1. Onan Ot 225 Transfer Switch

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1. Service Manual Transfer Switch BTPC 1200−4000 Amps English 3-2008 962−0519 (Issue 3).

i Table of Contents SECTION TITLE PAGE SAFETY PRECAUTIONS vi. INTRODUCTION 1-1. About This Manual 1-1. Transfer Switch Application 1-1. Bypass Switch Function 1-2. Drawout Isolation Mechanism 1-2. Utility-to-Genset Operation 1-2.

Utility-to-Utility Operation 1-2. Control Level 1-2. Chevy truck suspension upgrade. Removing and Replacing Electronic Control Components 1-3. Model Identification 1-3.

How to Obtain Service 1-3. COMPONENT DESCRIPTION 2-1.

Cabinet 2-1. Control Panel 2-1. Bar Graph Meter Panel 2-2. Switch Panel 2-2. Indicators 2-2.

Pushbuttons 2-2. Digital Display 2-2. Bypass Switch 2-3.

Contact Assemblies 2-3. Bypass Switch Controls 2-3. Indicators 2-3.

Drawout-Isolation Mechanism 2-4. Drawout Cranking Handle 2-4. Automatic Transfer Switch 2-4. Contact Assemblies 2-5. Linear Actuator 2-5. Motor Disconnect Switch 2-5. Auxiliary Contacts 2-6.

Electronic Control System 2-6. Electronic Control Circuit Modules 2-6. Digital Module 2-6. Power Module 2-7. Time Delays 2-8. System Sensors 2-9.

Two-Wire Starting 2-10. ii Table of Contents (Continued) SECTION TITLE PAGE Transfer Times 2-10. Testing With or Without Load 2-10. Generator Exercise Programs 2-11. Real-Time Clock 2-11. Control Options 2-11.

Relay Module 2-11. Load Monitoring 2-12. Remote Test Transfer 2-13. Auxiliary Relays 2-13.

Battery Charger Options 2-13. Original Float Battery Charger Options 2-13.

Current Float Battery Charger Options 2-14. 2-Amp Battery Charger 2-14. 15/12-Amp Battery Charger 2-15.

Load Shed 2-17. Security Key Switch 2-17. PowerCommand Network Interface Module 2-17. OPERATION 3-1. Automatic Operation 3-1.

Bypassing the Transfer Switch 3-2. Bypassing Load to Normal (Source 1) 3-2. Bypassing Load to Emergency (Source 2) 3-2. Isolating the Transfer Switch 3-3. Reconnecting the Transfer Switch 3-4.

Manual Operation 3-5. Manual Transfer to Source 2 3-5. Manual Transfer to Source 1 3-6. System Testing 3-6. Generator Set Start Test 3-6. With Load Standby Test 3-6.

Non-Load Break Transfer Switch Test 3-7. Generator Set Exercise 3-8. DIGITAL DISPLAY MENU SYSTEM 4-1. Main Menus 4-1. Setup Menus 4-1.

Navigation 4-1. Main Menu Navigation 4-2. Using the Previous Menu Button 4-2. iii Table of Contents (Continued) SECTION TITLE PAGE Main Menu Descriptions 4-3. Source 1 and Source 2 Submenus 4-4. Load Submenus 4-5. Statistics Submenus 4-6.

Prior to Software Version 1.12 4-6. Starting with Software Version 1.12 4-7.

Events Submenus 4-8. Setup Submenus 4-9.

Setup Menu Navigation and Description 4-10. Changing Setup Parameters 4-11. Software Versions Prior to Version 1.12 4-11. Starting with Software Version 1.12 4-12.

Onan Ot 225 Transfer Switch

Sensor 1 & Sensor 2 Submenus 4-13. Software Versions Prior to Version 1.12 4-13. Starting with Software Version 1.12 4-15. Sync Check Submenus 4-17. Time Delay Submenus 4-18.

Software Versions Prior to Version 1.12 4-18. Starting with Software Version 1.12 4-19. Test Submenus 4-20.

Exerciser Submenus 4-21. Software Versions Prior to 1.5.190 4-21. Starting with Software Version 1.5.190 4-23. Exercise Exceptions Submenus 4-25. Starting with Software Version 1.5.190 4-25. Starting with Software Version 1.12 4-27. Starting with Software Version 1.12 4-29.

Starting with Software Version 1.13.244 4-31. Starting with Software Version 1.13.244 4-33. Mode Submenu 4-35. Prior to Software Version 1.20.250 4-35.

Starting with Software Version 1.20.250 4-35. Clock Submenus 4-36. Sequencer Submenus 4-37. About Submenus 4-38. Prior to Software Version 1.20.250 4-38. Starting with Software Version 1.20.250 4-40. System Submenus 4-42.

iv Table of Contents (Continued) SECTION TITLE PAGE Active TD Submenus 4-43. Prior to Software Version 1.12 4-43. Starting with Software Version 1.12 4-44. TROUBLESHOOTING 5-1. InPower Service Tool 5-1. About Network Applications and Customer Inputs 5-1.

Digital Module 5-2. Power Module 5-2. Control LED Indicators and Switch 5-2. LED Indicators 5-2. Exerciser Enable/Disable Switch 5-2. Sequence of Events 5-3.

Transfer from Source 1 to Source 2 in Programmed Transition 5-3. Transfer from Source 2 to Source 1 5-4. Troubleshooting Using Fault Codes 5-5. Fault Events 5-5.

Fault Flash-Out 5-5. Fault Event Definitions 5-8. Controller Checksum Error 5-8. Low Controller Battery 5-8. ATS Fail to Close: Transfer 5-8.

ATS Fail to Close: Re-Transfer 5-8. Battery Charger Malfunction 5-8. Network Battery Low 5-8. Network Communications Error 5-8. Troubleshooting with Symptoms 5-9. Troubleshooting Warnings 5-9. AUTOMATIC TRANSFER SWITCH SERVICE 6-1.

General 6-1. Membrane Switch Test 6-1. Power Module Test 6-2. Digital Board Replacement 6-3. Initial Calibration 6-3. Setup with a Capture File 6-3. Setup Without a Capture File 6-3.

After the Setup is Completed 6-3. Removing the Automatic Transfer Switch 6-6. v Table of Contents (Continued) SECTION TITLE PAGE Bypass, Isolate, and Remove the Automatic Transfer Switch 6-6. To Bypass and Isolate the Automatic Transfer Switch 6-6. To Remove the Automatic Transfer Switch (1200-Amp Bypass) 6-10. To Remove the Automatic Transfer Switch (1600- to 3000-Amp Bypass) 6-13.

Install and Reconnect the Automatic Transfer Switch (When Finished) 6-13. To install the Automatic Transfer Switch (1200-Amp Bypass) 6-13. To Install the Automatic Transfer Switch (1600- to 4000-Amp Bypass) 6-13. To Reconnect the Automatic Transfer Switch 6-15. Linear Actuator Solenoid Removal and Replacement 6-16.

Removing Actuator Solenoid 6-16. Replacing Actuator Solenoid 6-17. Contact Assembly Removal and Replacement (1200 Amperes) 6-17. Removing the Contact Assemblies 6-17. Replacing the Contact Assemblies 6-20. Movable Contact Assembly Removal and Replacement (1600 − 2000 Amperes) 6-22.

Removing the Contact Assembly 6-22. Replacing the Contact Assembly 6-22. Movable Contact Assembly Removal and Replacement (3000 Amperes) 6-25. Removing the Contact Assembly 6-25.

Replacing the Contact Assembly 6-28. Auxiliary Switch Removal and Replacement 6-29.

Removing and Replacing an Auxiliary Switch Assembly. Mis-Wired Current Transformers 6-30. BYPASS SWITCH SERVICE 7-1. General 7-1. Disconnect AC Power 7-1. Reconnecting AC Power (When Finished) 7-1. Contact Assembly Removal and Replacement (1200 Amperes) 7-1.

Removing the Contact Assemblies 7-1. Replacing the Contact Assemblies 7-3. Movable Contact Assembly Removable and Replacement (1600 − 2000 Amperes) 7-6. Removing the Contact Assembly 7-6. Replacing the Contact Assembly 7-6. Movable Contact Assembly Removal and Replacement (3000 Amperes) 7-9.

Removing the Contact Assembly 7-9. Replacing the Contact Assembly 7-12. SCHEMATICS 8-1. vi Safety Precautions This manual includes the following symbols to indicate potentially dangerous conditions. Read the manual carefully and know when these conditions exist.

Then take the necessary steps to protect personnel and the equipment. DANGER This symbol warns of immediate hazards that will result in severe personal injury or death. WARNING This symbol refers to a hazard or unsafe practice that can result in severe personal injury or death. CAUTION This symbol refers to a hazard or unsafe practice that can result in personal injury or prod- uct or property damage. ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH High voltage in transfer switch components presents serious shock hazards that can result in severe personal injury or death.

Read and follow these suggestions. Keep the transfer switch cabinet closed and locked. Make sure only authorized personnel have the cabinet and operational keys.

Due to the serious shock hazard from high voltages within the cabinet, all service and adjustments to the trans- fer switch must be performed only by an electrician or authorized service representative. Whenever the bypass switch is in the Emergency position, an auxiliary switch closes a set of normally open contacts to provide a constant generator set start/run signal. The transfer switch, the emergency bus, and the load bus are energized by the output of the generator set and present a serious shock hazard whenever the bypass switch is in the Emergency position. UTILITY-TO-GENSET OR GENSET-TO- GENSET APPLICATIONS If the cabinet must be opened for any reason: 1. Move the operation selector switch on the generator set to Stop. Disconnect the battery charger.

Disconnect the starting batteries of the generator set or sets (remove the ground − lead first). Remove AC power to the automatic transfer switch. If the instructions require otherwise, use extreme caution due to the danger of shock hazard. UTILITY-TO-UTILITY APPLICATIONS If the cabinet must be opened for any reason, remove AC power to the automatic transfer switch. If the instruc- tions require otherwise, use extreme caution due to the danger of shock hazard. GENERAL PRECAUTIONS Place rubber insulative mats on dry wood platforms over metal or concrete floors when working on any electri- cal equipment. Do not wear damp clothing (particularly wet shoes) or allow skin surfaces to be damp when handling any electrical equipment.

Jewelry is a good conductor of electricity and should be removed when working on the electrical equipment. Wear safety glasses whenever servicing the transfer switch and and do not smoke near the batteries.

Do not work on this equipment when mentally or physically fatigued, or after consuming alcohol or any drug that makes the operation of equipment unsafe. WARNING INCORRECT SERVICE OR REPLACEMENT OF PARTS CAN RESULT IN DEATH, SEVERE PER- SONAL INJURY, AND/OR EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST BE TRAINED AND EXPERIENCED TO PERFORM ELECTRICAL AND/OR MECHANICAL SERVICE. BTPC-2. 1-1 1.

Introduction ABOUT THIS MANUAL This manual contains service procedures for By- pass Transfer Switch PowerCommandR (BTPC) automatic transfer switches (ATS) rated at 1200−4000 amperes. This is a bypass transition (BT) transfer switch equipped with PowerCom- mand Control (PC) and it is capable of executing Open Transition with Sync Check, Programmed Transition, and Closed Transition transfer modes. An Open Transition with Sync Check Transfer Mode executes an open transition when both sources of power are within specified tolerances of frequency, voltage, and relative phase difference. If both sources meet the tolerances, a fast transfer occurs. A Programmed Transition Transfer Mode exe- cutes an open transition by disconnecting the load from the source of power, pausing in the neutral position of the transfer switch (between switched positions) to allow transient currents from the load to diminish, and then the load is switched to the other source. A Closed Transition Transfer Mode executes a load transfer by momentarily paralleling both sources (a maximum of 100ms) before switching sources. Refer to the schematic and wiring diagram pack- age that was shipped with the ATS for specific in- formation about its configuration.

Use normal and necessary safety precautions be- fore starting any service procedure. Identify all hazards by referring to the Safety Precautions and observe all warnings and cautions within the manual. Whenever you are troubleshooting, re- member that the generator set, ATS, and utility power source are all interdependent. TRANSFER SWITCH APPLICATION The BTPC transfer switch combines an automatic transfer switch, a manual bypass switch and a drawout isolation mechanism into one unit. Transfer switches are an essential part of a build- ing’s standby or emergency power system. Power Source 1 (Normal), commonly the utility line, is backed up by Power Source 2 (Emergency), often a generator set.

The transfer switch automatically switches the electrical load from one source to the other. The load is connected to the common of the ATS (Figure 1-1). Under normal conditions, the load is supplied with power from Source 1 (illustrated as Normal).

If Source 1 is interrupted, the load is transferred to Source 2 (Emergency). When Source 1 returns, the load is retransferred to Source 1. The transfer and retransfer of the load are the two most basic functions of the ATS.

Automatic transfer switches, capable of automatic operation without operator intervention, perform the basic function of transferring the load to the available source. The controller monitors each source for suitable voltage and frequency range. SOURCE 1 (NORMAL) SOURCE 2 (EMERGENCY) LOAD ISOLATING CONTACTS AUTOMATIC TRANSFER SWITCH ES1968 BYPASS TRANSFER SWITCH FIGURE 1-1. BTPC TRANSFER SWITCH (TYPICAL FUNCTION)PowerCommandis a registered trademark of Onan Corporation.

Onan and Cummins are registered trademarks of Cummins Inc. 1-2 Bypass Switch Function The bypass switch allows the operator to manually connect the load to the available power source, by- passing the automatic transfer switch (Figure 1-1). When bypassed, the automatic transfer switch can be isolated for service or removal without causing a power interruption. Drawout Isolation Mechanism The drawout isolation mechanism allows the auto- matic transfer switch to be withdrawn for testing or service.

The transfer switch is mounted on rails and is connected to the load, power sources, and controls through isolation contacts. Turning a drawout cranking handle moves the automatic transfer switch either along a rail or on rollers then engages and disengages the isolation contacts without disconnecting power or control cables. UTILITY-TO-GENSET OPERATION In utility-to-genset applications, the transfer switch performs the following functions: 1. Senses the interruption of the Source 1 pow- er. Sends a start signal to the generator set (Source 2). Transfers the load to the Source 2. Senses the return of Source1.

Retransfers the load to Source 1. Sends a stop signal to the generator set. UTILITY-TO-UTILITY OPERATION In utility-to-utility applications, the transfer switch performs the following functions: 1. Senses the interruption of the Source 1 pow- er. Transfers the load to the Source 2. Senses the return of Source 1.

Retransfers the load to Source 1. The controller can control a two-utility configura- tion for prime power. One utility is designated the preferred source. The control automatically trans- fers the load between the two utilities and detects alarm conditions. The exercise routine is not avail- able with this configuration. The operator can select either source as the pre- ferred source (see Figure 2-1).

The Preferred Source menu is included in the Test submenus (see Figure 4-17). The PC service tool can also be used to designate either source as the preferred source. Y Preferred Source Source 1/Source 2 ' FIGURE 2-1. PREFERRED SOURCE SUBMENU CONTROL LEVEL Only a Level 2 control is used with BTPC transfer switches. The control board level can be viewed using the digital display (see Figure 2-2).

This menu is in- cluded in the About submenus (see Figure 4-29 or 4-30, depending upon software version). Y ATS Board Level B 2 FIGURE 2-2. CONTROL LEVEL SUBMENU The following configuration types are available with BTPC transfer switches. Utility-to-Genset. Utility-to-Utility The following transition types are available with BTPC transfer switches.

Open Transition with Sync-check. Programmed Transition. Closed Transition. 1-3 REMOVING AND REPLACING ELECTRONIC CONTROL COMPONENTS WARNING AC power within the cabinet and the rear side of the cabinet door presents a shock hazard that can cause severe personal injury or death. Disconnect connector J10/P10 before working on the electronic control sys- tem.

Disconnecting J10/P10 removes all power to the door. Be sure to remove all power before replacing elec- tronic control modules and components. This in- cludes removing one of the lithium batteries from the Digital Module. Reinstall the lithium battery af- ter performing service parts replacement. No special tools are required to remove and re- place control system components. Be sure to use all of the hardware when remounting components.

If possible, use the InPowert service tool to create a capture file of the calibration and adjust- ment settings in the Digital Module. Use the cap- ture file to write these settings to a replacement Digital Module. MODEL IDENTIFICATION Identify your model by referring to the Model and Specification number as shown on the nameplate. Electrical characteristics and application informa- tion are shown on the lower portion of the name- plate. The nameplate is located on the cabinet door.

If it’s necessary to contact a dealer or distributor re- garding the transfer switch, always give the com- plete Model, Specification, and Serial number as listed on the nameplate. This information is neces- sary to properly identify your unit among the many types manufactured. Refer to page 1-4 for a list of feature/option codes. The model number is made up of code segments that designate various features or options: BTPCE 00000 Spec.

A 1 2 3 4 1. BTPC − Bypass Transition PowerCommand Control. Ampere Rating: E = 1200 F = 1600 G = 2000 H = 3000 J = 4000 3. Assigned spec number − issued for each spe- cific combination of accessories, voltages, frequency and standards codes. Specification letter − advances with produc- tion modification.

HOW TO OBTAIN SERVICE When the transfer switch requires servicing, con- tact your nearest Cummins Power Generation dis- tributor. Factory-trained Parts and Service repre- sentatives are ready to handle all your service needs. To contact your local CPG distributor in the United States or Canada, call 1-800-888-6626 (this auto- mated service utilizes touch-tone phones only). By selecting Option 1 (press 1), you will be automati- cally connected to the distributor nearest you. If you are unable to locate a dealer or distributor, consult the Yellow Pages.

Typically, distributors are listed under: Generators-Electric, Engines-Gasoline or Engines-Diesel, or Recreational Vehicles-Equipment, Parts and Service. For outside North America, call Cummins Power Generation, 1-763-574-5000, 7:30 AM to 4:00 PM, Central Standard Time, Monday through Friday.

Or, send a fax to Cummins Power Generation us- ing the fax number 1-763-574-8087. When contacting your distributor, always supply the complete Model Number and Serial Number as shown on the nameplate. InPower is a trademark of Cummins, Inc. 1-4 FEATURE DESCRIPTION FEATURE OPTION Poles: 3 Poles 4 Poles A028 A029 Application: Utility to Genset Utility to Utility A035 A036 Agency Approvals: UL Listing A046 Frequency: 60 Hertz 50 Hertz A044 A045 Voltage: 190 VAC 208 VAC 220 VAC 240 VAC 380 VAC 416 VAC 440 VAC 480 VAC 600 VAC R038 R021 R022 R023 R024 R025 R035 R026 R027 Controls: Level 2 Switch Control C024 Control Options: Front Panel Security Key Digital Display LONWORKS Network Com.