Installation Manual: Bypass Isolation Transfer Switch

Installation Manual
Bypass Isolation Transfer Switch

150−4000 Amps
BTPCB (Spec A)
BTPCC (Spec A−B)
BTPCD (Spec A)
BTPCE (Spec A−B)
BTPCF (Spec A−B)
BTPCG (Spec A−B)
BTPCH (Spec A−B)
BTPCJ (Spec A)
English
Original Instructions 7-2017 0962−0619 (Issue 7)
Table of Contents
SECTION TITLE PAGE
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Installation manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Transfer Switch Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Transfer Switch Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Utility-to-Genset Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Utility-to-Utility Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Application and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
How to Obtain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
2. MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Moving the Bypass Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Mounting Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Against a Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Free-Standing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Open Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
3. WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
AC Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Converting the Phase Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Checking the Phase Rotation (3 Phase Switches) . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Connecting Load Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Activating Current Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Connecting Transfer Switch to Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Auxiliary Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Remote Test Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Transfer Inhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Load Shed Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Current Module Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Relay Module Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Auxiliary Relays Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Battery Charger Alarm Contacts Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Network Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Delta and WYE Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Transfer Switches in Fire Pump Circuit Applications . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Required Transfer Switch Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Isolating Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Separate ATS for Auxiliaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Shorting Bar Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
i Copyright  2017 Cummins Inc.

Table of Contents (Continued)
SECTION TITLE PAGE

Inspection and Cleanup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Transfer Switch Removel and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
150−1000 Amp Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
1200−4000 Amp Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
4. SETUP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Power-Up the Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Install the Digital Module and Network Communications Module Batteries . . . . 4-1
Install P1 and P10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Connect the Genset Battery (Utility-to-Genset Applications Only) . . . . . . . . . . . . 4-2
Connect AC Line Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Before Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Disable the Linear Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Controller Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Using the Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Main Menu Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Main Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Source 1 and Source 2 Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Load Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Statistics Submenus − Prior to Software Version 1.12 . . . . . . . . . . . . . . . . . . . . . 4-13
Statistics Submenus − Starting with Software Version 1.12 . . . . . . . . . . . . . . . . 4-14
Events Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Setup Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Setup Menu Navigation and Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Saving or Restoring Setup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Changing Setup Parameters − Software Versions Prior to Version 1.12 . . . . . 4-18
Changing Setup Parameters − Starting with Software Version 1.12 . . . . . . . . . 4-19
Voltage and Frequency Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Undervoltage Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
OverVoltage Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Frequency Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Voltage Imbalance Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Phase Rotation Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Loss of Single Phase Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Sensor 1 & Sensor 2 Submenus− Software Versions Prior to Version 1.12 . . . 4-22
Sensor 1 & Sensor 2 Submenus − Starting with Software Version 1.12 . . . . . . 4-24
Sync Check Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Active Sync Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Speed Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Sync Check Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Copyright  2017 Cummins Inc. ii

SECTION TITLE PAGE

Time Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Time Delay Engine Start (TDES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Time Delay Normal to Emergency (TDNE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Time Delay Emergency to Normal (TDEN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Time Delay Engine Cooldown (TDEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Time Delay Programmed Transition (TDPT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Time Delay Elevator (TDEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Time Delay Submenus − Software Versions Prior to Version 1.12 . . . . . . . . . . 4-29
Time Delay Submenus − Starting with Software Version 1.12 . . . . . . . . . . . . . . . . . 4-30
Source Selecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Generator Exercise Routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Test Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Exerciser Submenus − Software Versions Prior to 1.5.190 . . . . . . . . . . . . . . . . . 4-32
Exerciser Submenus − Starting with Software Version 1.5.190 . . . . . . . . . . . . . 4-34
Exercise Exceptions Submenus − Starting with Software Version 1.5.190 . . . 4-36
Exercise Submenus − Starting with Software Version 1.12 . . . . . . . . . . . . . . . . . 4-38
Exercise Exceptions Submenus − Starting with Software Version 1.12 . . . . . . 4-40
Exercise Submenus − Starting with Software Version 1.13.244 . . . . . . . . . . . . . 4-42
Exercise Exceptions Submenus − Starting with Software Version 1.13.244 . . 4-44
Mode of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
Mode Submenu − Prior to Software Version 1.20.250 . . . . . . . . . . . . . . . . . . . . . 4-46
Mode Submenu − Starting with Software Version 1.20.250 . . . . . . . . . . . . . . . . 4-46
Setting the Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Clock Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Sequencer Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
About Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
About Submenus − Starting with Software Version 1.20.250 . . . . . . . . . . . . . . . 4-51
System Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53
Active TD Submenus − Prior to Software Version 1.12 . . . . . . . . . . . . . . . . . . . . 4-54
Active TD Submenus − Starting with Software Version 1.12 . . . . . . . . . . . . . . . 4-55
Float Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
Battery Charger Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
Original Float Battery Charger Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
Current Float Battery Charger Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
2-Amp Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
15/12-Amp Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
Battery Charger Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
Battery Charger Alarm Contacts Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
Reconnect the Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
iii Copyright  2017 Cummins Inc.

SECTION TITLE PAGE
5. SYSTEM CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Starting Test (Utility-to-Genset Application) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Transfer with Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Utility-to-Genset Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Utility-to-Utility Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Control LED Indicators and Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Exercise Enable/Disable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Generator Set Start Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Non-Load Break Transfer Switch Test 150−1000 Amp Switches . . . . . . . . . . . 5-3
Non-Load Break Transfer Switch Test 1200−4000 Amp Switches . . . . . . . . . . 5-5
Generator Set Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Calibrating the Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
6. START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Setup Using the Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Setting the Date and Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Setting Exercise(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Setting the Unit to Test With or Without Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Saving the Settings and System Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Setup Using InPower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Setting the Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Setting Exercise(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Setting the Unit to Test With or Without Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Saving the Settings and System Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
About InPower Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
About Network Applications and Customer Inputs . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
7. SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Copyright  2017 Cummins Inc. iv

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 2. Disconnect the battery charger.
exist. Then take the necessary steps to protect per-
sonnel and the equipment. 3. Disconnect the starting batteries of the genera-
tor set or sets (remove the ground [−] lead first).
This symbol warns of immediate 4. Remove AC power to the automatic transfer
hazards that will result in severe personal injury switch. If the instructions require otherwise,
or death. use extreme caution due to the danger of shock
WARNING This symbol refers to a hazard or hazard.
unsafe practice that can result in severe per- UTILITY-TO-UTILITY APPLICATIONS
sonal injury or death.
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
damp when handling any electrical equipment.
Keep the transfer switch cabinet closed and locked.
Make sure only authorized personnel have the cabi- Jewelry is a good conductor of electricity and
net and operational keys. should be removed when working on the electrical
equipment.
Due to the serious shock hazard from high voltages
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.
UTILITY-TO-GENSET OR Do not work on this equipment when mentally or

GENSET-TO-GENSET APPLICATIONS physically fatigued, or after consuming alcohol or
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.
SERVICE PERSONNEL MUST BE QUALIFIED TO PERFORM ELEC-
TRICAL AND/OR MECHANICAL SERVICE.
OTPC-2
v Copyright  2017 Cummins Inc.

THIS PAGE INTENTIONALLY BLANK
Copyright  2017 Cummins Inc. vi

1. Introduction
INSTALLATION MANUAL SOURCE 1 SOURCE 2
(NORMAL) (EMERGENCY)
This installation manual provides information nec-
ISOLATING
essary for the installation of a BTPC transfer switch CONTACTS
and includes models produced under the Cum-
mins/Onan and Cummins Inc. brand names.
The BTPC is a bypass isolation transfer switch with
PowerCommand Control (PC). The BTPC can be
used in either utility-to-genset or utility-to-utility
control applications.
TRANSFER SWITCH APPLICATION ES1968
The transfer switch combines an automatic trans-

fer switch, a manual bypass switch and a drawout BYPASS
TRANSFER AUTOMATIC
isolation mechanism in one unit.
SWITCH TRANSFER
LOAD SWITCH
Transfer switches are an essential part of a build-
ing’s standby or emergency power system. Power FIGURE 1-1. BT TRANSFER SWITCH (TYPICAL
Source 1 (Normal), commonly the utility line, is FUNCTION)
backed up by Power Source 2 (Emergency), often
a generating set. The transfer switch automatically UTILITY-TO-GENSET OPERATION
switches the electrical load from one source to the In utility-to-genset applications, the transfer switch
other. performs the following functions:
The load is connected to the common of the trans- 1. Senses the interruption of the Source 1 power.
fer switch (Figure 1-1). Under normal conditions,
the load is supplied with power from Source 1 (as 2. Sends a start signal to the generator set
illustrated). If Source 1 is interrupted, the load is (Source 2).
transferred to Source 2. When Source 1 returns, 3. Transfers the load to the Source 2.
the load is retransferred to Source 1. The transfer
and retransfer of the load are the two most basic 4. Senses the return of Source1.
functions of a transfer switch.
5. Retransfers the load to Source 1.
TRANSFER SWITCH FUNCTION 6. Sends a stop signal to the generator set.
Automatic transfer switches, capable of automatic UTILITY-TO-UTILITY OPERATION

operation without operator intervention, perform
the basic function of transferring the load to the In utility-to-utility applications, the transfer switch
available source. The controller monitors each performs the following functions:
source for allowable voltage and frequency range. 1. Senses the interruption of the Source 1 power.
Transfer switches may interact with any of the LON-
MARK devices. 2. Transfers the load to the Source 2.
Genset 3. Senses the return of Source1.
Master Controller 4. Retransfers the load to Source 1.
Annunciator Panel The controller can control a two-utility configuration
Circuit Breaker for prime power. One utility is designated the pre-
1-1 Copyright  2017 Cummins Inc.

ferred source. The control automatically transfers distribution equipment, transfer switches, ventila-
the load between the two utilities and detects alarm tion equipment, mounting pads, and cooling, ex-
conditions. The exercise routine is not available in haust, and fuel systems. Each component must be
this configuration. correctly designed so the complete system func-
tions as intended. Application and design is an en-
The operator can select either source (Source 1 or gineering function generally done by specifying en-
Source 2) as the preferred source (see Figure 1-2). gineers or other trained specialists. Specifying
The Preferred Source menu is included in the Test engineers are responsible for the design of the
submenus (see Figure 4-30). The PC service tool complete standby system and for selecting the ma-
can also be used to designate the preferred source. terials and products required.
Installation refers to the actual set-up and assem-

Preferred Source
bly of the standby power system. The installers set
Source 1/Source 2
up and connect the various components of the sys-
tem as specified in the system design plan. The
complexity of the standby system normally re-
quires the special skills of qualified electricians,
FIGURE 1-2. PREFERRED SOURCE SUBMENU plumbers, sheetmetal workers, etc. to complete the
various segments of the installation. This is neces-
INSTALLATION OVERVIEW sary so all components are assembled using stan-
dard methods and practices.
These installation recommendations apply to typi-
cal installations. Whenever possible, these recom- Safety Considerations
mendations also cover factory designed options or
modifications. However, because of the many vari-
The transfer switch has been carefully designed to
ables in any installation, it is not possible to provide
provide safe and efficient service when properly
specific recommendations for every situation. If
installed, maintained, and operated. However, the
there are any questions not answered by this
overall safety and reliability of the complete system
manual, contact your nearest Cummins dealer or
depends on many factors outside the control of the
distributor for assistance.
manufacturer. To avoid possible safety hazards,
Application and Installation make all mechanical and electrical connections to
the transfer switch exactly as specified in this
Installations must be carefully planned and correct- manual. All systems external to the transfer switch
ly installed for proper operation. This involves two must comply with all applicable codes. Make cer-
essential elements: application and installation. tain all required inspections and tests have been
completed and all code requirements have been
Application refers to the design of the complete satisfied before certifying the installation is com-
standby power system that usually includes power plete and ready for service.
Copyright  2017 Cummins Inc. 1-2

MODEL IDENTIFICATION 4. Specification letter − advances with produc-
tion modification.
Identify your model by referring either to the Model
and Specification number as shown on the name- HOW TO OBTAIN SERVICE
plate, or via LONWORKS network. Electrical charac-
teristics are shown on the lower portion of the
nameplate, which is located on the cabinet door. When the transfer switch requires servicing, con-
tact your nearest dealer or distributor. Factory-
If it is necessary to contact a dealer or distributor re- trained Parts and Service representatives are
garding the transfer switch, always give the com- ready to handle all your service needs.
plete Model, Specification, and Serial number as
listed on the nameplate. This information is neces- Call 1−800−CUMMINSTM (1−800−286−6467) to
sary to properly identify your unit among the many contact the nearest Cummins Inc. distributor in the
types manufactured. United States or Canada (this automated service
utilizes touch-tone phones only).
BTPCB 00000 Spec. A
| | | | If you are unable to locate a dealer or distributor,
1 2 3 4 consult the Yellow Pages. Typically, our distributors
are listed under:
1. BTPC − Bypass Transition PowerCommand
Control.
Generators-Electric,
2. Ampere Rating: Engines-Gasoline or Diesel, or
B = 150−260 Recreational Vehicles-Equipment,
C = 300−400 Parts and Service.
D = 600−1000
E = 1200 For outside U.S. and Canada, call Cummins Inc.,
F = 1600 1-763-574-5000, 7:30 AM to 4:00 PM, Central
G = 2000 Standard Time, Monday through Friday. Or, send a
H = 3000 fax to Cummins Inc. using the fax number
J = 4000 1−763−528−7229.
3. Assigned spec number − issued for each spe- When contacting your distributor, always supply
cific combination of accessories, voltages, fre- the complete Model Number and Serial Number as
quency and standards codes. shown on the nameplate.
Cummins is a registered trademark of Cummins Inc.

PowerCommand is a registered trademark of Cummins Inc.
LONWORKS, LONMARK, and LonMaker are registered trademarks of Echelon Corp.


2. Mounting
LOCATION are near flammable liquids or gases, or are hot,
moist, or dusty.
The location of the bypass transfer switch in the ex- WARNING An electrical arc occurs during
isting electrical circuit varies with the application transfer that can ignite a flammable atmo-
and the type of entrance switch. The location and
sphere, resulting in severe personal injury or
wiring must comply with the contract drawings, the
death. The switch must not be located near bat-
NEC, and any local codes.
teries, fuel tanks, solvents, or other sources of
flammable liquids or gases, or in areas sharing
There must be a service disconnect in the commer- ventilation with such sources.
cial power line ahead of the transfer switch.
On all rear-connected transfer switches, allow at
least 36 inches (914 mm) at the rear of the cabinet
A typical installation is shown in Figure 2-1. Cabinet
for access to the cable compartment.
dimensions and weights are listed in Tables 2-1
and 2-2. NEC article 110-16 requires a minimum of 36 inch-
es (914 mm) clear space in front of the cabinet. In
Choose a vibration-free mounting surface that sup- addition to meeting this requirement, allow enough
ports the weight of the switch. Avoid locations that clear space to permit fully opening the cabinet door.
REMOTE CONTROL
WIRES CABLES TO SOURCE 2
SIDE OF TRANSFER
GENERATOR SET SWITCH
CONTROL HOUSING LOAD
CABLES
CABLES FROM SERVICE

DISCONNECT SWITCH
BOX AND METER
AUTOMATIC TRANSFER
SWITCH
FIGURE 2-1. TYPICAL WALL-MOUNT INSTALLATION

TABLE 2-1. APPROXIMATE NEMA 1 CABINET DIMENSIONS
Height Width Door Closed Door Open Weight
Amp Rating
in mm in mm in mm in mm lb kg
150, 225, 260 71.75 1822 36 914 22.75 578 55.2 1403 564 256
300, 400 83.25 2115 36 914 22.75 578 55.2 1403 639 291
600, 800, 1000 90.00 2286 48 1219 27.75 705 62.5 1588 1097 499
1200 3−pole* 90.00 2286 40 1016 27.00 686 67.0 1702 1980 898
1200 4−pole* 90.00 2286 46 1168 27.00 686 73.0 1854 2185 991
1600, 2000 3−pole 90.00 2286 40 1016 62.00 1575 102.0 2591 3085 1399
1600, 2000 4−pole 90.00 2286 50 1270 62.00 1575 112.0 2845 3650 1656
3000 3−pole 90.00 2286 40 1016 74.00 1880 114.0 2897 4100 1860
3000 4−pole 90.00 2286 50 1270 74.00 1880 124.0 3150 5010 2273
4000 3−pole 90.00 2286 47.5 1207 81.00 2057 128.5 3264 4730 2129
4000 4−pole 90.00 2286 54 1372 81.00 2057 135.0 3429 5930 2669
*1200-ampere transfer switch dimensions are for top entry connections only. For rear, side, or bottom entry, an adaptor
bay is required. The adaptor bay has a depth of 14 inches (356 mm).
TABLE 2-2. APPROXIMATE NEMA 3R, 4 AND 12 CABINET DIMENSIONS

Height Width Door Closed Door Open Weight
Amp Rating Cabinet Type
in mm in mm in mm in mm lb kg
150, 225, 260 71.75 1822 36.00 915 22.75 578 55.20 1402 564 256 Type 3R, 12,
150, 225, 260 71.75 1822 36.00 915 22.75 578 55.20 1402 564 256 Type 4
300, 400 83.25 2115 36.00 915 22.75 578 55.20 1402 639 290 Type 3R, 12
300, 400 83.25 2115 36.00 915 22.75 578 55.20 1402 639 290 Type 4
600, 800, 1000 90.00 2286 48.00 1214 27.75 705 62.50 1534 1097 498 Type 3R
600, 800, 1000 90.00 2286 48.00 1214 27.75 705 62.50 1534 1097 498 Type 12, 4
1200 3−pole (1) 90.00 2286 40.00 1016 28.25 718 65.50 1654 1980 748 Type 3R, 4, 12
1200 4−pole (1) 90.00 2286 46.00 1168 28.25 718 71.69 1821 2185 991 Type 3R, 12, 4
1600, 2000 3−pole (2) 90.00 2286 43.52 1105 62.77 1594 99.77 2534 3085 1399 Type 3R, 12, 4
1600, 2000 4−pole (2) 90.00 2286 53.52 1359 62.77 1594 109.77 2788 3650 1656 Type 3R, 12, 4
3000 3−pole (2) 90.00 2286 43.52 1105 74.77 1899 111.77 2839 5010 2273 Type 3R, 12, 4
3000 4−pole (2) 90.00 2286 53.52 1359 74.77 1899 121.77 3093 5010 2273 Type 3R, 12, 4
4000 3−pole 90.00 2286 48.5 1232 81.75 2076 131 3327 4730 2129 Type 3R, 12, 4
4000 4−pole 90.00 2286 55.0 1397 81.75 2076 137 3480 5930 2669 Type 3R, 12, 4

MOVING THE BYPASS TRANSFER
SWITCH
The recommended method for placement of the

H 455
transfer switch is lifting. For this purpose, the trans-
fer switches can be lifted with a forklift. Most cabi- SPREADER
nets have lifting channels on the bottom of the cabi-
net. These transfer switches are designed to be
moved in the upright position.
D
LIFTING EYES
When lifting with a forklift, 1200-ampere transfer
switches must be lifted from the rear. Take care not
to let the switch tip beyond its center of gravity. As
an alternative lifting method, lifting eyes are fas-
tened to the top of 600−1200-ampere transfer
switches (Figure 2-2). Approximate transfer switch CABINET
weights are listed in Table 2-2. WHEN LIFTING THE SWITCH, A SPREADER MUST
BE USED. THE HEIGHT H MUST BE EQUAL TO D/2.
M1912s
WARNING Improper lifting can cause severe FIGURE 2-2. LIFTING METHOD FOR
personal injury or death. Use adequate equip- 600−1200-AMPERE TRANSFER SWITCHES
ment and sufficient personnel for lifting and
mounting transfer switches. When lifting with a If it is necessary to jack the transfer switch for final
forklift, the 1200-ampere transfer switch must positioning, place the jack under a corner of the
be lifted from the rear. Never stand or work un- structure. Jacking should be used only for final
der a transfer switch while it is suspended. alignment. Do not drag or push the transfer switch.

MOUNTING METHODS 1200 Ampere Switches
WARNING If the 1200-ampere transfer switch
Transfer switches can be free-standing or mounted
does NOT include an adaptor bay, failure to ad-
to a wall. Follow the appropriate set of mounting in-
equately secure the cabinet can cause severe
structions and refer to the outline drawing for instal-
personal injury or death. Secure the cabinet at
lation dimensions, specifications and mounting
all four mounting holes.
hole patterns.
Anchor bolts and other mounting hardware must be
Against a Wall
provided by the installer.
1. Make sure that the wall where the ATS switch
is to be mounted is suitable to hold firmly the 1. If the transfer switch includes an adapter bay,
weight and size of the transfer switch, within a attach the adapter bay to the cabinet with the
reasonable safety factor. mounting hardware provided.
2. Check the location to be sure no wires or 2. If the transfer switch does not include an
plumbing, gas, or exhaust lines run behind the adapter bay, the cabinet must be secured to a
wall. wall. At the four embossed cabinet mounting
holes provided, bolt the cabinet to the wall.
3. Make sure that all anchorage fasteners used
to bolt the switch to wall are strong enough to Free-Standing
withstand the switch weight and its vibration
during operation, within a reasonable safety
A mounting bay is necessary if cables are to be run
factor.
to the switch from the back.
4. With the shipping box standing so that the cab-
150−400 Ampere Switches
inet is upright, carefully remove the top and
sides of the shipping box. 1. Secure the base of the cabinet by bolting the
C-channels to the floor at all four corners. If the
WARNING Improper lifting can cause se- mounting flange on the top of the cabinet is not
vere personal injury. Have sufficient per- bolted to the wall, the cabinet must be bolted
sonnel for lifting and mounting the cabinet. to the floor at all four corners to provide stabil-
ity.
5. Using lifting equipment and sufficient person-
nel, position the transfer switch. 600−1000 Ampere Switches
150−400 Ampere Switches 1. Provide stability by bolting the C-channels to
the floor at all four corners.
1. Bolt the mounting flange on the top of the cabi-
net to the wall.
1200 Ampere Switches
2. At the two front corners of the cabinet base,
bolt the C-channels to the floor. (If the cabinet 1. If local codes require anchoring the cabinet to
is against a wall, only the front two holes in the the floor; anchor bolts, floor-mounting chan-
C-channels are accessible.) nels, and other foundation material must be
provided by the installer. Refer to the outline
600−1000 Ampere Switches drawing for dimensions and specifications.
Anchor bolts, floor-mounting channels, and other 1600−4000 Ampere Switches

foundation material must be provided by the install-
er. 1. If local codes require anchoring the cabinet to
the floor; anchor bolts, floor-mounting chan-
1. Bolt all four corners of the cabinet to the floor. nels, and other foundation material must be
Refer to the outline drawing for dimensions, provided by the installer. Refer to the outline
specifications, and mounting hole pattern. drawing for dimensions and specifications.

OPEN CONSTRUCTION Sheet 1 of the outline drawing provides dimensions
for mounting the control plate and optional compo-
Enclosure nent panel in an enclosure (Figure 2-3).
Open construction installation of 150−1000 amp
Sheet 2 of the outline drawing shows a suggested
transfer switches is available (see Figure 2-3). Use
mounting location of the control plate on an enclo-
an enclosure of the required NEMA type. The door
sure door.
should be securable and have safety warnings re-
quired to meet all applicable codes. The minimum
cabinet size is determined by the current rating of Sheets 3 through 8 provide dimensions of various
the transfer switch. Refer to individual Tables 2-1 transfer switches and components. Use the draw-
and 2-2 for the minimum cabinet dimensions. ing that matches the accompanying switch.
The outline drawings supplied with the transfer See Section 3: Wiring for wiring instructions and re-
switch provide dimensions for mounting transfer fer to the wiring diagrams shipped with the bypass
switch components in an enclosure. transfer switch.

A A (SHT 2)
2.80
(71.1)
6.65
(169)
4.37
.59 24.80 (111.0)
0.40 3.57
(15) (630) (10.2) (90.7)
õ.28
.59 (7.0) 10.0 0.40
(15) (254) (10.2)
FIELD WIRING REQUIREMENTS
TB3, KNA, KEA, KGS, J14, J15
Use copper wire only.
4X õ .28
Torque to 7 Lbs−In (0.8 Nm)
(7.1) TB3
MEMBRANE
PANEL
24.80
(630)
DANGER
Hazardous Voltage.
24.61
(625.0)
23.62
or death.
(600)
23.82
(605.0)
1 2 3 4 5 6 7 8 9 10111213141516
1 2 3 4 5 6 7 8 9 10111213141516
APPROX 53 INCHES
TO BYPASS SW
K1 K2 K3 K5 K6
SHEET 3 THRU 8
P10
Model No.
Modele
Serie
IMPORTANT!
1400 73rd Avenue N.E.

R
Made in U.S.A. C
SA
Disconnect P10
before servicing
U
L
Voltage− VAC DANGER control panel. 1 2 3 4 5 6 7 8 9 10111213141516
Frequency− Hertz
Poles−
Appl−
FEATURES:
or death.
WIRING DIAGRAM:
servicing.
OPTIONS PANEL
25.98 SUPPLIED WITH THE FOLLOWING OPTIONS:
(660) NETWORK COMMUNICATIONS, AUXILIARY
RELAYS, LOAD MONITOR, RELAY MODULE,
STANDARD CONTROL PANEL TERMINAL BLOCK, LOAD SHED AND
BATTERY CHARGER ALARMS.
NOTE:
1. NEC TABLE (A) 373−6 SHALL APPLY WHEN THE CONDUCTOR

DOES NOT ENTER OR LEAVE THE ENCLOSURE THROUGH WIRE BENDING SPACE 1
THE WALL OPPOSITE ITS TERMINAL.
AMPS TABLE A TABLE B
NEC TABLE (B) 373−6 SHALL APPLY WHEN THE CONDUCTOR
ENTERS OR LEAVES THE ENCLOSURE THROUGH THE WALL 40−125 3−1/2 6
OPPOSITE ITS TERMINALS. 150−225 5 7
2. DIMENSIONS IN ( ) ARE MILLIMETERS. 260 6 10
300−400 8 15
3. APPROX. CONTROL PANEL WEIGHT : 48 LBS 600 8 14
MASS : 21.8 kgs 800 10 15
1000 12 16
310−1341
FIGURE 2-3. TYPICAL OPEN CONSTRUCTION FOR 150-1000 AMP TRANSFER SWITCHES

3. Wiring
This section describes the wiring and connections structions for removing and installing the
of a variety of transfer switches. Make sure the pro- switch are at the end of this section on page
cedures defined relate to the size of switch being 3-15.
installed. Follow the wiring diagrams shipped with
the transfer switch. AC CONNECTIONS
WARNING AC voltages and currents present Perform wiring in the following sequence:
an electrical shock hazard that can cause se- 1. Test the operation of the generator set from its
vere personal injury or death. Only trained and
own controls.
experienced personnel are to perform the fol-
lowing procedures. Make sure both AC power 2. Stop the generator set and remove the nega-
sources are disconnected. tive lead from the cranking battery to prevent
starting.
When installing conduit, observe the following pre-
cautions: WARNING Failure to prevent the genera-
1. Cover the transfer switch to prevent accidental tor set from starting before wiring proce-
entry of metal chips. dures are performed presents a shock haz-
ard that can cause severe personal injury
2. If using rigid conduit between the generator set or death. Disconnect generator set battery
and the transfer switch, install at least 2 feet (negative (−) terminal first) before proceed-
(610 mm) of flexible conduit between the rigid ing.
conduit and generator set to absorb vibration.
3. Connect conductors of sufficient size (see
3. Run control circuit wiring in separate conduit contract drawings, NEC and local codes).
from the AC wiring; otherwise, induced cur- Connect only Normal (Source 1) and Emer-
rents could cause operational problems within gency (Source 2) cables at this time. Terminal
the switch. lugs are marked A, B, and C (A, B, C, and N on
4-pole switches). A neutral bar with lugs is
4. Cutouts can be made through the top, bottom, standard on 3-pole switches.
or sides of the cabinet. (Refer to the transfer Refer to Table 3-1 for type and conductor size
switch outline drawings for the location and di- the transfer switch will accept.
mensions of the cable entrance areas.)
4. Locations of terminals and/or lugs for the Nor-
On 1200 Amp switches cutouts can only be mal and Emergency sources are shown in Fig-
made on the adaptor bay. Without the adaptor ures 3-2 thru Figure 3-4.
bay, the 1200 amp cabinet has top cable ac-
cess only. 150−100 Amp Transfer Switches: For ac-
cess to the terminal lugs remove the lug cov-
CAUTION Installation debris can cause
ers.
equipment failure and damage. Use ex-
treme care to keep drill chips and filings 1200 Amp Transfer Switches: For access to
out of the relays, contacts, and other parts the terminal lugs, open the cabinet door and
of the automatic transfer switch when remove the plastic switch cover and lug
mounting or connecting conduit. Do not shields. Remove the cabinet access panels as
use screwdrivers to pry filings or chips required (Figure 3-3).
from components inside the cabinet. In applications where the transfer switch is to
be side or bottom connected through the op-
5. Because the transfer switch is mounted in front tional adaptor bay, cables for power connec-
of the bypass switch on 150−1000 Amp tions must be routed to the top of the adaptor
switches, it is easier to make electrical con- bay, and then into the main cabinet through the
nections if the transfer switch is removed. In- removable back panel.

1600−4000 Amp Transfer Switches: For ac- CAUTION Incorrect placement of transformer
cess to the terminal connectors (lugs are op- jumper wires can cause damage to the control
tional), remove the rear, side and bottom cabi- when power is applied. To perform this conver-
net panels (Figure 3-4). sion procedure correctly, refer to and comply
with the schematics and wiring diagrams that
5. On three-phase switches, phase rotation must were shipped with the transfer switch.
be set up or checked and corrected (if neces- 1. Make sure that both AC power sources are dis-
sary) before any load cables can be con- connected.
nected.
2. Place the transformer jumper wires (on the
TABLE 3-1. TERMINAL LUG CAPACITY FOR Power Module) in the appropriate configura-
COPPER OR ALUMINUM CONDUCTORS tion shown on Sheet 3 of the schematic and
wiring diagram shipped with the switch.
Switch Current Wires per
Rating Phase
Size Range of Wires 3. After the transfer switch is powered up, set the
appropriate Phase System under the Sensing
150/225 1 6 AWG-300 MCM Cu-Al
parameter using the digital display or the PC
260 1 6 AWG-400 MCM Cu-Al
Service Tool. (See Section 4.)
150/225/260
1 4 AWG-500 MCM Cu-Al
(Optional) Checking the Phase Rotation (3 Phase
300/400 2 3/0 AWG-250 MCM Cu-Al Switches)
1 3/0 AWG-600 MCM Cu-Al
WARNING AC voltages and currents pres-
300/400 350−1000 MCM Cu-Al
1 ent an electrical shock hazard that can
(Optional) 2 AWG-600 MCM Cu-Al
cause severe personal injury or death.
600 2 250 to 500 MCM Cu-Al
Make sure that both AC power sources are
600 (Optional) 2 2 AWG-600 MCM Cu-Al disconnected.
800/1000 4 250 to 500 MCM Cu-Al
Power Poles 1. Make sure that both AC power sources are dis-
4 2 AWG-600 MCM Cu-Al
Neutral Bar 3 Pole Only
connected.
800/1000 3 300 to 750-MCM Cu-Al WARNING Accidental actuation of the lin-
(Optional) Power Poles ear actuators can cause severe personal
1/0 AWG-750 MCM Cu-Al
Neutral Bar 3-Pole Only injury or death. Disable the actuators as
described below before proceeding.
1200 4 2 AWG−600 MCM Cu-Al
Phase Lugs
2. Disable the Linear Motor.
Neutral Lugs 12 250 to 350 MCM Cu or
350 to 500 MCM Al For 150−1000 Amp switches, move the Draw-
1200 4 Pole 4 2 AWG to 600 MCM Cu-Al out Lever upwards.
1600−3000 8 2 AWG-600 MCM Cu-Al For 1200−4000 Amp switches, place the Mo-
4000 12 2 AWG-600 MCM Cu-Al tor Disconnect Switch (Figure 4-5) in the Off
(lugs optional) position.
4000 12 2 AWG-750 MCM Cu-Al
(lugs optional) 3. Connect a load-test panel, phase rotation me-
ter, or three-phase motor to the transfer switch
Lugs are optional on 1600−4000 Amp switches.
load terminals. With both AC power sources
disconnected, manually close the transfer
Converting the Phase Rotation switch to the Normal (Source 1 ) side. Connect
power to the Source 1 side of the transfer
switch.
Setting or converting a transfer switch from single-
phase to three-phase operation or from three- 4. Observe the rotation. If the rotation is wrong,
phase to single-phase operation is a three-step go to step 5. If the rotation is correct, go to step
procedure: 6.

5. Disconnect the Source 1 AC power source. Connecting Load Cables
WARNING AC voltages and currents pres- 1. On 240-volt single phase switches, connect
ent an electrical shock hazard that can the two hot lines to the A- and C-lugs and the
cause severe personal injury or death. Dis- neutral line to the Neutral lug.
connect the AC power source.
Reverse any two leads on the Source 1 side of 2. Connect power cables to the load terminals.
the transfer switch. On a 4-wire (center Tighten the lugs as indicated in Table 3-2.
tapped) delta service, the high leg must be the If equipped, install and activate the current
same for both Source 1 and Source 2. Reverse transformers on the load cables (Figure 3-1).
only the two legs that are adjacent to the neutral Connect the current transformer (CT) wires
center tap. For example, if the high leg is phase (white wire = X1, black wire = X2) to the termi-
B, then reverse phase A and C cables. Go to nal block (TB4) with the polarity mark facing
step 7. the bypass switch.
TABLE 3-2. LUG TORQUES
6. Disconnect the Source 1 AC power source.
Set Screw Socket Size Minimum Torque For
WARNING AC voltages and currents pres- (Across Flats) Proper Operation
ent an electrical shock hazard that can
3/16 In 80 In-lbs (9 Nm)
cause severe personal injury or death. Dis-
connect the AC power source. 1/4 In 200 In-lbs (23 Nm)
5/16 In 275 In-lbs (31 Nm)
7. With both AC power sources disconnected, 3/8 In 375 In-lbs (43 Nm)
manually close the transfer switch to the Emer-
1/2 In 500 In-lbs (57 Nm)
gency (Source 2) side. Connect power to the
Source 2 side of the transfer switch and check 9/16 In 600 In-lbs (68 Nm)
the phase rotation of the Source 2 lead connec-
tions on the transfer switch. If this phase rota-
tion is different than that of the Source 1 side,
go to step 8. If the rotation is the same, go to
step 9.
8. Stop the genset and disconnect the starting

LOAD LUG
battery (−) lead first. CURRENT
TRANSFORMER
WARNING AC voltages and currents pres-
cause severe personal injury or death. Dis-
connect the AC power source. POLARITY
MARK
Reverse any two leads on the Source 2 side of LOAD CABLE
the transfer switch. On a 4-wire (center tapped) TO LOAD
delta service, the high leg must be the same for
both Source 1 and Source 2. Reverse only the
two legs that are adjacent to the neutral center FIGURE 3-1. CURRENT TRANSFORMER
tap. For example, if the high leg is phase B, then PLACEMENT
reverse phase A and C cables. Go to step 10.
3. Reinstall lug covers, access panels and, if ap-
9. Stop the genset and disconnect the starting plicable, the plastic switch cover.
battery (−) lead first.
4. Make sure that both AC power sources are dis-
10. Remove the phase rotation test device. connected.

WARNING AC voltages and currents pres- Activating Current Transformers
cause severe personal injury or death.
On transfer switches equipped with a bargraph dis-
Make sure that both AC power sources are
play, each load cable must pass through a current
disconnected.
transformer in order to measure the current (Figure
5. 150−1000 Transfer Switches: After making 3-1).
the AC connections and checking the phase
rotation, place the transfer switch on the pivot- The current transformers are shorted during ship-
ing guide rails and reconnect the switch. In- ping. To activate, remove the shorting bar from the
structions for removing and installing the center of TB4 by loosening all the screws and lifting
switch are at the end of this section on page it out of the terminal block. TB4 is located inside the
3-15. cabinet. Save the shorting bar for future use.
LUG COVER
SOURCE 1
(NORMAL) LUGS
LOAD LOAD LUGS

LA LB LC LN
A B C N
NORMAL
NA NB NC
THESE NEUTRAL
LUGS PRESENT ON
3 POLE SWITCHES
SD1
GROUND LUGS
150−400 AMP
SWITCHES
GND
EA EB EC
A B C N
EMERGENCY
THESE NEUTRAL
SOURCE 2 LUGS PRESENT
(EMERGENCY) ON 4 POLE
GND
LUGS SWITCHES
GROUND LUGS LUG COVER

600−1000 AMP
SWITCHES 310−0711
FIGURE 3-2. 125−1000 AMPERE TRANSFER SWITCH TERMINAL ACCESS

REMOVABLE REMOVABLE
BACK PANEL PANELS
NEUTRAL
BAR LOAD LUGS
(3 POLE) EMERGENCY
LUGS
LUG NORMAL LUGS

SHIELDS
SWITCH
COVERS
TERMINAL BLOCKS
TB1, TB2, TB3 &
OPTIONAL AUX.
RELAYS
CABINET INTERIOR CABINET OPTIONAL
Front View (4 Pole) Side View ADAPTOR BAY
310−0566
FIGURE 3-3. 1200 AMP TRANSFER SWITCH TERMINAL LUG ACCESS (TYPE 1 CABINET)

REMOVABLE
PANELS
REMOVABLE PANEL
(Bottom of Cabinet)
Copyright  2017 Cummins Inc.

TERMINAL BLOCKS
TB1, TB2, TB3 &
OPTIONAL AUX.
RELAYS
TOP VIEW
LOAD LUGS
3-6
BYPASS
SWITCH
SOURCE 1 LUGS
(NORMAL) HANDLE
SOURCE 2 LUGS TRANSFER

(EMERGENCY) SWITCH
NEUTRAL BAR
(3 POLE)
GROUND BAR
FIGURE 3-4. 1600−4000 AMP TRANSFER SWITCH TERMINAL ACCESS (TYPE 1 CABINET)
CABINET CABINET INTERIOR
310−0568 (Side View) (Front View)
539−1942
TABLE 3-3. TERMINAL BLOCK & AUXILIARY RELAY LOCATIONS
Model Cabinet Type TB1 Location TB2 Location TB3 Location Aux. Relays
BTPC 150−1000 All Types Top of Transfer Top of Transfer Inside, upper left Inside, upper left
Amps Switch Switch wall wall
BTPC 1200 Amps Type 1 Inside cabinet, Inside cabinet, Inside cabinet, Inside cabinet,
on options plate on options plate on options plate on options plate
BTPC 1200 Amps Type 3R, 4, 12 Inside cabinet, Inside cabinet, Next to TB1 and Next to TB1 and
on indicator plate on indicator plate TB2 TB2
BTPC 1200−4000 Type 1 Inside cabinet Inside cabinet Inside cabinet Inside cabinet
Amps on right side on right side on right side on right side
BTPC 1200−4000 Type 3R, 4, 12 Inside cabinet, Inside cabinet, Next to TB1 and Next to TB1 and
Amps on indicator plate on indicator plate TB2 TB2
CONTROL CONNECTIONS TABLE 3-4. WIRE SPECIFICATIONS
Wire Distance in Feet, One Way

Connections of standard and optional control wir- Size (Multiply by 0.3 for Meters)
ing are made at terminal blocks TB1, TB2, TB3, the (AWG) Column A Column B Column C
Relay Module; and directly at the (optional) auxilia-
ry relays (Figure 3-5). Locations of terminal blocks 16 1000 125 25
and auxiliary relays vary with each transfer switch. 14 1600 200 40
Use Table 3-3 above to locate these items.
12 2400 300 60
Connecting Transfer Switch to Genset 10 4000 500 100
WARNING AC voltages and currents present Remote starting (for Cummins Inc. water-cooled
an electrical shock hazard that can cause se- generator sets only) uses terminals B+, GND
vere personal injury or death. Disconnect the (ground), and RMT of terminal block TB2 (Figure
AC power source. 3-5). Connect these terminals to like terminals on
the generator set. Refer to Interconnect Wiring dia-
Wire size depends on the distance and the type of gram shipped with the switch. A jumper is shipped
battery charger installed. Refer to Table 3-4 to de- with the transfer switch and is in a small envelope
termine the wire size required. attached to TB2.
 All leads to TB2 use Column A.  For PCC 3100 and PCC 2100 genset con-
 If the transfer switch is not equipped with a trols, install a jumper between TB2-1 and
battery charger, use Column A for all wires. TB2-2 for ground-to-start connection.
 If the transfer switch is equipped with a  For Detector 12 genset controls, install a
2-Amp charger, use Column B for B+ and jumper between TB2-2 and TB2−3 for B+
GND. Use Column A for all other wires. start.
 If the transfer switch is equipped with a  For PCC 3200 and PCC1301 genset con-
10-Amp charger, use Column C for B+ and trols requiring a dry contact start, do not
GND. Use Column A for all other wires. install a jumper.
 If the genset is equipped with an annuncia-
tor, use Column A for wires to the annuncia- Be sure to check the Interconnect Wiring diagram
tor. shipped with the transfer switch.
Wire resistance must not exceed 0.5 ohm per line. For network wiring instructions, refer to the Power-
Use stranded wire only. For connection to the Command Network and Operator’s Manual (PN
screw terminal, strip the insulation back 3/8 inch 900−0366 for TP-78 networks or 900−0529 for
(10 mm). FT-10 networks).

Auxiliary Contacts The Test function can be programmed to test only
the genset start command or to test with a load
Auxiliary contacts (switches), for external alarm or transfer. By default, the genset will warm-up prior to
control circuitry, are positioned on the Source 1 a transfer. The load transfers to the genset when
(Normal) and Source 2 (Emergency) sides of the genset power becomes available (acceptable).
transfer switch. (Refer to the Description section of the Operator’s
Manual.)
Connections for the auxiliary contacts are made on
terminal block TB1. Figure 3-5 shows the normally To install a remote test switch, connect normally
open and normally closed positions of the auxiliary open contacts (from a test switch) between TB2-5
contacts with the transfer and bypass switch in the and TB2-8 (Figure 3-5).
neutral position. The contacts have ratings of 10
amperes at 250 VAC. Use number 22 to number 12 AWG wire (maximum
resistance of 4 ohms per line). For connection to
Moving the transfer switch to Normal or Emergency the screw terminal, strip the insulation back 3/8
actuates the corresponding auxiliary contacts. inch (10 mm).
Use number 22 to number 12 AWG wire. For con- Transfer Inhibit

nection to the screw terminal, strip the insulation
back 3/8 inch (10 mm). This feature prevents automatic operation of the
transfer switch over to Source 2.
Remote Test Switch
To install transfer inhibit, connect normally open
The transfer switch can be wired with a remote test contacts between TB2-6 and TB2-8 (Figure 3-5).
transfer switch. Closure of a set of contacts be- Close the contact to activate transfer inhibit.
tween the remote test transfer input and common
causes the transfer switch to sense a (simulated) Use number 22 to number 12 AWG wire. For con-
utility power failure and send a start/run signal to nection to the screw terminal, strip the insulation
the generator set. back 3/8 inch (10 mm).
CHARGER
NO ALARMS
SOURCE 1
(NORMAL) NC
AUXILIARY SWITCH 41 COM
COM AC LINE
FAILURE 42 NC
NO 43 NO
SOURCE 2
(EMERGENCY) 1 GND 44 COM
NC HI BATTERY
AUXILIARY SWITCH
2 VOLTAGE 45 NC
COM
START 46 NO
3 B+ CONTACT
NO 47 COM
BYPASS SOURCE 1 LO BATTERY
(NORMAL) 4 VOLTAGE
48 NC
NC RMT
AUXILIARY SWITCH 49 NO
COM
5 REMOTE TEST
50
6 TRANSFER INHIBIT
NO NETWORK 51 DATA 1
BYPASS SOURCE 2 DATA 52 DATA 2
7 LOAD SHED (Optional)
(EMERGENCY) NC
AUXILIARY SWITCH RETRANSFER 53
COM 8 COMMON
INHIBIT 54
TB2 TB3
TB1
FIGURE 3-5. TERMINAL BLOCKS TB1, TB2, AND TB3

Load Shed Option Current Module Option
NOTE: Load Shed is not used in Utility-to-Utility ap- The current module senses the four load currents
plications. (three line currents and the neutral current), three
Load shed is initiated by the closing of contacts load voltages, and three power factor angles. The
across terminals 7 and 8 of TB2. When the load control calculates the real load power and the ap-
shed function is initiated, the switch is moved from parent load power.
the Source 2 position to the neutral position. When
load shed is in effect, a return of Source 1 utility This module requires current transformers
power causes immediate retransfer to Source 1. If installed on the load cables (see Figure 3-6), and a
the load shed signal is removed before Source 1 re- bargraph display panel. The option consists of cur-
turns, the switch transfers back to Source 2 if the rent transformers, a current board, wire leads, and
Source 2 is available. a wire harness.
LH SIDEWALL
OF CABINET
OPTIONS PLATE
600 VOLT
TRANSFORMER
LOAD SHED
CURRENT
MODULE
TB4 RELAY MODULE
FIGURE 3-6. 150−1000 AMP OPTION CONFIGURATION

Relay Module Option emergency. Connections at J15-15 and J15-16 are
input from load shed to the control. This contact is
The Relay Module provides nine sets of Form-C used by the load shed circuit and is not available for
contacts and two sets of normally open contacts customer use.
that are rated for 2 Amps at 30 VDC or 0.60 Amps at
120 VAC (Figure 3-7). The Relay Module is The Elevator Pre-Transfer signal delays transfer
mounted on the options plate on 150−1000 Amp (or retransfer) gives warning to an elevator control
switches (Figure 3-6) and on the control plate on that a transfer (or retransfer) is about to occur.
1200−4000 Amp switches.
The Not-In-Auto relay is energized when any one of
On 1200−4000Amp switches, an additional 30
the following is active:
position terminal block is supplied with the module
(TB3).  Motor Disconnect Switch is set to Off
 Fail-to-Disconnect event is active
The Source 1 or Source 2 Connected relays are en-  Control is locked out
ergized when the respective power source is pro-  Wiring harness is disconnected from J12 on
ducing power and connected to the load. the Power Module
The Source 1 or Source 2 Available relays are en-  Controller is set to Offline
ergized when their respective power sources are  Bypass switch is connected
available and within the acceptable limits of the  The Operator Release key switch is in the
voltage sensors. Unlocked (Manual) position − This only ap-
plies to models that include the optional ex-
The Test/Exercise relay is energized when the sys- ternal manual operation handle.
tem is in a test or exercise routine.
Connections are made directly to terminal blocks
The Load Shed relay (optional) is energized when J14 and J15. Refer to Sheet 1 of the wiring diagram
the transfer switch is signaled to shed load from shipped with the transfer switch.
TB3
TB3
FAILURE TO
TRANSFER /
RETRANSFER
FAIL TO
SYNCHRONIZE
FAILURE TO
DISCONNECT
CONNECTIONS TO TB3 NOT

J16 REQUIRED ON 150-1000 AMP SWITCHES
FIGURE 3-7. OPTIONAL RELAY MODULE

Auxiliary Relays Option Battery Charger Alarm Contacts Option
Connections to the auxiliary relays are made di- The optional 10-ampere battery charger can in-
rectly to the relay terminals. Relays can be located clude three sets of Form-C relay contacts, as an
in various areas of the transfer switch. Refer to additional option.
Table 3-3. The terminals accept wire sizes from one
number 18 AWG wire to two number 12 AWG Under normal operating conditions, the Low Bat
wires. For connection to the screw terminal, strip and AC Fail relays are energized and the High Bat
the insulation back 3/8 inch (10 mm). relay is de-energized. In response to a Low Bat or
There are two types of auxiliary relay coils (12 VDC AC Fail condition, the appropriate normally ener-
and 24 VDC). gized relay (Low Bat or AC Fail) drops out. In re-
sponse to a High Bat condition, the normally de-en-
Table 3-5 lists several auxiliary relay options. ergized High Bat relay is energized.
TABLE 3-5. AUXILIARY RELAY DESIGNATIONS
The charger contains contacts rated for 4 amperes
24 VDC COIL INSTALLED, NOT WIRED −−−−
at 120 VAC or 30 VDC. Connections to these con-
24 VDC COIL EMERGENCY RELAY KEA tacts are from J5 on charger to terminals 41-42-43
24 VDC COIL NORMAL RELAY KNA (AC failure), 44-45-46 (high battery voltage), and
12 VDC COIL INSTALLED, NOT WIRED −−−− 47-48-49 (low battery voltage) of TB3. See Figure
12 VDC COIL EMERGENCY RELAY KEA 3-5.
12 VDC COIL NORMAL RELAY KNA Digital Modules have an input dedicated to monitor
All relays have two normally open and two normally the AC Line failure on the battery charger. This in-
closed contacts that are rated for 10 amperes at put is located at J27-23 and activated when
600 VAC (Figure 3-8). grounded. (As of this printing, this input is only
available at J27-23.)
Network Connections
For installations that include a PowerCommand
Network Communications Module (NCM), connect
stranded twisted pair network cable to the left side
of terminals 51 and 52 on TB3 (see Figure 3-5). The
NCM is located on the left side of the digital module
(see Figure 4-1).
FIGURE 3-8. AUXILIARY RELAYS

DELTA AND WYE CONFIGURATIONS 1. Disconnect the neutral sensing wires marked
TB12-7 and TB14-7 (see Figure 3-9).
The transfer switch is wired at the factory for a
4-wire, 3-phase Wye configuration with grounded NOTE: Leave the short jumpers as they are.
neutral. If this transfer switch is being connected to
a Delta power system or a Wye without a grounded 2. Insulate the terminals and secure them to the
neutral, modify the wiring as follows: harness with a wire tie.
REMOVE
WIRE
FROM
REMOVE TB12-7
WIRE
FROM
TB14-7
POWER MODULE
FIGURE 3-9. OPTIONAL DELTA CONFIGURATION JUMPER

TRANSFER SWITCHES IN FIRE PUMP 2. Programmed Transition enabled
CIRCUIT APPLICATIONS
3. Phase Rotation Enabled.
Figure 3-10 shows the typical fire pump controller/
transfer switch arrangement for transfer switches 4. Momentary Test Switch (on cabinet door)
in the range of 40 to 1000 amps. 5. UL Type 4 or 12 cabinet
Required Transfer Switch Features Location
1. A BTPC transfer switch (one ATS per fire The transfer switch and Source 2 (generator) iso-
pump) lating switch must be located in the fire pump room.
FIRE PUMP SOURCE 2

FEEDER (GENERATOR)
SOURCE 1
BREAKER
(NORMAL)
FIRE PUMP
SERVICE DISCONNECT
ALTERNATE
SOURCE
UPSTREAM GENERATOR
OVERCURRENT NORMAL FEEDER
DEVICE (FUSE OR SOURCE BREAKER
CIRCUIT BREAKER)
PUMP ROOM ISOLATING N E

SWITCH
BYPASS
TRANSFER
SWITCH TO OTHER LOADS
PUMP ROOM
FIRE PUMP
CONTROLLER
FIRE PUMP
MOTOR
FIGURE 3-10. TYPICAL FIRE PUMP CONTROLLER AND TRANSFER SWITCH ARRANGEMENT

Isolating Switch  Wiring does not contact sharp or abrasive
surfaces.
The contractor must furnish and install a lockable
isolating switch, with auxiliary contacts, on the  No wiring is left loose and unconnected.
Source 2 (generator) side of the ATS.
After mounting and wiring the cabinet, clean the in-
Supervision terior with a vacuum cleaner to remove any chips,
filings, or dirt from the cabinet interior and compo-
The isolating switch auxiliary contacts must be con- nents.
nected to the ATS controls to prevent generator set
starting when the isolating switch is open. Refer to Installation is not yet complete.
the site interconnection drawing.
Do not energize the transfer switch until
Separate ATS for Auxiliaries instructed to do so in Sections 4 and 5.
A separate ATS must supply all pump room auxilia-
ries. MOUNTING
PLATE
SHORTING BAR REMOVAL
The current transformers are shorted during ship-
ment. The shorting bar in terminal block TB4 con-
nects all outputs to ground. The shorting bar must
be removed in order for current metering to func-
tion. To remove the shorting bar from the center of
CURRENT
TB4 (see Figure 3-11): MODULE
1. Remove the protective cover. TERMINAL RAIL

AND TERMINAL
2. Loosen all the the shorting bar screws and lift BLOCK (TB4)
it out of the terminal block.
SHORTING
3. Reinstall the protective cover. Save the short- BAR JUMPER
ing bar for reuse. WIRES
INSPECTION AND CLEANUP

Inspect all wiring to be certain that:
 Wiring does not interfere with switch opera- PROTECTIVE
tion. COVER
 Wiring is not damaged as door opens and
closes. FIGURE 3-11. SHORTING BAR REMOVAL

TRANSFER SWITCH REMOVAL AND TABLE 3-6. TRANSFER SWITCH WEIGHT
INSTALLATION 150−260 Amp 290 lbs. (141 kg)
150−1000 Amp Switches 300−400 Amp 360 lbs. (163 kg)
600−1000 Amp 610 lbs. (276 kg)
Isolate the Transfer Switch
WARNING Improper lifting can cause se-
1. Check that the bypass switch is in the Bypass vere personal injury. Have adequate equip-
to Normal position. If it is not, use the dead ment and sufficient manpower for lifting
source interlock override to move the bypass and mounting the switch assembly. Lifting
operator handle. must only be done with equipment specifi-
Dead Source Interlock Override: There are cally intended for this use. Never stand or
two small holes adjacent to the bypass opera- work under a switch assembly while it is
tor handle. One hole is near the Bypass to Nor- suspended.
mal position, and one hole is near the Bypass 4. Carefully guide and lift the transfer switch as-
to Emergency position. sembly off the rails and away from the cabinet.
To override the interlock that prevents bypass-
ing to a dead source, insert the tip of a screw- 5. Place the transfer switch assembly on a stable
driver into the hole on the Bypass to Normal work surface using wooden blocks to prevent
side and push the interlock plunger in, against placing any weight on the isolation contact fin-
its spring. Slowly move the bypass handle to- gers (Figure 3-12).
ward the Bypass to Normal position.
When the handle mechanism passes the inter-
lock plunger, remove the screwdriver and
complete the movement of the bypass handle
to the Bypass to Normal position.
2. Lift the Drawout Lever and turn the drawout
cranking handle counterclockwise to move the
automatic transfer switch to the Isolated posi-
tion. Release the Drawout Lever after the
transfer switch travels past the Test position.
ES1974
3. Turn the cranking handle until the Drawout Le- FIGURE 3-12. TRANSFER SWITCH ASSEMBLY
ver drops, locking the cranking handle. As the ON WORK SURFACE
automatic transfer switch is being drawn out,
mechanical interlocks force the switch to the Install the Transfer Switch
neutral position. 1. Lubricate the transfer switch roller assemblies
with a light grease. Remove excess grease
4. Check that the word “Isolated” appears in the with a clean cloth.
Drawout Position indicator slot. Return the
drawout cranking handle to its stored position. 2. Connect the lifting device to the lifting holes
provided on the sides of the transfer switch as-
Remove the Transfer Switch sembly.
1. Open the transfer switch cabinet door. 3. Move the transfer switch assembly onto the
pivoting guide rails.
2. Lower the pivoting guide rails and move the 4. Carefully position the transfer switch assem-
transfer switch assembly onto the guide rails. bly on the rails so that it can be engaged by the
drawout mechanism.
3. Connect a lifting device to the lifting holes pro-
vided on the sides of the transfer switch as- 5. Push the transfer switch all the way into the by-
sembly. Refer to Table 3-6 for weights of vari- pass frame assembly. Lift the pivoting guide
ous switches. rails.

Reconnect the Transfer Switch
Make sure the transfer switch is pushed all the way
into the bypass frame. The cranking handle will not
turn unless the bypass switch is connected to
Source 1 or Source 2.
1. Lift the Drawout Lever and turn the drawout Manual Bypass
cranking handle clockwise to move the auto- Handle in Closed
matic transfer switch back to the Connected Position
position. Release the Drawout Lock after the
transfer switch travels past the Test position. Selector Switch in
Normal Position
2. Turn the cranking handle until the Drawout Le-

ver drops, locking the cranking handle. As the
automatic transfer switch is being cranked
back to the Connected position, mechanical Transfer Switch is
interlocks force the switch to the neutral posi- Bypassed to
Source 1
tion. (Normal)
3. Check that the word “Connected” appears in

the Drawout Position indicator slot. FIGURE 3-13. MANUAL BYPASS OPERATION
1200−4000 AMP SWITCHES
4. Return the drawout cranking handle to its
stored position. 2. Use the Drawout cranking handle to move the
ATS to the TEST position by cranking the han-
1200−4000 Amp Switches dle counterclockwise. Once the ATS reaches
the TEST position, verify the ATS In Test lamp
Isolate the Transfer Switch is lit and the ATS Inhibit lamp is not lit.
1. Check that the bypass switch is in the Bypass 3. Continue cranking counter clockwise until the
to Normal position. If it is not, place the selector automatic transfer switch reaches the Isolate
switch in the Normal position and use the position (see Figure 3-14).
Manual Bypass operator handle to bypass the
unit to the Normal side (see Figure 3-13). 4. Verify that the word “Isolated” appears in the
Verify that the Bypass Normal and ATS In- drawout position indicator slot. Return the
hibit lamps are lit. drawout cranking handle to its stored position.

WARNING Improper lifting can cause se-
vere personal injury. Have adequate equip-
ment and sufficient manpower for lifting
and mounting the switch assembly. Lifting
must only be done with equipment specifi-
cally intended for this use. Never stand or
work under a switch assembly while it is
Pointer in suspended.
Test Position
3. Carefully guide and lift the transfer switch as-
sembly away from the cabinet.
4. Place the transfer switch assembly on a stable

work surface using wooden blocks to prevent
placing any weight on the isolation contact fin-
gers (Figure 3-12).
SC1640s
1200 AMP TRANSFER SWITCHES Install the Transfer Switch

1. Use a clean cloth to remove excess grease off
of the ATS contacts.
2. Connect a lifting device to the ATS and guide

it back into the bypass enclosure, making sure
Pointer in the contacts align correctly.
Test Position
Reconnect the Transfer Switch
Make sure the transfer switch is pushed all the way
into the bypass frame. The cranking handle will not
turn unless the bypass switch is connected to
Source 1 or Source 2.
1. Turn the cranking handle clockwise to connect

the ATS back into the bypass. Make sure that
you reach the TEST position and that the ATS
In Test lamp is lit and the ATS Inhibit lamp is
SC1641 not lit.
2. Turn the cranking handle until the ATS reaches

the AUTO position. Verify that the Bypass
1600−4000 AMP TRANSFER SWITCHES Normal and ATS Inhibit lamps are lit.
FIGURE 3-14. DRAWOUT POSITION POINTER 3. Use the Manual Bypass operator handle to
disconnect the bypass from the Normal posi-
Remove the Transfer Switch
tion. On the larger units, this procedure may
1. Open the transfer switch cabinet door. require a fast snapping action.
2. Roll the ATS out of the bypass enclosure and 4. Place the selector switch in the center (OFF)
attach a lifting device. position.


4. Setup and Adjustments
This section describes how to power up the transfer
switch and set up the controller for operating the DIGITAL
system. MODULE
CONTROLLER
After the transfer switch is installed, the control set- BATTERIES
tings can be adjusted. Setup and adjustment pro-
cedures can be performed using the digital display
or a PC service tool. Refer to the InPower User’s
Guide for details on using the PC service tool.
NETWORK
POWER-UP THE TRANSFER SWITCH COMMUNICATIONS
MODULE
Install the Digital Module and Network
NETWORK
Communications Module Batteries BATTERIES
The digital module requires two batteries. Although

the optional early production Network Communica-
tions Modules (NCMs) required two batteries (see
Figure 4-1 and 4-2), the current NCM does not use
batteries (see Figure 4-3). These batteries are in-
cluded with the transfer switch. Install the batteries BATTERY BRACKET
in the two battery holders on the module(s). Orient
the batteries according to the polarity marks on the
battery holders. If the batteries are missing, use FIGURE 4-2. BATTERY LOCATIONS (EARLY
3-volt Lithium, 2/3A batteries. Secure the batteries PRODUCTION, VERSION 2)
to each board with the battery clips/battery bracket.
DIGITAL
MODULE
CONTROLLER CONTROLLER
BATTERIES BATTERIES
DIGITAL
MODULE
BATTERY LEAD
NETWORK
BATTERIES
BATTERY
CLIPS
NETWORK
NETWORK COMMUNICATIONS
COMMUNICATIONS MODULE
MODULE
FIGURE 4-1. BATTERY LOCATIONS (EARLY FIGURE 4-3. BATTERY LOCATIONS (CURRENT
PRODUCTION, VERSION 1) PRODUCTION)
InPower is a trademark of Onan Corporation.

Install P1 and P10 jewelry. Use insulated tools, stand on a dry rub-
ber mat or wood platform.
Remove the blank plug and label.
2. Close the cabinet door.
Connect plugs P1 and P10 into receptacles J1 and
J10 when all wiring is complete. 3. Connect AC power to the transfer switch. The
Source 1 Connected and Source 1 Available
On 1200−4000 Amp switches, install J3/P3 (Fig- LEDs should light (see Figure 5-2).
ure 4-5) and check to verify that J20/P20 is con-
nected. BEFORE ADJUSTING
Make sure all ribbon cable and harness connectors Disable the Linear Motor
on PC boards are pushed in all the way and all ter-
minal block screws are tight. WARNING Accidental actuation of the linear
motor can cause severe personal injury or
Connect the Genset Battery death. Disable the motor before making adjust-
(Utility-to-Genset Applications Only) ments.
Place the RUN switch on the generator in the STOP To disable the linear motor and prevent the transfer
position and connect the starting battery (negative switch from transferring back and forth during the
[−] lead last). If applicable, reconnect the external setup procedure, bypass the switch to Source 1. In-
battery charger. terior components are shown in Figures 4-6 thru
4-9.
WARNING Ignition of explosive battery gases
can cause severe personal injury or death. Do 150−1000 Amp Switches
not smoke or cause any arc, spark, or flame
Bypass the transfer switch (see Figure 4-4). The
while servicing batteries.
transfer switch should be connected to Source 1.
Place the generator control switch in the AUTO 1. Turn and hold the Bypass Source Select
position. The generator set will crank and start. switch in the Normal position.
Connect AC Line Power 2. Move the bypass switch handle up to the By-
pass to Normal position.
1. If the transfer switch main contacts are not
closed to the Source 1 (Normal) power source 3. Release the Bypass Source Select switch.
side, manually close the transfer switch to
4. Extend the drawout cranking handle from the
Source 1 (Normal).
cabinet.
WARNING AC power in the cabinet and the
5. Lift the Drawout Lever and turn the cranking
rear side of the cabinet door present a shock handle counter-clockwise 1/2 turn — or,
hazard that can cause severe personal injury or enough to hold the Drawout Lock up.
death. Use extreme caution to avoid touching
electrical contacts when the cabinet door is Holding the Drawout Lever up disconnects
open. Do not wear long hair, damp clothing, or the linear motor.

1200−4000 Amp Switches
Open the cabinet door and place the Motor Discon-
nect Switch (see Figure 4-5) in the OFF position be-
fore making adjustments. Return the switch to the
SOURCE SELECT
SWITCH
Auto position after adjustments are completed.
DRAWOUT
RELEASE
Bypass the transfer switch. The transfer switch
CONNECTED DRAWOUT POSITION should be connected to Source 1.
INDICATOR
1. Turn the Source Selector Switch to the Normal
position.
DRAWOUT LEVER
2. Insert the cranking handle (see Figure 5-5 thru
Figure 5-8) and move the bypass switch up to
the Bypass position (see Figure 5-4).
3. Insert the cranking handle in the transfer
switch and turn counterclockwise until the
pointer is in the “Isolate” position.
4. Remove the cranking handle.
BYPASS SWITCH
POSITION INDICATOR 5. Close the cabinet door.
BYPASS SWITCH MOTOR DISCONNECT

HANDLE SWITCH
(Open Position)
DRAWOUT CRANK
HANDLE
CONNECTORS
BYPASS SWITCH
POSITION INDICATOR
FIGURE 4-4. BYPASS PANEL

(150−1000 AMP SWITCHES ONLY)
FIGURE 4-5. MOTOR DISCONNECT SWITCH

(1200−4000 AMP SWITCHES ONLY)

SOURCE
OPTIONAL
DIGITAL SELECT
BATTERY
BOARD SWITCH
CHARGER
BARGRAPH
POWER
TRANSFORMER
CONTROL
RELAYS
DIGITAL
DISPLAY
POWER
MODULE
BYPASS
SWITCH
HANDLE
DRAWOUT
CRANK
HANDLE
FIGURE 4-6. INTERIOR/COMPONENTS − 150−400 AMP SWITCH (TYPE 1 CABINET)

OPTIONAL
BATTERY SOURCE
CHARGER DIGITAL BOARD
SELECT
SWITCH
BARGRAPH
POWER
TRANSFORMER
CONTROL
RELAYS
DIGITAL
DISPLAY
POWER
MODULE
BYPASS
SWITCH
HANDLE
DRAWOUT
CRANK
HANDLE
FIGURE 4-7. INTERIOR/COMPONENTS − 600−1000 AMP SWITCH (TYPE 3R CABINET)

POWER MODULE
BARGRAPH
DIGITAL BOARD
DIGITAL DISPLAY
BATTERY
MOUNTING
TB1 PLATE
MOTOR
DISCONNECT
SWITCH
TB2
ATS RELAY
ASSEMBLY
FIGURE 4-8. INTERIOR/COMPONENTS − 1200 AMP SWITCH (TYPE 1 CABINET)

CONTROL PANEL POWER MODULE
TB1
BARGRAPH
DIGITAL BOARD
DIGITAL DISPLAY
TB2 BATTERY
MOUNTING
PLATE
MOTOR
DISCONNECT
SWITCH
NEUTRAL BAR
ASSEMBLY
DRAWOUT MANUAL
CRANKING BYPASS ATS
HANDLE HANDLE
FIGURE 4-9. INTERIOR/COMPONENTS − 1600−4000 AMP SWITCH (TYPE 3, 4 AND 12 CABINETS)

CONTROLLER SETUP USING THE DIGITAL DISPLAY
If using the PC service tool, connect the interface This section describes the Digital Display Menu
cable to the digital board and establish a connec- System and navigation through the menus. The
tion, or connect remotely through the network mod- menus display status information, events, and set-
ule modem. up menus.
The Digital Display Menu System is a 2-line by

If using the digital display to change the setup, 20-character graphical display screen and six but-
make sure the key switch is in the Program position tons. The screen or menu displays status informa-
(see Figure 4-10). tion, parameters, events and messages. The but-
tons change screens and parameters. Two buttons
If the digital display will be used to setup the param- have names: Home and Previous Menu. These
eters, an overview of how to navigate through the buttons are used for navigation. Messages include
screen menus is located at the end of this section. navigational indicators for the other four buttons.
POWER COMMAND
BAR GRAPH
METER PANEL
(OPTIONAL)
SWITCH PANEL
(STANDARD)
SECURITY
KEY SWITCH
(OPTIONAL)
DIGITAL DISPLAY
FIGURE 4-10. CABINET WITH OPTIONS

Main Menu bypass the password and examine, but not change
(read only), current parameter settings (Figure
The main menu system consists of three top-level 4-20). When parameters are changed in any setup
menus that list vertical menus (or sub-menus) (Fig- menu, you are prompted to either save the
ure 4-11). The sub-menus display status informa- changes or restore the old values.
tion. This information cannot be changed in the
main menus. The main menus contain eight sub-
Navigation
menus including the Setup Menus.
Setup Menu Refer to Figures 4-55 through 4-60 at the end of this
section for an overview of menu navigation. These
To change setup parameters, you must enter a illustrations can also be used to locate a submenu
password (574) (Figure 4-18); however, you can 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 4-11. 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 4-12. 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
If the Source is two phase, the display will read voltages at L12 and
L31.
Line-to-Line Voltage
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.)
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 4-13. SOURCE 1 AND 2 SUBMENUS

FIRST MAIN MENU − Load Submenus
This subset 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 4-14. 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 undervoltage, 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. Sen- Status of optional generator
sing 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 4-15. 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 undervoltage, 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 4-16. 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
From this display, the PRE-
The Events program include Fault codes, VIOUS MENU button and HOME
active time delays or significant power
button returns program to the
system changes.
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 4-17. 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 4-18. 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 4-38 or 4-39.
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 4-40.
Nominal Voltage Programmed Transition Load Sequencer is a software fea-
Undervoltage Settings Elevator Pre-Transfer ture, available only with LonWorks
Overvoltage Settings Refer to Figure 4-28 or 4-29 for Time NetWork Communication Module.
Time Delays Delay submenus. This program allows the user to send
Frequency Settings Test submenus allow programming a predetermined sequence of event
Imbalance Settings the front panel test switch to test the announcements in a timed, sequen-
Phase Loss source with or without a load. See tial order to turn the load off and on.
Phase Rotation Figure 4-30. See FIgure 4-41.
See Figure 4-25 or 4-26 for Sensor Exerciser submenus allows program-
submenus. ming an exercise routine for Power
The SynchChck sensor submenus Source 2 and are available only on
allow programming synchronous utility-to-genset controls. The number
conditions for Source 1 and Source of exercise programs that can be set
2 that must be met before is dependent upon the software ver-
transferring from one to the other sion installed and the type of control.
source. See Figure 4-27 for Sync See Figure 4-31, 4-32, 4-34 or 4-36
Check submenus. for Exercise submenus. Exercise sub-
menus also allow for adding and de-
leting exercise exceptions. See Fig-
ure 4-33, 4-35, or 4-37 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 4-19. 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-

Save
vokes this screen when exiting the Setup Submenu Groups.
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 4-20. 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

Save changes
screen when exiting the Setup Submenu Groups.
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 4-21. CHANGING SETUP PARAMETERS (STARTING WITH SOFTWARE VERSION 1.12)

VOLTAGE AND FREQUENCY SENSING OverVoltage Sensing
If frequent (over/under) voltage event messages
All controls include overvoltage sensors for
occur, the voltage sensors may require recalibra-
Source 1 and Source 2 that can be disabled and
tion. Refer to Section 5, System Checkout.
not used. When a sensor detects a high voltage
Setup menus for Voltage and Frequency Sensing are condition over a specified time period (delay), it ini-
the first group within the Setup menus under the sec- tiates a transfer. When the source voltage falls to
ond main menu (Figures 4-25 and 4-26). These fig- an acceptable value again, the sensor initiates a re-
ures also include information on how to change the transfer.
displayed parameter.
These parameters are adjustable. The overvoltage
Undervoltage Sensing sensing range (dropout) for a rising voltage is 105
All controls include undervoltage sensors for Source to 135% of the nominal voltage setpoint. The de-
1 and Source 2. When a sensor detects a low voltage fault value is 110%. The pickup range for a falling
condition over a specified time period, it initiates a voltage is 95 to 100% of the dropout setting. The
transfer. When the source voltage returns to an ac- default value is 95%. The adjustable range for the
ceptable value again, the sensor initiates a retransfer. delay time period is 0.5 to 120.0 seconds in 1 sec-
ond intervals. The default delay time is 3.0 sec-
If frequent (over/under) voltage event messages onds. The overvoltage sensing feature is enabled
occur, the voltage sensors may require recalibra- by default. These values are set with the PC ser-
tion. Refer to Section 5: Setup and Adjustments. vice tool or the digital display, when it is available.
These parameters are adjustable. The undervol- Figure 4-23 shows an example using the default
tage sensing range for a falling voltage (dropout) is values.
75 to 98% of the pickup voltage setting. The default
value is 90%. The pickup range for a rising voltage Example using Default Settings
is 85 to 100% of the nominal voltage setpoint. The for Nominal Voltage of 240 VAC
default value is 90%. The adjustable range for the
Nominal Pickup Drop-out
time delay period is 0.1 to 1.0 seconds in 0.1 sec- Setpoint Setting Setting
ond increments. The default delay time is 0.5 sec- (240V) (251V) (264V)
ond. These values are set with the PC service tool
or the digital display when it is available. Figure VOLTS
4-22 shows an example using the default values.
95% of 110% of
Example using Default Settings Drop-out Nominal
for Nominal Voltage of 240 VAC
FIGURE 4-23. OVERVOLTAGE SENSING
Drop-out Pickup Nominal
Setting Setting Setpoint
(194V) (216V) (240V)
VOLTS
90% of 90% of
Pickup Nominal
FIGURE 4-22. UNDERVOLTAGE SENSING

Frequency Sensing voltage is greater than a user-specified value be-
tween 2 and 10% (dropout) of the average voltage
in 1% increments. The pickup value is fixed at 10%
All controls include frequency sensors for Source 1 of the dropout. The time delay for the imbalance
and Source 2 that can be disabled and not used. sensor dropout is adjustable (2−20 seconds).
When a sensor detects a high or low frequency
condition over a specified delay time period, it initi-
ates a transfer. When the frequency returns to an To enable this sensor, see Figure 4-25 or 4-26. This
acceptable value again, the sensor initiates a re- sensor is inactive for single phase systems and in-
transfer (Figure 4-24). dicates no failures. To prevent nuisance faults, the
setting can be increased up to 10% of the nominal
voltage.
These parameters are adjustable. The nominal fre-
quency can be set between 45.0 and 60.0 Hz in
0.1 Hz increments. The default frequency is 60 Hz. Phase Rotation Sensing
The acceptable frequency bandwidth (pickup) is 5
to 20% of the nominal frequency setpoint. The de-
Three phase Level 2 controllers include a phase
fault value is 10%. The dropout frequency is 1 to 5%
rotation sensor. This feature monitors the phase
beyond the pickup. The default value is 1%. The
rotation of the source opposite from the connected
range for the delay time period is 0.1 to 15 seconds.
source. When the alternate source is out of phase
The default delay time is 1.0 second. The frequen-
rotation with the connected source, transfer is in-
cy sensing feature is enabled by default. These val-
hibited. This generally occurs on new installations
ues are set with PC service tool or the digital display
or after storm damage or generator rewiring. This
when it is available.
feature protects against equipment damage by
preventing transfer to a source that is out of phase.
This feature is required in fire pump applications.
Example using Default Settings
for Nominal Frequency of 60 Hz
60 Hz
Both voltage sources have to be applied in order to
check phase rotation. Generally, a power source
may become out of phase rotation in new installa-
tions, after a storm, or when there is generator re-
wiring.
Pickup Frequencies This feature is enabled by default. To disable it, see

54 Hz 66 Hz Figure 4-25 or 4-26.
Drop-out Frequencies
53.5 Hz 66.7 Hz
Loss of Single Phase Sensing
FIGURE 4-24. FREQUENCY SETTING

Three phase Level 2 controllers include a loss of
Voltage Imbalance Sensing single phase sensor. This feature initiates a trans-
fer from a source that has lost a single phase and
prevents a transfer to a source that has lost a single
Three phase Level 2 controllers include a voltage phase. This is generally caused by a single phase
imbalance sensor for both Source 1 and Source 2. to line ground or open. The controller indicates a
This feature informs the operator when there is sig- fault when the relative phase angle between any
nificant voltage imbalance between the phases of line-to-line phase angle drops to less than 90 de-
Source 1 or Source 2. This feature is used for grees. This feature is mainly used to protect three
equipment protection. phase devices, such as motors.
A voltage imbalance is typically caused by severe To enable this sensor, see Figure 4-25 or 4-26. This
single phase loading. The sensor indicates a failure sensor is inactive for single phase systems and in-
when the maximum deviation from the average dicates no failures.

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
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
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 2 Controls are Line-to- +
Neutral Voltages. − __ ________
Undervoltage Sensor Pickup

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)
Undervoltage Sensor Dropout
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 undervoltage pickup per-
end of the range. The + button in-
centage (90%)
creases the value to its highest range,
then begins again at the low end of the
Undervoltage Dropout 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.
Overvoltage 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
Overvoltage Pickup pressed during an editing session, the
This adjusts the overvoltage pickup data will not be changed.
S1 OV Pickup
as a percentage of the overvoltage If the HOME button is pressed during
dropout 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 4-25. 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
Overvoltage Dropout 15.0 seconds (5 Seconds)
Enter a percentage between 105 and
135% of the nominal voltage (110%) S1 Imbalance Sensor
Enabled/Disabled
S1 OV Time Delay
3.0 Seconds Detects unbalanced voltages
on 3-phase sources (Disabled)
Overvoltage Time Delay
Enter a range between 0.5 and
Imbalance Dropout
120 seconds (3 Seconds)
5%
S1 Frequency Sensor
Enter a percentage between
Enabled/Disabled 2 and 10% (5%)
Monitors line frequency on

A-Phases of both sources Imbalance Delay
(Enabled) 5 Seconds
Nominal Frequency
Enter a time between
60 Hz 2 and 20 seconds (5 Seconds)
Enter a frequency between 45

and 65 Hz (60 Hz) S1 Loss of Phase
Enabled/Disabled
Frequency Pickup
The loss of single phase sensing can
10 %
be enabled or disabled (Disabled)

Phase Rotation
20% of the nominal frequency (10%)
Enabled/Disabled
Frequency Dropout The phase rotation sensing can

1% be enabled or disabled (Enabled)
Enter a percentage between 1 and Note: Default values are

5% of the frequency pickup (1%) in parenthesis.
FIGURE 4-25. 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. 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 2 Controllers are Line-to-
Neutral Voltages. When entering numerical values, the
range, then begins again at the top
Undervoltage Sensor Pickup 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.
Undervoltage Sensor Dropout 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 undervoltage pickup per- to the previous menu.
centage (90%). Changing any data within the setup
submenus will invoke a SAVE
Undervoltage Dropout 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
Overvoltage Sensing Enable S1 OV Enable an editing session, the SAVE
CHANGES/CANCEL CHANGES screen is
Choose Enabled or Disabled Enabled/Disabled
invoked.
(Enabled).
Overvoltage Pickup Note 1: Default values are in parenthesis.

This adjusts the overvoltage pickup Note 2: Not all sensing choices are valid for
S1 OV Pickup
as a percentage of the overvoltage for all combinations of Level 2 and
dropout. 95% 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 4-26. 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
Overvoltage Dropout 15.0 seconds (5.0 seconds).
135% of the nominal voltage (110%).
S1 Imbalance Sensor
Enabled/Disabled
S1 OV Time Delay
3.0 Seconds
Detects unbalanced voltages
on 3-phase sources (Disabled).
Overvoltage Time Delay
Enter a range between 0 and
120 seconds (3 seconds). Imbalance Dropout
4%
S1 Frequency Sensor
Enter a percentage between
Enabled/Disabled
2 and 10% (4%).
Monitors line frequency on

A-Phases of both sources (Enabled). Imbalance Delay
5.0 Seconds
Nominal Frequency
Enter a time between
60.0 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 The phase rotation sensing can

1% be enabled or disabled (Enabled).

Note: Default values are in parenthesis.
5% of the frequency pickup (1%).
FIGURE 4-26. SETUP GROUP 1 − SENSOR SUBMENUS (STARTING WITH SOFTWARE VERSION 1.12)
(Continued)

SYNC CHECK SENSOR the transfer switch control can send a Sync Enable
command to the genset to synchronize with the util-
If enabled, the Sync Check sensor overrides pro- ity. This command is activated just before the Sync
grammed transition whenever transferring be- Check sensor is activated. When the genset con-
tween two live sources. If only one power source is trol receives a Sync Enable command and detects
available, programmed transition overrides the the Source 1 bus voltages, the genset control auto-
Sync Check sensor. matically synchronizes its speed and phase to
match the Source 1 bus. The Sync Check sensor
The Sync Check sensor is disabled on BTPC trans- monitors both sources. When they are synchro-
fer switches. The transfer switch mode setting can nized, a transfer or retransfer command is initiated.
be changed with the PC Service tool or with the dig- The genset must be capable of reacting to a
ital display (see Figure 4-27) when it is available. Sync Enable command.
Sync Check is used to determine when both
sources of power are within specified tolerances of To use the Active Sync feature, it must first be en-
frequency, voltage, and relative phase difference. If abled. The Active Sync feature can be enabled with
both sources are within this range, a fast transfer the PC Service tool or the digital display (see the Ac-
occurs. tive Sync sub-menu in Figure 4-27).
Synchronicity parameters are adjustable. The fre- When the Active Sync feature is enabled, the con-
quency bandwidth range is from 0.1 and 1.0 Hz. trol runs an Active Sync Time Delay (if greater than
The default value is 1.0 Hz. The frequency differ- 0) and sends the Sync Enable command to the gen-
ence between the sources must be equal to or less set. The Active Sync Time Delay is used to check
than the set value in order for transfer to occur. The the stability of the system before transferring to the
voltage window is from 5 and 25 volts. The default other source. The two sources must remain syn-
value is 10 volts. The average voltage difference chronized for this period of time period before a
between the two sources must be equal to or less transfer command is given. The Active Sync Time
than the set value in order for transfer to occur. The Delay is adjustable from 0 to 5 seconds in 0.1 sec-
manual offset range is from −25 to +25 millisec- ond increments (default = 0.5 seconds). The Active
onds. The default value is 0 milliseconds. The Sync Delay timer can be set with the PC Service
transfer switch controller measures non-pro- tool or the digital display (see Figure 4-27). The Ac-
grammed transition transfer times from one source tive Sync Delay should not be used unless the
to another. It takes into account relay coils and so- generator set can actively synchronize to the
lenoids energizing. These values can be set with utility (for example, a paralleling genset). Con-
the PC Service tool or with the digital display (see tact your dealer or distributor for more informa-
Figure 4-27) when it is available. tion.
Another feature included with controls that have a

Speed Adjust
Sync Check sensor is the Return to Programmed
Transition. If the two sources fail to synchronize
within two minutes, a Failed to Synchronize event If a PowerCommand transfer switch and a non-par-
occurs and the ATS will not transfer. However, if the alleling genset are networked together, the transfer
Return to Programmed Transition feature is en- switch control can send a Speed Adjust command
abled, the control reverts the ATS to the pro- to the genset to increase its speed just enough to
grammed transition mode and executes an open increase its frequency by 0.5 Hz. The command is
transition. This feature is enabled by default and activated just before the Sync Check sensor is acti-
can be changed with the PC Service tool or with the vated. It is used when the genset takes a long time
digital display (see Figure 4-27) when it is avail- to drift in sync with the utility. This increases the
able. number of “in-phase” opportunities to satisfy the
Sync Check sensor. Speed Adjust is always en-
Active Sync Feature abled unless the Active Sync is enabled. The gen-
set must be capable of reacting to a Speed Ad-
If a PowerCommand transfer switch and a Power- just command. This feature is only available if a
Command paralleling genset are used together, PowerCommand network is installed.

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.
FIGURE 4-27. SYNC CHECK SUBMENUS (STARTING WITH SOFTWARE VERSION 1.20.250)

TIME DELAYS Time Delay Engine Cooldown (TDEC)
Refer to the display menus in Figure 4-28 or Figure This time delay maintains availability of the genset
4-29. for immediate reconnection and allows gradual
cool-down at no load before stopping. This feature
Time Delay Engine Start (TDES) is not available on utility-to utility applications.
This brief time delay prevents the generator set The delay is adjustable from 0 to 30 minutes in 1
from starting during short power interruptions. minute increments. The default value is 10 min-
utes. It begins timing when the load is retransferred
The delay is adjustable from 0 to 120 seconds in 1
to Source 1. At the end of the delay, the stop signal
second increments. The default value is 3 sec-
is sent to the generator set.
onds. Timing begins at the Source 1 power inter-
ruption. If the duration of interruption exceeds the For Utility-to-Utility configurations, this time delay is
delay time, the control system starts the generator. not used.
The value is set with the PC service tool or the digi-
tal display when it is available. Time Delay Programmed Transition
For Utility-to-Utility configurations, this time delay is
(TDPT)
not used.
Program Transition introduces a delay (TDPT) dur-
Time Delay Normal to Emergency (TDNE) ing transition of the switch. Programmed transition
stops the switch in the neutral position for an ad-
This brief time delay allows the generator set to sta- justable interval of time. In this position, the load is
bilize before the load is applied. This delay begins not connected to either Source 1 or 2. This delay al-
when the Source 2 (typically the generator) voltage lows residual current from inductive loads to decay
and frequency reaches the settings of the control. to an acceptable level before transfer is completed.
After the delay, the transfer switch transfers the
load to Source 2. The length of time that the transfer switch is in the
neutral position can be adjusted from 0 to 60 sec-
The delay is adjustable from 0 to 120 seconds in onds in 1 second increments. The default value is 0
1 second increments. The default value is 10 sec- seconds. The proper adjustment is a function of the
onds. load. This feature is enabled by default.
Time Delay Emergency to Normal (TDEN) Time Delay Elevator (TDEL)
This delay begins the moment Source 1 line volt- Used in elevator applications, this delay sets a time
age and frequency return to specified values. After to wait for an elevator pre-transfer signal. This sig-
the delay, the transfer switch can retransfer the nal allows the elevator to come to a complete stop
load to Source 1. The delay allows the Power before the switch transfers.
Source 1 to stabilize before retransfer.
The delay is adjustable from 0 to 60 seconds. The
The delay is adjustable from 0 to 30 minutes in 1 delay begins when a transfer or retransfer signal
minute increments. The default value is 10 min- signal has been sent to the relays. The default val-
utes. ue is 0.

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 2: On early versions of software, the sequence of the first
three menus were as follows: TDESa, TDNE, and TDEN.
FIGURE 4-28. SETUP GROUP 2 − TIME DELAY SUBMENUS (SOFTWARE VERSIONS PRIOR TO 1.12)

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 120 (Level 2 to the next field.
controls) seconds (3.0 seconds). See
Notes 2 and 3. When entering numerical values, the
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
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 4-29. SETUP GROUP 2 − TIME DELAY SUBMENUS (STARTING WITH SOFTWARE VERSION 1.12)

SOURCE SELECTING All controllers have a Test pushbutton on the front
panel that enables the system to simulate a failure,
start the genset and transfer the load. Within the
For Utility-to-Utility configurations, select the Prior-
Setup menus the Test submenus allow setting the
ity Source as 1 or 2. The selection display is under
Test routine to run with or without load (Figure
the Test submenus within the Setup group. See
4-30).
Figure 4-30.
For utility-to-genset configurations, the exercise

GENERATOR EXERCISE ROUTINES clock initiates genset start and run cycles at speci-
fied intervals for specified durations. Exercise rou-
Programmable generator exercises (see Figures tines are not used in utility-to-utility configurations.
4-31, 4-32, 4-34 or 4-36) and exercise exceptions
(Figures 4-33, 4-35, or 4-37) are generally pro- After programming exercise routines, a button-
grammed to be recurring. They can be pro- type switch on the Digital Module enables or dis-
grammed from the PC service tool or the digital disables exercise routines. This feature is discussed
play when it is available. further in Section 5: System Checkout. Be sure to
enable this switch.
Level 2 controllers include eight programmable
generator events and eight programmable excep- NOTE: For Utility-to-Utility configurations Test and
tions. Exercise routines are not available.
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 Utility-to-Utility

Utility-to-Genset applications applications
Preferred Source
Test
With/Without Load Source 1/Source 2
Allows an operator to automatically Allows for the selection of the

test the transfer switch, generator Preferred Source
and power system. (Default = Source 1)
Sets the function of the Test
Switch on the front panel
(Default = Test With Load).
FIGURE 4-30. 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
FIGURE 4-31. 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 4-31. 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

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

Exercise 1 Duration
cycle will run.
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)
FIGURE 4-32. 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 4-32. 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 4-33. 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.

VERSION 1.5.190) (Continued)

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

Exercise 1 Duration
run.
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.
FIGURE 4-34. 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)
FIGURE 4-34. SETUP GROUP 2 − EXERCISE SUBMENUS (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 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 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.
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.

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 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).
# (Enabled/Disabled)
NOTE: Exercises 1 through 8 are available 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 4-18) 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.
FIGURE 4-36. SETUP GROUP 2 − EXERCISE SUBMENUS (STARTING WITH SOFTWARE VERSION
1.13.244)

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

Exercise # Duration
run.
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
FIGURE 4-36. SETUP GROUP 2 − EXERCISE SUBMENUS (STARTING WITH SOFTWARE VERSION
1.13.244) (Continued)

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

Test More >>
GROUP 2
Level 2 Controllers allow for setting exceptions to the
eight exercise programs setup from the digital display
screen.
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).
# (Enabled/Disabled)
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 4-18) 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.
VERSION 1.13.244)

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)
VERSION 1.13.244) (Continued)

MODE OF OPERATION 0 open transition with programmed
transition (OT mode),
The Mode sub-menus allow selecting the method 1 open transition with synch check,
the system used to operate. Choices are: 2 momentary closed transition.
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 4-38. 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 4-39. SETUP GROUP 3 − MODE SUBMENU (STARTING WITH SOFTWARE VERSION 1.20.250)

SETTING THE CLOCK time ensures that event and fault codes are time-
stamped when they occur and that exercise rou-
The Clock sub-menus (see Figure 4-40) allow tines take place.
setting the actual date and time. If the equipment
is located in an area where daylight savings time In the event of a power failure, and the controller
is enforced, that also can be enabled. Setting the batteries expire, the clock will require resetting.
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 4-40. 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 4-41. 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
Displays the configuration of the control- Test Mode
ler. Changes are made by service per-
sonnel using the PC service tool.
ATS Configuration
Data  Util−Gen
Utility−Utility
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 4-42. 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
FIGURE 4-42. 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 4-43. 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
FIGURE 4-43. 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 4-44. 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 4-45. 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
applications only)
No Timer Active
This message is displayed only if
there are no active time delays.
FIGURE 4-46. THIRD MAIN MENU − ACTIVE TD SUBMENUS (STARTING WITH SOFTWARE VERSION 1.12)

FLOAT BATTERY CHARGER relay is de-energized. In response to a Low Bat or
AC Fail condition, the appropriate normally ener-
Battery Charger Options gized relay (Low Bat or AC Fail) drops out. In re-
sponse to a High Bat condition, the normally de-en-
Originally, either a 2-amp or a 10-amp battery char- ergized High Bat relay is energized.
ger was available for use with an OTPC transfer
switch. Those battery chargers have now been re-
placed with new 2-amp and 15/12-amp battery
chargers.
When present, the status of the battery charger can

be viewed using the digital display (see Figure
4-47). The battery charger status submenu is in-
cluded in the Statistics submenus (see Figure 4-15
or 4-16).
Battery Charger
Ok/Fault
ES1692 SC1613
2-AMP 10-AMP
CHARGER CHARGER
FIGURE 4-47. BATTERY CHARGER STATUS
SUBMENU FIGURE 4-48. ORIGINAL FLOAT BATTERY
CHARGERS
Original Float Battery Charger Option
Current Float Battery Charger Option
A float-charge battery charger regulates its charge
voltage to continuously charge without damage to A float-charge battery charger regulates its charge
the battery. As the battery approaches full charge, voltage to continuously charge without damage to
the charging current automatically tapers to zero the battery. As the battery approaches full charge,
amperes or to steady-state load on the battery. the charging current automatically tapers to zero
amperes or to steady-state load on the battery.
Two chargers were available (Figure 4-48). One
battery charger is rated for 10 amperes at 12 or 24
VDC. The other battery charger is rated for 2 am-
peres at 12 or 24 VDC.
The 2-ampere battery charger has an ammeter to

indicate charging current and a fuse to protect the
battery charger circuit.
The 10-ampere battery charger has three fuses

(two on the AC input and one on the DC output),
three fault display LEDs, and an ammeter for indi-
cation of charging current.
On the 10-ampere charger, three sets of (Form-C)

alarm contacts (corresponding to the three fault
LEDs) are also available. Using an optional alarm 2-AMP CHARGER 15-AMP (12 VOLT), 12-AMP
contact harness, these contacts can be wired by (24 VOLT) CHARGER
the installer to activate other audible or visual
alarms. FIGURE 4-49. CURRENT BATTERY CHARGERS
Under normal operating conditions, the Low Bat Two battery chargers are available (Figure 4-49).
and AC Fail relays are energized and the High Bat One battery charger is rated for 2 amperes at 12 or

24 VDC. The other battery charger is rated for 15 Control Panel
amperes at 12 VDC or 12 amperes at 24 VDC.
The 2-amp charger control panel includes a digital
2-Amp Battery Charger
display, a RESET button, and an LED status indica-
The 2-ampere battery charger (see Figure 4-50) tor (see Figure 4-51).
has a 5 amp DC output circuit breaker switch on the
front of the battery charger. The charger also in-  The 2-line x 16-character digital display dis-
cludes a 5 amp AC fuse to protect the battery char- plays menus and faults.
ger circuit.  The RESET button is used to select menu op-
tions and to clear fault messages.
 The status LED displays the appropriate color
for the following conditions.
− Green − On solid indicates unit is charg-
ing
− Red − On solid indicates a fault condition.
The fault number is shown on the digital
display.
RESET DIGITAL LED STATUS

BUTTON DISPLAY INDICATOR
FIGURE 4-50. 2-AMP POWERCOMMAND BATTERY FIGURE 4-51. 2-AMP CHARGER CONTROL PANEL
CHARGER
Under normal operating conditions, the Low Bat Battery Charger Configuration
and AC Fail relays are energized and the High Bat
relay is de-energized. In response to a Low Bat or The RESET button on the control panel (see Figure
AC Fail condition, the appropriate normally ener- 4-51) is used to configure the battery charger for
gized relay (Low Bat or AC Fail) drops out. In re- the correct battery voltage. (More information on
sponse to a High Bat condition, the normally de-en- Setup menus is included in the Battery Charger
ergized High Bat relay is energized. Operator’s Manual.)

15/12-Amp Battery Charger digital display, a Reset button, and an LED status
indicator (see Figure 4-53).
There are two types of 15/12-amp PowerCom-
mand battery chargers (see Figure 4-52). All  The 2-line x 16-character digital display dis-
15/12-amp battery chargers have a 20 amp DC cir- plays menus and faults.
cuit breaker switch on the front of the battery char-  The Reset button is used to select menu op-
ger. The 120, 208, and 240 VAC battery chargers tions and to clear fault messages.
include two 10 amp AC circuit breaker switches  The status LED is displays the appropriate col-
and a circuit breaker guard, while the 277, 380, or for the following conditions.
416, and 600 VAC battery chargers include two AC − Green − On solid indicates unit is charg-
fuse holders. ing
− Amber − On solid indicates Equalizing
Control Panel − Red − On solid indicates a fault condition.
The fault number is shown on the digital
The 15/12-amp charger control panel includes a display.
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 4-52. 15/12-AMP POWERCOMMAND BATTERY CHARGERS

NOTE: A factory installed battery charger is
set up for the proper DC battery volt-
age requested on the production or-
der, with the Lead-Acid battery type
selected as the default.
 Battery Equalization − Battery equalization

is available for lead-acid batteries that are
completely charged, using the Equalize Bat-
tery screen in the Setup menus. When bat-
tery equalization is in process, the LED sta-
RESET DIGITAL LED STATUS
INDICATOR
tus indicator turns amber.
BUTTON DISPLAY
Battery Charger Alarm Contacts Option
FIGURE 4-53. 15/12-AMP CHARGER CONTROL
PANEL The optional 10-ampere battery charger can in-
clude three sets of Form-C relay contacts, as an
Optional Battery Temperature Sensor additional option.
A connector for an optional battery temperature Under normal operating conditions, the Low Bat
sensor is located on the front of the battery charger. and AC Fail relays are energized and the High Bat
When used to monitor battery temperature, the op- relay is de-energized. In response to a Low Bat or
tional battery temperature sensor is connected AC Fail condition, the appropriate normally ener-
from the battery charger to the positive terminal of gized relay (Low Bat or AC Fail) drops out. In re-
the battery. A fault message (fault code 2263) is sponse to a High Bat condition, the normally de-en-
displayed if the battery temperature is too high ergized High Bat relay is energized.
(reaches 131 degrees F (55 degrees C)).
The contacts are rated for 4 amperes at 120 VAC or
Battery Charger Configuration 30 VDC. Connections to these contacts are made
at terminals 41-42-43 (AC failure), 44-45-46 (high
The RESET button on the control panel (see Figure battery voltage), and 47-48-49 (low battery volt-
4-53) is used to configure the battery charger. age) of TB3 (Figure 4-54). See Figure 3-5 for TB3
(More information on Setup menus is included in wiring.
the Battery Charger Operator’s Manual.)
Use number 22 to number 12 AWG stranded wire.
 Battery Voltage and Type − The battery For connection to the screw terminal, strip the in-
charger must be correctly configured, using sulation back 3/8 inch (10 mm).
the Setup menus, for the correct battery volt-
age and type before it is connected to the Level 2 Digital Modules have an input dedicated to
battery. The battery voltage can be set for 12 monitor the AC Line failure on the battery charger.
or 24 VDC (default = 12 VDC). The battery This input is located at J27-23 and activated when
type can be set for Lead-Acid, Gel, or AGM grounded. (As of this printing, this input is only
batteries (default = Lead-Acid). available at J27-23.)

setup program. When setups are complete, recon-
TB3
nect the transfer switch.

AC C
LINE NC 1. Extend the drawout cranking handle.
FAILURE NO
2. Hold the Drawout Lever up and rotate the
HIGH C cranking handle clockwise until the Drawout
BATTERY NC Lever drops.
VOLTAGE NO
3. Return the cranking handle to its stored posi-
LOW C
tion.
BATTERY NC
VOLTAGE NO 4. Place the bypass switch handle to the center
position.
NETWORK DATA
(OPTIONAL) − USE DATA1
TWISTED PAIR
WIRING DATA2 1. Insert the cranking handle into the transfer
switch and rotate it clockwise until the pointer
is in the “Auto” position.
2. Remove the cranking handle and store.
FIGURE 4-54. BATTERY CHARGER ALARM
CONTACTS AND NETWORK CONNECTIONS 3. Place the Motor DIsconnect Switch in the Auto
position.
RECONNECT THE TRANSFER SWITCH 4. Insert the manual bypass handle and move the
handle down. Turn the Source Selector Switch
After all setups are completed, save the setups and to the OFF position.
verify the settings. Place the panel lock key switch
in the Locked position to prevent changes to the 5. Close the cabinet door(s).

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
To First
Group 1 Setup Group 2 Setup Group 3 Main Menu
< Sensor1 < TimeDelay Exercise >
Volts L12 L23 L31 < Mode Sequencer >
Run Time Source1 < Sensor2 More >> To < Test More >> To
Group 2 Group 3 < Clock More >> To
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 Delay
Output 1 Time 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
4-61
Save/Restore
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 Frequency Delay Program 2 Repeat
*May not be displayed in v1.0
4th Most Recent Event
Phase Rotation Exercise 2 Note 1 − This menu is available with utility-to-utility
applications only.
Save/Restore Save/Restore
FIGURE 4-55. MENU SYSTEM MAP − PRIOR TO SOFTWARE VERSION 1.5.190

< Source1 Load > < Statistic Setup > Enter Password + Enter Password Enter Password < About Active TD >
Setup
Group 1 To First
Setup Group 2 Setup Group 3 Main
< Sensor1 < TimeDelay Exercise > Menu
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 Delay Active Exceptions
Volts L1n L2n L3n Next Exercise In * Output 1 Time Delay
TDPT Time Network Module
Control Batteries Cancel Exceptions
Amps l1 l2 l3 S1 OV Enable Exercise 1 Enable
TDEL 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
4-62
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
Exercise 2 Repeat
4th Most Recent Event Exception 2 Repeat *May not be displayed in v1.5.190
Phase Rotation
Exercise 2 Note 1 − This menu is available with utility-to-utility
Save/Restore
Save/Restore applications only.
FIGURE 4-56. MENU SYSTEM MAP − STARTING WITH SOFTWARE VERSION 1.5.190
Setup
Group 1 To First
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 Delay Active Exceptions
Volts L1n L2n L3n Next Exercise In Output 1 Time Delay
Time ATS Board Level
Control Batteries Cancel Exceptions
Amps l1 l2 l3 S1 OV Enable Exercise 1 Enable
TDNE 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
4-63
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
Imbalance Dropout
TDESb Exercise 2 Start Date
Most Recent Event Frequency Pickup Exception 2 Start Date
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
Phase Rotation Note 1 − This menu is available with utility-to-utility
Save/Restore Exercise 2 applications only.
Save/Restore
Save/Restore

Setup
Group 1 To First
< Sensor1 < TimeDelay Exercise >
Volts L12 L23 L31 < Mode Sequencer > Menu
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 Enable
Control Batteries Output 8 Time Delay
Frequency
S1 OV Enable
Exercise 1 Start Date Exception 1 Enabled Save/Cancel Changes ATS Board Level
TDESb Save/Cancel Changes
4-64
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
Phase Rotation Test in Process
Frequency Delay Exercise 2 Repeat
Exception 2 Repeat
Note 1 − This menu is available with utility-to-utility
Save/Cancel Changes
Exercise 2 applications only.
Save/Cancel Changes
Note 2 − This menu is available with utility-to-genset
applications only.
FIGURE 4-58. MENU SYSTEM MAP − STARTING WITH SOFTWARE VERSION 1.12
Setup
Group 1 To First
Group 1
Run Time Source2
Sensing Test
Frequency
Delta/Wye TDNE Note 1 Load Sequencer
Bootcode Version
Avg CT Transfer Test w/ w/o Load 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 Delay
TDEL Exercise # Enable
Frequency
S1 OV Enable
Exercise # Start Date Exception # Save/Cancel Changes ATS Board Level
TDESb Save/Cancel Changes
4-65
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
Frequency Dropout NWEST ATS#16 750kW NWEST GEN#16 750kW

Phase Rotation Frequency Delay
Note 1 − This menu is available with utility-to-utility applications only.
Test in Process
Note 2 − This menu is available with utility-to-genset applications only.
Save/Cancel Changes
Note 3 − Level 2 Controllers can have up to eight exercise periods and eight exercise exceptions.

Setup
Group 1 To First
Setup Group 2 Setup Group 3 Main Menu
< Sensor1 SynchChck < TimeDelay Exercise >
Group 1
Run Time Source2
Sensing Frequency Bandwidth Test
Frequency

Delta/Wye Voltage Window Note 1 Load Sequencer
Bootcode Version
Avg CT Transfer Test w/ w/o Load 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 Delay Active Sync Delay
Exercise # Enable
Frequency
S1 OV Enable TDNE
Exercise # Start Date Exception # Save/Cancel Changes ATS Board Level
Save/Cancel Changes
4-66
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
TDESb Note 3
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
Frequency Dropout NWEST ATS#16 750kW NWEST GEN#16 750kW
Changeover Enable
Phase Rotation Frequency Delay Note 1 − This menu is available with utility-to-utility applications only.
Changeover Delay Test in Process
Note 2 − This menu is available with utility-to-genset applications only.
Save/Cancel Changes
Save/Cancel Changes Note 3 − Level 2 Controllers can have up to eight exercise periods and eight exercise exceptions.
5. System Checkout
Use the Digital Display to check operation of the At the end of the TDEN time delay, the load re-
switch. Refer to Section 4 for setup details. transfers from Source 2 to Source 1. The
Source 1 Available lamp lights immediately.
WARNING AC power within the cabinet and The Source 1 Connected lamp lights indicating
the rear side of the cabinet door presents a that retransfer has occurred. The controller is-
shock hazard that can cause severe personal sues an engine cool-down time delay and
injury or death. Use extreme caution to avoid turns off the generator. The Test/Exercise LED
touching electrical contacts whenever the cab- is turned off.
inet door is open.
5. Check operation of the Bar Graph Meters (if
STARTING TEST (UTILITY-TO-GENSET equipped) on the cabinet door.
APPLICATION)
6. Press the Test button again. After the time de-
WARNING Improper operation of the genera- lays, the transfer switch retransfers the load to
tor set presents a hazard that can cause severe Source 1 and stops the generator set after
personal injury or death. Observe all safety cool-down.
precautions in your generator set Operation
and Installation manuals. Do not wear long hair, 7. Reset the Test With/Without Load variable to
damp clothing, or jewelry. Use insulated tools, the desired value for regularly scheduled exer-
stand on a dry rubber mat or wood platform. cise routines.
1. Move the selector switch on the engine control Utility-to-Utility Control

to Run. The generator set should start and run.
Time delay functions for generator starting and
2. Move the selector switch to Remote. The gen- stopping (TDES, TDEC) are disabled. All other au-
erator set should stop. tomatic functions are the same at utility-to-genera-
tor control. The Test pushbutton and Exercise rou-
TRANSFER WITH LOAD TEST tines are also disabled in the configuration.
Utility-to-Genset Control CONTROL LED INDICATORS AND

SWITCH
The software variable Test−With/Test Without
Load must be set to the With Load value.
LED Indicators
The digital module located on the inside of the
1. To activate the switch panel, turn the key
switch enclosure door contains ten LED indicators.
switch on the front panel to PROGRAM.
The indicators provide more detailed information
2. Start the genset by pressing and holding the about the current control status. These indicators
Test button on the front panel for 2 seconds may be helpful in troubleshooting the transfer
(Figure 5-2). switch if the Digital Display is not available. See
Figure 5-1 and Table 5-1.
3. After the Engine Start time delay, and Source Exercise Enable/Disable Switch
2 output is acceptable, the brief Normal to
Emergency time delay begins. The Source 2 The Exercise Enable/Disable switch (Figure 5-1)
Available lamp is lit and the linear actuator en- allows the controller to exercise the genset for fu-
ergizes and drives the transfer switch contact ture scheduled exercise routines. When Exercise
mechanism to neutral or Source 2. The Source is enabled the LED indicator remains lit. The indica-
2 Connected lamp lights. tor flashes during an exercise routine. The operator
can also enable and disable Exercise routines by
4. To end the test routine, press the Test button using this button; or at the Digital Display through
again. The controller issues a retransfer time the Setup menus, or using the PC Service Tool.
delay. Each utility supercedes each other.

DIGITAL MODULE
STATUS
S1 AVAILABLE
S2 AVAILABLE
START A/TDES-A
DANGER START B/TDES-B
RETRANSFER TDEN
TRANSFER TDNE
NOT USED
58 114
57 1 12
K1 K2 K3 K5 K6
P1
TDPT
P10 EXERCISER-ENABLED
DANGER
Hazardous Voltage.
Will cause severe injury
or death.
Disconnect all electrical
supply sources before
servicing.
TRANSFER SWITCH
INNER DOOR PANEL
LED INDICATORS
EXERCISE
ENABLE/DISABLE
SWITCH
FIGURE 5-1. LED LOCATION ON DIGITAL MODULE (SHOWN ON THE 150−1000 AMP SWITCH)
TABLE 5-1. DIGITAL MODULE LED INDICATORS
Indicator Definition
Status Blinks at 1/2 Hz rate when the controller has power and the program is running
without 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 some-
times referred to as the heart beat because it blinks constantly when the controller
does not have an active event.
S1 Available Lights when Power Source 1 has acceptable voltage and frequency limits. This in-
dicator 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 in-
dicator 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 not used with a BTPC transfer switch. This indicator is only used
for genset-to-genset applications when Source 1 is a generator 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)

Indicator Definition
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)
Synch Check Blinks when synchronization between Source 1 and Source 2 is achieved.
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 oper-
ator can also enable and disable the exerciser from the Digital Display when it is
available.
SYSTEM TESTING
Generator Set Start Test
This routine tests the start circuits of the Power-

Command control and starts the generator set. The
linear actuators and contact mechanisms are not
tested and there is no transfer of load to the Emer-
gency source (Source 2).
1. Place the key switch in the PROGRAM posi-

tion.
FIGURE 5-2. SWITCH PANEL
2. Set the software Test−With/Test Without
Load variable to the Without Load value. Non-Load Break Transfer Switch Test
3. Start the genset by pressing and holding the
Test button on the front panel for 2 seconds When the transfer switch is in the Test position, the
(Figure 5-2). load-supplying contacts of the automatic transfer
switch are out of service, but the PowerCommand
4. After the time delays, the generator starts and control and the linear actuator are powered and ful-
the Source 2 Available lamp is lit. ly operational. In this position, the control, the linear
actuator, and the contact mechanisms can be
NOTE: Pressing the Override button on the tested.
front panel will cancel any time delays except
for Programmed Transition, Engine Cool-down 1. Turn and hold the Bypass Source Select
and Elevator signal. switch in the Normal position and move the by-
pass switch handle to the Normal position.
5. To end the test routine, press the Test button Check that the word CLOSED is shown in the
again to stop the generator. Bypass to Normal Indicator slot and release
the Bypass Source Select switch (Figure 5-3).
6. Reset the Test−With/Without Load variable
to the desired value for regularly scheduled WARNING AC power within the cabinet
test routines. Refer to Generator Set Exercise and the rear side of the cabinet door pres-
on page 5-7. ents a shock hazard that can cause severe
personal injury or death. Use extreme cau-
tion to avoid touching electrical contacts
whenever the cabinet door is open. Do not
wear long hair, damp clothing, or jewelry.
Use insulated tools, stand on a dry rubber
mat or wood platform.

2. Lift the Drawout Lever and turn the drawout matic transfer switch back to the Connected
cranking handle counterclockwise to move the position.
automatic transfer switch to the TEST position.
3. After three rotations of the cranking handle, re-

lease the Drawout Lever. When the transfer
switch reaches the TEST position, the Draw-
out Lever engages, locking the transfer switch BYPASS SOURCE
SELECT SWITCH
in the Test position.
RELEASE
4. As the automatic transfer switch is being DRAWOUT POSI-
drawn out, mechanical interlocks force the TION
switch to the neutral position. Check that the INDICATOR
word TEST appears in the Drawout Position DRAWOUT LEVER
Indicator slot. Return the drawout cranking
handle to its stored position.
5. Select the software variable Test−With/Test

Without Load to the With Load value.
NOTE: With Load variable must be selected in

order to test the linear actuator and the contact
mechanisms. Because the automatic transfer BYPASS SWITCH
switch is bypassed and isolated from the load, POSITION INDICA-
there will NOT be an actual transfer of load. TOR
6. Press and hold the TEST pushbutton on the

front panel. BYPASS SWITCH
HANDLE
The generator set will start and run. After the
(Open Position)
transfer time delay, the linear actuator will
drive the contact mechanism to the Emergen-
DRAWOUT CRANK
cy side. Because the automatic transfer switch HANDLE
is bypassed and isolated from the load, there
is NO transfer of load to the Emergency source BYPASS SWITCH
and NO interruption of power to the load. POSITION INDICA-
TOR
7. Press the TEST pushbutton to end the test FIGURE 5-3. 150−1000 AMP BYPASS PANEL
routine. After the retransfer time delay, the lin-
ear actuator will drive the contact mechanism 9. After three rotations of the cranking handle, re-
back to the Normal side. lease the Drawout Lever. As the automatic
transfer switch is being cranked back to the
To avoid the retransfer time delay, press the Connected position, mechanical interlocks
OVERRIDE pushbutton (the switch returns to force the switch to the neutral position.
Normal). The generator will stop after the cool-
down time delay. 10. Check that the word CONNECTED appears in
the Drawout Position indicator slot and return
8. Lift the Drawout Lever and turn the drawout the drawout cranking handle to its stored posi-
cranking handle clockwise to move the auto- tion.

11. After the automatic transfer switch has re- 3. Rotate the drawout cranking handle (Figures
turned to the Normal position, move the by- 5-5 and 5-6) counterclockwise to move the au-
pass switch handle to the center position. tomatic transfer switch to the TEST position.
Check that the word OPEN is shown in both
the Bypass to Normal and the Bypass to Emer-
gency indicator slots.

to the desired value for regularly scheduled
test routines.
After the automatic transfer switch is returned to Manual Bypass

the Connected position and the Drawout Lever is Handle in Closed
released, the switch will respond to transfer/retran- Position
sfer signals from the PowerCommand control. In
this procedure, the switch returns to the Normal
Selector Switch
position, provided the retransfer time delay has ex- in
pired. Normal Position
Non-Load Break Transfer Switch Test

1200−4000 Amp Switches Transfer Switch is
Bypassed to
Source 1
WARNING AC power within the cabinet and
(Normal)
the rear side of the cabinet door presents a
shock hazard that can cause severe personal
injury or death. Use extreme caution to avoid FIGURE 5-4. MANUAL BYPASS OPERATION
touching electrical contacts whenever the cab- 1200−4000 AMP SWITCHES
inet door is open. Do not wear long hair, damp
clothing, or jewelry. Use insulated tools, stand
on a dry rubber mat or wood platform.
The software variable Test−With/Test Without
Load must be set to the With Load value in order to
test the linear actuators and the contact mecha-
nisms. Because the automatic transfer switch is by-
passed and isolated from the load, there will NOT
be an actual With Load test.
1. Insert the Manual Bypass handle into the by-

pass drive mechanism.
2. Turn the Bypass Selector switch to the Normal

position and move the Manual Bypass handle
up (Figure 5-4). Drawout Handle
and Mechanism SC1638s
Check that the Bypass Normal and ATS In-
hibit lamps are lit. FIGURE 5-5. 1200 AMP DRAWOUT MECHANISM

Pointer in
Test Position
Drawout Handle
and Mechanism SC1640s
FIGURE 5-7. 1200 AMP DRAWOUT POSITION

FIGURE 5-6. 1600−4000 DRAWOUT MECHANISM POINTER
Check that the automatic transfer switch posi-

tion pointer is aligned with the word Test (Fig-
ures 5-7 and 5-8).
Check that the ATS in Test lamp is lit. and that Pointer in
the ATS Inhibit lamp is not lit. Test Position
4. Return the drawout cranking handle to its

stored position.
In the Test position, the load-supplying con-
tacts of the automatic transfer switch are out of
service, but the PowerCommand control and
the linear actuators are powered and fully op-
erational. In this position, the control, the linear
actuators, and the contact mechanisms can
be tested.
NOTE: The cranking handle operates only SC1641

when power is available. The bypass and the
automatic transfer switches must be con- FIGURE 5-8. 1600−4000 AMP DRAWOUT POSITION
nected to the same source. POINTER
5. Make sure the Test With/Without Load vari- 7. Press and hold the TEST button on the front
able is set to With Load. panel.
The generator set will start and run. After the
6. Move the Motor Disconnect toggle switch (lo- transfer time delay, the linear actuators will
cated on the control plate) to the AUTO posi- drive the contact mechanism to the Emergen-
tion to enable the automatic transfer switch lin- cy side. Because the automatic transfer switch
ear actuators. Close the cabinet door. is bypassed and isolated from the load, there
is NO transfer of load to the Emergency source
and NO interruption of power to the load.

8. At the end of the test routine and time delays, fer switch will respond to transfer/retransfer
the linear actuators will drive the contact signals from the PowerCommand control.
mechanism back to the Normal side.
To avoid any retransfer time delays, press the to the desired value for regularly scheduled ex-
Override button. The generator will stop after ercise routines. Refer to Generator Set Exer-
the stop time delay. cise below.
9. Move the Motor Disconnect toggle switch (lo- GENERATOR SET EXERCISE
cated on the control plate) to the OFF position
to disable the automatic transfer switch linear Run the generator for at least 30 minutes once
actuators. each week with at least 50 percent load (if pos-
sible). If exercise routines are not desired, use the
switch, as described below, to test the generator
10. Move the automatic transfer switch back to the
set each week.
Auto position by rotating the drawout cranking
handle clockwise. The ATS Inhibit lamp will Exercise routines can be programmed for specified
light. exercise periods and are used to exercise the gen-
erator set automatically with or without load. The
11. Make sure the position pointer is aligned with Digital Display can set parameters for two exercise
the word AUTO. Return the drawout cranking periods and two exceptions and the PC Service
handle to its stored position. Tool can set parameters for eight exercise periods
and eight exceptions.
12. Move the Motor Disconnect toggle switch to
the AUTO position. Close the cabinet door. All controllers have a switch to enable or disable
the exerciser clock (see Figure 5-1) for future
13. Move the Manual Bypass handle down. Check scheduled exercise routines. The pushbutton is lo-
cated on the Digital Module above the batteries
that the ATS Inhibit, Bypass Normal and the
next to the LED light bar display. The operator can
Bypass Emergency indicator lamps are not
enable and disable Exercise routines using this
lit.
button or, at the Digital Display through the Setup
menus, or using the PC Service Tool. Each utility
14. Return the Manual Bypass handle to its stored supercedes each other.
position.
If a power failure occurs during the exercise rou-
After the automatic transfer switch is returned tine, the controller overrides the routine and trans-
to the Auto position, the Motor Disconnect fers the load.
toggle switch is moved to the Auto position,
and the bypass switch is moved to the open To manually initiate an exercise routine, refer to the
(disconnected) position, the automatic trans- procedure for Transfer With Load Test on page 5-1.

CALIBRATING THE TRANSFER SWITCH 6. Set the S1 Nominal Voltage to the voltage read
in Step 1.
If frequent (over/under) voltage event messages
occur, the voltage sensors may require recalibra- 7. Set the Undervoltage Pickup, Dropout and
tion. To calibrate voltage: time delay to the desired points.
1. Using a True RMS meter, measure and record
the voltage at Source 1 and 2 and the load volt- 8. Set the Overvoltage Pickup, Dropout and time
ages. delay to the desired points.
2. Using a power factor meter, measure and re- 9. When moving back to the main menu, select
cord the power factor for each individual phase Save to save changes or select Restore to re-
of the load. turn to the original settings
3. Using the digital display panel, navigate to the 10. Follow steps 1 through 9 for Sensor 2.
second main menu and select Setup.
4. Use the Up/Down keys to cycle through the Calibrate Level 1 controllers from Phase to Phase.
choices and enter the password.
Calibrate Level 2 controllers from Phase to Neutral.
5. Press the right-pointing arrow key until the Multiply the phase by 0.732 to obtain neutral if no
Sensor 1, Sensor 2 or More is displayed. neutral wire is installed.

6. Start-up Checklist
This start-up checklist provides the steps necessary Setting Exercise(s)
to complete a typical setup. It also includes informa-
Navigate to the Exercise sub-menus and set ex-
tion on setting up a programmed exercise.
ercise(s):
The transfer switch control is programmed at the fac- [ ] Select “Enabled” to enable the exercise fea-
tory with the voltage, frequency, and options listed on ture.
the nameplate. Make sure the application matches [ ] Select “Enabled” to enable an exercise.
the nameplate values. Check the remote start con- [ ] Select a day between Sunday and Saturday.
nections before powering up the transfer switch. [ ] Enter the time of day the exercise cycle is to
begin (hr = 0−23, mn = 0−59).
Verify that the remote start connections are correct
for your application. For more information on jump- [ ] Set the duration the exercise cycle will run
er placement, determine the control type and refer (hr = 0−23, mn = 0−59).
to the Wiring section of your transfer switch Instal- [ ] Enter the number of weeks between each ex-
lation Manual. ercise (interval) (0 = one time only, 1 = once a
week, 2 = once every two weeks, 52 = once
For Level 2 controls with 3-wire, 3-phase Delta ap- every 52 weeks).
plications, refer to the Installation Manual for spe- [ ] Select whether or not you want the exercise
cial wiring instructions. 240V Delta configurations to run the generator(s) with or without a load.
must be set to 139 VAC nominal voltage. The default is “Without Load.”
NOTE: Exercise exceptions are also available
The transfer switch is released with the appropriate
through the digital display menus. For more informa-
calibration and settings that allow the unit to function
tion, see the Operator’s Manual. Exercise exceptions
properly without any additional adjustments.
can be cancelled in the “Cancl Active Excpts” sub-
menu (change from “Normal” to “Cancel”).
The clock must be set in order to maintain an accurate
log of events and exercises. In addition, you may wish Setting the Unit to Test With or Without Load
to set exercise periods and set the transfer switch to
Navigate to the Test sub-menu and set the Test
test with or without load (default = Without Load).
Switch to Test With or Without Load:
A setup can be done using the digital display or In- [ ] Select whether or not you want your transfer
Power. If InPower is available, use the checklist on switch to test “With” or “Without Load.” The
the other side of this page. default is “Without Load.”
Saving the Settings and System Verification
SETUP USING THE DIGITAL DISPLAY Before exiting the Setup sub-menus, save the
changes made to the control settings on the
Using the digital display, navigate to the the Setup Save/Restore sub-menu.
sub-menu and enter the password (574).
Next, verify that the transfer switch is operating
properly.
Setting the Date and Time
[ ] Check to make sure the correct time is dis-
played.
Navigate to the Clock sub-menu and program the
clock: [ ] View the “Next Exercise In” sub-menu to
verify that a time is displayed.
[ ] Set the date − Month (January = 1, December [ ] Do a complete system check, including simu-
= 12), Date (1−31), and Year (1−9999). lating a power outage. For more information,
[ ] Enter the time − Hours (0−23), Minutes see the Operation section (Section 3) of the
(0−59, and Seconds (0−59). transfer switch Operator’s Manual.
Features
[ ] Enable/Disable Daylight Savings time. Ad-
justs clock setting for daylight savings time. Loss of phase detection and voltage imbalance sens-
The default is “Disabled.” ing are disabled at the factory. Before enabling them,
InPower is a trademark of Onan Corporation.

see the Operator’s Manual to review the feature de- “True” for the new interval to take effect. The setting
scriptions. will automatically switch back to “False” again.
CAUTION Level 1 controls do not support three- NOTE: Exercise exceptions are available through the
phase sensing on Source 2. Do not select the three- Adjustments  Exceptions folder. Refer to the Inpow-
phase option for the Source 2 Sensing adjustment er User’s Guide for more information.
with Level 1 controls, even if the system is three
phase. This setting will prevent Source 2 from be- Setting the Unit to Test With or Without Load
coming available.
Navigate to the Test  Setup folder.
SETUP USING INPOWER [ ] Set the Test Switch to test “With” or “Without
Load.” The default is “Without Load.”
Setting the Clock
[ ] Select the “Save Adjustments” icon.
Using InPower, navigate to the Adjustments 
Saving the Settings and System Verification
Real Time Clock Folder.
[ ] Set the date − Month (January thru Decem- To store your settings in a capture file, select the
ber), Date (1−31), and Year (1−9999). Device” pull-down menu and select “Capture to
file.”
[ ] Enter the time − Hours (0−23), and Minutes
(0−59). Next, verify that the transfer switch is operating
[ ] Enable/Disable Daylight Savings time. Ad- properly.
justs clock setting for daylight savings time. [ ] Do a complete system check, including simu-
The default is “Disabled.” lating a power outage. For more information,
[ ] Select the appropriate date format (North see the Checkout section of your transfer
American or International). switch Installation Manual.
[ ] Select the “Save Adjustments” icon. [ ] Review settings.
Setting Exercise(s) Features
Navigate to the Adjustments  Feature Enable Loss of phase detection and voltage imbalance sens-
folder. ing are disabled at the factory. Before enabling them,
see the Operator’s Manual to review the feature de-
[ ] Select “Enabled” to enable an exercise. scriptions.
[ ] Select the “Save Adjustments” icon.
CAUTION Level 1 controls do not support three-
Navigate to the Adjustments  Exerciser Clock phase sensing on Source 2. Do not select the three-
folder. phase option for the Source 2 Sensing adjustment
with Level 1 controls, even if the system is three
[ ] Enable Program 1. phase. This setting will prevent Source 2 from be-
[ ] Select a start day between Sunday and Sat- coming available.
urday.
About InPower Service Tool
[ ] Set the time the exercise cycle is to begin (hr
= 0−23, mn = 0−59). The InPower service tool can be used to test the trans-
[ ] Set the duration of the exercise cycle (hr = fer switch using functions, including Remote Test,
0−23, mn = 0−59). Transfer Inhibit, Retransfer Inhibit, etc. InPower,
when used improperly, can cause symptoms like
[ ] Enter an interval that the exercise cycle will
warnings and shutdowns that appear to be a defective
repeat (0 = one time only, 1 = once a week,
control. When these problems occur, always verify
2 = once every two weeks, 52 = once every
that a Test feature was not left enabled with InPower.
52 weeks).
Always disable test features before disconnecting In-
[ ] Select whether or not you want the exercise Power.
to run the generator(s) with or without a load.
The default is “Without Load.” About Network Applications and Customer
[ ] Select the “Save Adjustments” icon. Inputs
NOTE: The Reset Exerciser Repeat Count feature, in In applications with networks and remote customer in-
the Controller Mode folder, can be used to change a puts, these inputs may cause unexpected genset or
repeat interval. Switch the setting from “False” to transfer switch operation. These symptoms may ap-

pear to be caused by the transfer switch control. Verify
that the remote input is not causing the symptom or
isolate the control from these inputs before trouble-
shooting the control.

This Page Intentionally Left Blank.

7. Schematics
SCHEMATIC PAGE
125−1000 Amp Typical Interconnection Diagram 630-1974 (Sheet 1 of 10) . . . . . . . . . . . . . . . . . . 7-5
125−1000 Amp Typical Interconnection Diagram 630-1974 (Sheet 6 of 10) . . . . . . . . . . . . . . . . . 7-10
125−1000 Amp Typical Interconnection Diagram 630-1974 (Sheet 10 of 10) . . . . . . . . . . . . . . . . 7-14

Application Considerations for Closed Transition Transfer Switches
Closed transition power transfer introduces risk to the power system because two live sources are momen-
tarily connected together. The following simple installation practices can minimize these risks.
Prevent multiple transfer switches from transferring at the same time. Multiple transfer switches transfer-
ring simultaneously can result in the genset voltage being unstable during transfer. Two methods for pre-
venting simultaneous transfer are:
oStaggering time delays between switches and
oInterconnecting aux contacts with inhibit functions.
Prevent the two sources from remaining connected indefinitely by connecting the ATS fail to disconnect
output to the shunt trip input of one of the breakers feeding the ATS. This function is actually required by
many utilities.
Staggering Time Delays

Setting time delays on different transfer switches to different values will prevent the switches from transfer-
ring at the same time. For example setting the Emergency to Normal Time Delays (TDEN) to different val-
ues on each switch will prevent the switches from re−transferring to the normal source at the same time
after the source has returned after a failure or at the end of a test. When using this method care should be
taken to make sure that all of the sensing settings are the same on each of the switches to make sure that
the switches recognize the source as being available at the same time.
Note that it is only necessary to stagger the time delays when transferring between live sources. After a
utility failure it is not necessary to stagger time delays for switching loads on to the genset unless the genset
needs time to recover after taking on the individual loads as is often the case when starting large motors.
Re−transfer and Transfer Inhibit Functions

The transfer and re−transfer inhibit functions can be used to prevent multiple transfer switches from trans-
ferring at the same time. For example to prevent two switches from re−transferring from the genset to the
utility at the same time wire the normally closed contact that indicates the first ATS is connected to the nor-
mal source into the retransfer inhibit input of the transfer switch that is intended to transfer second. Ground
the common aux contact on the first switch so that the re−transfer inhibit input on the second switch is
grounded when the first transfer switch is not connected to the normal source. This will inhibit the second
switch from beginning its retransfer sequence (including all time delays) until after the first transfer switch
has transferred back to the normal source. A similar wiring scheme can be used when transferring to the
emergency source so that only one switch transfers at a time. Switch position outputs are available on the
relay signal module which is included with all Cummins closed transition ATS models. Figures 7−1 and 7−2
illustrate how this can be accomplished withall of Cummins’ closed transition transfer switch models.

ATS 1
ATS 2
RELAY SIGNAL MODULE
J14−3 TB2−9 RETRANSFER

INHIBIT
SOURCE 1
CONNECTED
J14−2
J14−6 TB2−6 TRANSFER

INHIBIT
SOURCE 2
CONNECTED
J14−5
FIGURE 7-1. USING SOURCE CONNECTED CONTACTS TO INHIBIT TRANSFERS SUCH THAT ONLY
ONE ATS WILL TRANSFER AT A TIME FOR CHPC AND BTPC 1600 − 3000 AMP TRANSFER
SWITCHES.
ATS 1
ATS 2
RELAY SIGNAL MODULE
J14−3 TB3−53 RETRANSFER

INHIBIT
SOURCE 1
CONNECTED
J14−2
J14−6 TB2−6 TRANSFER

INHIBIT
SOURCE 2
CONNECTED
J14−5
FIGURE 7-2. USING SOURCE CONNECTED CONTACTS TO INHIBIT TRANSFERS SUCH THAT ONLY
ONE ATS WILL TRANSFER AT A TIME FOR OTPC 1000 − 4000 AND BTPC 125−1200 AND 4000 AMP
TRANSFER SWITCHES.

Fail to disconnect
The Fail to Disconnect relay is active when the transfer switch remains connected to both sources for more
than 100 msec during a closed transition transfer. It should be wired to the shunt trip of the breaker feeding
the ATS on either the normal or the emergency side. The fail to disconnect relay is located on the relay
signal module. See Figure 7−3.
RELAY SIGNAL MODULE
BREAKER
J15−9 SHUNT TRIP
FAIL TO
DISCONNECT
J15−8
FIGURE 7-3. FAIL TO DISCONNECT RELAY LOCATION ON THE RELAY SIGNAL MODULE.

Cummins Inc.
FIGURE 7-4. 125−1000 AMP TYPICAL INTERCONNECTION DIAGRAM (SHT 1 OF 10)

Cummins Inc.
FIGURE 7-5. 125−1000 AMP TYPICAL INTERCONNECT DIAGRAM (SHT 2 OF 10)

Cummins Inc.

Cummins Inc.

Cummins Inc.

Cummins Inc.

Cummins Inc.

Cummins Inc.

Cummins Inc.

Cummins Inc.

Cummins Inc.

Cummins Inc.

Cummins Inc.

Cummins Inc.

Cummins Inc.

Cummins Inc.

Cummins Inc.

Cummins Inc.

Cummins Inc.

This Page Intentionally Left Blank.

power.cummins.com
Copyright 2017 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.

Installation Manual: Bypass Isolation Transfer Switch

Uploaded by

Copyright:

Available Formats

Installation Manual: Bypass Isolation Transfer Switch

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Installation Manual: Bypass Isolation Transfer Switch

Uploaded by

Copyright:

Available Formats

Installation Manual

Bypass Isolation Transfer Switch

i Copyright  2017 Cummins Inc.

SECTION TITLE PAGE

Copyright  2017 Cummins Inc. ii

SECTION TITLE PAGE

iii Copyright  2017 Cummins Inc.

SECTION TITLE PAGE

5. SYSTEM CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Copyright  2017 Cummins Inc. iv

UTILITY-TO-GENSET OR Do not work on this equipment when mentally or

v Copyright  2017 Cummins Inc.

Copyright  2017 Cummins Inc. vi

TRANSFER SWITCH APPLICATION ES1968

The transfer switch combines an automatic trans-

Automatic transfer switches, capable of automatic UTILITY-TO-UTILITY OPERATION

1-1 Copyright  2017 Cummins Inc.

Installation refers to the actual set-up and assem-

Copyright  2017 Cummins Inc. 1-2

Cummins is a registered trademark of Cummins Inc.

1-3 Copyright  2017 Cummins Inc.

Copyright  2017 Cummins Inc. 1-4

CABLES FROM SERVICE

FIGURE 2-1. TYPICAL WALL-MOUNT INSTALLATION

2-1 Copyright  2017 Cummins Inc.

TABLE 2-2. APPROXIMATE NEMA 3R, 4 AND 12 CABINET DIMENSIONS

Copyright  2017 Cummins Inc. 2-2

The recommended method for placement of the

2-3 Copyright  2017 Cummins Inc.

Anchor bolts, floor-mounting channels, and other 1600−4000 Ampere Switches

Copyright  2017 Cummins Inc. 2-4

2-5 Copyright  2017 Cummins Inc.

1400 73rd Avenue N.E.

1. NEC TABLE (A) 373−6 SHALL APPLY WHEN THE CONDUCTOR

Copyright  2017 Cummins Inc. 2-6

3-1 Copyright  2017 Cummins Inc.

Copyright  2017 Cummins Inc. 3-2

8. Stop the genset and disconnect the starting

3-3 Copyright  2017 Cummins Inc.

LOAD LOAD LUGS

GROUND LUGS LUG COVER

FIGURE 3-2. 125−1000 AMPERE TRANSFER SWITCH TERMINAL ACCESS

Copyright  2017 Cummins Inc. 3-4

LUG NORMAL LUGS

3-5 Copyright  2017 Cummins Inc.

Copyright  2017 Cummins Inc.

SOURCE 2 LUGS TRANSFER

CONTROL CONNECTIONS TABLE 3-4. WIRE SPECIFICATIONS

Wire Distance in Feet, One Way

3-7 Copyright  2017 Cummins Inc.

Use number 22 to number 12 AWG wire. For con- Transfer Inhibit

FIGURE 3-5. TERMINAL BLOCKS TB1, TB2, AND TB3

Copyright  2017 Cummins Inc. 3-8

TB4 RELAY MODULE

FIGURE 3-6. 150−1000 AMP OPTION CONFIGURATION

3-9 Copyright  2017 Cummins Inc.

CONNECTIONS TO TB3 NOT

FIGURE 3-7. OPTIONAL RELAY MODULE

Copyright  2017 Cummins Inc. 3-10

Source1 Load Source1 Load

Statistic Setup Statistic Setup

About Active TD About Active TD

Source1 Load Statistic Setup About Active TD

Use the buttons on left to navigate through these screens.

Use the buttons on left to navigate through these screens.