 450kW SWEST GEN#1 0kW

Auto S1=ON S2=NA Warning Lo Batt
Operational State
Status of Unit
NWEST ATS#16750kW NWEST GEN#16 750kW

NonAuto S1=NA,S2=Ok Auto Running
If no Generator Sets are connected to the

system, the message “No GenSets Found”
is displayed.
The Master Control menu displays information on:

ATS Master 1. Power (kW)
Generator 2. Master Control Status
(Non Auto, Ready, Norm Fail, Test)
3. Voltage Source Status
EXAMPLE ([N=Source1, E=Source2], On, OK, or NA).
If a Master Control is not connected to the system,
Master >###0 kW the message “No Master Control” is displayed.
Shutdwn N=On, E=NA NOTE: The Master Control menu is not available
in early versions of software.
FIGURE 4-31. THIRD MAIN MENU − SYSTEM SUBMENUS

THIRD MAIN MENU − Active TD Submenus − Prior to Software Version 1.12
About Active TD
System More >>
HOME PREVIOUS
MENU
EXAMPLES
Shows Time Delay activity
If there are no active time delays,

Test in Process
the message “No Timer Active” is
TDNE n displayed.
Shows type of Time Delay

and a countdown
Test in Process
TDPT n
NOTE: Active TD menus were not available on early versions of software.
FIGURE 4-32. THIRD MAIN MENU − ACTIVE TD SUBMENUS (SOFTWARE VERSIONS PRIOR TO 1.12)

THIRD MAIN MENU − Active TD Submenus − Starting with Software Version 1.12
About Active TD
System More >>
Home Previous
Menu
EXAMPLES
Shows name of Time Delay
TDNE
nnnn Sec
Shows the remaining time,

in seconds
This menu shows a Preferred

Changeover in Source Changeover Timer and
nnn Day nn Hr nn Min remaining time (Utility-to-Utility
and Genset-to-Genset applica-
tions only)
No Timer Active
This message is displayed only if
there are no active time delays.
FIGURE 4-33. THIRD MAIN MENU − ACTIVE TD SUBMENUS (STARTING WITH SOFTWARE VERSION 1.12)

First Main Menu Second Main Menu Third Main Menu
< Source1 Load > < Statistic Setup > Enter Password + Enter Password Enter Password < About
< Source2 More >> < Events More >> < System More >>
Setup
Group 1 To First
Setup Group 2 Setup Group 3 Main Menu
< Sensor1 < TimeDelay Exercise >
Volts L12 L23 L31 < Mode Sequencer >
Run Time < Sensor2 More >> To < Test More >> To
Group 2 Group 3 < Clock More >> To
Source1 Group 1
Volts L1N L2N L3N Name of Switch
Run Time Source2
Sensing Test
Frequency
Transfer Mode Software Version
Average Trans Time TDNE See
Preferred Source
S1 Nominal Voltage Note 1
Source 1 (2) Save/Restore Load Sequencer
Build Date
Number of Transfers
TDEN Save/Restore
Run Time Source1 (2) S1 UV Pickup
Sequence Activation
TDESa ATS Configuration
Total Source1 Fail Exercise Enable
S1 UV Dropout
Volts L12 L23 L31 Sequence Length
TDECa Date ATS Type
Total Source2 Fail Next Exercise *
Volts L1n L2n L3n
S1 UV Time
Output 1 Time Delay
Delay TDPT Time Network Module
Program 1
Control Batteries
Amps l1 l2 l3 S1 OV Enable
TDEL Start Day 1 Relay Module
Daylight Saving
Battery Charger Output 8 Time Delay
Frequency S1 OV Pickup
TDESb Start Time 1 Save/Restore Load Module
Save/Restore
4-47
Real Power kW Control On Time
S1 OV Dropout TDECb Duration 1
Apparent Power kVA
S1 OV Time Delay Changeover Program 1 Repeat
Power Factor
Changeover Delay Exercise 1
S1 Frequency Sensor
Neutral Current ATS Generator
Save/Restore Program 2
S1 Imbalance Sensor
Nominal Frequency
Start Day 2 SWEST ATS#1450kW SWEST GEN#1 0kW
Imbalance Dropout
Most Recent Event Frequency Pickup
Start Time 2
NWEST ATS#16 750kW NWEST GEN#16 750kW
2nd Most Recent Event Imbalance Delay Frequency Dropout
Duration 2
3rd Most Recent Event S1 Loss of Phase Level 2 Controllers Only

Frequency Delay Program 2 Repeat
4th Most Recent Event

Phase Rotation Exercise 2 *May not be displayed in v1.0
Note 1 − This menu is available with utility-to-utility and genset-to-genset
Save/Restore Save/Restore applications only.
FIGURE 4-34. MENU SYSTEM MAP − PRIOR TO SOFTWARE VERSION 1.5.190
Copyright  2021 Cummins Inc.

< Source1 Load > < Statistic Setup > Enter Password + Enter Password Enter Password < About Active TD >
Setup
Group 1 To First
Source1 Group 1
Run Time Source2
Sensing Test
Frequency
Average Trans Time TDNE See
Preferred Source

Build Date
Number of Transfers
TDEN Save/Restore
Sequence Activation
TDESa ATS Configuration
Total Source1 Fail
S1 UV Dropout
Volts L12 L23 L31 Exercise Feature Sequence Length
TDECa Date ATS Type
Total Source2 Fail
S1 UV Time Active Exceptions
Volts L1n L2n L3n Next Exercise In * Output 1 Time Delay
Delay TDPT Time Network Module
Control Batteries Cancel Exceptions
Amps l1 l2 l3 S1 OV Enable Exercise 1 En-
TDEL able Relay Module
Daylight Saving
Battery Charger Exercise 1 Start Date Exception 1 Enabled Output 8 Time Delay
TDESb Save/Restore Load Module
Exception 1 Start Date Save/Restore
4-48
Real Power kW Control On Time Exercise 1 Start Time
S1 OV Dropout TDECb
Exercise 1 Duration Exception 1 Start Time
Apparent Power kVA
S1 OV Time Delay Changeover Enable
Exercise 1 Repeat Exception 1 Duration

Power Factor
Changeover Delay
S1 Frequency Sensor
Exercise 1 Exception 1 Repeat
Neutral Current ATS Generator Master
Save/Restore
S1 Imbalance Sensor
Nominal Frequency Exercise 2 Eanble Exception 2 Enabled
SWEST ATS#1450kW SWEST GEN#1 0kW Test in Process
Imbalance Dropout Exercise 2 Start Date
Most Recent Event Frequency Pickup Exception 2 Start Date
Test in Process
Exercise 2 Start Time NWEST ATS#16 750kW NWEST GEN#16 750kW
2nd Most Recent Event Imbalance Delay Exception 2 Start Time
Frequency Dropout
Exercise 2 Duration
3rd Most Recent Event S1 Loss of Phase Exception 2 Duration Test in Process
Frequency Delay Level 2 Controllers Only
Exercise 2 Repeat
4th Most Recent Event Exception 2 Repeat
Phase Rotation *May not be displayed in v1.5.190
Exercise 2 Note 1 − This menu is available with utility-to-utility and genset-to-genset
Save/Restore
Save/Restore applications only.
FIGURE 4-35. MENU SYSTEM MAP − STARTING WITH SOFTWARE VERSION 1.5.190
Setup
Group 1 To First
Source1 Group 1
Run Time Source2
Sensing Test
Frequency
Avg Transfer Time Preferred Source See
Build Date
Number of Transfers Save/Restore
Sequence Activation
ATS Configuration
Total Source1 Fail
S1 UV Dropout
Volts L12 L23 L31 Exercise Feature Sequence Length
Date ATS Type
Total Source2 Fail
S1 UV Time Active Exceptions
Volts L1n L2n L3n Next Exercise In Output 1 Time Delay
Delay Time ATS Board Level
Control Batteries Cancel Exceptions
Amps l1 l2 l3 S1 OV Enable Exercise 1 En-
TDNE able Daylight Saving Network Module
Battery Charger Exercise 1 Start Date Exception 1 Enabled Output 8 Time Delay
TDEN Save/Restore Relay Module
Exception 1 Start Date Save/Restore
4-49
Real Power kW Control On Time Exercise 1 Start Time
S1 OV Dropout TDESa Load Module
Exercise 1 Duration Exception 1 Start Time
Apparent Power kVA
S1 OV Time Delay TDECa
Exercise 1 Repeat Exception 1 Duration
Power Factor
S1 Frequency Sensor TDPT
Neutral Current ATS Generator Master
S1 Imbalance Sensor TDEL
Nominal Frequency Exercise 2 Eanble Exception 2 Enabled
SWEST ATS#1450kW SWEST GEN#1 0kW Test in Process
TDESb Exercise 2 Start Date
Imbalance Dropout Exception 2 Start Date
Most Recent Event Frequency Pickup
Test in Process
TDECb Exercise 2 Start Time NWEST ATS#16 750kW NWEST GEN#16 750kW
2nd Most Recent Event Imbalance Delay Exception 2 Start Time
Frequency Dropout
Changeover Enable Exercise 2 Duration
3rd Most Recent Event S1 Loss of Phase Exception 2 Duration Test in Process
Frequency Delay
Changeover Delay Exercise 2 Repeat
4th Most Recent Event Exception 2 Repeat Level 2 Controllers Only
Phase Rotation
Save/Restore Exercise 2 Note 1 − This menu is available with utility-to-utility and genset-to-genset
Save/Restore
Save/Restore applications only.

Setup
Group 1 To First
Source1 Group 1
Run Time Source2
Sensing Test
Frequency
Avg OT Transfer Preferred Source See

Delta/Wye TDNE Note 1 Load Sequencer
Source 1 (2) Save/Cancel Changes
Bootcode Version
See
Avg CT Transfer Test w/ w/o Load
Run Time Source1 (2) S1 Nominal Voltage TDEN Note 2
Sequence Activation
Save/Cancel Changes
Build Date
Number of Transfers TDESa
S1 UV Pickup
Date Switch Mechanism
Total Source1 Fail TDECa Exercise Feature
Volts L1n L2n L3n S1 UV Dropout
Output 1 Time Delay
Active Exceptions Time ATS Configuration
Total Source2 Fail TDPT Next Exercise In
Amps l1 l2 l3 S1 UV Time
Delay Cancel Exceptions Daylight Saving ATS Type
TDEL Exercise 1 En-
Control Batteries Output 8 Time Delay
Frequency S1 OV Enable able
Exercise 1 Start Date Exception 1 Enabled Save/Cancel Changes ATS Board Level
TDESb Save/Cancel Changes
4-50
Real Power kW Battery Charger
S1 OV Pickup Exception 1 Start Date
Exercise 1 Start Time Network Module
TDECb
Apparent Power kVA
Control On Time
S1 OV Dropout Exercise 1 Duration Exception 1 Start Time
Changeover Enable Relay Module
Power Factor
S1 OV Time Delay Exercise 1 Repeat Exception 1 Duration
Changeover Delay Load Module
Neutral Current
S1 Imbalance Sensor
S1 Frequency Sensor Save/Cancel Changes
ATS Generator Master
Exercise 2 Eanble Exception 2 Enabled
Imbalance Dropout
Most Recent Event Nominal Frequency
Exercise 2 Start Date SWEST ATS#1450kW SWEST GEN#1 0kW Test in Process
Exception 2 Start Date
2nd Most Recent Event Imbalance Delay Frequency Pickup
Exercise 2 Start Time
Exception 2 Start Time Test in Process
NWEST ATS#16 750kW NWEST GEN#16 750kW
3rd Most Recent Event S1 Loss of Phase
Frequency Dropout Exercise 2 Duration
Exception 2 Duration
4th Most Recent Event Level 2 Controllers Only
Phase Rotation Test in Process
Frequency Delay Exercise 2 Repeat
Exception 2 Repeat
Note 1 − This menu is available with utility-to-utility and genset-to-genset
Save/Cancel Changes applications only.
Exercise 2
Save/Cancel Changes Note 2 − This menu is available with utility-to-genset applications only.
FIGURE 4-37. MENU SYSTEM MAP − STARTING WITH SOFTWARE VERSION 1.12
Setup
Group 1 To First
Source1 Group 1
Run Time Source2
Sensing Test
Frequency
Delta/Wye TDNE Note 1
Source 1 (2) Save/Cancel Changes Load Sequencer
Bootcode Version
See
Run Time Source1 (2) S1 Nominal Voltage TDEN Note 2
Sequence Activation
Save/Cancel Changes
Build Date
Number of Transfers TDESa
S1 UV Pickup
Total Source1 Fail TDECa Next Exercise In
Volts L1n L2n L3n S1 UV Dropout
Output 1 Time Delay
Total Source2 Fail TDPT Exercise #
Amps l1 l2 l3 S1 UV Time
TDEL Exercise # En-
Exercise # Start Date Exception # Save/Cancel Changes ATS Board Level
TDESb Save/Cancel Changes
4-51
S1 OV Pickup Exception # Enabled
Exercise # Start Time Network Module
TDECb
Apparent Power kVA
Control On Time
S1 OV Dropout Exercise # Duration Exception # Start Date
Changeover Enable Relay Module
Power Factor
Exercise # Repeat Exception # Start Time
S1 OV Time Delay
Changeover Delay Load Module
Neutral Current
Exercise w/ w/o Load Exception # Duration
S1 Imbalance Sensor
S1 Frequency Sensor Save/Cancel Changes
Exception # Repeat ATS Generator Master

Imbalance Dropout
Most Recent Event Nominal Frequency See
Note 3
Save/Cancel Changes SWEST ATS#1450kW SWEST GEN#1 0kW Test in Process
3rd Most Recent Event

Test in Process
S1 Loss of Phase NWEST ATS#16 750kW
Frequency Dropout Level 2 Controllers Only NWEST GEN#16 750kW
4th Most Recent Event Note 1 − This menu is available with utility-to-utility and genset-to-genset applications only.
Phase Rotation Frequency Delay
Note 2 − This menu is available with utility-to-genset applications only. Test in Process
Save/Cancel Changes Note 3 − Level 1 Controllers can have up to two exercise periods and two exercise exceptions.
Level 2 Controllers can have up to eight exercise periods and eight exercise exceptions.

Setup
Group 1 To First
< Sensor1 SynchChck < TimeDelay Exercise >
Source1 Group 1
Run Time Source2
Sensing Frequency Bandwidth Test
Frequency

Delta/Wye Voltage Window Note 1
Source 1 (2) Save/Cancel Changes Load Sequencer
Bootcode Version
See
Run Time Source1 (2) S1 Nominal Voltage Manual Offset Note 2
Sequence Activation
Save/Cancel Changes
Build Date
Number of Transfers
S1 UV Pickup Return PT Enable
Total Source1 Fail Next Exercise In
Volts L1n L2n L3n S1 UV Dropout Active Sync
Output 1 Time Delay
Total Source2 Fail Exercise #
Amps l1 l2 l3 S1 UV Time Active Sync Delay
Exercise # En-
TDNE Exception #
Exercise # Start Date Save/Cancel Changes ATS Board Level
Save/Cancel Changes
4-52
S1 OV Pickup TDEN Exception # Enabled
Exercise # Start Time Network Module
Apparent Power kVA
Control On Time
S1 OV Dropout TDESa Exercise # Duration Exception # Start Date
Relay Module
Power Factor
TDECa Exercise # Repeat Exception # Start Time
S1 OV Time Delay
Load Module
Neutral Current
TDPT Exercise w/ w/o Load Exception # Duration
S1 Imbalance Sensor
S1 Frequency Sensor
TDEL Exception # Repeat ATS Generator Master

Imbalance Dropout
Most Recent Event Nominal Frequency See
Note 3
TDESb Save/Cancel Changes SWEST ATS#1450kW SWEST GEN#1 0kW Test in Process
TDECb
3rd Most Recent Event
Test in Process
S1 Loss of Phase NWEST ATS#16 750kW
Frequency Dropout Level 2 Controllers Only NWEST GEN#16 750kW
Changeover Enable
4th Most Recent Event Note 1 − This menu is available with utility-to-utility and genset-to-genset applications only.
Phase Rotation Frequency Delay
Changeover Delay Note 2 − This menu is available with utility-to-genset applications only. Test in Process
Save/Cancel Changes Note 3 − Level 1 Controllers can have up to two exercise periods and two exercise exceptions.
Level 2 Controllers can have up to eight exercise periods and eight exercise exceptions.
Save/Cancel Changes
5. Events
This section describes the Events feature and con- vice tool and the digital display can display the
tains a list of all non-fault events. Events can be dis- events. See the Digital Display Menu System sec-
played on the PC service tool and on transfer tion for how to display previous events.
switches that are equipped with the digital display.
NOTE: The controller automatically saves a record
EVENT TYPES of events twice a day. If power is lost, the controller
attempts to save a record of current events. If the
The controller has two types of events: fault events controller batteries and power are removed, event
and non-fault events. All events have the same for- history may be lost. To save a record of current
mat within the control software. events, use the digital display (Save button in the
Setup sub-menus) or InPower (Save Adjustments)
A fault event is an alarm when the transfer switch or before removing power or the batteries from the
ATS controller is not operating correctly. These transfer switch.
events are detected by the main control software
FAULT EVENTS
subsystems. Fault events can be in either of two
states: active or inactive. Fault events are used in The events listed below describe misoperation of
troubleshooting transfer switch problems. See the ATS. Some faults will require operator interven-
Section 6: Troubleshooting for a list of the fault tion either at the front panel level or physically ser-
events. vice the ATS mechanism.
A non-fault event is a power system fault or a situa- ATS Common Alarm

tion in which the power system is not in the normal
state. Non-fault events can be in either an active or This event is activated if one or more of the follow-
inactive state. Non-fault events provide a chrono- ing codes are active:
logical history of power system behavior.
 Checksum Error (343)
Active events consist of a text message, a date/  Low Controller Battery (441)
time stamp, and an asterisk. Pressing the Reset
button on the control panel acknowledges all active  Fail to Close − Transfer (1113)
events, clears the current event from the display  Fail to close − Retransfer (1114)
and moves it to the history file. The asterisk indica-
tor is part of an active event message until the  S1 Fail to Close
event has been acknowledged.  S1 Fail to Open
Event History  S2 Fail to Close

 S2 Fail to Open
The controller displays the last event that occurred
on the digital display, until it is acknowledged or  Fail to Charge Spring
another event occurs. If another event occurs be-
fore the displayed event is acknowledged, it is dis-  Fail to Disconnect
played and the previous event moves to the history  Control Lockout
file, unacknowledged. Unacknowledged events
are acknowledged when the reset button is  Battery Charger Fault
pressed.  Network Battery Low (477)
The control records up to 50 events in the event his-  Network Comm Error (1468)
tory file. When the history file is full and a new event
occurs, the control adds it to the history file and de-
letes the oldest event in the history file. The PC ser-

Control Locked Out the Fail to Open Time Delay. The controller also
verifies that the transfer switch moved from Neutral
This event gets triggered whenever any of the fol- to Source 2 within the time limit defined in the Fail to
lowing events happen. Close Time Delay.
 S1 Fail to Close For closed transition transfer switches, the control-
ler verifies that the ATS retransferred from Source
 S1 Fail to Open
1 to Source 2 within the time limits.
 S2 Fail to Close
If the time limits are exceeded, the controller
 S2 Fail to Open changes the fault status to active. The fault remains
active until the Reset button is pressed.
Fail to Retransfer
S1 Failed to Close
For utility-to-genset applications, this event is ac-
tive if the transfer switch failed to move from Source While attempting to transfer the load to Source 1,
2 to Neutral or Neutral to Source 1 within a preset this event is detected if the control is not able to
time limit. close the Source 1 contacts. This event is followed
by a “Control Locked Out” event.
For utility-to-utility and genset-to-genset applica-
tions, this event is active if the transfer switch failed S1 Failed to Open
to move from the backup source to the preferred
source within a preset time limit. While attempting to transfer the load to Source 2,
this event is active if the control is not able to open
For open transition transfer switches, the controller the Source 1 contacts. This event is followed by a
first verifies that the transfer switch moved from “Control Locked Out” event.
Source 2 to Neutral within the time limit defined in
the Fail to Open Time Delay. The controller also S2 Failed to Close
verifies that the transfer switch moved from Neutral
While attempting to transfer the load to Source 2,
to Source 1 within the time limit defined in the Fail to
this event is detected if the control is not able to
Close Time Delay.
close the Source 2 contacts. This event is followed
For closed transition transfer switches, the control- by a “Control Locked Out” event.
ler verifies that the ATS transferred from Source 2
S2 Failed to Open
to Source 1 within the time limits.
While attempting to transfer the load to Source 1,
If the time limits are exceeded, the controller this event is active if the control is not able to open
changes the fault status to active. The fault remains the Source 2 contacts. This event is followed by a
active until the Reset button is pressed. “Control Locked Out” event.
Fail to Transfer NON-FAULT EVENTS
For utility-to-genset applications, this event is ac- The events listed below describe the status of the
tive if the transfer switch failed to move from Source power system or the ATS, but are not ATS faults.
1 to Neutral or Neutral to Source 2 within a preset These events are meant to provide a historical log
time limit. of the power system behavior over time.
For utility-to-utility and genset-to-genset applica- Press the Reset button on the control panel to ac-
knowledge the event and clear the message from
tions, this event is active if the transfer switch failed
the display.
to move from the preferred source to the backup
source within a preset time limit. Controller Loss of Power
For open transition transfer switches, the controller The controller signals the network card and other
first verifies that the transfer switch moved from devices that the ATS controller is going to shut-
Source 1 to Neutral within the time limit defined in down due to a lack of power. This signal triggers a

time-delay start or other sequences. After the se- After a Fail to Sync event occurs, another Fail to
quences are complete the controller shuts itself off Sync event may occur or, if set up to do so, the
in order to conserve the back-up batteries. The net- transfer switch may go to open transition. If not set
work card responds by not communicating to the up to go to open transition, a series of Fail to Sync
controller. events may repeat until the system synchronizer is
adjusted or repaired.
CT Enabled
Generator A Common Alarm
This event is active whenever a closed transition
transfer or retransfer is pending. This event is active when the Generator A Com-
mon Alarm input is activated. This input is usually
Emergency Start A only used in genset-to-genset applications. When
this input is active, it indicates that generator A is
This event is active whenever the controller re- shutdown (and locked out).
quires the Source 2 genset to start at rated speed—
Generator B Common Alarm
otherwise known as an emergency start. There is
also a discrete output called Emergency Start A. This event is active when the Generator B Com-
mon Alarm input is activated. This input is usually
Emergency Start B only used in genset-to−genset applications. When
this input is active, it indicates that generator B is
This event is active whenever the controller re- shutdown (and locked out).
quires the Source 1 genset to start at rated speed.
This event is only used in genset-to-genset control Load Sequencer Outputs (1-8)
modes. There is also a discrete output called Emer-
gency Start B. The Load Sequencer feature consists of eight pro-
grammable timers which can control eight different
Exercise in Progress network devices in a timed sequence. Each Load
Sequencer output is an independent Event An-
This event is active whenever an exercise se- nouncement. This is necessary for the Network
quence is active. There is an associated LED out- Control Module (NCM) to receive and transmit
put on the front panel and a relay output on the event changes.
Relay Module.
When these outputs are active, the transfer switch
Exercise Sequence is typically inhibiting another transfer switch from
loading the active source. This allows a gentle
loading of a transfer switch when performing a
This event is active whenever the controller per-
transfer or retransfer sequence.
forms an Exercise sequence. This event is identical
to the Test Start-A and Test Start-B event descrip- The Event Handler generates an Event Announce-
tions. However, an exercise event is initiated by the ment whenever the Load Sequencer outputs (1-8)
controller itself rather than by an external switch in- change state.
put.
Network Wink
Fail to Sync
The network wink event is active whenever the Net-
This event indicates the two power sources have work Control Module (NCM) performs a logical
failed to synchronize either voltage, phase, or fre- write command to the controller. Network wink
quency within the time limit of 120 seconds. events are used by network service technicians to
identify a particular network device—the technician
The event stays active until the Reset/Lamp Test winks a device in order to identify it from other de-
button on the front panel is pressed. The Fail to vices. The controller responds to an active network
Sync relay output stays closed until the Reset but- wink event by placing a Network Wink message on
ton is pressed. the digital display.

Neutral Current Warning Phase Rotation Failure
This event is detected only on switches equipped This event is active whenever Source 1 and Source
with the Load Monitoring bargraph. This event is 2 voltages have difference phase sequences.
active when the neutral current (amps) exceeds the Preferred Source 1 (or 2)
threshold for neutral current.
This event is active when the preferred source vari-
Not in Auto: ATS Motor Disconnected able changes from either Source 2 to Source 1 or
Source 1 to Source 2. The event is inactive when
This event is active whenever the ATS Motor Dis- the preferred source is Source 1.
connect input is active. This input causes the con- Service Tool Connected
troller to enter a non-automatic mode—it does not
try to move the transfer switch mechanism. This event is be active, whenever there is a PC ser-
vice tool connected to the controller. The purpose
Not in Auto: Common Output (Network for this event is to provide a chronological service
Only) history, which is stored at the ATS.
This event is used only in utility-to-utility control
This event is used to support the multiple Not In modes.
Auto conditions. This output has the same value (or
status) as the hardware LED output located on the Source 1 Available
ATS front panel and the Relay Module output.
This event is active whenever the Source 1 sensors
(over/under voltage, over/under frequency, phase
Whenever any of the Not In Auto events are true—
rotation, loss of phase, voltage imbalance) indicate
including, ATS Motor Disconnected, Load Shed,
that Source 1 is within acceptable limits. There is
Transfer Inhibit, Retransfer Inhibit, Bypassed to
an associated LED output on the front panel and a
Source 1, and Bypassed to Source 2—the control
relay output on the Relay Module.
makes this event active.
Source 1 Connected or Bypassed Source 1
The Network Annunciator uses this event to indi-
This event is active whenever the Source 1 position
cate the general status of the ATS Not In Auto out-
input is active. There is an associated LED output
put.
on the front panel, a relay output on the Relay Mod-
ule, and a digital display screen that also indicate
Not in Auto: Load Shed Source 1 Connected.
This event is active whenever the Load Shed input Source 1 Loss of Phase Failure
is active, or the network nviLoadShedCmd input is
This event is active whenever Source 1 is missing
active.
one or more of its (three-phase) voltage sources.
Not in Auto: Retransfer Inhibit Source 1 Over-Voltage Failure
This event is active whenever the Transfer Inhibit This event is active whenever Source 1 voltage is
input is active, or the network nviReTransfer- greater than the acceptable limits, set in the con-
InhCmd input is active. Even though the Not-in- troller.
Auto light is lit, the transfer switch will function cor- Source 1 Over/Under Frequency Failure
rectly.
This event‘ is active whenever Source 1 frequency
Not in Auto: Transfer Inhibit is outside acceptable limits, set in the controller.
Source 1 Under-Voltage Failure

This event is active whenever the Transfer Inhibit
input is active, or the network nviTransferInhCmd This event is active when ever Source 1 voltage is
input is active. less than the acceptable limits, set in the controller.

Source 1 Voltage Imbalance Failure This signal causes the genset to increase speed
(1/2 Hz) to sync with the utility. This signal ends
This event is active whenever Source 1 voltage is when the transfer is complete.
outside acceptable limits set in the controller.
Sync Check Active
Source 2 Available
This event is active whenever an in-phase transfer
This event is active whenever the Source 2 sensors (using the Sync Check Sensor) is pending.
(over/under voltage, over/under frequency, phase
rotation, loss of phase, voltage imbalance) indicate Sync Enable
that Source 2 is within acceptable limits. There is This event is only displayed if active synchronicity
an associated LED output on the front panel and a is enabled. This event becomes active when the
relay output on the Relay Module. control sends a Sync Enable message to a network
generator control.
Source 2 Connected
Test In Progress
This event is active whenever the Source 2 position
input is active. There is an associated LED output This event is active whenever a test sequence is
on the front panel, a relay output on the Relay Mod- active. There is an associated LED output on the
ule, and a digital display screen that also indicate front panel and a relay output on the Relay Module.
Source 2 Connected.
Test Start A
Source 2 Loss of Phase Failure
This event is active whenever the controller per-
This event is active whenever Source 2 is missing forms a Test sequence. The controller also acti-
one or more of its (three−phase) voltage sources. vates the Emergency Start A output in order for the
generator to interpret that a Test/Exercise start is
Source 2 Over-Voltage Failure called for.
This event is active whenever Source 2 voltage is There is also a discrete output called Test Start A
greater than the acceptable limits set in the control- that goes to the Start Type input on gensets with
ler. PowerCommand 3200 controls.
Source 2 Over/Under Frequency Failure Time Delay Engine Cool-Down (TDEC)

This event is active whenever the Time Delay En-
This event is activate whenever Source 2 frequen-
gine Cool-down timer is active—also called the
cy is outside acceptable limits set in the controller.
time delay stop. This event is inactive whenever the
timer expires or is not active. The control activates
Source 2 Under-Voltage Failure
this output whenever the control is cooling down
the generator set.
This event is active whenever Source 2 voltage is
less than the acceptable limits set in the controller. The digital display shows this event when it be-
comes active, in addition, it displays an active
Source 2 Voltage Imbalance Failure countdown, in seconds, of the time delay.
This event is active whenever Source 2 voltage is Time Delay Programmed Transition
outside acceptable limits set in the controller (TDPT)
Speed Adjust This event is active whenever the programmed
transition timer is active (whenever the control is
This event is used to send a Speed Adjust mes- delaying the transfer switch in the neutral position).
sage to a network generator control. The controller This event is inactive whenever the timer expires or
sends the message and logs the event. is not active.

The digital display shows this event when it be- ever the timer expires or is not active. The main
comes active, in addition, it displays an active control loop activates this output whenever the
countdown, in seconds, of the time delay. control requires generator set (A) to start.
Time Delay Source 1 (N) to Source 2 (E) The digital display shows this event when it be-
(TDNE) comes active, in addition, it displays an active
countdown, in seconds, of the time delay.
This event is active whenever the Time Delay
Source 1 to Source 2 timer is active—also called
the time delay transfer. This event is inactive when- Time Delay Start B (TDES-B)
ever the timer expires or is not active. The control
activates this output when the control is counting This event is active whenever the Time Delay
down to transfer the switch from Source 1 to Start B timer is active. This event is inactive when-
Source 2. ever the timer expires or is not active. The control
activates this output whenever the control requires
The digital display displays this event when it be- generator set (B) to start. This event is only present
comes active, in addition, it displays an active for controllers configured for Genset-Genset con-
countdown, in seconds, of the time delay. trol mode.
Time Delay Source 2 (E) to Source 1 (N)
The digital display shows this event when it be-
(TDEN)
comes active, in addition, it displays an active
This event is active whenever the Time Delay countdown, in seconds, of the time delay.
Source 2 to Source 1 timer is active—also called
the time delay retransfer. This event is inactive Transfer Pending (TDEL)
whenever the timer expires or is not active. The
control activates this output when the control is Whenever the Elevator Pretransfer output is active,
counting down to transfer the switch from Source 2 the controller sets this event to active. The control
to Source 1. activates this event whenever a transfer pending
signal is needed in the power system—this is typi-
The digital display shows this event when it be- cally used as an early warning signal for elevator
comes active, in addition, it displays an active systems. When the timer expires, the event will go
countdown, in seconds, of the time delay. inactive.
Time Delay Start A (TDES-A)
The digital display shows this event when it be-
This event is active whenever the Time Delay comes active, in addition, it displays an active
Start A timer is active. This event is inactive when- countdown, in seconds, of the time delay.

6. Troubleshooting
This section describes a typical transfer switch Se- the symptom or isolate the control from these inputs
quence of Events, followed by a description of the before troubleshooting the control.
Control LED indicators and two troubleshooting
procedures. WARNING Improper operation of the genera-
tor set presents a hazard that can cause severe
The first troubleshooting procedure uses fault personal injury or death. Observe all safety pre-
codes from the controls diagnostics. The second cautions in your generator set manuals.
procedure uses conditional schematics and symp-
WARNING AC power within the cabinet and the
toms to diagnose all possible problems, including
rear side of the cabinet door presents a shock
those not covered by the fault codes.
hazard that can cause severe personal injury or
death. Use extreme caution to avoid touching
INPOWER SERVICE TOOL electrical contacts with body, tools, jewelry,
The InPower service tool can be used to test the hair, clothes, etc. Remove power to the door by
transfer switch with functions, including Remote disconnecting connector J1/P1 (on the acces-
Test, Transfer Inhibit, Retransfer Inhibit etc. InPow- sory control panel) before removing and replac-
ing components. The following procedures are
er, when used improperly, can cause symptoms like
to be performed only by technically trained and
warnings and shutdowns that appear to be a defec-
experienced personnel.
tive control. When these problems occur, always
verify that a Test feature was not left enabled with DIGITAL MODULE
InPower. Always disable test features before dis-
connecting InPower. The digital module contains the logic and timing cir-
cuits that control transfer switch operation. This
ABOUT NETWORK APPLICATIONS AND module also contains many of the customer inter-
CUSTOMER INPUTS face circuits (including the genset start signal and
network port), the RS-232 communications port for
In applications with networks and remote customer the service tool, and drivers for the control panel in-
inputs, the genset may start unexpectedly or fail to dicators, switches, and meters.
crank as a result of these inputs. These symptoms
may appear to be caused by the transfer switch Two versions of this module are provided: one for
control. Verify that the remote input is not causing Level 1 controls and one for Level 2 controls.
TROUBLESHOOTING PAGE
Control LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Sequence of Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Troubleshooting Using Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Source 1 Power Fails, But Genset Does Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Genset Starts, But Does Not Assume Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Transfer Switch Does Not Retransfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Genset Continues to Run After Retransfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Genset Starts During Normal Power Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Genset Does Not Exercise Or Exercises But Does Not Transfer Load . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Digital Display Not Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Bar Graph Not Working Or Inaccurate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Unable To Activate Front Panel Switches (Test and Override) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

POWER MODULE The indicators provide some information about the
current control status. These indicators may be
The power modules contain a power supply for the helpful in troubleshooting the transfer switch when
digital modules, voltage sensing transformers, and the Digital Display is not available. See Figure 6-1
relays. These modules also contain the interface and Table 6-1.
circuits for the transfer switch including the position
sensing switches and relay drivers. Exerciser Enable/Disable Switch
Two versions of this module are provided: one for The Exerciser Enable/Disable switch (Figure 6-1)
Level 1 controls and one for Level 2 controls. The enables the control to exercise the genset during fu-
power modules are available in four different volt- ture scheduled exercise periods and lights the Ex-
age ranges. erciser Enabled indicator or disables the scheduled
exercise period and turns the indicator off. If the Ex-
CONTROL LED INDICATORS AND ercisor Enable/Disable switch is enabled, the oper-
SWITCH ator can also enable/disable the exerciser from the
Digital Display, when it is available or from the PC
LED Indicators Service Tool.
The digital module located on the inside of the

switch enclosure door contains ten LED indicators.
DIGITAL MODULE
STATUS
S1 AVAILABLE
S2 AVAILABLE
START A/TDES-A
START B/TDES-B
RETRANSFER TDEN
TRANSFER TDNE
NOT USED
TDPT
EXERCISER-ENABLED
TRANSFER SWITCH
ENCLOSURE DOOR INSIDE
LED INDICATORS
EXERCISER
ENABLE/DISABLE
SWITCH
FIGURE 6-1. LED LOCATION ON DIGITAL MODULE (SHOWN ON THE 40 TO 125 AMP SWITCH)

TABLE 6-1. DIGITAL MODULE LED INDICATORS
Indicator Definition
Status Blinks at 1/2 Hz rate when the controller has power and the program is running with-
out error. This indicator flashes the event code of an active event until the event is
acknowledged with the Reset switch on the front panel. This indicator is sometimes
referred to as the heart beat because it blinks constantly when the controller does not
have an active event. (Refer to Table 4-2.)
S1 Available Lights when Power Source 1 has acceptable voltage and frequency limits. This indi-
cator lights when the Source 1 Available indicator on the control panel lights.
S2 Available Lights when Power Source 2 has acceptable voltage and frequency limits. This indi-
cator lights when the Source 2 Available indicator on the control panel lights.
Start A/TDES-A 1. Lights constantly when the control has commanded Source 2 to start
2. Blinks at 1/2 Hz rate during the time delay to engine start (TDESa)
Start B/TDES-B This indicator is only used for genset-to-genset applications when Source 1 is a gen-
erator not a utility.
1. Lights constantly when the control has commanded Source 1 to start
2. Blinks at 1/2 Hz rate during the time delay to engine start (TDESb)
Retransfer/TDEN 1. Lights when the control energizes the Retransfer relay
2. Blinks at 1/2 Hz rate during the time delay to retransfer (TDEN)

Transfer/TDNE 1. Lights when the control energizes the Transfer relay
2. Blinks at 1/2 Hz rate during the time delay to transfer (TDNE)

TDPT Time Delay Programmed Transition
Blinks at 1/2 Hz rate during the programmed transition time delay
Exerciser Enabled Lights when the Exerciser clock is enabled and blinks during an exercise period. The
small switch next to the indicator enables and disables the exerciser. The operator
can also enable and disable the exerciser from the Digital Display when it is available.
SEQUENCE OF EVENTS cified limits with the under-voltage, over-volt-

age, frequency, phase rotation, or loss of
The control executes a prescribed sequence of phase sensors.
events for all transfer switch operations. See Figure
6-1. The operations for a typical loss of main power 2. Source 1 Available indicator goes out.
and a return of that main power are:
3. The control initiates a TDES (time delay, en-
gine start) that delays engine start up for
Transfer from Source 1 to Source 2 Source 2.
This sequence of events includes a programmed 4. If TDES expires without a return to acceptable
transition and begins with Source 1 supplying pow- Source 1 power, the control starts the genset.
er to the load. The Source 1 Available and Source 1 The control issues a Start signal by de-energiz-
Connected indicators are lit. The sequence ends ing relay K10. The Start A/TDES-A indicator is
with Source 2 (generator) assuming the load. on steady.
1. Source 1 fails. The control senses that Source 5. As soon as the control senses that the genera-
1 voltage and frequency are not within the spe- tor (Source 2) output is within the specified volt-

age and frequency limits, it initiates a TDNE 1. Source 1 is restored.
(time delay, Source 1 to Source 2 transfer) to
give the genset time to stabilize. The Source 2 2. The control senses when Source 1 output is
Available indicator lights, and the Transfer/ within the specified voltage and frequency lim-
TDNE indicator begins blinking. its. The Source 1 Available indicator lights
when Source 1 power is within the specified
6. When TDNE expires, the control energizes the limits.
Transfer relay which energizes relay K2. The
switch starts moving toward the neutral posi- 3. The control initiates a TDEN (time delay,
tion. Switch S5 opens interrupting current Source 2 to Source 1) to give Source 1 time to
through the switch motor so that the switch stabilize. The Retransfer/TDEN indicator starts
stops in the neutral position. The Source 1 blinking.
Connected indicator goes out.
4. When TDEN expires, the control energizes the
7. The control verifies that the switch has moved Retransfer relay which energizes relay K1. The
to the neutral position. switch starts moving toward the neutral posi-
tion. Switch S9 opens interrupting current
8. The control initiates a TDPT (time delay, pro- through the switch motor so that the switch
grammed transition) so that residual voltage stops in the neutral position. The Source 2
from an inductive load can decay. The TDPT in- Connected indicator goes out and the Source
dicator starts blinking. 2 Available indicator remains lit.
If the Commit to Transfer function (control ver- 5. The control verifies that the switch has moved
sion 1.33 or higher) is enabled when the switch to the neutral position.
is on neutral, TDPT is not 0, and Source 1 is
available, then the transfer switch ignores 6. The control initiates TDPT so that residual volt-
source 1 and continues to transfer to Source 2. age from an inductive load can decay. The
TDPT indicator starts blinking.
If this is not a programmed transition, TDPT
equals 0 seconds. If this is not a programmed transition, TDPT
equals 0 seconds.
9. When TDPT expires, the control energizes the
Programmed Transition relay which energizes 7. When TDPT expires, the control energizes the
relay K3. The TDPT indicator stops blinking. Programmed Transition relay which energizes
The switch starts moving toward the Source 2 relay K3. The TDPT indicator stops blinking.
position. Switch S8 opens interrupting current The switch starts moving toward the Source 1
through the switch motor so that the switch position. Switch S4 opens interrupting the cur-
stops in the Source 2 position. The generator rent through the switch motor so that the switch
assumes the load. The Source 2 Connected in- stops in the Source 1 position. Source 1 (utility)
dicator lights. assumes the load. The Source 1 Connected in-
dicator lights.
Transfer from Source 2 to Source 1
8. The control initiates a TDEC (time delay, en-
This sequence of events includes a programmed gine cool−down) so that the engine can cool
transition and begins with Source 2 (generator) down under no load conditions.
supplying power to the load. The Source 2 Con-
nected and Source 2 Available indicators are lit. The 9. When TDEC expires, the control turns the en-
sequence ends with Source 1 assuming the load gine off. The Source 2 Available indicator goes
and the generator cooling down. out.

TROUBLESHOOTING USING FAULT with the Reset switch on the front panel. The control
CODES flashes each digit of the fault code with a pause be-
tween digits and a longer pause between repeti-
The Digital Display shows two types of events: fault tions.
events and non-fault events. The last 50 active or
inactive events, both fault and non-fault events (re- The control moves acknowledged events to the
fer to the Events section of the Operator Manual), event history file (refer to Events section). This file
can be viewed with the Digital Display. You can also can hold a maximum of 50 fault and non-fault
read all events in the event history file by using the events. The digital display and the PC Service Tool
PC Service Tool. can read the contents of the Event history file.
Fault Events
The controller displays the fault message on the
Fault events should be considered alarms for the Digital Display with an asterisk indicator. You must
ATS operator. They indicate that the ATS is not op- press the Reset button on the control panel to ac-
erating correctly. Table 6-2 lists the fault codes and knowledge a fault and clear the display.
fault message and Table 6-3 gives corrective ac-
tions for each fault code. Faults can be viewed on transfer switches, without
the digital display by observing the status LED on
TABLE 6-2. FAULT CODES AND MESSAGES the digital module (see Figure 6-1).
1125 ATS Common Alarm
Troubleshooting Warnings
343 Controller Checksum Error
441 Low Controller Battery WARNING Improper operation of the genera-
1113 ATS Fail to Close: Transfer tor set presents a hazard that can cause severe
personal injury or death. Observe all safety pre-
1114 ATS Fail to Close: Retransfer cautions in your generator set manuals.
597 Battery Charger Malfunction
477* Network Battery Low
1468 Network Communications Error hazard that can cause severe personal injury or
* Fault Code 477 (Network Battery Low) only death. Use extreme caution to avoid touching
applies to older installations that includes a Net- electrical contacts with body, tools, jewelry,
work Communications Module with batteries. hair, clothes, etc. Remove power to the door by
disconnecting connector J1/P1 (on the acces-
Fault Flash-Out sory control panel) before removing and replac-
ing components. The following procedures are
The control flashes an active fault code on the Digi- to be performed only by technically trained and
tal Module Status indicator until it is acknowledged experienced personnel.

TABLE 6-3. TROUBLESHOOTING
WARNING Some ATS service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of electricity
and machinery hazards should perform service. See Safety Precautions.
ATS COMMON ALARM (1125)

One or more of the following codes are active: Checksum Error (343), Low Controller Battery (441), Fail
to Close − Transfer (1113), Fail to Close − Retransfer (1114), Fail to Open s1, Fail to Close s1, Fail to
Open s2, Fail to Close s2, Fail to Charge Spring, Fail to Disconnect, Control Lockout, Battery Charger
Fault, Network Battery Low (477), Network Comm Error (1468).
Corrective Action:
1. Clear all the faults mentioned above.
1. Press the Reset button on the front panel.
CONTROLLER CHECKSUM ERROR (343)

The checksum of the Flash EPROM does not match the checksum stored in the controller
Corrective Action:
1. Reset the control by removing power (including the batteries). If checksum error is repeated on pow-
er up, replace the Digital Module.
LOW CONTROLLER BATTERY (441)

Low Lithium battery voltage
Corrective Action:
1. Replace controller batteries. (See Figure 2-5.)
3. Reset real-time clock. (See Figure 4-27.)
ATS FAIL TO CLOSE: TRANSFER (1113)

A transfer between Source 1 and Neutral failed or the allotted transfer time was exceeded.
Corrective Action:
2. Refer to the fault definitions following this table.
3. Refer to Table 6-5.
ATS FAILED TO CLOSE: RETRANSFER (1114)

A transfer between Source 2 and Neutral failed or the allotted retransfer time was exceeded.
Corrective Action:
3. Refer to Table 6-6.

TABLE 6-3. TROUBLESHOOTING (CONTINUED)
WARNING Some ATS service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of electricity
and machinery hazards should perform service. See Safety Precautions.
BATTERY CHARGER MALFUNCTION (597)

The battery charger status signal indicates a fault condition.
Corrective Action:
2. Check the battery charger fuse(s). Replace, if necessary, with fuses of the correct rating. Fuse cur-
rent ratings are shown on the charger faceplate.
NETWORK BATTERY LOW (477)

The Network Control Module (NCM) indicates that the network battery voltage is low.
Corrective Action:
1. Replace the Network Module batteries.
Fault Code 477 only applies to older installations that include an NCM with batteries. NCM boards on current
production models do not use batteries.
NETWORK COMMUNICATIONS ERROR (1468)

The Network Control Module (NCM) indicates that a network communications error has occurred.
Corrective Action:
1.Press the Reset button on the front panel.
1. Press the Reset button on the Network Board at S2.
2. Check LEDs on the board for activity.
DS5 for Network
DS4 for I/O
DS3 for Status
DS2 for Error
DS1 for PC service tool
3. Make sure that J27-21 is installed and tied to B+.

FAULT EVENT DEFINITIONS the Fail to Close Time Delay. The controller will au-
tomatically retry to close the switch every 30 sec-
Controller Checksum Error onds.
The controller checks the Flash EPROM checksum If the Fail to Close time limit is exceeded, the con-
after each microprocessor reset. The checksum is troller changes the fault status to active. The fault
stored in nonvolatile EPROM. If a checksum error remains active until the Reset button is pressed.
fault occurs, the controller still attempts a normal
boot-up sequence. Battery Charger Malfunction
The controller Fault Flash-out subsystem flashes The controller monitors the status of the optional
this fault on the Status indicator until the fault is ac- battery charger. If the Battery Charger Fault input is
knowledged (reset). Reset the control by removing active, this event is active.
power (including the batteries). If checksum error is
repeated on power up, replace the Digital Module. The controller Fault Flash-out subsystem flashes
this fault until the fault is acknowledged (reset).
Low Controller Battery
Network Battery Low
The controller monitors the voltage of the Lithium
batteries that supply power to the controller. If the This event is detected by the optional Network
battery voltage drops to 5.2 VDC, the controller Communications Module (NCM) and is communi-
sets the fault status to active. cated to the controller. If the battery voltage drops,
the controller sets the fault status to active.
The controller Fault Flash-out subsystem flashes
this fault until the fault is acknowledged (reset). The controller Fault Flash-out subsystem flashes
this fault on the Status indicator until the fault is ac-
ATS Fail to Close: Re-Transfer knowledged (reset).
The controller first verifies that the transfer switch Network Communications Error
moved from Source 2 to Neutral within the time limit
defined in the Fail to Close Time Delay. The control- This event is detected by the Network Communica-
ler also verifies that the transfer switch moved from tions Module (NCM) and is communicated to the
Neutral to Source 1 within the time limit defined in transfer switch controller. This indicates that the de-
the Fail to Close Time Delay. The controller will au- vice is no longer communicating with other devices
tomatically retry to close the switch every 30 sec- on the network.
onds.
The controller Fault Flash-out subsystem flashes
If the Fail to Close time limit is exceeded, the con- this fault until the fault is acknowledged (reset).
troller changes the fault status to active. The fault
remains active until the Reset button is pressed. Controller Loss of Power
ATS Fail to Close: Transfer The controller signals the network card and other
devices that the ATS controller is going to shutdown
The controller first verifies that the transfer switch due to a lack of power. This signal triggers a time-
moved from Source 1 to Neutral within the time limit delay start or other sequences. After the sequences
defined in the Fail to Close Time Delay. The control- are complete the controller shuts itself off in order to
ler also verifies that the transfer switch moved from conserve the back-up batteries. The network card
Neutral to Source 1 within the time limit defined in responds by not communicating to the controller.

TROUBLESHOOTING WITH SYMPTOMS ground connections are made. Correct wiring prob-
lems before performing any test or replacing any
Use the troubleshooting guide to help diagnose components.
transfer switch problems. It is divided into sections
based on the symptom. Common problems are Troubleshooting Warnings
listed with their possible causes. Refer to the cor-
rective action column for the appropriate test or ad-
justment procedure. The section page number in
the right column lists the location of the test or ad- rear side of the cabinet door presents a shock
justment procedure in the manual. hazard that can cause severe personal injury or
Conditional schematics are used to highlight the cir- electrical contacts with body, tools, jewelry,
cuit that is energized during the sequence of the hair, clothes, etc. Remove power to the door by
events. These conditional schematics are for a typi- disconnecting connector J1/P1 (on the acces-
cal transfer switch with options. Always refer to the sory control panel) before removing and replac-
schematic and wiring diagram package that was ing components. The following procedures are
shipped with the transfer switch for specific informa- to be performed only by technically qualified
tion about its configuration. Be aware that relays are personnel.
pulsed and the controller automatically retrys to
close the switch every 30 seconds. WARNING Improper operation of the genera-
tor set presents a hazard that can cause severe
Make a thorough inspection of the transfer switch personal injury or death. Observe all safety pre-
wiring to make sure that good wire harness and cautions in your generator set manuals.

6-10
LEGEND:
ENERGIZED
CHANGING POSITION
CONDITION: SOURCE 1 POWER FAILED
AFTER TIME DELAY START (TDES), K10 DE-EN-
ERGIZED TO SEND GENSET START SIGNAL
GENSET STARTS
SOURCE 2 AVAILABLE INDICATOR LIGHTS
AFTER TRANSFER TIME DELAY (TDNE), TRANS-
FER RELAY ENERGIZES
RELAY K2 IS ENERGIZED
SWITCH MOVES TOWARD NEUTRAL POSITION
SWITCH S5 OPENS STOPPING SWITCH IN NEU-
TRAL POSITION
SOURCE 1 POSITION SWITCH S3 OPENS
SOURCE 1 CONNECTED INDICATOR GOES OUT
FIGURE 6-2. TYPICAL CONDITIONAL SCHEMATIC − LOSS OF SOURCE 1 POWER OCCURS, TRANSFER FROM SOURCE 1 TO NEUTRAL
WARNING AC power within the cabinet and the rear side of the cabinet door presents a shock hazard
that can cause severe personal injury or death. Use extreme caution to avoid touching electrical con-
tacts when the cabinet door is open. Remove power to the door by disconnecting connector J1/P1 (on
the accessory control panel) before removing and replacing components. The following procedures
are to be performed only by technically trained and experienced personnel.
WARNING Improper operation of the generator set presents a hazard that can cause severe personal
injury or death. Observe all safety precautions in your generator set manuals.
TABLE 6-4. SOURCE 1 POWER FAILS, BUT GENSET DOES NOT START
Trouble Possible Cause Corrective Action Section-

Page
Start/TDES mode 1. Engine Start time delay active. 1. Wait for Engine Start time delay to 3-2
expire. If Source 1 becomes avail-
able during time delay, the time
delay resets.
2. Press the Override Button on front
panel to bypass the time delay.
Not in Auto indicator 1. Transfer or Retransfer Inhibit rou- 1. Press the Override button. 2-1
tine is active.
2. Selector Switch on genset not in 2. Set the selector switch to the Auto
Auto position. position
3. Load Shed to neutral is active 3. If Source 1 has failed, manually 2-13
move the transfer switch to Source
2, or press the Override button.
Genset cranks but 1. Genset problem. 1. Check the fuel system. Refer to the
does not start. genset service manual.
1a.Genset may have a time delay set-
up between cranking attempts
Genset does not 1. Wiring, Battery, or Genset prob- 1a.Start genset at genset control. If it
crank. lem starts, check wiring of TB2 per the
wiring diagram (See Wiring Diagram
Section). Check the wiring between
the transfer switch and the genset. If
it is OK, go to next possible cause −
No genset start signal.
1b.If it does not crank, check batteries
and cable connections.
1c. If it cranks but does not start at the
genset control, check fuel system
and refer to genset service manual.
Start/TDES indicator 1. No genset start signal. 1. Check for start signal by labeling
OFF and removing the remote start wir-
ing from the genset at TB2-2 and
TB2-4. Attach an ohmmeter be-
tween TB2-2 and TB2-4. Press and
hold the Test button for 2 seconds.
After the TDES has expired, the re-
sistance should change from infinity
to 0 ohms. If the start signal is not
present, and the wiring between
TB2-2 and J27-6 and between
TB2-4 and J27-8 is good, the Digital
module is defective.

6-12
LEGEND:
ENERGIZED
CHANGING POSITION
CONDITION: SOURCE 1 POWER FAILED, SWITCH
IN NEUTRAL POSITION
RELAY K10 REMAINS DE-ENERGIZED
RELAY K2 REMAINS ENERGIZED
PROGRAMMED TRANSITION RELAY IS ENER-
GIZED
SWITCH MOVES TOWARD SOURCE 2 POSITION
SWITCH S8 OPENS STOPPING SWITCH IN
SOURCE 2 POSITION
SOURCE 2 CONNECTED INDICATOR LIGHTS
SWITCH S7 CLOSES
FIGURE 6-3. TYPICAL CONDITIONAL SCHEMATIC − SOURCE 2 AVAILABLE − TRANSFER FROM NEUTRAL TO SOURCE 2
TABLE 6-5. GENERATOR SET STARTS, BUT DOES NOT ASSUME LOAD

Page
Not in Auto indica- 1a.Motor Disconnect switch S1 1a.Move Motor Disconnect switch to AUTO.
tor is ON*. OFF. 1b.J12 disconnected or defective wiring.
2. Transfer Inhibit input active. 2. Remove Transfer Inhibit signal
3. Load Shed input active. 3. Remove Load Shed signal.
Source 2 Avail- 1. Bad connection at P1. 1. Check P1 connection.
able indicator is 2. Genset output voltage not ac- 2a.Measure genset output voltage.
OFF. ceptable or Source 2 voltage 2b.Verify voltage settings in control with digital
settings wrong. display or service tool.
2c. Improper phase rotation (Level 2 only).
3. Defective Power module. 3a.Verify Source 2 voltage input to Power module. 7-3, 7-4
3b.Verify Power module transformer output.
4. Defective Digital module. 4. Replace Digital module. 7-3, 7-4
5. Voltage Imbalance Failure 5. Check voltage imbalance settings. 7-5
Source 2 Avail- 1. Transfer time delay active. 1. Wait for Transfer time delay to expire.
able indicator is
ON, TDNE indica-
tor blinking.
Source 2 Avail- 1. No Transfer signal. 1a.Check Transfer Relay: 10 VDC at J12-17 indi-
able and TDNE cates active Transfer signal.
indicators ON, 1b.Check relay K2, K2 should be momentarily en-
Switch remains in ergized.
Source 1 position.
1c. Check cable between Digital Module and Pow-
(Fault 1113) er Module.
1d.Check Digital Module Source 2 voltage input to 6-3
Power Module and Power Module transformer
voltage output.
1e.Check wiring supplying the lineare motor for
operation print 626−2311 (2 of 5).
Source 2 Avail- 1. No Programmed Transition sig- 1a.Check Programmed Transition Relay: J12-18
able and TDNE nal. indicates an active Programmed Transition
indicators ON, signal.
Switch in neutral 1b.Check relay K3, K3 should be momentarily en-
position ergized.
(Fault 1113) 1c. Check cable between Digital Module and Pow-
er Module.
1d.Check Digital Module and switch
* With motor disconnect switch OFF, Digital Module will send Genset Start signal after 20 second delay.

6-14
LEGEND:
ENERGIZED
CHANGING POSITION
CONDITION: SOURCE 1 POWER RESTORED

RELAY K10 REMAINS DE-ENERGIZED
SOURCE 1 AVAILABLE LIGHTS
AFTER RETRANSFER TIME DELAY
RETRANSFER RELAY ENERGIZED
SWITCH MOVES TOWARD NEUTRAL POSITION
SWITCH S9 OPENS STOPPING SWITCH IN NEU-
TRAL POSITION
SOURCE 2 POSITION SWITCH S7 OPENS
SOURCE 2 CONNECTED INDICATOR GOES OUT
FIGURE 6-4. TYPICAL CONDITIONAL SCHEMATIC − SOURCE 1 RETURNS − RETRANSFER FROM SOURCE 2 TO NEUTRAL
TABLE 6-6. TRANSFER SWITCH DOES NOT RETRANSFER WHEN SOURCE 1 POWER IS RESTORED
AFTER A POWER FAILURE OR ON INITIAL INSTALLATION

Page
Not in Auto indicator is 1. Motor Disconnect switch OFF. 1a.Move Motor Disconnect switch to
ON. AUTO.
1b. J12 disconnected or defective wiring.
2. Retransfer Inhibit input active. 2. Remove Retransfer Inhibit signal
Source 1 Available indi- 1. Time delay to retransfer (TDEN) 1. Wait for TDEN to expire.
cator ON, TDEN indica- has not expired.
tor blinking
Source 1 Available and 1. No Retransfer signal. 1a.Check Retransfer relay: 10 VDC at
TDEN indicators ON, J12-4 indicates an active retransfer
switch remains in signal.
Source 2 position 1b.Check Relay K1, K1 should be mo-
(FAULT 1114) mentarily energized.
1c. Check cable between Digital Module
and Power Module.
1d.Check Digital Module and switch.
1e.Wait for five seconds to one minute to
make sure the motor saver timer is
not activated.
2. Switch problem 2. Check switch and switch wiring
Source 1 Available and 1. No Programmed Transition sig- 1a.Check Programmed Transition relay:
TDEN indicators ON, nal. 10 VDC at J12-1 indicates an active
switch in neutral posi- programmed transition signal.
tion 1b.Check Relay K3, K3 should be mo-
(Fault 1114) mentarily energized.
1c. Check cable between Digital Module
and Power Module.
1d.Check Digital Module and switch.
1e.Wait for five seconds to one minute to
make sure the motor saver timer is
not activated.
Source 1 Available indi- 1. Source 1 voltage not within spe- 1. Measure Source 1 voltage.
cator OFF cified limits.
2. Bad connection at connector P1. 2. Check for continuity through P1.
3. Source 1 voltage settings 3. Verify voltage settings with digital
wrong. display or service tool
4. Defective Digital Module or 4. Replace Digital Module or Power
Power Module. Module.
Source 1 Available indi- 1. Test or Exercise with load ac- 1. Wait for Test or Exercise to complete
cator ON, Test/Exercise tive. or press Test again to end test.
Active indicator lit

6-16
CONDITION: SOURCE 1 RESTORED, SWITCH IN
NEUTRAL POSITION
K10 REMAINS DE-ENERGIZED UNTIL AFTER EN-
GINE COOLDOWN
PROGRAMMED TRANSITION RELAY K3 ENER-
GIZED RELAY K1 IS ENERGIZED
SWITCH MOVES TOWARD SOURCE 1 POSITION
SWITCH S4 OPENS STOPPING SWITCH IN
SOURCE 1 POSITION
LEGEND: SOURCE 1 POSITION SWITCH S3 CLOSES
SOURCE 1 CONNECTED INDICATOR LIGHTS
ENERGIZED
CHANGING POSITION AFTER ENGINE COOL-DOWN DELAY (TDEC)
RELAY K10 OPENS
GENSET STOPS
FIGURE 6-5. TYPICAL CONDITIONAL SCHEMATIC − SOURCE 1 AVAILABLE − TRANSFER FROM NEUTRAL TO SOURCE 1
TABLE 6-7. GENERATOR SET CONTINUES TO RUN AFTER RETRANSFER OF LOAD TO SOURCE 1

Page
Source 2 Available indica- 1. Time Delay Engine Cool-down 1. Wait for TDEC to expire.
tor ON. (TDEC) still active.
Test/Exercise Indicator 1. Exercise program active. 1. Check Exercise setup.
ON. 2. Test in progress. 2. Check Test switch and Test switch
circuit.
TDES-A/Start A Indicator 1. RMT signal still active. 1. Measure voltage between TB2-2
ON and TB2-4. Zero VDC indicates
an active RMT signal that holds
the genset ON.
2. No network start signal. 2. Restart the network.
TABLE 6-8. GENERATOR SET STARTS DURING NORMAL POWER SERVICE

Page
Genset starts during nor- 1. Selector switch on genset not 1. Set selector switch to Remote.
mal power service. set on Remote.
2. Exercise period set on exerciser 2. Refer to exerciser clock program-
clock. ming instructions.
3. Remote test customer input. 3. Check for remote test input at
J4-5.
4. Test switch defective on front 4. Remove ribbon cable, if genset 7-1
panel. stops test switch is defective.
5. Momentary voltage dip from nor- 5. Check undervoltage settings, ad-
mal source. just if needed.
6. Power Module no longer sens- 6a.Verify Source 1 voltage input to 7-3, 7-4
ing Source 1 voltage. Power Module.
6b.Verify Power Module transformer 7-3, 7-4
output.
6c. Check the Event History Log to
find out if the number of Source 1
failures (such as over/under volt-
age, momentary spike that
caused the over/under voltage
timer to time out, phase rotation,
or phase imbalance) is intermit-
tent on the Power Module.
7. Network input for remote start. 7. Remove network remote start in-
put.
8. Voltage imbalance failure. 8. Check voltage imbalance settings.
9. Test input active from PC Ser- 9. Cycle power on control or remove
vice tool. test input with PC Service tool.

TABLE 6-9. GENERATOR SET DOES NOT EXERCISE OR EXERCISES BUT DOES NOT TRANSFER LOAD
Section-
Trouble Possible Cause Corrective Action
Page
Genset does not exercise. 1. Motor disconnect switch not in 1. Set motor disconnect switch to
Auto. Auto.
2. Selector switch on genset not set 2. Set selector switch to Remote.
on Remote.
3. Exerciser program not enabled. 3. Check control LED (Figure 4-1).
Use Digital Display if equipped or
PC Service tool to program.
NOTE: Some software versions in-
clude an exercise feature enable/
disable function. This function must
be enabled before any individual ex-
ercise periods can be enabled.
4. Exercise period not programmed. 4. Refer to exerciser clock program-
ming instructions.
5. Exception program set to prevent 5a.Check exerciser exception pro-
exercise. gram settings either with the digi-
tal display or the PC Service tool.
5b.If desired, cancel all exercise ex-
ceptions either with the digital
display or the PC Service tool.
6. Genset cranks but does not start. 6. Genset fuel system or other gen-
set problem, refer to genset ser-
vice manual.
7. No start signal from transfer 7. Check for start signal by labeling
switch when exercise clock is in and removing the remote start
program mode or remote start wiring from the genset at TB2-2
signal present. and TB2-4. Attach an ohmmeter
between TB2-2 and TB2-4.
Press and hold the Test button
for 2 seconds. After the TDES
has expired, the resistance
should change from infinity to 0
ohms. If the start signal is not
present, and the wiring between
TB2-2 and J27-6 and between
TB2-4 and J27-8 is good, the
Digital module is defective.
Genset exercises at wrong 1. Real-time clock not set. 1. Check or change program with
time. digital display if equipped or the
PC Service tool. Check to see if
more than one exercise is sched-
uled at the same time.
Genset exercises but does 1. Control programmed to exercise 1. Check or change program with
not assume load. without load. digital display if equipped or PC
Service tool.
2. Transfer Inhibit active. 2. Remove Transfer Inhibit signal.

TABLE 6-10. TRANSFER SWITCHES WITH DIGITAL DISPLAY

Page
Front panel display not 1. Feature not enabled. 1. Enable this feature using the PC
working. Service tool.
2. In sleep mode. 2a.Press any button to wake up dis-

play. If display does not wake up,
check status light (Figure 4-1). If
status light flashing, check touch
panel.
2b.Defective connector between 7-1
Digital Module and Digital Dis-
play.
3. Status light on continuous/status 3a.Reset control by removing J1
light not blinking (digital display connector and batteries from
locked up). Digital Module. Reinstall batter-
ies and reconnect J1.
Reprogram real-time clock.
4. Status light off (no power to Digi- 4a.No power to Digital Module. Re- 7-3
tal Module). move J12 from Power Module (to
eliminate short that could load
down the Power Module). Check
for 10 VDC at J18 or J19 (mea-
sure between J18 & J12-13 or
J19 & J12-13 ). If 10 VDC is
present − defective Digital Mod-
ule. If 10 VDC is not present −
defective Power Module.
4b.Make sure line voltage is pres-
ent.
Front panel display kW 1. Current transformers are mis− 1a.Check current transformer wiring
and kVAR inaccurate or wired, reversed, or have an open installation and correctly wire the
negative number. wire. current transformers.
1b.Make sure the current transform-
ers are oriented correctly with the
polarity markes (typically a dot)
facing the transfer switch load
lugs (refer to the installation
manual).
2. Requires calibration. 2a.Update the calibration.
2b.Calibrate the voltage and current
with the PC Service Tool.

TABLE 6-11. TRANSFER SWITCHES WITH BAR GRAPH

Page
Bar Graph − no display 1. Feature not enabled. 1. Requires PC Service tool. The
feature must be enabled and
saved using InPower. Then the
control must be repowered.
Check ribbon cable connector.
Bar Graph display inaccu- 1. CTs mis-wired, CTs reversed, 1a.Check CT wiring installation and 7-45
rate. open wire on CTs. correctly wire CTs.
1b.Make sure the shorting bar on
the CT terminal block is properly
installed.
2. Requires calibration. 2. For minor adjustment use the PC
Service tool.
The bar graph will not illuminate when the transfer switch is in the neutral position; only the bottom
frequency LED will be lit.
TABLE 6-12. TRANSFER SWITCHES WITH KEY SWITCH

Page
Unable to activate Front 1. Key switch in Panel Lock posi- 1. Turn key to Program position.
Panel input switches (Test tion.
and Override) 2. Key switch defective or mis- 2. Check key switch wiring per
wired. Installation drawing and key
switch contacts for proper opera-
tion.
Unable to change setup 1. Key switch in Panel Lock posi- 1. Turn key to Program position.
parameters. (Parameters tion.
can only be read). 2. Key switch defective or mis- 2. Check key switch wiring per
wired. Installation drawing and key
switch contacts for proper opera-
tion.

15/12 AMP BATTERY CHARGER Fault Alarm Output Connector
TROUBLESHOOTING AND FAULTS
The battery charger includes a fault output relay
The 15/12-amp battery charger includes one set of that is activated (contacts close) when faults occur.
Form B alarm contacts (corresponding to the status The contacts are rated at 2 amps/30 VDC. This fea-
LED on the control panel). When red, this LED indi- ture can be used by wiring a fault indicator to the
cates a fault condition. The control panel also dis- fault alarm output connector located on the front of
plays the fault codes listed in Table 6-13. the battery charger (see Figure 2-27). A 2-pin plug
connector (323−1678−02) is shipped with the
When a fault occurs, the red fault LED lights and a 15/12-amp transfer switch battery charger.
brief description of the fault and the numeric fault
code is displayed on the digital display (see Fig-
ure 6-6). To correct the fault, find the fault code
number in Table 6-13 and take the suggested cor-
rective actions. If the problem persists, call an au-
thorized Cummins Inc. distributor for help.
Clearing Faults
Most displayed faults are cleared by removing the
fault. However, faults 379 − OVER CURR, 442 −
HIGH BATT VOLT, and 9115 − BATT FAIL can only
be cleared by cycling completely through the Setup
RESET DIGITAL LED STATUS
menus or by powering down the charger after the BUTTON DISPLAY INDICATOR
fault is corrected. (More information on Setup me-
nus is included in the Battery Charger Operator’s FIGURE 6-6. 15/12-AMP CHARGER CONTROL
Manual.) PANEL

TABLE 6-13. BATTERY CHARGER TROUBLESHOOTING USING FAULT CODES
WARNING Some battery charger service procedures present hazards that can result in se-
vere personal injury or death. Only trained and experienced personnel may perform service.
WARNING Ignition of explosive battery gasses can cause severe personal injury. Do not
smoke or cause any spark, arc, or flame while servicing batteries.
Fault Description Possible Cause Solution
379 − OVER CURR Output Overload Output current is excessive. Cycle through the Setup
Charger control may be menus to try and clear the
failing. fault. If the fault returns, the
charger control may have
failed.
441 − LOW BATT Low Batteryy Voltage
g 1.No battery connected. Connect the battery.
VOLT 2.Output breaker is in the Verify the output breaker is in
“Off” (down) position. “On” (up) position.
3.A 12V battery is con- Attach a 24V battery or set
nected but the charger is the charger for 12V charging.
set for 24V charging.
4.Battery can no longer Replace the battery.
maintain charge.
5.The wire between the Check the wire.
charger and the battery is
loose or broken.
442 − HIGH BATT High Battery 1.A 24V battery is con- Attach a 12V battery or set
VOLT Voltage nected but the charger is the charger for 24V charging.
set for 12V charging.
2.Large load dump may Cycle through the Setup
have caused momentary menus to clear the fault and
voltage rise. restart charging.
2331 − LOW AC Low Input Voltage AC input voltage is more Check level of input voltage.
VOLT than 10% below nominal Charger will not operate with
rated voltage. voltage 10% or more below
nominal.
2358 − HIGH AC High Input Voltage AC input voltage is more Check level of input voltage.
VOLT than 10% above nominal Charger will not operate with
rated voltage. voltage 10% or more above
nominal.
2263 − HIGH BATT Battery Temp above 1.Battery’s ambient temper- Move the battery into a
TEMP 55 degrees C ature is too high. cooler location. Charger will
automatically begin charging
(For installations again after the battery
that include the temperature lowers.
optional battery
temperature 2.Possible shorted cells Replace the battery.
sensor) within the battery is caus-
ing an excessive battery
temperature increase.

TABLE 6-13. BATTERY CHARGER TROUBLESHOOTING USING FAULT CODES (CONT.)
WARNING Some battery charger service procedures present hazards that can result in se-
vere personal injury or death. Only trained and experienced personnel may perform service.
WARNING Ignition of explosive battery gasses can cause severe personal injury. Do not
smoke or cause any spark, arc, or flame while servicing batteries.
Fault Description Possible Cause Solution
2544 − OVER Charger is 1.Charger’s ambient tem- Move the charger to a cooler
TEMP overheating perature is too high. location. The charger will
automatically begin charging
again after the internal
temperature lowers.
2.Charger’s internal cooling Verify that the charger’s air
fan is blocked, failed, or air inlets on the side of the
inlets are covered. charger are not blocked and
nothing is interfering with fan
rotation.
9115 − BATT FAIL Unrecoverable The battery can no longer Replace the battery and
battery hold a charge or has been cycle through the Setup
damaged excessively due to menus to clear the fault.
extremely deep discharge.
NOTE: Faults 379 (OVER CURR), 442 (HIGH BATT VOLT), and 9115 (BATT FAIL) can only be cleared:
By disconnecting the charger harness plug,
By cycling completely through the Setup menus,
or
By recycling the power.
Battery Charger Fails to Charge that the two 10 amp AC circuit breaker switches
have not been tripped (are in the up position). If the
WARNING AC power within the cabinet and the circuit breakers are in the “On” position, call your
rear side of the cabinet door presents a shock dealer or distributor.
hazard that can cause severe personal injury or
death. Use extreme caution to avoid touching For 277, 380, 416, and 600 VAC battery chargers,
electrical contacts whenever the cabinet door is check the battery charger fuse(s). Replace, if nec-
open. essary, with fuses of the correct rating. Fuse am-
pere ratings are shown on the charger faceplate. If
WARNING Ignition of explosive battery gases the fuse is OK, call your dealer or distributor.
can cause severe personal injury. Do not smoke Battery Loses Charge
or cause any spark or flame while servicing bat-
teries. Battery charger float voltage could be too low (if
equipped with battery charger). Call your dealer or
For 120, 208, and 240 VAC battery chargers, verify distributor.

Troubleshooting placement fuses are listed in the battery charger
Operator’s Manual.
Most troubleshooting issues result in fault codes
that are displayed on the battery charger’s digital WARNING Voltages within the charging sys-
display (see Table 6-13). Overload conditions or tem present an electrical shock hazard that can
equipment failures may require additional trouble- cause severe personal injury or death. Discon-
shooting (see Table 6-14). nect all sources of AC and DC power from the
Loss of AC Power battery charger before servicing.
1. Disconnect the battery charger from AC power
When there is a loss of power, the battery charger
and the battery.
relay contacts announce this fault as an AC power
loss. Since the charger is no longer powered, noth- 2. Unscrew the fuse holders from the front of the
ing is displayed on the digital display. battery charger.
Replacing Fuses 3. Check the fuses and replace the blown

fuses(s).
When replacing a blown fuse on battery charger
4. Reinstall the fuse holders.
models that use them, be sure to use a fuse of the
same rating and type. Do not use fuses of a higher 5. Reconnect the battery charger to AC power
rating. Fuses must be UL and CSA certified. Re- and reconnect the charger to the battery.
TABLE 6-14. BATTERY CHARGER TROUBLESHOOTING PROCEDURES
WARNING AC power within the cabinet and the rear side of the cabinet door presents a shock haz-
ard that can cause severe personal injury or death. Some battery charger service procedures pres-
ent hazards that can result in severe personal injury or death. The following procedures are to be
performed only by trained and experienced personnel. Use extreme caution to avoid touching elec-
trical contacts when the cabinet door is open. Do not wear jewelry or loose clothing. Stand on a dry,
non-conductive surface such as a rubber mat or wooden platform. Before removing or replacing
components, remove power to the door by disconnecting connectors J1(removes power to the
door) and J2 (removes power from the battery in the control panel) (both connectors are on the relay
panel assembly)
WARNING Improper operation of the generator set presents a hazard that can cause severe person-
al injury or death. Observe all safety precautions in your generator set manuals.
WARNING Ignition of explosive battery gasses can cause severe personal injury. Do not smoke or
cause any spark, arc, or flame while servicing batteries.
Problem Possible Cause Corrective Action
No DC Output 1.Tripped DC circuit breaker. 1.Correct the possible overload and re-
set the circuit breaker.
2.Blown AC fuse(s) (277, 380, 416, 2.Correct the possible overload and re-
480, and 600 VAC battery chargers). place the fuse(s), as described below.
3.Tripped AC circuit breaker(s) (120, 3.Correct the possible overload and re-
208, and 240 VAC battery chargers). set the circuit breaker.
Low DC Output 1.Faulty battery 1.Replace the battery.
2.Charger failure 2.Call a service representative.
High DC Output Charger failure Call a service representative.

7. Transfer Switch Service
GENERAL MEMBRANE SWITCH TEST
This section provides test procedures for the control All control panels include three membrane
panel membrane switches and Power Module and switches. Control panels with the digital display in-
also covers the removal and replacement proce- clude nine membrane switches. This procedure
dures for the transfer switch assembly. checks the resistance of each membrane switch
from a cable connector on the membrane panel.
REMOVING AND REPLACING
ELECTRONIC CONTROL COMPONENTS
1. Remove the connector from J25 on the Digital
WARNING AC power within the cabinet and the Module circuit board. See Figure 7-1.
hazard that can cause severe personal injury or 2. Press the switch down and measure the resist-
death. Disconnect connector J1/P1 before ance between the switch common (pin 10) and
working on the electronic control system. each switch. Measure the resistance on the
solder points on the connector. The resistance
Disconnecting J1/P1 removes all power to the of a closed membrane switch should be in the
door. range of 0 to 200 ohms depending on how hard
you press. Figure 7-2 shows membrane switch
Be sure to remove all power before replacing elec-
configuration and Table 8-1 lists the pin con-
tronic control modules and components. This in-
nections corresponding to the membrane
cludes removing one of the two Lithium batteries
switches.
from the digital display module. The battery can be
replaced after replacing or adding new compo-
nents. No special tools are required to remove and 3. Attach the connector to J25.
replace control system components. Be sure to use
all of the hardware when remounting components. 4. Close and lock the enclosure door.
DIGITAL MODULE
PIN 1 PIN 10
CONNECTOR J25
FIGURE 7-1. LOCATION OF CONNECTOR J25

TABLE 8-1. MEMBRANE SWITCH PINS 1. Make sure to disconnect any electrical compo-
nents from the membrane panel before start-
PIN SWITCH SWITCH NAME ing.
1 S1 TEST
2. Start to remove exisiting membrane panel from
2 S2 OVERRIDE the surface by pulling from one corner and con-
3 S3 RESET/LAMP TEST tinue pulling with an even force until the entire
4 S4 PREVIOUS MENU membrane panel is removed. Discard mem-
brane panel.
5 S5 HOME
6 S6 3. Generously spray a clean cloth towel with iso-
7 S7 propyl alcohol, and saturate the adhesive area
with the soaked cloth towel and allow to sit for
8 S8
3−5 minutes. (To prevent isopropyl alcohol
9 S9 from dripping into the electronics behind the
10 COMMON cutouts in the door panel, do not over saturate
the towel.) Goo Gone spray gel may be used in
the same manner as the isopropyl alcohol.
Make sure to clean the surface with isopropyl
S1 S2 S3 alcohol after using the Goo Gone to remove
Goo Gone residue prior to installing the re-
placement membrane panel.
S6 S8 4. Once the isopropyl alcohol or Goo Gone gel
has soaked into the adhesive, use 2−inch
masking tape or duct tape as a carrier for re-
S7 S9 moving the adhesive by pressing the tape onto
S5 S4 the adhesive. Keep working the tape on the
adhesive by applying and removing it until all
the adhesive has been removed.
FIGURE 7-2. SWITCH LOCATIONS
(AS YOU FACE THE CONTROL PANEL) 5. Wipe the entire surface with a clean cloth towel
sprayed with isopropyl alcohol to remove adhe-
sive and Goo Gone residue before applying the
replacement membrane panel. Make sure all
REMOVING AND REPLACING MEMBRANE the old adhesive is removed and the surface is
PANEL AND ADHESIVE dirt and oil free.
6. Apply the replacement mem brane panel.

Procedure completion time: Maximum 1 hour from
start to finish. 7. Reconnect the electrical components.

POWER MODULE TEST TABLE 8-2. POWER MODULE 1 (300-5148)
When a Power Module failure occurs, the most INPUT OUTPUT TERMINAL**
common part to fail is the transformer. Use the fol- NA 3 VDC J11 − 1
lowing information to determine if a Power Module Source 1 NB 3 VDC J11 − 3
transformer(s) is causing the error condition. NC 3 VDC J11 − 5
Power Module 1 10 VDC* J18, J19
EA/EC 3 J11 − 7
Source 2
Table 8-2 provides the test points and voltage level VDC
that should be found at each test point for a good 10 VDC* J18, J19
board. Refer to page 8-32 for Power Module 1 wir-
CR3, CR4, J11 − 29
ing diagram. CR5
20-30 VDC
A wiring break-out tool (34 pin) is required to mea- * Use only one source when checking for regulated DC.
sure J11 test points. This tool is contained in the
Cummins PCC Tool Kit, P/N 3824746. ** Use J12-13 for DC ground.
CONNECTOR J11 J18
J12-13
(DC GND)
12 13
14 15
16 17
18 19
J19
TB11
FIGURE 7-3. POWER MODULE 1 PCB COMPONENT LOCATIONS

Power Module 2 TABLE 8-3. POWER MODULE 2 (300-5149)
INPUT OUTPUT TERMINAL**
Table 8-3 provides the test points and voltage level
that should be found at each test point for a good NA 18 VAC J11 − 1 & 2
board. Refer to page 6-26 for Power Module 2 wir- Source 1 NB 18 VAC J11 − 3 & 4
ing diagram and test point locations. NC 18 VAC J11 − 5 & 6
A wiring break-out tool (34 pin) is required to mea- 10 VDC* J18, J19
sure J11 test points. This tool is contained in the EA 18 VAC J11 − 7 & 8
Cummins PCC Tool Kit, P/N 3824746. Source 2 EB 18 VAC J11 − 9 & 10
EC 18 VAC J11 − 11 & 12
10 VDC* J18, J19
CR1, CR4 20-30 VDC J11 − 29
* Use only one source when checking for regulated DC.
** Use J12-13 for DC ground.
CONNECTOR J11 J18
TB14 TB12
J12-13
(DC GND)
12 13
14 15
16 17
18 19
TB13
J19
TB11
FIGURE 7-4. POWER MODULE 2 PCB COMPONENT LOCATIONS

DIGITAL BOARD REPLACEMENT 4. Connect connector P1.
This procedure describes the replacement of Initial Calibration

300−5146 and 300−5147−01, 02, and 03 digital
boards on automatic transfer switches. Use InPower to perform an initial calibration on the
replacement digital board. Select the calibration
Digital Board ATS Description settings and features to match the transfer switch
nameplate values.
300−5146 Level 1 Control
For the changes to take effect, remove all power
300−5147−01 Level 2 Control with Open
Transition from the digital board, including the batteries. This
will update the “Restore Factory Settings” to the val-
300−5147−02 Level 2 Control with Momentary ues written to the digital board during the initial cal-
Closed Transition ibration.
300−5147−03 Level 2 Control with Extended NOTE: Do not apply the initial calibration to a
Paralleling closed transition board, as it will perma-
nently disable the closed transition feature
The InPower service tool is required to set up the and require the board to be replaced.
replacement digital board. The setup can be auto-
mated with a capture file. If a good capture file is not Setup with a Capture File
available, individual parameters need to be set up
If you have a capture file from the original board
for the application.
when it was working properly, use InPower to
WARNING AC power within the cabinet and the write the capture file to the replacement board. All
inside of the cabinet door presents a shock haz- your settings should be updated automatically on
ards that can result in severe personal injury or the new board. Review all the settings before plac-
death. Use extreme caution to avoid touching ing the motor disconnect switch in the “On” position.
electrical contacts when the cabinet door is NOTE: The use of a capture file updates the “Real
open. Remove power to the door by disconnect-
Time Clock” with settings from the old data. After
ing connector J1/P1 before working on the elec-
writing the capture file, update each of the Real
tronic control system. All service and adjust-
Time Clock settings.
ments to the transfer switch must be performed
by trained and experienced personnel only. Setup Without a Capture File
1. Place the motor disconnect switch in the “Off” Use InPower to set up the parameters listed in
position. Table 8-4.
2. Disconnect connector P1. After the Setup is Completed
3. Remove the old digital board and install the After the board setup is complete, place the motor
new one. disconnect switch back in the “On” position.

TABLE 8-4. SETUP PARAMETERS (SHEET 1 OF 2)
Adjustments Folder:
Controller Mode Folder:
Configuration Menu:
Default: Offline
This setting must to be changed to one of the following for proper operation.
(The control will not function if left offline)
Utility to Generator: (Level 1 and Level 2 boards)
Utility to Utility: (Level 2 boards only)
Generator to Generator: (Level 2 boards only)
Switch Mechanism Type Menu:
Zenith: Default setting
Ok if used on a delayed/closed transition Zenith switch OTPC / BTPC
(1000 Amp through 4000 Amp). For program transition, open transition with
sync check, and closed transition.
OTPC/BTPC: Use this setting for all OTPC / BTPC switches between 40 and 1000 amps.
PLT: PLTH, PLTS, PLTO
OHPC/CHPC: OHPC and CHPC
Zenith 2: OK if used on non-delayed transition Zenith switch OTPC/BTPC (1200 through
4000 amp). For open transition with sync check only.
Dual Linear Motor: For BTPCB/C/D unit with Closed Transition Momentary (A079−7) transition mode.
Select the “Save Adjustments” icon to save your changes.
Current Adjustment Folder:
Nominal Current: Default: 125 amps
Must be set to nameplate rating.
Feature Enable Folder:
Refer to nameplate for system features.
Alphanumeric Display Default: Enabled (Always enabled)
Bargraph Meter (Level 2 control only) Default: Disabled (Feature Code D009)
Load Shed Default: Disabled (Feature Code M007)
Lonworks Communications Default: Disabled (Feature Code M020)
Exerciser Enable Default: Disabled (must be enabled to use the
exercise function)
Nominal Current Folder:
Must be set to nameplate rating Default: 125 Amps
Nominal Frequency Folder:
Must be set to nameplate rating Default: 60 Hertz
Nominal Voltage Folder:
Must be set to nameplate rating Default: 120 Volts AC
Note:
On a Level 2 board this is the line-to-neutral voltage of the system voltage.
On a Level 1 board this is the line-to-line voltage of the system voltage.
240V Delta configurations must be set to 139 Volts AC.

TABLE 8-4. SETUP PARAMETERS (SHEET 2 OF 2)
Adjustments Folder (continued):

Source 1 and Source 2 Sensing Folders:
Source 1 or Source 2 sensing Default: 3 Phase (see the Caution below)
Source 1 or 2 over voltage sensing Default: Enabled
Source 1 or 2 frequency sensing Default: Enabled
Source 1 or 2 voltage imbalance sensing Default: Disabled (See Note)
Source 1 or 2 loss of phase sensing Default: Disabled (See Note)
Phase rotation sensing Default: Enabled (See Note)
Note: Before changing this setting, review the feature description on the following page.
Voltage Adjustment Folder:
Connection type Default: Wye (Must be set to match application)
Calendar / Clock Settings:
Real Time Clock Folder:
Must be set
Select month, day of month, year, hour (24 hour format), minute
Enable or disable daylight savings time
Date format (North American or International)
Exerciser Clock − To be set only if an exercise is desired:
Feature Enable Folder:
Exerciser enable
Exerciser Clock Folder:
Enable Program 1
Set exercise start day of week
Set exercise start time (24-hour format)
Set exercise duration (HR:MN format)
Enter repeat interval of exercise
Example: 0 = exercise once, 1 = weekly, 2 = every two weeks, 52 = once every 52 weeks
Exercise with / without load
Note: The Reset Exerciser Repeat Count feature, in the Controller Mode folder, can be used to change a repeat interval.
Switch the setting from “False” to “True” for the new interval to take effect. The setting will automatically switch back to
“False” again.
Test Folder:
Setup Folder:
Test: With / Without Load Default: Without Load
CAUTION Level 1 controls do not support three-phase sensing on Source 2. Do not select the three-
phase option for the Source 2 Sensing adjustment with Level 1 controls, even if the system is three
phase. This setting will prevent Source 2 from becoming available.

SWITCH ASSEMBLY connect the set starting battery negative [−]
REMOVAL/REPLACEMENT PROCEDURE cable.
There are four separate switch assemblies. Each WARNING The transfer switch presents a
assembly corresponds to a particular current range. shock hazard that can cause severe personal
The four current range groups are: 40-70-125 am- injury or death unless all AC power is removed.
peres, 150-225-260 amperes, 300-400-600 am- Disconnect all sources of AC power to the
peres, and 800-1000 amperes. transfer switch before servicing. Be sure to set
the generator set operation selector switch to
For servicing purposes, each transfer switch as- Stop, disconnect the battery charger from its
sembly can be separated into the following compo- AC power source, and disconnect the starting
nents: battery negative [−] cable.
 Linear Actuator RECONNECTING AC POWER
 Block and Crossbar Assembly (WHEN FINISHED)
 Auxiliary Switches After all service procedures are completed:
A separate section covers the removal and replace-  If Source 2 (Emergency) is a generator, con-
ment procedures for each major component within nect the negative (−) battery cable to the
a particular range. starting battery. If applicable, connect the bat-
tery charger to its AC power source.
DISCONNECT AC POWER
 Reconnect Source 1 (Normal) Source 2
Before beginning any service procedure: (Emergency).
 If a generator set provides Source 2 (Emer-
gency) power, turn the operation selector  Set the operation selector switch on the gen-
switch to Stop. (The selector switch is located set to in the Remote position.
on the generator set control panel.)
 Disconnect all sources of AC power from rear side of the cabinet door presents a shock
the transfer switch. hazard that can cause severe personal injury or
 If there is an external battery charger, discon- electrical contacts whenever the cabinet door is
nect it from its AC power source. Then dis- open.

LINEAR ACTUATOR REMOVAL AND 3. Separate the actuator lead wires from the rest
REPLACEMENT (40 TO 125 AMPERES, of the wiring harness. Remove wire ties as re-
THREE−POLE TRANSFER SWITCHES quired.
ONLY)
4. Pry the capacitor(s) loose from the bracket. Re-
move the end cap and disconnect the red and
If Source 2 is a genset, set the operation selector white actuator leads from the capacitor and the
switch on the generator control panel to Stop. Dis- black lead from circuit breaker. Note the lead
connect both Source 1 and Source 2 from the connections to the capacitor terminals.
transfer switch. If there is an external battery char-
ger, disconnect it from AC power. Then disconnect 5. Remove the socket head capscrews and lock
the genset starting battery (negative [−] lead first). washers that secure the actuator to the block
assemblies (Figure 7-6). Note the ground wire
WARNING AC power within the cabinet pres- connection to the lower left capscrew.
ents an electrical shock hazard that can cause
severe personal injury or death. Disconnect all 6. Disengage the actuator rod from the switch
sources of AC power from the transfer switch handle and remove the actuator from the block
before servicing. assembly.
7. Remove one of the hex head capscrews and

The following procedures cover the removal and re-
lock washers that secure the rod end assembly
placement of the linear actuator for 40- to 125-am-
to the actuator rod.
pere switches.
8. Remove the rod end assembly from the actua-
Removing Actuator tor rod (Figure 7-5) and slide the rod out of the
actuator.
CAUTION Electric Shock Hazard
Capacitors are considered stored energy and Replacing Actuator
present an electrical shock hazard that can
1. Insert the actuator rod into the replacement ac-
cause personal injury.
tuator motor from the side opposite the ground
Make sure all capacitors are safely and fully dis-
brush (Figure 7-5). Install the rod end assembly
charged before working on equipment.
and tighten the capscrew to 70-75 in-lbs
(7.9-8.5 N m).
1. Open the transfer switch cabinet door.
2. Position the actuator motor on the block as-
2. Loosen and remove the four machine screws semblies so the load wires are at the bottom,
(with flat washers) that secure the plastic and fit the rod assembly into the handle of the
switch cover to the switch base, and lift it off. closed switch assembly.
ACTUATOR GROUND ROD END

ROD BRUSH ASSEMBLY
HEX HEAD CAPS-

CREW WITH
LOCK WASHER
FIGURE 7-5. LINEAR ACTUATOR (40 TO 125 AMPERES, 3 POLE TRANSFER SWITCHES ONLY)
1
ACTUATOR
ROD
LINEAR A A
ACTUATOR
ROD END
ASSEMBLY
2
TERMINAL
BRACKET
GROUND
CONNECTION
1 1
1 TORQUE TO 25-30 IN-LBS (2.8-3.4 N M).

VIEW A−A
FIGURE 7-6. TRANSFER SWITCH COVER (40 TO125 AMPERES, 3 POLE TRANSFER SWITCHES ONLY)

3. Secure the actuator motor to the block assem- BLOCK AND CROSS-BAR ASSEMBLY
blies using socket head capscrews (4) and lock REMOVAL AND REPLACEMENT
washers (4). Be sure to reconnect the ground (40 TO 125 AMPERES, THREE POLE
wire to the lower left screw (Figure 7-6). Tight- TRANSFER SWITCHES ONLY)
en capscrews to 25-30 in-lbs (2.8-3.4 N m).
If Source 2 is a genset, set the operation selector
CAUTION Do not overtighten screws or switch on the generator control panel to Stop. Dis-
the switch can be damaged. connect both Source 1 and Source 2 from the
ger, disconnect it from AC power. Then disconnect
4. Connect the black actuator lead wire to the cir- the genset starting battery (negative [−] lead first).
cuit breaker, and connect the red and white ac-
tuator lead wires to the following capacitor ter- WARNING AC power within the cabinet pres-
minals: ents an electrical shock hazard that can cause
severe personal injury or death. Disconnect all
sources of AC power from the transfer switch
Red Lead Wire - Connect to capacitor C1,
before servicing.
Terminal 1.
White Lead Wire - If one capacitor, connect placement of the block and crossbar assemblies for
to capacitor C1, Terminal 2. If two capacitors, 40- to 125-ampere switches.
connect to capacitor C2, Terminal 2. Removing the Block and Cross-Bar
Assembly (Normal or Emergency)
Transfer switches for voltage ranges 347,
380/416, 440/480 and 480 use two capacitors (C1 1. Remove the linear actuator as described in the
and C2) wired together in series. A single jump- Linear Actuator Removal and Replacement
er wire is placed between terminal 2 on C1 and section for 40 to 125 ampere switches. Follow
Terminal 1 on C2. steps 1-6 in the Removing Actuator section.
2. Remove the round head machine screws and
5. Replace the capacitor end cap(s) and install flat washers that secure the interlock bar to the
the capacitor(s) in the bracket(s). Use wire ties interlock arms (see Figure 7-7) and remove the
to hold actuator lead wires in place. interlock bar.
3. Disconnect the control wiring leads from the
6. Check transfer switch operation and alignment jumper bus bars.
of the actuator rod by manually opening and
closing both the Source 1 (Normal) and Source 4. Remove the hex head machine screws, ring
2 (Emergency) switch assemblies. terminals, flat washers, lock washers, and nuts
that secure the jumper bus bars (see Fig-
ure 7-7) to the load bus bars.
7. Place the plastic switch cover in position and
secure with machine screws (4) and flat wash- 5. Remove the hex head machine screws and
ers (4). Tighten to 25-30 in-lbs (2.8-3.4 N m) spring washers that secure the jumper bus
torque. bars to the block assemblies, and lift off the
jumper bus bars.
8. If Source 2 is a genset, connect the starting bat- 6. Remove the control wiring leads from the pow-
tery (negative [−] lead last). If applicable, con- er source terminals (Figure 7-8).
nect the battery charger to AC power. Recon-
nect Source 1 and Source 2. Set the opera- 7. Loosen the lug terminal screws and remove the
tion selector switch to Auto (or Remote). power source supply wires from the lug termi-
nals.
9. Test the switch for proper operation and close 8. Remove the two round head machine screws,
the cabinet. lock washers, and flat washers that secure the

block assembly to the base; and carefully re- 6. Apply a thin coat of joint compound between
move the assembly. the mating surfaces of the jumper bus bars,
braided strap connector, and load bus bars.
CAUTION Use care when removing the
block and cross-bar assembly from the 7. Install the jumper bus bars and secure to the
base. Carefully disengage the cross bar switch assemblies with hex head machine
from the auxiliary switch lever to avoid screws and spring washers. Tighten to 25-30
cracking the switch lever. in-lbs (2.8-3.4 N m) torque.
8. Secure the jumper bus bars to each load bus

Replacing the Block and Cross-Bar bar using a hex head machine screw, ring ter-
Assembly minal, flat washer, lock washer, and nut. Tight-
en to 25-30 in-lbs (2.8-3.4 N m) torque.
1. Clean all current-carrying surfaces with a wire
brush. 9. Connect the control wiring leads to the corre-
sponding jumper bus bar terminal. Control
wires are marked LOAD A,B,C.
2. Hold the block assembly in position on the base
and check the alignment of the auxiliary switch 10. Apply thread sealant (blue Loctite 242) to the
lever. When the main switch contacts are threads of the interlock bar machine screws.
closed, the auxiliary switch lever must be Install the interlock bar and secure to each in-
aligned vertically, as shown in Figure 7-7. Move terlock arm with a round head machine screw
the auxiliary switch lever as required to get cor- and flat washer. Tighten to 15-20 in-lbs (1.7-2.3
rect alignment. N m) torque.
3. Secure the block assembly to the base with 11. Attempt to close both sides of the transfer
round head machine screws (2), lock washers switch. The interlock assembly must hold one
(2), and flat washers (2). Tighten the screws to side open so that only one side closes at a time.
25-30 in-lbs (2.8-3.4 N m).
12. Replace the linear actuator as described in Lin-
ear Actuator Removal And Replacement sec-
4. Install the power source supply wires and se- tion for 40- to 125-ampere switches. Follow
curely tighten the lug terminals. steps 2 through 8 in the Replacing Actuator
section. Apply a thin coat of lubricant (Nova-
5. Connect the control wiring leads to the corre- gard silicone G624) to the slot in the handle.
sponding power source terminals. Control
wires are marked NORM A,B,C or EMER 13. Test the switch for proper operation and close
A,B,C for identification. the cabinet.

INTERLOCK LOAD BUS
2 BAR BARS
JUMPER 1 1
BUS BAR
JUMPER
BUS BAR
LOAD BUS
BAR
VIEW C−C VIEW D−D

FIGURE 7-7. SWITCH ASSEMBLY (40 TO 125 AMPERES, 3 POLE TRANSFER SWITCHES ONLY)

POWER SOURCE
LEAD TERMINAL
CONTROL WIRING
TERMINAL
FIGURE 7-8. CONTROL WIRING TERMINALS (40 TO 125 AMPERES, 3 POLE TRANSFER SWITCHES ONLY)

AUXILIARY SWITCH REMOVAL AND Replacing Auxiliary Switch Assembly
REPLACEMENT (40 TO 125 AMPERES,
THREE POLE TRANSFER SWITCHES 1. Place the auxiliary switch lever in the bracket
ONLY) as shown in Figure 7-9. Note that the end of the
lever with the octagonal hole must engage the
If Source 2 is a genset, set the operation selector transfer switch cross bar when the auxiliary
switch on the generator control panel to Stop. Dis- switch assembly is installed.
connect both Source 1 and Source 2 from the
transfer switch. If there is an external battery char- 2. Install the auxiliary switches (4) and insulating
ger, disconnect it from AC power. Then disconnect barriers (5) in the bracket, and secure with hex
the genset starting battery (negative [−] lead first). head machine screws (2) and nuts (2).Tighten
to 10-15 in-lbs (1.1-1.7 N m) torque. Note that
WARNING AC power within the cabinet pres- each switch must be assembled so the side
ents an electrical shock hazard that can cause with two terminals (Figure 7-9) is facing inward,
severe personal injury or death. Disconnect all toward the other auxiliary switch.
before servicing. 3. Manually close the contacts that will be
coupled to the auxiliary switch lever.
placement of the auxiliary switch for 40- to 125-am-
4. Hold the auxiliary switch assembly in position
pere switches.
on the base and check the alignment of the
Removing Auxiliary Switch Assembly auxiliary switch lever. When the transfer switch
is closed, the auxiliary switch must be aligned
1. Open the transfer switch cabinet door. as shown in Figure 7-9. Move the auxiliary le-
ver as required to get the correct alignment.
2. Loosen and remove the four machine screws
(with flat washers) that secure the plastic 5. Secure the bracket to the base using the hex
switch cover to the switch base, and lift it off. head machine screws and tighten to 25-30 in-
lbs (2.8-3.4 N m) torque.
3. Loosen the two machine screws that secure
the terminal bracket to the base. Move the ter- 6. Install control wiring leads on the correspond-
minal bracket to allow access to the auxiliary ing switch terminals. Leads are marked with
switches. terminal numbers (S2/N0, S7/NC, S9/C, etc..)
for identification. Refer to Figure 7-9 for identifi-
4. Remove the control wiring leads from the auxil- cation of the auxiliary switch terminals.
iary switch terminals (Figure 7-9).
7. Place the terminal bracket in position on the
5. Remove the hex head machine screws that se- base and secure it with hex head machine
cure the auxiliary switch assembly bracket to screws. Tighten to 25-30 in-lbs (2.8-3.4 N m).
the base.
6. Disengage the auxiliary switch lever from the
secure with machine screws (4) and flat wash-
transfer switch crossbar and lift out the auxilia-
ers (4). Tighten to 25-30 in-lbs (2.8-3.4 N m).
ry switch assembly.
CAUTION Use care when disengaging the 9. If Source 2 is a genset, connect the starting bat-
switch lever from the crossbar to avoid tery (negative [−] lead last). If applicable, con-
cracking the switch lever. nect the battery charger to AC power. Recon-
nect Source 1 and Source 2. Set the opera-
7. Remove the hex head machine screws and tion selector switch to Auto (or Remote).
nuts that secure the auxiliary switches to the
bracket (Figure 7-9); and lift out the four 10. Test the switch for proper operation and close
switches, insulating barriers, and switch lever. the cabinet.

SIDE WITH TWO
TERMINALS
SWITCH LEVER IN
CLOSED POSITION
NORMAL SIDE EMERGENCY SIDE
INSULATING
BARRIERS
MACHINE
SCREWS
1
AUXILIARY
SWITCH LEVERS
BRACKETS
FIGURE 7-9. AUXILIARY SWITCHES (40 TO 125 AMPERES, 3 POLE TRANSFER SWITCHES ONLY)

LINEAR ACTUATOR REMOVAL AND to the switch assemblies (Figure 7-10), and lift
REPLACEMENT (150 TO 260 AMPERES out the spacers (4) and barriers (2).
TRANSFER SWITCHES AND 40 TO 125
AMPERES, FOUR POLE TRANSFER 7. Disengage the actuator rod from the switch
handle and remove the actuator from the
SWITCHES)
switch assembly.
switch on the generator control panel to Stop. Dis- 8. Remove one of the hex head capscrews and
connect both Source 1 and Source 2 from the lock washers that secure the rod end assembly
transfer switch. If there is an external battery char- to the end of the actuator rod.
the genset starting battery (negative [−] lead first). 9. Remove the rod end assembly from the actua-
tor rod (Figure 7-10) and slide the rod out of the
WARNING AC power within the cabinet pres- actuator motor.
severe personal injury or death. Disconnect all Replacing Actuator
before servicing. 1. Insert the actuator rod into the replacement ac-
tuator motor (Figure 7-11). Hold the actuator
The following procedures cover the removal and re- ground brush up slightly to allow passage of the
placement of the linear actuator for 150- to 260-am- actuator rod. Install the rod end assembly and
pere switches. tighten capscrew to 70-75 in-lbs (7.9-8.5 N m).
Removing Actuator 2. Hold the actuator motor in position over the

switch assemblies so the lead wires are at the
CAUTION Electric Shock Hazard bottom, and fit the rod assembly into the handle
Capacitors are considered stored energy and of the closed switch assembly.
present an electrical shock hazard that can
cause personal injury. 3. Secure the actuator motor to the switch assem-
Make sure all capacitors are safely and fully dis- blies using hex head capscrews (4), lock wash-
charged before working on equipment. ers (4), flat washers (4), barriers (2), and
spacers (4). Tighten the capscrews to 25-27 in-
1. Open the transfer switch cabinet door. lbs (2.8-3.0 N m).
2. Loosen and remove the two self-locking nuts 4. Connect the black actuator lead wire to the cir-
and two machine screws (with flat washers) cuit breaker, and the red and white actuator
that secure the plastic switch cover to the lead wires to the following capacitor terminals:
switch base, and lift off the cover. (Figure 7-10)
3. Separate the actuator lead wires from the rest Red Lead  Capacitor C1, Terminal 1
of the wiring harness; remove wire ties as re- White Lead  One capacitor,
quired. Capacitor C1, Terminal 2.
4. Pry the capacitor(s) loose from the bracket. Re-  Two capacitors,
move the end cap and disconnect the red and Capacitor C2, Terminal 2.
white actuator lead wires from the capacitor
terminals. Transfer switches for voltage ranges 347,
380/416, and 440/480 use two capacitors (C1 and
5. Disconnect the black actuator wire from the cir- C2) wired together in series. A single jumper
cuit breaker and disconnect the ground wire wire is placed between terminal 2 on C1 and ter-
from the end of the actuator. minal 1 on C2.
6. Remove the hex head capscrews, flat wash- 5. Replace the capacitor end cap(s) and install
ers, and lock washers that secure the actuator the capacitor(s) in the bracket(s).

1
ROD END
ASSEMBLY
LINEAR
ACTUATOR
ACTUATOR
ROD
BARRIER 2
TERMINAL
BRACKET
SPACER 3
3
VIEW A−A
3 TORQUE TO 25-30 IN-LBS (2.8-3.4 N-M).
FIGURE 7-10. TRANSFER SWITCH COVER (150 TO 260 AMPERES, 3 POLE TRANSFER SWITCHES AND
40 TO 125 AMPERES, 4 POLE TRANSFER SWITCHES)

6. Connect the ground wire to the end of the ac-
tuator. Use wire ties to hold the actuator lead
wires in place with the wiring harness.
7. Check operation of the transfer switch and

alignment of the actuator rod by manually
opening and closing both the Normal and
Emergency switch assemblies.

secure with machine screws (2), flat washers
(2), and self-locking nuts (2). Tighten to 25-30
in-lbs (2.8-3.4 N m) torque.
GROUND
9. If Source 2 is a genset, connect the starting bat- BRUSH
tery (negative [−] lead last). If applicable, con-
tion selector switch to Auto (or Remote).
FIGURE 7-11. LINEAR ACTUATOR
(150 TO 260 AMPERES TRANSFER SWITCHES
10. Test the switch for proper operation and close AND 40 TO 125 AMPERES, 4 POLE TRANSFER
the cabinet. SWITCHES)

BLOCK AND CROSS-BAR ASSEMBLY two hex head capscrews that secure the load
REMOVAL AND REPLACEMENT lug support block. Carefully remove the jumper
(150 TO 260 AMPERES TRANSFER bus bar/load bus bar/load lug support block as-
SWITCHES AND 40 TO 125 AMPERES, sembly.
FOUR POLE TRANSFER SWITCHES)
7. Remove the control wiring leads from the pow-
er source terminals.
switch on the generator control panel to Stop. Dis-
8. On 4-pole switches (Figure 7-13): Before the
connect both Source 1 and Source 2 from the
block and cross-bar assembly can be re-
moved, the neutral block assembly must be
loosened and pivoted slightly out of the way.
the genset starting battery (negative [−] lead first).
A. Remove the two machine screws that se-
WARNING AC power within the cabinet pres-
cure the arc chute cover. Remove the cov-
er and the arc chute.
sources of AC power from the transfer switch B. Remove the hex head capscrew, terminal
before servicing. ring, spring washer, and load lug that se-
cure the neutral jumper bus bar. Remove
the neutral jumper bus bar.
placement of the block and cross-bar assemblies
for 150- to 260-ampere switches.
C. Remove the two Phillips screws and the
spacer that secure the source lug side of
Removing the Block and Cross-Bar
the neutral block.
Assembly (Normal or Emergency)
D. Pivot the neutral block slightly away from
1. Loosen the lug terminal screws and remove the the block and cross-bar assembly.
power source supply wires from the lug termi-
nals. CAUTION Use care when removing the
block and cross-bar assembly from the
2. Remove the linear actuator as described in the base. Carefully disengage the cross-bar
Linear Actuator Removal and Replacement from the auxiliary switch assembly to avoid
section for 150- to 260-ampere switches. Fol- cracking the switches.
low steps 1 through 7 in the Removing Actuator
section. 9. Remove the remaining hex head capscrews
that secure the block and cross-bar assembly
3. Remove the hex head capscrews, lock wash- to the base, and carefully remove the assem-
ers, and flat washers that secure the interlock bly.
bar to the interlock arms (Figures 7-12 and
7-13), and remove the interlock bar. 10. Remove the two threaded hex spacers from
the back of each block assembly and save for
4. Remove the round head machine screws and reuse.
mounting plate that secure the handle assem-
bly to the switch assembly, and lift off the han- 11. On 4-pole switches (Figure 7-13): With a
dle assembly. screwdriver, dig the glue out of the cavity in the
base of the neutral block. Remove the machine
5. Disconnect the control wiring leads from the screw that secures the neutral block, and re-
jumper bus bars. move the neutral block.
6. Remove the hex head capscrews and spring 12. Remove the two round head machine screws
washers that secure the A, B, and C jumper bus that secure the interlock arm to the block and
bars to the block and cross-bar assemblies. cross-bar assemblies, and lift off the interlock
Remove the two Phillips head screws and the arm.

13. Remove the hex head capscrews, ring termi-
nals, spring washers, and lug terminals from
the block and cross-bar assembly.
JUMPER LOAD BUS NEUTRAL

BUS BARS BARS BAR
2
INTERLOCK
ARM
INTERLOCK
2 4
1 4 BAR

2 TORQUE TO 10-12 FT-LBS (13.6-16.3 N M).
FIGURE 7-12. 3-POLE SWITCH ASSEMBLY (150 TO 260 AMPERES)

JUMPER LOAD BUS
BUS BARS BARS
2
2
INTERLOCK
ARM
2
1 INTERLOCK 4
4 BAR


Replacing Block and Cross-Bar Assembly 8. Clean the current-carrying surfaces of the
jumper bus bars and load bus bars with a wire
1. Install the lug terminals on the block and cross- brush.
bar assembly and secure with hex head caps-
crews, ring terminals, and spring washers. 9. Install the A, B, and C jumper bus bar/load bus
Tighten to 10-12 ft-lbs (13.6-16.3 N m). bar/load lug support block assembly. Secure to
the block and cross-bar assemblies with hex
2. Install the interlock arm and secure with the two
head capscrews and spring washers. Tighten
round head capscrews. Tighten the screws to
to 10-12 ft-lbs (13.6-16.3 N m) torque. Secure
15-20 in-lbs (1.7-2.3 N m) torque.
the load lug support block with the four screws.
3. Install the two threaded hex spacers in the back Tighten to 70-75 in-lbs (7.9-8.5 N m) torque.
of the block and cross-bar assembly.
10. Connect the control wiring leads to the corre-
4. On 4-pole switches (Figure 7-13): Secure the sponding jumper bus bar terminals. Control
neutral block with the machine screw that was wires are marked LOAD A, B, C, N.
removed from the center hole. Tighten to 70-75
in-lbs (7.9-8.5 N m). Fill the cavity in the block 11. Place the handle assembly in position on the
with adhesive silicone to completely cover the block and cross-bar assembly and secure with
screw head. Pivot the neutral block to permit the two machine screws and mounting plate.
placement of the block and cross-bar assem- Tighten to 15-20 in-lbs (1.7-2.3 N m) torque.
bly.
Apply a thin coat of lubricant (Novagard sili-
5. Secure the block and cross-bar assembly to cone G624) to the slot in the handle.
the base with the hex head capscrews. Tighten
to 70-75 in-lbs (7.9-8.5 N m) torque. 12. Apply thread sealant (blue Loctite 242) to the
threads of the interlock bar capscrews. Install
6. On 4-pole switches (Figure 4-9): the interlock bar and secure to each interlock
arm with a hex head capscrew, lock washer,
A. Pivot the neutral block back to its correct and flat washer. Tighten to 70-75 in-lbs (7.9-8.5
position. N m) torque.
B. Secure the neutral block with the two Phil-
lips screws and the spacer. Tighten to 13. Attempt to close both sides of the transfer
70-75 in-lbs (7.9-8.5 N m) torque. switch. The interlock assembly must hold one
side open so that only one side closes at a time.
C. Secure the neutral jumper bus bar with the
hex head capscrew, terminal ring, spring 14. Replace the linear actuator as described in the
washer, and load lug. Tighten to 10-12 ft- Linear Actuator Removal and Replacement
lbs (13.6-16.3 N m) torque. section for 150- to 260-ampere switches. Fol-
low steps 2 through 9 in the Replacing Actuator
D. Position the neutral block arc chute and section.
cover. Secure the arc chute cover with the
two machine screws. Tighten to 25-30 in-
15. Install the power source supply wires and se-
lbs (2.8-3.4 N m) torque.
curely tighten the lug terminals to the torque
7. Connect the control wiring leads to the corre- value specified on the plastic cover.
sponding power source terminals. Control
wires are marked NORM A,B,C,N or EMER 16. Test the switch for proper operation and close
A,B,C,N for identification. the cabinet.

AUXILIARY SWITCH REMOVAL AND 7. Remove the hex head capscrews and nuts that
REPLACEMENT (150 TO 260 AMPERES secure the auxiliary switches to the brackets
TRANSFER SWITCHES AND 40 TO 125 (Figure 7-14), and lift out the four auxiliary
AMPERES, FOUR POLE TRANSFER switches and insulating barriers.
SWITCHES) Replacing Auxiliary Switch Assembly
If Source 2 is a genset, set the operation selector 1. Install the insulating barriers (5) and auxiliary
switch on the generator control panel to Stop. Dis- switches (4) in the brackets and secure with
connect both Source 1 and Source 2 from the hex head machine screws (2) and nuts (2).
Tighten to 10-15 in-lbs (1.1-1.7 N m). Note that
each switch must be assembled so the side
with two terminals faces inward (Figure 7-14)
WARNING AC power within the cabinet pres- when the auxiliary switch assembly is installed
ents an electrical shock hazard that can cause on the base.
on the base (the side with two terminals must
before servicing.
face inward) and secure the bracket to the base
The following procedures cover the removal and re- using the hex head machine screws. Tighten to
placement of the auxiliary switch assembly for 150- 25-30 in-lbs (2.8-3.4 N m) torque.
to 260-ampere switches.
3. Install the control wiring leads on the corre-
Removing Auxiliary Switch Assembly sponding switch terminals. Leads are marked
with the terminal numbers (S2/NO, S5/NC,
1. After disconnecting all sources of AC power, S7/C, etc..) for identification. Refer to Figures
open the transfer switch cabinet door. 7-12, 7-13, and 7-14 for identification of auxilia-
ry switch terminals.
2. Loosen and remove the two self-locking nuts
and the two machine screws (with flat washers) 4. Place the terminal bracket in position on the
that secure the plastic switch cover to the base and secure it with the hex head machine
switch base, and lift off the cover. screws. Tighten to 25-30 in-lbs (2.8-3.4 N m).
3. Remove the three machine screws that secure 5. Place the plastic switch cover in position and
the terminal bracket (Figure 7-10) to the base. secure with machine screws, flat washers, and
Move the terminal bracket to allow access to self-locking nuts. Tighten to 25-30 in-lbs
the auxiliary switches. (2.8-3.4 N m) torque.
4. Remove the control wiring leads from the auxil- 6. If Source 2 is a genset, connect the starting bat-
iary switch terminals (Figure 7-14). tery (negative [−] lead last). If applicable, con-
5. Remove the hex head machine screws that se- nect Source 1 and Source 2. Set the opera-
cure the auxiliary switch assembly bracket to tion selector switch to Auto (or Remote).
the base.
7. Test the switch for proper operation and close
6. Lift out the auxiliary switch assembly. the cabinet.

NO
TORQUE TO 10-15 IN-LBS

(1.1-1.7 N M).
NC
COM
BARRIERS
FIGURE 7-14. AUXILIARY SWITCH (150 TO 260 AMPERES TRANSFER SWITCHES AND 40 TO 125 AMPERES,
4 POLE TRANSFER SWITCHES)

LINEAR ACTUATOR REMOVAL AND 7. Disengage the actuator rod from the switch
REPLACEMENT (300 TO 600 AMPERES) handle and remove the actuator from the
switch assembly.
switch on the generator control panel to Stop. Dis- 8. Remove one of the hex head capscrews and
connect both Source 1 and Source 2 from the lock washers that secure the rod end assembly
transfer switch. If there is an external battery char- to the end of the actuator rod.
9. Remove the rod end assembly (Figure 7-15)
and slide the actuator rod out of the actuator
motor.
Replacing Actuator
1. Insert the actuator rod into the replacement ac-
before servicing.
tuator motor (Figure 7-16). Hold the actuator
ground brush up slightly to allow passage of the
The following procedures cover the removal and re- actuator rod. Install the rod end assembly and
placement of the linear actuator for 300- to 600-am-
tighten capscrew to 70-75 in-lbs(7.9-8.5 N m).
pere switches.
2. Hold the actuator motor in position over the
Removing Actuator switch assemblies so the lead wires are at the
bottom and fit the rod assembly into the handle
CAUTION Electric Shock Hazard of the closed switch assembly.
Capacitors are considered stored energy and
present an electrical shock hazard that can 3. Secure actuator motor to switch assemblies
cause personal injury. using hex head capscrews (4), lock washers
Make sure all capacitors are safely and fully dis- (4), flat washers (8), and spacers (4). Tighten
charged before working on equipment. capscrews to 25-27 in-lbs (2.8-3.0 N m).
1. Open the transfer switch cabinet door. 4. Connect the black actuator lead wire to the cir-
cuit breaker, and the red and white actuator
2. Loosen and remove the four machine screws lead wires to the following capacitor terminals:
that secure the plastic switch cover to the trans-
fer switch, and lift off the cover (Figure 7-15). Red Lead  Capacitor C1, Terminal 1
White Lead  One capacitor,
3. Separate the actuator lead wires from the rest Capacitor C1, Terminal 2.
of the wiring harness; remove wire ties as re-
quired.  Two capacitors,
Capacitor C2, Terminal 2.
4. Pry the capacitor(s) loose from the bracket. Re-
move the end cap and disconnect the red and Transfer switches for voltage ranges 347,
white actuator lead wires from the capacitor 380/416, and 440/480 use two capacitors (C1 and
terminals. C2) wired together in series. A single jumper
wire is placed between terminal 2 on C1 and ter-
minal 1 on C2.
5. Disconnect the black actuator lead from the cir-
cuit breaker and the ground wire from the end 5. Replace the capacitor end cap(s) and install
of the actuator. the capacitor(s) in the bracket(s).
6. Remove the hex head capscrews, flat wash- 6. Connect the ground wire to the end of the ac-
ers, and lock washers that secure the actuator tuator. Use wire ties to hold actuator lead wires
to the switch assemblies (Figure 7-15). in place with the rest of the wiring harness.

ACTUATOR
ROD CAPSCREW
1
ROD END
ASSEMBLY
LINEAR AC-
TUATOR
ACTUATOR
2 CAPSCREW
BARRIER
TERMINAL
BRACKET
VIEW A−A

FIGURE 7-15. TRANSFER SWITCH COVER (300 TO 600 AMPERES)

7. Check the operation of the transfer switch and 9. If Source 2 is a genset, connect the starting bat-
the alignment of the Actuator rod by manually tery (negative [−] lead last). If applicable, con-
opening and closing both the Normal and nect the battery charger to AC power. Recon-
Emergency switch assemblies. nect Source 1 and Source 2. Set the opera-
8. Install the plastic switch cover on the switch
with the four screws. Tighten to 25-30 in-lbs 10. Test the switch for proper operation and close
(2.8-3.4 N m). the cabinet.
ACTUATOR
ACTUATOR
ROD
MOTOR
GROUND
BRUSH
WHITE
RED
BLACK
FIGURE 7-16. LINEAR ACTUATOR (300 TO 600 AMPERES)

BLOCK AND CROSS-BAR ASSEMBLY 5. Remove the control wiring leads from the pow-
REMOVAL AND REPLACEMENT er source terminals.
(300 TO 600 AMPERES)
6. Remove the lug terminal screws and the power
If Source 2 is a genset, set the operation selector supply wires from the lug terminals. Remove
switch on the generator control panel to Stop. Dis- the lug mounting screws and then remove the
connect both Source 1 and Source 2 from the solder-less lugs from the switch assemblies.
ger, disconnect it from AC power. Then disconnect 7. Remove the hex head capscrews, ring termi-
the genset starting battery (negative [−] lead first). nals, spring washers, flat washers, lock wash-
ers, and nuts that secure the jumper bus bars
WARNING AC power within the cabinet pres- to the load bus bars.
severe personal injury or death. Disconnect all 8. Remove the hex head capscrews and spring
sources of AC power from the transfer switch washers that secure the jumper bus bars to the
before servicing. block assemblies, and lift off the jumper bus
bars.
placement of the block and cross-bar assemblies 9. Remove the four screws, lock washers, and flat
for the 300- to 600-ampere switches. washers that secure the block and cross-bar
assembly to the base. On 4-pole switches, re-
Removing the Block and Cross-bar move the screw that secures the small bearing
Assembly (Normal or Emergency) bracket to the neutral block (Figure 7-18). Re-
move the block and cross-bar assembly. Save
1. Remove the linear actuator as described in the the bearing bracket and screw for reuse.
Linear Actuator Removal and Replacement
section for 300- to 600-ampere switches. CAUTION Use care when removing the
2. Remove the hex head capscrews, lock wash- base. Carefully disengage the crossbar
ers, and flat washers that secure the interlock from the auxiliary switch assembly to avoid
bar to the interlock arm (Figures 7-17 and cracking the switches.
7-18), and remove the interlock bar.
10. On 4-pole switches (Figure 7-18): Remove the
3. Disconnect the control wiring leads from the four screws that secure the block and contact
jumper bus bars. assembly to the base, and lift off the block and
contact assembly.
4. Remove the round head shoulder screws and
lock washers that secure the handle assembly 11. Remove hex head capscrew and lock washer
to the block and cross-bar assembly, and lift off that secure the interlock arm assembly to the
the handle assembly. block assembly and lift off the interlock arm.

INTERLOCK INTERLOCK 2 INTERLOCK 1
ARM BAR ARM
BLOCK AND
CROSSBAR
1 ASSEMBLY
LUG
TERMINALS
JUMPER 3
BUS BAR
LOAD BUS
JUMPER
BAR
BUS BAR


INTERLOCK INTERLOCK 2 3 3 INTERLOCK
ARM BAR ARM 1
NEUTRAL
BLOCK AND
1 CROSSBAR
ASSEMBLY
BLOCK AND
CROSSBAR
ASSEMBLY
LUG
TERMINALS
JUMPER
BUS BAR 3
JUMPER
LOAD BUS
BUS BAR
BAR


Replacing the Block and Cross-bar tween the current-carrying surfaces. Tighten to
Assembly (Normal or Emergency) 70-75 in-lbs (7.9-8.5 N m).
7. Install the actuator handle on the block assem-

1. Install interlock arm on block assembly using bly with the shoulder screws and lock washers.
capscrew and lock washer (Figures 7-17 and Tighten to 25-30 in-lbs (2.8-3.4 N m). Apply a
7-18). Torque to 70-75 in-lbs (7.9-8.5 N m).
thin coat of lubricant (Novagard silicone
G624) to the slot in the handle.
2. On 4-pole switches (Figure 7-17): Secure the
block and contact assembly to the base using 8. Connect the power source supply wires to the
the four screws removed in step 10 above. lug terminals. Tighten the lug terminals to the
Tighten the screws to 25-30 in-lbs (2.8-3.4 torque value silkscreened on the transfer
N m). Place the bearing bracket (removed in switch cover.
step 9) in position on the end of the cross-bar
assembly. 9. Connect the control wiring leads to the power
source terminals. Control wires are marked
3. Install the block and cross-bar assembly on the NORM A, B, C or EMER A, B, C.
transfer switch base (with screws, lock wash- 10. Connect the control wiring leads to the jumper
ers, and flat washers), carefully engaging auxil- bus bars. Control wires are marked LOAD A, B,
iary switches. Tighten to 70-75 in-lbs (7.9-8.5 C for identification.
N m). On 4-pole switches, tighten the bearing
bracket screw to 25-30 in-lbs (2.8-3.4 N m). 11. Apply thread sealant (blue Loctite 242) to the
threads of the interlock bar capscrews. Install
4. Clean the current-carrying surfaces of the the interlock bar and secure to each interlock
block assembly and the lug terminals with a arm with a hex head capscrew, lock washer,
wire brush. Install the lug terminals with the and flat washer. Tighten to 70-75 in-lbs (7.9-8.5
round head screws and lock washers. Tighten N m).
to 70-75 in-lbs (7.9-8.5 N m).
12. Attempt to close both sides of the transfer
5. Secure the jumper bus bars to the block as- switch. The interlock assembly must hold one
sembly with the capscrews and spring wash- side open so that only one side closes at at
ers. Make sure the mating surfaces have a time.
coating of electrical joint compound. Tighten 13. Replace the linear actuator as described in the
the capscrews 10-12 ft-lbs (13.6-16.3 N m). Linear Actuator Removal and Replacement
section for 300- to 600-ampere switches. Fol-
6. Secure the load bus bars to the jumper bus low steps 2 through 9 in the Replacing Actuator
bars with the capscrews, lock washers, flat section.
washers, spring washers, ring terminals, and
nuts (Figures 7-17 and 7-18). Be sure to apply 14. Test the switch for proper operation and close
a thin coat of electrical joint compound be- the cabinet.

AUXILIARY SWITCH REMOVAL AND 2. Loosen and remove the four machine screws
REPLACEMENT (300 TO 600 AMPERES) that secure the plastic switch cover to the trans-
fer switch, and lift off the cover.
switch on the generator control panel to Stop. Dis- 3. Loosen and remove the four machine screws
connect both Source 1 and Source 2 from the that secure the terminal bracket (Figure 7-15)
transfer switch. If there is an external battery char- to the base. Move the terminal bracket to allow
ger, disconnect it from AC power. Then disconnect access to the base.
4. Remove the control wiring leads from the auxil-
WARNING AC power within the cabinet pres- iary switch terminals (Figure 7-19).
severe personal injury or death. Disconnect all 5. Close the transfer switch to the side you are
sources of AC power from the transfer switch working on and remove the hex head machine
before servicing. screws that secure the auxiliary switch assem-
The following procedures cover the removal and re- bly bracket to the base.
placement of the auxiliary switch assembly for 300-
to 600-ampere switches. 6. Lift out the auxiliary switch assembly.
Removing Auxiliary Switch Assembly 7. Remove the hex head machine screws and
nuts that secure the auxiliary switches to the
1. After disconnecting all sources of AC power, bracket (Figure 7-19) and lift out the auxiliary
open the transfer switch cabinet door. switches and insulating barriers.
NO

(1.1-1.7 N M).
NC
COM
BARRIERS
FIGURE 7-19. AUXILIARY SWITCH (300 TO 600 AMPERES)

Replacing Auxiliary Switch Assembly with the terminal numbers (S2/N0, S5/NC,
S7/C, etc..) for identification. Refer to Figures
1. Install the insulating barriers (5) and auxiliary 7-17, 7-18, and 7-19 for identification of the
switches (4) in the brackets, and secure with auxiliary switch terminals.
hex head machine screws (2) and nuts (2). 4. Place the terminal bracket in position on the
Tighten to 10-15 in-lbs (1.1-1.7 N m). Note that base and secure it with the hex head machine
each switch must be assembled so the side screws. Tighten to 25-30 in-lbs (2.8-3.4 N m).
with two terminals faces inward (Figures 7-17,
7-18, and 7-19) when the auxiliary switch as- 5. Place the plastic cover in position and secure
sembly is installed on the base. with the hex head screws and flat washers.
Tighten to 25-30 in-lbs (2.8-3.4 N m).
6. If Source 2 is a genset, connect the starting bat-
on the base (the side with two terminals must
tery (negative [−] lead last). If applicable, con-
face inward) and secure the bracket to the base
with the hex head machine screws. Tighten to
25-30 in-lbs (2.8-3.4 N m).
3. Install the control wiring leads on the corre- 7. Test the transfer switch for proper operation
sponding switch terminals. Leads are marked and close the cabinet.

LINEAR ACTUATOR REMOVAL AND 7. Disconnect the black actuator lead wire from
REPLACEMENT (800 AND 1000 the circuit breaker and the ground wire from the
AMPERES) end of the actuator.
8. Remove the hex head capscrews, flat wash-
If Source 2 is a genset, set the operation selector ers, and lock washers that secure the actuator
switch on the generator control panel to Stop. Dis- to the switch assemblies (Figure 7-20) and lift
connect both Source 1 and Source 2 from the out the spacers and actuator motor.
ger, disconnect it from AC power. Then disconnect Replacing Actuator
1. Hold the actuator motor and spacers (4) in
WARNING AC power within the cabinet pres- position over the switch assemblies with the
ents an electrical shock hazard that can cause lead wires at the bottom.
sources of AC power from the transfer switch 2. Secure the actuator motor to the switch assem-
before servicing. blies using hex head capscrews (4), lock wash-
ers (4), and flat washers (4). Tighten the caps-
The following procedures cover the removal and re- crews to 70-75 in-lbs (7.9-8.5 N m).
placement of the linear actuator for 800- and
3. Connect the black actuator lead wire to the cir-
1000-ampere switches.
cuit breaker, and the red and white actuator
lead wires to the following capacitor terminals:
Removing Actuator
Red Lead  Capacitor C1, Terminal 1
CAUTION Electric Shock Hazard
Capacitors are considered stored energy and White Lead  One capacitor,
present an electrical shock hazard that can Capacitor C1, Terminal 2.
cause personal injury.
 Two capacitors,
Make sure all capacitors are safely and fully dis-
Capacitor C2, Terminal 2.
charged before working on equipment.
White Lead Wire - Connect to capacitor C2 -
Terminal 2.
2. Remove a hex head capscrew, flat washer, and Transfer switches for voltage ranges 347,
lock washer that secures one of the rod end as- 380/416, and 440/480 use two capacitors (C1 and
semblies to the end of the actuator rod. C2) wired together in series. A single jumper
wire is placed between terminal 2 on C1 and ter-
3. Remove the rod end assembly (Figure 7-20) minal 1 on C2.
and slide the actuator rod out of the actuator Transfer switches for voltage ranges 115,
motor. 190/200, 208, and 220/240 use two capacitors
(C1 and C2) wired in parallel. Two jumper wires
4. Loosen and remove the twelve machine are used. One is placed between terminal 1 on
screws (with flat washers) that secure the three C1 and terminal 1 on C2. The other is placed be-
plastic switch covers to the switch base, and lift tween terminal 2 on C1 and terminal 2 on C2.
off the switch covers (Figure 7-20).
4. Replace the capacitor end cap(s) and install
5. Separate the actuator lead wires from the rest the capacitor(s) in the bracket(s).
of the wiring harness; remove the wire ties as 5. Connect ground wire to the end of the actuator.
required. Use wire ties to hold the actuator lead wires in
place with the rest of the wiring harness.
6. Pry the capacitors loose from the brackets. Re-
move the end cap and disconnect the red and 6. Place the plastic switch covers in position and
white actuator lead wires from the capacitor secure with machine screws and flat washers.
terminals. Tighten to 25-30 in-lbs (2.8-3.4 N m) torque.

ACTUATOR
ROD
LINEAR
ACTUATOR
ROD END
ASSEMBLY
2 ACTUATOR
ROD CAPSCREW
2
ACTUATOR
CAPSCREW
SPACER
1

2 TORQUE TO 70-75 IN-LBS (7.9-8.5 N M). VIEW A−A
115−240V 347−480V
PARALLEL SERIES
FIGURE 7-20. TRANSFER SWITCH COVER (800 - 1000 AMPERES)

7. Insert the actuator rod into the replacement ac- opening and closing both the Normal and
tuator motor (Figure 7-21). Hold the actuator Emergency switch assemblies.
ground brush up slightly to allow passage of the
actuator rod.
10. If Source 2 is a genset, connect the starting bat-
8. Secure the rod end assembly to the actuator tery (negative [−] lead last). If applicable, con-
rod with the hex head capscrew, flat washer, nect the battery charger to AC power. Recon-
and lock washer. Tighten the capscrew to nect Source 1 and Source 2. Set the opera-
70-75 in-lbs (7.9-8.5 N m). Fit rod assembly tion selector switch to Auto (or Remote).
into the handle of the closed switch assembly.
9. Check the operation of the transfer switch and 11. Test the switch for proper operation and close
the alignment of the actuator rod by manually the cabinet.
ROD END
ASSEMBLY ACTUATOR
ACTUATOR
ROD
MOTOR
GROUND
BRUSH
RED
WHITE
BLACK
CAPSCREW
WITH LOCK
WASHER
FIGURE 7-21. LINEAR ACTUATOR (800 - 1000 AMPERES)

BLOCK AND CROSS-BAR ASSEMBLY 6. Remove hex head capscrews, spring washers,
REMOVAL AND REPLACEMENT and bushings that secure the jumper bus bars
(800 AND 1000 AMPERES) to the switch assemblies. Lift off the jumper bus
bars. (The neutral pole on the 4-pole switches
If Source 2 is a genset, set the operation selector does not have a bushing at this connection.)
connect both Source 1 and Source 2 from the 7. Remove the control wiring leads from the pow-
transfer switch. If there is an external battery char- er source terminals.
the genset starting battery (negative [−] lead first). 8. Loosen lug terminal screws and remove power
source supply wires from the lug terminals.
ents an electrical shock hazard that can cause 9. With a screwdriver, dig the glue out of the insu-
severe personal injury or death. Disconnect all lator cups that cover and insulate the block as-
sources of AC power from the transfer switch sembly mounting screws.
before servicing.
The following procedures cover the removal and re- 10. Remove hex head capscrews and flat washers
placement of the block and cross-bar assemblies that secure the block assemblies (Figures 7-22
for 800- and 1000-ampere switches. and 7-23) to the base, and lift off the block as-
semblies (note where spacers are used).
Removing the Block and Cross-bar
Assembly (Normal or Emergency)  On 3-pole switches, the A-phase block on
the Normal side and C-phase block on the
1. Remove the linear actuator as described in the Emergency side have a spacer under their
Linear Actuator Removal and Replacement outer mounting tabs. On 4-pole switches,
section for 800- and 1000-ampere switches. the A-phase block on the Normal side and
neutral block on the Emergency side have
2. Lift the arc chute covers off the arc chutes. this spacer. Make certain that you install
new block assemblies with the spacers in
3. Remove the hex head capscrews, lock wash-
their original positions.
ers, and flat washers that secure the interlock
bar to the interlock arm (Figures 7-22 and
7-23); and remove the interlock bar.  The block assemblies are not identical.
The A- and C-phase blocks, and the neu-
4. Disconnect the control wiring leads from the tral block on 4-pole switches, are different
jumper bus bars. from the B-phase block. Refer to parts
manual and part numbers stamped on re-
5. Remove hex head capscrews, ring terminals placement block assemblies to make cer-
and spring washers that secure jumper bus tain that you install new block assemblies
bars (Figures 7-22 and 7-23) to load bus bars. in their correct positions.

11. Remove round machine screws, lock washers, 14. Remove shoulder screws and self-locking nuts
and flat washers that secure arc chutes (Fig- that secure the two halves of the handle as-
ures 7-22 and 7-23) to block assemblies; and sembly together. Remove the shoulder screws
lift out arc chutes, barriers, and spacers. Dis- and lock washers that secure the handle as-
card arc chute barriers and spacers. sembly to the block and cross-bar assembly.
12. Remove the Allen head capscrews and lug ter- Slide the two halves of the handle apart and re-
minals from the block assemblies. move them.
13. Remove the hex head capscrews and flat 15. Remove the two round head machine screws
washers that secure the cross-bar assembly to that secure the interlock arm to the cross-bar
the base, and lift off the cross-bar assembly. assembly, and lift of the interlock arm.
CAUTION Use care when removing the
base. Carefully disengage the crossbar
from the auxiliary switch assembly to avoid
cracking the switch.

INTERLOCK CROSSBAR
ARM 3 ASSEMBLY
3 5 INTERLOCK
BAR
BLOCK 3 JUMPER 2
ASSEMBLY BUS BAR
ARC 1
2 CHUTE
6
ARC
4 CHUTE
BARRIER
ARC
CHUTE
SPACER
LOAD BUS
SPACER JUMPER
BAR
BUS BAR
1 TORQUE TO 15-20 IN-LBS (1.7-2.3 N M). 4 TORQUE TO 28-33 FT-LBS (40.0-44.7 N M).
FIGURE 7-22. 3-POLE SWITCH ASSEMBLY (800 - 1000 AMPERES)

INTERLOCK CROSSBAR
ARM 3 ASSEMBLY INTERLOCK
3 5 BAR
3 JUMPER 2
BUS BAR
BLOCK
ASSEMBLY 1
2 ARC
CHUTE ARC
6
CHUTE
BARRIER
4
ARC
CHUTE
SPACER
LOAD BUS JUMPER

SPACER BAR BUS BAR
FIGURE 7-23. 4-POLE SWITCH ASSEMBLY (800 - 1000 AMPERES)

Replacing the Block and Cross-bar mal side and the neutral block on the
Assembly (Normal or Emergency) Emergency side have this spacer. Make
certain that you install new block assem-
1. Install the interlock arm on the cross-bar as- blies with the spacers in their original posi-
sembly and secure with the round head ma- tions.
chine screws. Tighten the screws to 15-20 in-
lbs (1.7-2.3 N m) torque.  The block assemblies are not identical.
The A- and C-phase blocks, and the neu-
2. Apply a thin coat of lubricant (Novagard sili- tral block on 4-pole switches, are different
cone G624) to the slot in the handle. Place the than the B-phase block. Refer to the parts
handle assembly in position on the switch as- manual and the part numbers stamped on
sembly and secure with the shoulder screws, the replacement block assemblies to
lock washers, and locknuts. Tighten to 25-30 make certain that you install new block as-
in-lbs (2.8-3.4 N m). semblies in their correct positions.
3. Secure the cross-bar assembly to the base 7. Fill the insulator cups that cover and insulate
with the hex head capscrews (4), lock washers the block assembly mounting screws with
(4), and flat washers (4). Tighten to 70-75 in-lbs adhesive silicone to completely cover the
(7.9-8.5 N m) torque. washers and screw heads.
4. Apply a thin coat of glyptol between the arc 8. Install the power source supply wires and se-
chute spacers and the arc chute barrier. Place curely tighten the lug terminals to 10-12 ft-lbs
the arc chute spacers (2), arc chute barrier, and (13.6-16.3 N m) torque.
arc chute in position on each block assembly;
9. Connect the control wiring leads to the power
and secure with round head machine screws
source terminals. Control wires are marked
(2), lock washers (2) and flat washers (2).
NORM A,B,C or EMER A,B,C for identification.
Tighten to 15-20 in-lbs (1.7-2.3 N m) torque.
10. Apply a thin coat of electric joint compound be-
5. Apply a thin coat of electrical joint compound tween the mating surfaces of the jumper bus
between the mating surfaces of the block as- bars, the braided strap connectors, and load
sembly and the lug terminals. Install the lug ter- bus bars.
minals on the block assemblies and secure
with the Allen head capscrews. Tighten to 11. Install the jumper bus bars and secure to the
28-33 ft-lbs (40.0-44.7 N m) torque. switch assemblies with hex head capscrews,
spring washers, and bushings. (The neutral
6. Place each block assembly in position on the pole on 4-pole switches does not have a bush-
base and secure with the hex head capscrews ing at this connection.) Tighten to 18-20 ft-lbs
and flat washers. Refer to Figures 4-18 and (24.4-27.1 N m) torque.
4-19 to determine where the spacers are re-
quired. Tighten the capscrews to 70-75 in-lbs 12. Secure the jumper bus bars to the load bus
(7.9-8.5 N m) torque. bars with hex head capscrews, ring terminals,
and spring washers. Tighten to 10-12 ft-lbs
 On 3-pole switches, the A-phase block on (13.6-16.3 N m) torque.
the Normal side and the C-phase block on
the Emergency side have a spacer under 13. Connect the control wiring leads to the jumper
their outer mounting tabs. On 4-pole bus bars. Control wires are marked LOAD
switches, the A-phase block on the Nor- A,B,C for identification.

14. Apply thread sealant (blue Loctite 242) to the The following procedures cover the removal and re-
threads of the interlock bar capscrews. Install placement of the auxiliary switch assembly for 800-
the interlock bar and secure to each interlock and 1000-ampere switches.
arm with a hex head capscrew, lock washer,
and flat washer. Tighten to 70-75 in-lbs (7.9-8.5 Removing Auxiliary Switch Assembly
N m).
15. Place the arc chute covers in position over the
arc chutes.
2. Remove the hex head capscrew, flat washer,
16. Attempt to close both sides of the transfer and lock washer that secures one of the rod
switch. The interlock assembly must hold one end assemblies to the end of the actuator rod.
side open so that only one side closes at at
time. 3. Remove rod end assembly (Figure 7-20) and
slide the actuator rod out of the actuator motor.
17. Replace the linear actuator as described in the
Linear Actuator Removal and Replacement 4. Loosen and remove the twelve machine
section for 800- and 1000-ampere switches. screws (with flat washers) that secure the three
Follow steps 2 through 10 in the Replacing Ac- plastic switch covers to the switch base, and lift
tuator section. off the switch covers (Figure 7-20).
18. Test the switch for proper operation and close 5. Remove the hex head machine screws that se-
the cabinet. cure the terminal bracket to the base. Move the
bracket to the side to allow access to the auxil-
AUXILIARY SWITCH REMOVAL AND
iary switch terminals.
REPLACEMENT (800 AND 1000
AMPERES) 6. Remove the control wiring leads from the auxil-
If Source 2 is a genset, set the operation selector iary switch terminals (Figure 7-24).
connect both Source 1 and Source 2 from the 7. Close the transfer switch to the side you are
transfer switch. If there is an external battery char- working on and remove the hex head machine
ger, disconnect it from AC power. Then disconnect screws that secure auxiliary switch assembly
the genset starting battery (negative [−] lead first). brackets to the base. Lift out the auxiliary
switch assembly.
ents an electrical shock hazard that can cause 8. Remove round head machine screws, flat
severe personal injury or death. Disconnect all washers, and nuts that secure the auxiliary
sources of AC power from the transfer switch switches to bracket (Figure 7-24); and lift out
before servicing. the auxiliary switches and insulating barriers.

Replacing Auxiliary Switch Assembly 5. Place the plastic covers in position and secure
them with machine screws and flat washers.
1. Install the insulating barriers and auxiliary Tighten to 25-30 in-lbs (2.8-3.4 N m) torque.
switches in the brackets and secure with hex
head capscrews (2) and nuts (2). Note that 6. Insert the actuator rod into the replacement ac-
each switch must be assembled so the side tuator motor. Hold the actuator ground brush
with two terminals faces inward (Figure 7-24) up slightly to allow passage of the actuator rod.
when the auxiliary switch assembly is installed.
7. Secure the rod end assembly to the actuator
2. Install the auxiliary switch assembly on the
rod with the hex head capscrew, flat washer,
base and secure the bracket to the base using
and lock washer. Tighten capscrew to 70-75 in-
the hex head machine screws. Tighten to
lbs (7.9-8.5 N m). Fit the rod assembly into the
25-30 in-lbs (2.8-3.4 N m) torque.
handle of the closed switch assembly.
3. Install control wiring leads on switch terminals.
The leads are marked with the terminal num- 8. If Source 2 is a genset, connect the starting bat-
bers (S2/N0, S5/NC, S7/C, etc..) for identifica- tery (negative [−] lead last). If applicable, con-
tion. Refer to figures 7-22, 7-23, and 7-24 for nect the battery charger to AC power. Recon-
identification of the auxiliary switch terminals. nect Source 1 and Source 2. Set the opera-
4. Place terminal bracket in position on base and
secure it with the hex head machine screws (4). 9. Test the transfer switch for proper operation
Tighten to 25-30 in-lbs (2.8-3.4 N m) torque. and close the cabinet.
NO

(1.1-1.7 N M).
NC
COM
BARRIERS
FIGURE 7-24. AUXILIARY SWITCH (800 - 1000 AMPERES)

MIS-WIRED CURRENT TRANSFORMERS wired CT. Do not remove any CT wires from
TB4.
If a current transformer (CT) is installed backwards,
you will get erroneous readings (unusual power fac- 6. Once all wiring is properly secured, remove the
tor and negative kilowatts). shorting bar.
The shorting bar in terminal block TB4 is removed 7. Reinstall the protective cover on TB4.
when the transfer switch is installed. To correct CT
wiring without removing power to the transfer 8. If Source 2 is a genset, set the operation selec-
switch, the shorting bar must be reinstalled (see tor switch on the generator control panel to ON.
Figure 7-25).
MOUNTING
CAUTION Do not disconnect the current mod- PLATE
ule while the current transformers are ener-
gized unless the secondaries are shorted.
To correct CT mis-wiring,
1. If Source 2 is a genset, set the operation selec-

tor switch on the generator control panel to
STOP. CURRENT
MODULE
2. Open the transfer switch cabinet door. TERMINAL RAIL
AND TERMINAL
WARNING AC power within the cabinet BLOCK (TB4)
presents an electrical shock hazard that
can cause severe personal injury or death.
SHORTING
Use extreme caution to avoid touching BAR JUMPER
electrical contacts whenever the cabinet WIRES
door is open.
3. Remove the protective cover from TB4.
4. Attach the shorting bar to the center of TB4,

making sure to tighten each screw. PROTECTIVE
COVER
5. Verify which CT is mis-wired. Reverse the
jumper wires on the current module for the mis- FIGURE 7-25. SHORTING BAR INSTALLATION


8. Schematics
SCHEMATIC PAGE
Power Module 1 and 2 (Pin-outs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Power Module 1 and 2 (Power Connections − Pin-outs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Digital Module Level 1 and 2 (Pin-outs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Typical Interconnection Diagram 630-1974 (Sheet 1 of 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Typical Interconnection Diagram 630-1974 (Sheet 6 of 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Typical Interconnection Diagram 630-1974 (Sheet 10 of 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Typical Level 2 Wiring Diagram 626-2311 (Sheet 1 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Typical Level 2 Generator Set−to−Generator Set Wiring Diagram 626−2327 (Sheet 1 of 5) . . . . . . . . . . . 8-25
Power Module 1 PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
Power Module 2 PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
Typical Interconnection Diagram − Genset to Genset, Plant to Plant . . . . . . . . . . . . . . . . . . . . . . . 8-32
Typical Interconnection Diagram − Genset to Genset, Dual Standby System . . . . . . . . . . . . . . . . 8-33

TABLE 9-1. POWER MODULE 1 AND 2
J12 (POWER MODULES 1 AND 2) J13 (POWER MODULE 2)

PIN # DESCRIPTION DESCRIPTION
1 N/O close normal CT N/O contact normal
2 Common voltage feed (not used) CT N/O contact normal
3
4 N/O open emergency
5 Transfer switch S1 (normal) position sensor (gnd)
6
7 Transfer switch S2 (Emergency) position sensor
(gnd)
8 Motor disconnect switch input (gnd)
9
10 Loop ground for motor disconnect switch
11 Loop ground for normal/emergency transfer switch Bypass switch S1 (normal) position sensor (gnd)
position indicators
12 Common ground for all control relays Bypass switch S2 (emergency) position sensor
(gnd)
13 Loop ground for normal/emergency bypass position
indicators
14
15 CT N/O contact emergency
16 Common voltage feed (not used) CT N/O contact emergency
17 N/O open normal
18 N/O close emergency
TABLE 9-2. POWER MODULE 1 & 2 AC POWER CONNECTIONS
POWER MODULE #1 POWER MODULE #2

TB# LINE CONNECTIONS TB# LINE CONNECTIONS
TB11-1 “A” Phase TB11-5 “A” Phase
TB11-4 “B” Phase TB12-1 “B” Phase
TB11-7 “C” Phase TB12-4 “C” Phase
TB# GENERATOR CONNECTIONS TB# GENERATOR CONNECTIONS
TB11-8 “A” Phase TB13-5 “A” Phase
TB11-11 “C” Phase TB14-1 “B” Phase
TB14-4 “C” Phase

TABLE 9-3. DIGITAL MODULE LEVEL 1 AND 2
J27 (DIGITAL MODULE LEVEL 1) J27 (DIGITAL MODULE LEVEL 2)

PIN # DESCRIPTION DESCRIPTION
1 Retransfer inhibit (grounded input) Retransfer inhibit (grounded input)
2 Remote engine start (gnd) not used Remote engine start (gnd) not used
3 Remote test (grounded input) Remote test (grounded input)
4 Transfer inhibit (grounded input) Transfer inhibit (grounded input)
5 Panel lock (grounded input) Panel lock (grounded input)
6 Engine start #1 relay common Engine start #1 relay common
7 Test #1 start (gnd) not used Test #1 start (gnd)
8 Engine start #1 relay N/C Engine start #1 relay N/C
9 Generator #1 alarm (gnd) not used Generator #1 alarm (gnd)
10 Engine start #1 relay N/O not used Engine start #1 relay N/O
11 Terminal block common ground Terminal block common ground
12 Ground Ground
13 Load shed (grounded input) Load shed (grounded input)
14 Test #2 start (gnd)
15 Synch enable
16 Engine start #2 common
17 Generator #2 alarm (gnd)
18 Engine start #2 relay N/C
19 Standby start
20 Engine start #2 relay N/O
21 B+ input B+ input
22 Ground Ground
23 Battery charge input Battery charge input
24 Not used Not used


Drawing Name: 0630−1974 Revision: R
TYPICAL INTERCONNECTION DIAGRAM (SHEET 1 OF 12)












THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR TROU-
BLESHOOTING, REFER TO THE SCHEMATIC
AND WIRING DIAGRAM PACKAGE THAT WAS
SHIPPED WITH THE TRANSFER SWITCH.
No. 626−2311 Sh 1 of 5
Rev. F
Modified 8/2008
TYPICAL LEVEL 2 WIRING DIAGRAM (SHEET 1 OF 5)

No. 626−2311 Sh 2 of 5
Rev. F
Modified 8/2008

No. 626−2311 Sh 3 of 5
Rev. F
Modified 8/2008

No. 626−2311 Sh 4 of 5
Rev. F
Modified 8/2008

No. 626−2311 Sh 5 of 5
Rev. F
Modified 8/2008

No. 626−2303 Sh 1 of 5
Rev. E
Modified 9/2008

No. 626−2303 Sh 2 of 5
Rev. E
Modified 9/2008

No. 626−2303 Sh 3 of 5
Rev. E
Modified 9/2008

No. 626−2303 Sh 4 of 5
Rev. E
Modified 9/2008

No. 626−2303 Sh 5 of 5
Rev. E
Modified 9/2008

TYPICAL LEVEL 2 GENERATOR SET−TO−GENERATOR SET WIRING DIAGRAM (SHEET 1 OF 5)





No. 300-5148 Sh 1 of 2
Rev. J
Modified 9/2006
POWER MODULE 1 PCB ASSEMBLY

No. 300-5149 Sh 1 of 2
Rev. H
Modified 1/2006
POWER MODULE 2 PCB ASSEMBLY

No. 630−2108 Sh 3 of 4
Rev. E
Modified 1/2008
TYPICAL INTERCONNECT DIAGRAM − GENSET TO GENSET, PLANT TO PLANT

No. 630−2024 Sh 3 of 4
Rev. F
Modified 7/2003
TYPICAL INTERCONNECT DIAGRAM GENSET TO GENSET, DUAL STAND-BY SYSTEM

Copyright  2021 Cummins Inc. 836

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Copyright 2021 Cummins Inc. All rights reserved.
Cummins, the “C” logo, PowerCommand, AmpSentry, and InPower are trademarks of Cummins Inc.
Other company, product, or service names may be trademarks or service marks of others.
Specifications are subject to change without notice.

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Service Manual

i Copyright  2021 Cummins Inc.

Copyright  2021 Cummins Inc. ii

iii Copyright  2021 Cummins Inc.

Copyright  2021 Cummins Inc. iv

v Copyright  2021 Cummins Inc.

Copyright  2021 Cummins Inc. vi

vii Copyright  2021 Cummins Inc.

INCORRECT SERVICE OR REPLACEMENT OF PARTS CAN RESULT IN

Copyright  2021 Cummins Inc. viii

This manual contains service procedures for an

Refer to the schematic and wiring diagram pack-

Use normal and necessary safety precautions be-

TRANSFER SWITCH APPLICATIONS

Transfer switches are an essential part of a build-

1-1 Copyright  2021 Cummins Inc.

 Master Controller Preferred Source

 Circuit Breaker Level 2 Controllers Only

The OTPC ATS supports utility-to-generator, utility-

UTILITY-TO-GENSET OPERATION GENERATOR-TO-GENERATOR

UTILITY-TO-UTILITY OPERATION In Dual Standby genset-to-genset applications, the

Copyright  2021 Cummins Inc. 1-2

GENSET B GENSET B UTILITY

GEN-TO-GEN CONFIGURATION IN GEN-TO-GEN CONFIGURATION IN

FIGURE 1-3. GENERATOR-TO-GENERATOR CONFIGURATION IN PRIME POWER

1-3 Copyright  2021 Cummins Inc.

8. If desired, use the Time Delay sub-menus un-

Testing the System by Turning Off the Pre-

Changeover Delay 1. With the preferred source genset running and

Copyright  2021 Cummins Inc. 1-4

1-5 Copyright  2021 Cummins Inc.

Copyright  2021 Cummins Inc. 1-6

HOW TO OBTAIN SERVICE

1-7 Copyright  2021 Cummins Inc.

Copyright  2021 Cummins Inc. 1-8

FIGURE 2-1. CONTROL PANEL ON CABINET DOOR (INCLUDES OPTIONS)

2-1 Copyright  2021 Cummins Inc.

The ammeter displays percent of full load currents

The power meter displays the real power in percent

The transfer switch is not in auto when any of the

Copyright  2021 Cummins Inc. 2-2

For genset-to-genset applications, there is no

2-3 Copyright  2021 Cummins Inc.

NOTE: NCM boards on current production models do not use batteries.

FIGURE 2-5. INTERIOR/COMPONENTS: 40-125 AMP SWITCH

Copyright  2021 Cummins Inc. 2-4

WARNING Improper calibration or adjustment

Calibration and adjustment procedures are de-

WARNING AC power within the cabinet and

Electronic Control Circuit Modules J24 J28 K10 J25

Digital Module: The digital module (see Figures

2-5 Copyright  2021 Cummins Inc.

Level 1 power modules contain four pilot relays de- T8 T5

Motor Disconnect Switch

Copyright  2021 Cummins Inc. 2-6

Auxiliary Contacts 1 GND

FIGURE 2-11. TB2: START CONNECTIONS,

2-7 Copyright  2021 Cummins Inc.

Programmable generator exercises and exercise

The PowerCommand network interface option in-

Figure 4-28. Auto S1=ON S2=NA

Example using Default Settings Enabled/Disabled