Service Manual

Transfer Switch
40−1000 Amps

OTECA (Spec A)
OTECB (Spec A)
OTECC (Spec A)
OTECD (Spec A)

English
Original Instructions 8-2021 A045A460 (Issue 7)
Table of Contents
SECTION TITLE PAGE
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Transfer Switch Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Transfer Switch Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
How to Obtain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
2. DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Control Function LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
ATS Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Membrane Pushbuttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Electronic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Transfer Inhibit Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Retransfer Inhibit Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Remote Test Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Remote Override Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Two-Wire Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Auxiliary Relays and Elevator Signal Relay Options . . . . . . . . . . . . . . . . . . . . . . 2-9
Battery Charger Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Original Float Battery Charger Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Current Float Battery Charger Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2-Amp Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
15/12-Amp Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Battery Charger Alarm Contacts Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
External Exercise Clock Option (0307−3053) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Removing and Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Transfer Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Contact Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Linear Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Auxiliary Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
3. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Time Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Time Delay Engine Start (TDES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Time Delay Engine Cooldown (TDEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Time Delay Normal to Emergency (TDNE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Time Delay Emergency to Normal (TDEN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Time Delay Programmed Transition (TDPT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Time Delay Elevator (TDEL) Pre-Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Elevator Post Transfer Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
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 Utility Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Generator Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Phase Check Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Return to Programmed Transition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Automatic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Pushbutton Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Test Pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Override Pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Set Exercise Pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Test With or Without Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Test With Load Sequence of Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Test Without Load Sequence of Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Generator Set Exerciser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Exercise With or Without Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Integrated Exerciser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Power Loss Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Setting the Integrated Exercise Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Canceling Repeat Exercise Periods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Canceling An Active Exercise Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Power Source Failure During An Active Exercise Period . . . . . . . . . . . . . . . . . 3-11
Exercise Without Load Sequence of Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Exercise With Load Sequence of Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
External Exerciser Clock Option [TR 610 top2] (A049B864) . . . . . . . . . . . . . . . . 3-12
Optional External Exerciser
(0307−3053) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Using the Menu Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Using the +/− Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Using the ok Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Setting the Clock with Summer/Winter Time (Daylight Savings Time) . . . . . . . 3-32
Setting Exercise Start and Stop Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Checking the Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Reviewing Exercise Start/Stop Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Deleting Exercise Start/Stop Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Erasing (Clearing) A Programmed Exercise Period . . . . . . . . . . . . . . . . . . . . . . . 3-40
Erasing (Clearing) All Programmed Exercise Periods . . . . . . . . . . . . . . . . . . . . . 3-42
Initiating or Overriding an Exercise Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Initiating an Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Overriding an Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Selecting Permanent On/Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Selecting Permanent On/Off Mode Without an Active Exercise . . . . . . . . . . . 3-44
Selecting Permanent On/Off Mode With an Active Exercise . . . . . . . . . . . . . . 3-44
Adding A Security Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
After Programming the Exerciser Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Resetting the Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
4. CONTROL PANEL CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Accessing the Front Panel Configuration Editor . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Modifying the Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
5. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
About Customer Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

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 Control Panel LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Sequence of Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Normal to Emergency Sequence of Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Emergency to Normal Sequence of Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Troubleshooting With Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Transfer Switch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Troubleshooting Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Utility Power Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Utility Power Is Restored . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Miscellaneous Troubleshooting Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
6. TRANSFER SWITCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Switch Assembly Removal/Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . 6-1
Disconnect AC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Reconnecting AC Power (When Finished) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Linear Actuator Removal and Replacement (40 to 125 Amperes) . . . . . . . . . . . 6-2
Removing Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Replacing Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Block and Cross-Bar Assembly Removal and Replacement (40 to 125 Amperes, Three
Pole Transfer Switches Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Removing the Block and Cross-Bar Assembly (Normal or Emergency) . . . . . 6-4
Replacing the Block and Cross-Bar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Auxiliary Switch Removal and Replacement (40 to 125 Amperes, Three Pole Transfer
Switches Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Removing Auxiliary Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Replacing Auxiliary Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Linear Actuator Removal and Replacement (150 to 260 Amperes Transfer Switches and
40 to 125 Amperes, Four Pole Transfer Switches) . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Removing Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Replacing Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Block and Cross-Bar Assembly Removal and Replacement (150 to 260 Amperes Trans-
fer Switches and 40 to 125 Amperes, Four Pole Transfer Switches) . . . . . . . . . 6-14
Removing the Block and Cross-Bar Assembly (Normal or Emergency) . . . . . 6-14
Replacing Block and Cross-Bar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Auxiliary Switch Removal and Replacement (150 to 260 Amperes Transfer Switches
and 40 to 125 Amperes, Four Pole Transfer Switches) . . . . . . . . . . . . . . . . . . . . 6-18
Removing Auxiliary Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Replacing Auxiliary Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Linear Actuator Removal and Replacement (300 to 600 Amperes) . . . . . . . . . . 6-20
Removing Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Replacing Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Block and Cross-Bar Assembly Removal and Replacement
(300 to 600 Amperes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Removing the Block and Cross-bar Assembly (Normal or Emergency) . . . . . . 6-23
Replacing the Block and Cross-bar Assembly (Normal or Emergency) . . . . . . 6-26
Auxiliary Switch Removal and Replacement (300 to 600 Amperes) . . . . . . . . . 6-27
Removing Auxiliary Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Replacing Auxiliary Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Linear Actuator Removal and Replacement (800 and 1000 Amperes) . . . . . . . 6-29
Removing Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Replacing Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Block and Cross-Bar Assembly Removal and Replacement
(800 and 1000 Amperes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
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 Removing the Block and Cross-bar Assembly (Normal or Emergency) . . . . . . 6-32
Replacing the Block and Cross-bar Assembly (Normal or Emergency) . . . . . . 6-36
Auxiliary Switch Removal and Replacement (800 and 1000 Amperes) . . . . . . . 6-37
Removing Auxiliary Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Replacing Auxiliary Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
7. SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

iv
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.
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
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.
UTILITY-TO-GENSET APPLICATIONS
If the cabinet must be opened for any reason:
1. Move the operation selector switch on the generator set to Stop.
2. Disconnect the battery charger.
3. Disconnect the starting batteries of the generator set or sets (remove the ground [−] lead first).
4. Remove AC power to the automatic transfer switch. If the instructions 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 RE-

SULT IN DEATH, SEVERE PERSONAL INJURY, AND/OR EQUIP-
MENT DAMAGE. SERVICE PERSONNEL MUST BE QUALIFIED
TO PERFORM ELECTRICAL AND/OR MECHANICAL SERVICE.

OTEC-1
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vi
1. Introduction
ABOUT THIS MANUAL supplied with power from the utility (as illustrated).
If utility power is interrupted, the load is transferred
This manual contains service procedures for an to the generator set (genset). When utility power re-
OTEC automatic transfer switch (ATS). This is an turns, the load is retransferred to the utility. The
open transition transfer switch that includes an au- transfer and retransfer of the load are the two most
tomatic transfer switch (ATS) control. With an open basic functions of a transfer switch.
transition switch, there is never a time when both
sources are supplying power to the load. TRANSFER SWITCH FUNCTION
Refer to the schematic and wiring diagram pack- Automatic transfer switches, capable of automatic
age that was shipped with the ATS for specific infor- operation without operator intervention, perform
mation about its configuration. the basic function of transferring the load to the
available power source. The controller monitors
Use normal and necessary safety precautions be-
each source for allowable voltage and frequency
fore starting any service procedure. Identify all haz-
range.
ards by referring to the Safety Precautions and ob-
serve all warnings and cautions within the manual.
Whenever you are troubleshooting, remember that
the generator set, ATS, and utility power source are
This automatic transfer switch, capable of automat-
all interdependent.
ic operation without operator intervention, is de-
TRANSFER SWITCH APPLICATION signed for utility-to-genset applications. In utility-to-
genset applications, the transfer switch performs
Transfer switches are an essential part of a build- the following functions:
ing’s standby or emergency power system. The 1. Senses the interruption of utility power.
utility line (normal power), is backed up by a gener-
ator set (emergency power). The transfer switch 2. Sends a start signal to the genset.
automatically switches the electrical load from one 3. Transfers the load to the genset.
source to the other. 4. Senses the return of utility power.
The load is connected to the common of the ATS 5. Retransfers the load to the utility.
(Figure 1-1). Under normal conditions, the load is 6. Sends a stop signal to the genset.

1-1
 UTILITY
(NORMAL POWER)

OVERCURRENT
PROTECTIVE
DEVICE
(CUSTOMER
SUPPLIED)

LOAD

OVERCURRENT
PROTECTIVE
DEVICE
(CUSTOMER
SUPPLIED)
GENERATOR SET
(EMERGENCY POWER)

FIGURE 1-1. LOAD TRANSFER SWITCH

(TYPICAL FUNCTION)

1-2
 MODEL IDENTIFICATION 4 5

Identify your model by referring to the Model and

Specification number as shown on the nameplate. 1. OTEC - Open transition transfer switch
Electrical characteristics are shown on the lower
portion of the nameplate (see Figure 1-2), which is 2. Ampere Rating:
located on the cabinet door. A = 40, 70, 125
B = 150, 225, 260
If it is necessary to contact a distributor regarding C = 300, 400, 600
the transfer switch, always give the complete Mod- D = 800, 1000
el, Specification, and Serial number. This informa-
tion is necessary to properly identify your unit 3. Assigned spec number - issued for each spe-
among the many types manufactured. cific combination of accessories, voltages, fre-
quency and standards codes. This number is
only repeated for standard product.
1 2 3
4 5 4. Serial Number − A unique number assigned to
the transfer switch.

5. 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 Cummins Inc. distributor in

the U.S. or Canada, call 1-800−CUMMINSTM
(1−800−286−6467). (This automated service uti-
lizes touch-tone phones only.) By selecting Option
1 (press 1), you will be automatically connected to
the distributor nearest you.

If you are unable to contact a distributor using the

automated service, consult the Yellow Pages. Typi-
cally, our distributors are listed under:
Generators-Electric,
Engines-Gasoline or Engines-Diesel, or
Figure 1-2. Nameplate
Recreational Vehicles-Equipment,
Parts and Service.
The model number is made up of code segments
that designate various features or options: For outside U.S. and Canada,visit http://www.cum-
mins.com/support for global solution center infor-
OTECA00000 mation list.
| | |
1 2 3 When contacting your distributor, always supply
the complete Model, Specification, and Serial
Serial Number Spec.A Number as shown on the generator set nameplate.
| |

1-3
 FEATURE FEATURE
FEATURE DESCRIPTION FEATURE DESCRIPTION
OPTION OPTION
Poles: Battery Charges:
3 Poles A028 2 Amp, 12/24VDC K001
4 Poles A029 10 Amp, 12VDC − No Longer Available K002
10 Amp, 24VDC − No Longer Available K003
Agency Approvals:
15 Amp, 12 VDC KB59
UL Listing A046 12 Amp, 24 VDC KB60
Frequency: Auxiliary Relays:
60 Hertz A044
24 VDC Coil L101
50 Hertz A045
Emergency Position L102
Voltage: Normal Position L103
12 VDC Coil L201
120 VAC R020
Emergency Position L202
190 VAC R038
Normal Position L203
208 VAC R021
220 VAC R022 Miscellaneous:
240 VAC R023
380 VAC R024 Terminal Block − 30 Position M003
416 VAC R025 Elevator Signal Relay M032
440 VAC R035 Genset Starting Battery − 12 VDC M033
480 VAC R026 Genset Starting Battery − 24 VDC M034
600 VAC R027 Terminal Block − Battery Charger N002
Alarms
Control Options:
External Exercise Clock J030 Cabinet:
Type 1 B001
Phase: Type 3R B002
Single Phase, 2 or 3 Wire A041 Type 4 B003
Three Phase, 3 or 4 Wire A042 Type 12 B010

1-4
2. Description

CABINET  Type 1 Indoor − General Purpose

 Type 3R Outdoor − Rainproof
Cabinets are available in various configurations  Type 4 Outdoor − Watertight
that meet Underwriters Laboratories (ULR) and  Type 12 Indoor − Dust Tight
National Electrical Manufacturer’s Association
(NEMA) requirements. Each cabinet includes an The door of a typical cabinet is shown in Figure 2-1.
identification label. The standard cabinet offerings Interior components are shown in Figures 2-2 thru
are: 2-5.

TEST CONTROL
LED FUNCTION
LEDs

Test

UTILITY
POWER GENSET
AVAILABLE POWER
Control operation could be delayed by external source.
LED AVAILABLE
Exercise LED

TEST Test Override Set Exercise GENSET

pushbutton CONNECTED
LED

SET EXERCISE EXERCISE

UTILITY OVERRIDE pushbutton LED
CONNECTED LED pushbutton

FIGURE 2-1. CABINET Door

2-1
 OPTIONAL OPTIONAL
EXTERNAL RELAYS AUTOMATIC
CONTROL TERMINAL
EXERCISE TRANSFER
PANEL BLOCK
CLOCK SWITCH
TB1

TRANSFER
SWITCH HAN-
DLES

J1

J2
POWER
TRANSFORMER
(600 VOLT
UNITS ONLY)
GROUND
ACCESSORY LUGS
OPTIONAL TB2
RELAY PLATE BATTERY
CHARGER

FIGURE 2-2. INTERIOR COMPONENTS: 40−125 Amp Switch, Type 1 Cabinet

2-2
 OPTIONAL
RELAYS AUTOMATIC
OPTIONAL TERMINAL TRANSFER
EXTERNAL BLOCK TB1 SWITCH
OPTIONAL BATTERY CONTROL EXERCISE
CHARGER PANEL CLOCK

J1

J2

ACCESSORY
RELAY PLATE
GROUND
TB2 TRANSFER POWER
LUGS
SWITCH TRANSFORMER
HANDLES (600 VOLT
UNITS ONLY)

FIGURE 2-3. INTERIOR COMPONENTS: 150−225 Amp Switch, type 4 Cabinet

2-3
 OPTIONAL
OPTIONAL RELAYS AUTOMATIC
EXTERNAL TERMINAL TRANSFER
BLOCK TB1 SWITCH
CONTROL EXERCISE
PANEL CLOCK
J1

ACCESSORY OPTIONAL BATTERY J2

RELAY CHARGER
PLATE
GROUND TRANSFER
LUGS TB2 POWER
SWITCH TRANSFORMER
HANDLES (600 VOLT UNITS
ONLY)

FIGURE 2-4. INTERIOR COMPONENTS: 260 Amp Switch, Type 3R and 12 Cabinet

2-4
 OPTIONAL
RELAYS AUTOMATIC
OPTIONAL
TERMINAL TRANSFER NEUTRAL
EXTERNAL TB1
CONTROL BLOCK SWITCH BUS BAR
EXERCISE
PANEL CLOCK

LINEAR
ACTUATOR

ACCESSORY
RELAY
PLATE

J1

J2

TB2
OPTIONAL BATTERY
CHARGER TRANSFER
GROUND POWER
SWITCH HAN-
LUGS TRANSFORMER
DLES
(600 VOLT UNITS
ONLY)

FIGURE 2-5. INTERIOR COMPONENTS: 300−600 Amp Switch, Type 3R and 12 Cabinet
(800−1000 Amp Similar)

2-5
 CONTROL PANEL Genset Connected − This amber LED is lit when
the genset is supplying power to the load.
Figure 2-1 shows the control panel on the cabinet
door. The control features are divided into three This LED flashes once per second if there is a fail-
groups: ure to connect to or disconnect from genset power,
when commanded. The control makes five at-
 Control Function LEDs tempts (there is 10 seconds between each attempt)
 ATS Status LEDs to connect to or disconnect from genset power be-
 Membrane Pushbuttons fore it flashes the failure.

Control Function LEDs Test − This amber LED is lit when there is an active
test period. This LED flashes twice per second
The control panel (see Figure 2-1) includes eight when the Test pushbutton is pressed to set or can-
LEDs that display codes that indicate various con- cel a test period.
trol functions that can be configured. The first five
LEDs display the function code and the last three Exercise − This amber LED lights when repeat ex-
LEDs display the value code for the displayed func- ercise periods have been set. This LED flashes
tion. For information on configuring these func- twice per second when the Set Exercise pushbut-
tions, see Section 4. ton is pressed to set or cancel an exercise. This
LED flashes once per second during an active ex-
With the exception of the first LED (Test), normally ercise period.
these LEDs are off and are only lit when in Configu-
Membrane Pushbuttons
ration Mode. The Test LED is also used to notify the
user of test periods. The control panel includes three membrane push-
buttons.
ATS Status LEDs
Test − The Test pushbutton is used to set or cancel
The control panel includes six LEDs that provide a test period. The control can be configured to test
Automatic Transfer Switch (ATS) status informa- the genset with or without load. For more informa-
tion. tion, see Section 3.

Utility Power Available − This green LED is lit The Test pushbutton is also used in the Configura-
when the utility power source has acceptable out- tion Mode to step through the function codes (see
put voltage. Section 4).

Override − The Override pushbutton is used to ter-

Genset Power Available − This amber LED is lit
minate or bypass some time delays, to stop the Util-
when the genset power source has acceptable out-
ity Connected and Genset Connected LEDs from
put voltage and frequency.
flashing as a result of a failure to connect to or dis-
connect from a power source, and to cancel an ac-
Both power source LEDs can be lit simultaneously.
tive exercise period. For more information, see
Section 3.
Utility Connected − This green LED is lit when util-
ity power is supplying power to the load. The Override pushbutton is also used in the Config-
uration Mode to step through the value codes (see
This LED flashes once per second if there is a fail- Section 4).
ure to connect to or disconnect from utility power,
when commanded. The control makes five at- Set Exercise − The Set Exercise pushbutton is
tempts (there is 10 seconds between each attempt) used to set or cancel repeat exercise periods using
to connect to or disconnect from utility power be- the integrated exerciser. For more information, see
fore it flashes the failure. “Integrated Exercises” on page 3−8.

2-6
 ELECTRONIC CONTROL SYSTEM A transfer inhibit input is set up by connecting a dry
(voltage free) contact between TB2-6 and TB2-8.
This section describes the standard and optional Closing the contact enables the feature and open-
components of the electronic control system. ing the contact disables it.
WARNING Improper calibration or adjustment Pressing the Override pushbutton on the control
of electronic control modules can cause death, panel bypasses the transfer inhibit input and by-
severe personal injury, and equipment or prop- passes TDNE. The TDNE runs if the transfer inhibit
erty damage. Calibration and adjustment of input is disabled.
these components must be performed by tech-
nically qualified personnel only. A jumper can be temporarily connected between
TB2-6 and TB2-8 to test this feature.
Installation of these components and calibration
and adjustment procedures are described in the Retransfer Inhibit Input
Installation Manual (which is shipped with the
transfer switch) and in the Service Manual (which is This feature is used to prevent the ATS from auto-
available through your distributor). matically transferring the load back to the utility.
When enabled, load transfer will not take place un-
WARNING Accidental actuation of the linear
less the Override pushbutton on the control panel is
motor could cause severe personal injury. pressed, the retransfer inhibit input is disabled, or
WARNING AC power within the cabinet and the genset fails. If the genset fails, retransfer inhibit
the rear side of the cabinet door presents a is ignored.
shock hazard that can cause severe personal
A retransfer inhibit input is set up by connecting a
injury or death. When the cabinet door is open,
dry (voltage free) contact between TB2-7 and
use extreme caution to avoid touching electri-
TB2-8. Closing the contact enables the feature and
cal contacts with body, tools, jewelry, clothes,
opening the contact disables it.
hair, etc.

Transfer Inhibit Input Pressing the Override pushbutton on the control

panel bypasses the retransfer inhibit input and by-
This feature is used to control load transfer to gen- passes the TDEN. The TDNE runs if the retransfer
sets. When enabled, load transfer will not take inhibit input is disabled.
place unless the Override pushbutton on the con-
trol panel is pressed or the transfer inhibit input is A jumper can be temporarily connected between
disabled. TB2-7 and TB2-8 to test this feature.

1 GND 1 GND
2 2 2 2

3 B+ 3 B+
4 RMT 4 RMT
5 Remote Test 5 Remote Test
6 Transfer Inhibit
ÁÁ 6 Transfer Inhibit
7

8
RETRANSFER INHIBIT
Common
ÁÁ 7

8
RETRANSFER INHIBIT
Common

TB2 TB2
FIGURE 2-6. TB2 CONNECTIONS FOR FIGURE 2-7. TB2 CONNECTIONS FOR
TRANSFER INHIBIT RETRANSFER INHIBIT

2-7
Remote Test Input Closing the contact causes the transfer switch to
sense a (simulated) utility power failure and sends
The transfer switch may be wired for a remote test a start/run signal to the genset. If the control is set
input. The input is used to start and stop remotely up to test with load, the load is transferred to the
initiated system tests. As with the control panel Test genset when the genset becomes available. The
pushbutton, the remote test input can be config- Utility Power Available LED remains on to show
ured to test with or without load. More information that the utility did not fail.
on testing is included in Section 3.
A jumper can be temporarily connected between
A remote test input is set up by connecting a dry TB2-5 and TB2-8 to test this feature.
(voltage free) contact between TB2-5 and TB2-8.
Closing the contact starts a test and opening the Remote Override Input
contact cancels the test. The Test LED flashes to
signify the start of a test and stays on during the The transfer switch may be wired with a remote
test. Override Switch that functions the same as the
control panel Override pushbutton.

A remote override input is set up by connecting a

dry (voltage free) contact between P4-2 on the
1 GND back of the control panel and TB2-8 (see Figure
2 2 2-9). Closing the contact enables the feature and
opening the contact disables it.
3 B+
Two-Wire Starting
4 RMT

5 Remote Test The starting circuit is a basic supervisory function

of the electronic control. Water-cooled generator
6 Transfer Inhibit
sets use a two-wire start control.
7 RETRANSFER INHIBIT
Although the logic is more involved, the two-wire
8 Common starting circuit can be thought of as a single pole,
single throw switch. A closed switch starts the gen-
erator set. An open switch stops the generator.
TB2
FIGURE 2-8. TB2 CONNECTIONS FOR NOTE: Three-wire starting is not available on
REMOTE TEST TRANSFER OTEC transfer switches.

1 GND

22
3B+

4RMT

5RETRANSFER INHIBIT
6Remote Test

7 Transfer Inhibit
8Common

TB2

FIGURE 2-9. Connections for Remote Override Input

2-8
 CONTROL OPTIONS
MOUNTING PANEL
(LOCATED ON THE
Auxiliary Relays and Elevator Signal UPPER LEFT SIDE,
INSIDE THE TRANS-
Relay Options FER SWITCH CAB-
INET)
Optional 12 and 24 VDC auxiliary relays provide
contacts for energizing external alarms, remote in-
dicators, and control equipment such as louver mo-
tors and water pumps. The auxiliary relay options
are: Auxiliary
TB3 Relays
 Installed, not wired
 Emergency position relay
 Normal position relay

Optional elevator signal relay contacts are used to

provide a warning that a transfer or retransfer is
about to occur. If a TDEL has been set, the relay is
energized during the time delay.

Connections to the auxiliary and elevator relays are

made directly to the relay terminals. Figure 2-10
shows the location of the Auxiliary Relays on the
options panel. The terminals accept wire sizes from
one number 18 AWG wire to two number 12 AWG
wires. For connection to the screw terminal, strip
the insulation back 3/8 inch (10 mm).

Table 2-1 lists the available auxiliary relay and ele-

vator signal relay options, along with their feature
codes.

FIGURE 2-10. CONTROL WIRING CONNECTIONS

All relays have two normally open and two normally
closed contacts that are rated for 6 amperes at 600
VAC (see Figure 2-11).

TABLE 2-1. AUXILIARY AND ELEVATOR SIGNAL

RELAYS
13 21 31 43 A1
CODE COIL TYPE DESCRIPTION
L101 24 VDC COIL INSTALLED, NOT WIRED
L102 24 VDC COIL EMERGENCY POSITION RELAY 14 22 32 44 A2
L103 24 VDC COIL NORMAL POSITION RELAY
L201 12 VDC COIL INSTALLED, NOT WIRED
L202 12 VDC COIL EMERGENCY POSITION RELAY
L203 12 VDC COIL NORMAL POSITION RELAY
M032 12 OR 24 ELEVATOR SIGNAL RELAY
VDC COIL FIGURE 2-11. RELAY TERMINALS

2-9
Battery Charger Options the installer to activate other audible or visual
alarms.
Originally, either a 2-amp or a 10-amp battery char-
ger was available for use with an OTPC transfer Under normal operating conditions, the Low Bat
switch. Those battery chargers have now been re- and AC Fail relays are energized and the High Bat
placed with new 2-amp and 15/12-amp battery relay is de-energized. In response to a Low Bat or
chargers. Battery chargers are used with utility-to- AC Fail condition, the appropriate normally ener-
genset and genset-to-genset applications. gized relay (Low Bat or AC Fail) drops out. In re-
sponse to a High Bat condition, the normally de-en-
When so equipped, a battery charger can be used ergized High Bat relay is energized.
for charging genset starting and control batteries.
These chargers are current limiting and supply au-
tomatic constant voltages.

When the battery approaches the full charge preset

voltage, the charging current automatically tapers
to zero amperes or to a steady-state load on the
battery.

Original Float Battery Charger Options

A float-charge battery charger regulates its charge

voltage to continuously charge without damaging
the battery. As the battery approaches full charge,
the charging current automatically tapers to zero
amperes or to steady-state load on the battery.

Two battery chargers are available (see Figure 2-AMP CHARGER 10-AMP CHARGER
2-12). One battery charger is rated for 10 amperes
at 12 or 24 VDC. The other battery charger is rated Figure 2-12. Original BATTERY CHARGERs
for 2 amperes at 12 or 24 VDC.
The battery charger may be a 10- or 2-amp supply
The 2-ampere battery charger has an ammeter to with an output of 12 or 24 volts. Ten amp chargers
indicate charging current and a fuse to protect the contain alarm LEDs that indicate AC Power Fail-
battery charger circuit. ure, and Low or High Battery Voltage faults. Option-
al wiring harness brings signals out to the terminal
The 10-ampere battery charger has three fuses block for easy customer connections.
(two on the AC input and one on the DC output),
three fault display LEDs, and an ammeter for indi- Float Voltage Adjustments for:
cation of charging current.
12 volt 24 volt
On the 10-ampere charger, three sets of (Form-C)
alarm contacts (corresponding to the three fault Lead Acid Batteries 13.2 volts26.4 volts
LEDs) are also available. Using an optional alarm
contact harness, these contacts can be wired by NiCad Batteries 14 volts28 volts

2-10
Current Float Battery Charger Options Control Panel
The 2-amp charger control panel includes a digital
A float-charge battery charger regulates its charge display, a RESET button, and an LED status indica-
voltage to continuously charge without damage to tor (see Figure 2-15).
the battery. As the battery approaches full charge,
the charging current automatically tapers to zero  The 2-line x 16-character digital display dis-
amperes or to steady-state load on the battery. plays menus and faults.
 The RESET button is used to select menu op-
Two battery chargers are available (see Figure tions and to clear fault messages.
2-13). One battery charger is rated for 2 amperes at  The status LED displays the appropriate color
12 or 24 VDC. The other battery charger is rated for for the following conditions.
15 amperes at 12 VDC or 12 amperes at 24 VDC. − Green − On solid indicates unit is charg-
ing
− Red − On solid indicates a fault condition.
The fault number is shown on the digital
display.

2-AMP CHARGER 15-AMP (12 VOLT),

12-AMP (24 VOLT)
CHARGER

Figure 2-13. Current BATTERY CHARGERs

FIGURE 2-14. 2-Amp PowerCommand Battery
Charger
2-Amp Battery Charger

The 2-ampere battery charger (see Figure 2-14)

has a 5 amp DC output circuit breaker switch on the
front of the battery charger. The charger also in-
cludes a 5 amp AC fuse to protect the battery char-
ger circuit.

Under normal operating conditions, the Low Bat

RESET DIGITAL LED STATUS
and AC Fail relays are energized and the High Bat BUTTON INDICATOR
DISPLAY
relay is de-energized. In response to a Low Bat or
AC Fail condition, the appropriate normally ener- FIGURE 2-15. 2-AMP CHARGER CONTROL PANEL
gized relay (Low Bat or AC Fail) drops out. In re-
Battery Charger Configuration
sponse to a High Bat condition, the normally de-en-
ergized High Bat relay is energized. The RESET button on the control panel (see Figure
2-15) is used to configure the battery charger for
ATTENTION: To avoid a possible battery failure, the correct battery voltage. (More information on
make sure the application does not draw more than Setup menus is included in the Battery Charger
two amps. Operator’s Manual.)

2-11
15/12-Amp Battery Charger − Green − On solid indicates unit is charg-
ing
There are two types of 15/12-amp PowerCom- − Amber − On solid indicates Equalizing
mand battery chargers (see Figure 2-17). All
− Red − On solid indicates a fault condition.
15/12-amp battery chargers have a 20 amp DC cir-
The fault number is shown on the digital
cuit breaker switch on the front of the battery char-
display.
ger. The 120, 208, and 240 VAC battery chargers
include two 10 amp AC circuit breaker switches
and a circuit breaker guard, while the 277, 380,
416, and 600 VAC battery chargers include two AC
fuse holders.

Control Panel

The 15/12-amp charger control panel includes a

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

STATUS
CONTROL LED
PANEL

120, 208, and 240 VAC

battery chargers

277, 380, 416, 480, and 600 VAC

battery chargers

CIRCUIT
BREAKER
GUARD

FAULT ALARM
OUTPUT
CONNECTOR 20 AMP DC OUTPUT
CIRCUIT BREAKER
SWITCH (SHOWN IN “ON”
POSITION)
FUSE
HOLDERS

OPTIONAL BATTERY
TEMPERATURE
SENSOR
CONNECTOR

FIGURE 2-17. 15/12-AMP POWERCOMMAND BATTERY CHARGERS

2-12
Optional Battery Temperature Sensor relay is de-energized. In response to a Low Bat or
AC Fail condition, the appropriate normally ener-
A connector for an optional battery temperature gized relay (Low Bat or AC Fail) drops out. In re-
sensor is located on the front of the battery charger. sponse to a High Bat condition, the normally de-en-
When used to monitor battery temperature, the op- ergized High Bat relay is energized.
tional battery temperature sensor is connected
from the battery charger to the positive terminal of The contacts are rated for 4 amperes at 120 VAC or
the battery. A fault message (fault code 2263) is 30 VDC. Connections to these contacts are made
displayed if the battery temperature is too high at terminals 41-42-43 (AC failure), 44-45-46 (high
(reaches 131 degrees F (55 degrees C)). battery voltage), and 47-48-49 (low battery volt-
age) of TB3 (Figure 2-18). See Figure 2-10 for the
Battery Charger Configuration location of TB3 on the option panel.
The RESET button on the control panel (see Figure
2-16) is used to configure the battery charger. Use number 22 to number 12 AWG wire. For con-
(More information on Setup menus is included in nection to the screw terminal, strip the insulation
the Battery Charger Operator’s Manual.) back 3/8 inch (10 mm).

 Battery Voltage and Type − The battery char- The Level 1 and Level 2 Digital Modules have an
ger must be correctly configured, using the input dedicated to monitor the AC Line failure on
Setup menus, for the correct battery voltage the battery charger. This input is located at J27-23
and type before it is connected to the battery. and activated when grounded. (As of this printing,
The battery voltage can be set for 12 or 24 this input is only available at J27-23.)
VDC (default = 12 VDC). The battery type can
be set for Lead-Acid, Gel, or AGM batteries
(default = Lead-Acid). TB3

NOTE: A factory installed battery charger is

AC C
set up for the proper DC battery volt-
age requested on the production or- LINE NC
der, with the Lead-Acid battery type FAILURE NO
selected as the default. HIGH C
 Battery Equalization − Battery equalization is BATTERY NC
available for lead-acid batteries that are com- VOLTAGE NO
pletely charged, using the Equalize Battery LOW C
screen in the Setup menus. When battery BATTERY NC
equalization is in process, the LED status indi- VOLTAGE NO
cator turns amber.
NETWORK DATA
Battery Charger Alarm Contacts Option (OPTIONAL) − USE DATA1
TWISTED PAIR
WIRING DATA2
The optional 10-ampere battery charger can in-
clude three sets of Form-C relay contacts, as an
additional option.

Under normal operating conditions, the Low Bat FIGURE 2-19. BATTERY CHARGER ALARM
and AC Fail relays are energized and the High Bat CONTACTS AND NETWORK CONNECTIONS

2-13
External Exercise Clock Option dard) time. The exercise clock can be used with 12
(0307−3053) or 24 VDC operation.

Up to 28 programs are available to set exercise

12 15 18 21 24 start and stop times. One program is required to
start an exercise period and a second one is re-
Auto
9
quired to stop an exercise period.
6
03 01 04
Off
The exercise clock has a built-in test feature that
11:30
3 AM
0
can be used to initiate an exercise that hasn’t been
1 2 3 4 5 6 7
programmed or cancel a programmed exercise in
process.

Information on setting the clock is included in Sec-

tion 3.
Figure 2-20. External Exercise Clock
NOTE: The clock includes a non-replaceable lithi-
The optional external exercise clock includes a um battery with a life expectancy of at least
real-time clock that keeps track of the time and ten years. If the clock battery is weak during
date. The clock can be set for automatic change- a power failure, the clock will need to be re-
over for summer/winter (Daylight Savings/Stan- placed.

2-14
 REMOVING AND REPLACING Linear Actuator
COMPONENTS
The linear actuator is a linear induction motor that
WARNING AC power within the cabinet and moves the contact assemblies between the con-
the rear side of the cabinet door presents a tacts of both power sources. Linear actuator opera-
shock hazard that can cause severe personal tion is initiated automatically by the transfer switch
injury or death. Disconnect connectors J1 and control. Manual operation of the switch is also pos-
J2 before working on the electronic control sible. Refer to Manual Operation in Section 3.
system.
Auxiliary Contacts
Disconnecting the J1 connector removes all
Auxiliary contacts are provided on the utility and
power to the door.
genset sides of the transfer switch (see Figure
2-21). They are actuated by operation of the trans-
Disconnecting the J2 connector removes bat- fer switch during transfer and retransfer. The utility
tery voltage from the control panel. auxiliary contact switch is actuated when the trans-
fer switch connected to the utility. The genset auxil-
Be sure to remove all power before replacing elec- iary contact switch is actuated when the transfer
tronic components. This includes removing the switch is connected to the genset. The auxiliary
Lithium battery from the control. No special tools contacts have current ratings of 10 amperes at 250
are required to remove and replace control system VAC. The contacts are wired to terminal block TB1.
components. Be sure to use all of the hardware
when remounting components.

TRANSFER SWITCH ASSEMBLY UTILITY

AUXILIARY
CONTACTS
The transfer switch (see Figures 2-2 thru 2-5)
opens and closes the contacts that transfer the
load between the power sources. The switch is me-
chanically interlocked to prevent simultaneous
closing to both power sources. The main parts of
the switch discussed here are the contact assem-
blies, linear actuator, and auxiliary contacts.

Contact Assemblies

The automatic transfer switch has either three or

four poles. Three pole transfer switches are pro- GENSET
AUXILIARY
vided with a neutral bar. The contact assemblies CONTACTS
make and break the current flow. When closed to
either power source the contacts are mechanically
held. A mechanical interlock prevents them from
closing to both power sources at the same time. FIGURE 2-21. AUXILIARY CONTACTS

2-15
THIS PAGE LEFT INTENTIONALLY BLANK

2-16
3. Operation
This section describes the operation of the transfer Time Delay Engine Cooldown (TDEC)
switch and includes information on time delays,
sensors, automatic/manual operation, pushbutton This time delay allows the generator to cool down
operation, testing with/without load, and setting (under no load conditions) before the control turns
genset exercises. it off.

The Time Delay Engine Cooldown (TDEC) starts

Many of the features described in this section can
timing when the load is retransferred to utility pow-
be adjusted using the control panel.
er. This time delay is configurable for 0 (disabled),
0.1, 5, 10, 15, 20, 25 or 30 minutes (default = 10
TIME DELAYS minutes).

The transfer switch control uses various time de- When the TDES expires, the stop signal is sent to
lays to break from one power source and reconnect the generator and the timer is reset. Pressing the
to the other source. The control panel can be used Override pushbutton or grounding the Override in-
to adjust these time delays (see Section 4). put has no effect on this time delay.

Time Delay Normal to Emergency (TDNE)

In the following descriptions of time delays, it is im-
portant to remember that: This time delay allows the generator to stabilize be-
 When the transfer switch is connected to Nor- fore the load is applied.
mal, it is connected to the utility power source.
While connected to Normal, this time delay starts
 When the transfer switch is connected to
after utility power fails and the generator becomes
Emergency, it is connected to the Genset pow-
available (the amber Genset Power Available LED
er source.
is lit). This time delay also starts after the generator
 When the transfer switch is in the Neutral posi- becomes available when a with load Test or Exer-
tion, it is not connected to either power source. cise period is activated.

The time delay is configurable for 0 (disabled), 1, 2,

Time Delay Engine Start (TDES) 3, 5, 30, 120, or 300 seconds (default = 5 seconds).
If the generator fails any time during a TDNE, the
This time delay prevents the generator from start- control resets the timer and restarts it once the gen-
ing during brief utility power interruptions. This tim- erator is again available.
er starts the instant the utility fails, as detected by
the Undervoltage Sensor. If the Override pushbutton is pressed or the Over-
ride input is grounded while the TDNE timer is ac-
When the control senses a utility failure, the control tive, the TDNE timer immediately expires. The
starts the Time Delay Engine Start (TDES) timer. TDNE timer will not begin if a Transfer Inhibit input
This time delay is configurable for 0 (disabled), 0.5, is active.
1, 2, 3, 4, 6, or 10 seconds (default = 3 seconds).
Time Delay Emergency to Normal (TDEN)
If utility power returns while the TDES timer is ac- While connected to Emergency, this time delay al-
tive, the timer is reset. When the timer expires, the lows utility power to stabilize before the retransfer
control de-energizes the start relay, closing the command is issued. This delay also allows the gen-
start contact signalling the generator to start. The erator to operate under load for a minimum amount
timer is not reset until utility power returns. If the of time before transferring back to utility power.
Override pushbutton is pressed or the Override in-
put is grounded while the TDES timer is active, the This time delay starts with the transfer switch con-
TDES timer immediately expires. nected to the generator and after the utility be-

3-1
comes available following an outage (The green nal. This signal allows the elevator to come to a
Utility Power Available LED is lit). This time delay complete stop before the switch transfers.
also starts when an active Test or Exercise period is
ended. After the delay, the transfer switch can re- The elevator pre-transfer signal and associated
transfer the load to the utility power source. time delay, is used to signal an elevator control sys-
tem that there is an impending transfer or retransfer
The time delay is configurable for 0 (disabled), 0.1, (i.e., the elevator is going to see a brief power fail-
5, 10, 15, 20, 25 or 30 minutes (default = 10 min- ure).
utes). If the utility fails any time during this time
delay, the control resets the timer and restarts it This delay is disabled during an actual source fail-
once utility power becomes available. If the gener- ure. If the timer is set for more than 0 seconds, then
ator fails at any time during this time delay, the timer the control activates the elevator pre-transfer out-
expires and the normal retransfer sequence takes put and time delay prior to transferring the transfer
place. switch between two live sources. If the control is in
a Test or Exercise sequence, the control adds an
If the Override pushbutton is pressed or the Over- additional delay prior to activating the transfer and
ride input is grounded while the TDEN timer is ac- retransfer commands. After the TDNE (and/or
tive, the TDEN timer immediately expires. The TDEN) time delay expires, the control activates the
TDEN timer will not begin if a Retransfer Inhibit in- Elevator output and starts the TDEL timer.
put is active. The output relay has two normally open and two
normally closed contacts, rated 10 amps at 600
Time Delay Programmed Transition volts.
(TDPT)
When the timer expires, the control issues the
This feature causes the transfer switch to pause in transfer (or retransfer) command. When the timer
the Neutral position for an adjustable period of time is inactive or expires, the control deactivates the
whenever there is a transfer from one source to relay output.
another. The intentional delay allows the residual
voltage of an inductive load to sufficiently decay be- The Elevator Pre-transfer Time Delay is configur-
fore connecting it to another power source. This able for 0 (disabled), 1, 2, 3, 5, 30, 120, or 300 sec-
delay prevents potentially damaging voltage and onds (default = 0 seconds).
current transients in the customer’s power system.
If TDPT is set to zero, then the transfer switch Transfer Inhibit and Retransfer Inhibit do NOT af-
transfers from one source to the other with no neu- fect or delay the elevator pre-transfer delay while it
tral position delay. is active.
The Override pushbutton or Override input has no
The control activates a Program Transition Time
effect on this time delay.
Delay (TDPT) whenever the transfer switch has
disconnected from one source and is in the Neutral The OTEC control also includes a feature called
position. The time delay is configurable for 0 (dis- Elevator Post Transfer Delay that keeps the eleva-
abled), 0.5, 1, 2, 3, 4, 6 or 10 seconds (default = 0 tor output active for the same TDEL time period af-
seconds). The control also detects if the transfer ter the transfer switch transfers. For more informa-
switch has disconnected from the first source be- tion, see “Elevator Post Transfer Delay” below.
fore connecting it to the second source.
Elevator Post Transfer Delay
If there is a power source failure while the TDPT is
active, the control only transfers to the remaining The Elevator Post Transfer Delay feature keeps the
active power source. The control does not termi- elevator output active for the same TDEL time peri-
nate the TDPT timer if either source fails while the od after the transfer switch transfers. Instead of de-
transfer switch is in the Neutral position. activating the elevator output when the pre-transfer
time delay expires, the control keeps the output ac-
Time Delay Elevator (TDEL) Pre-Transfer tive and starts the TDEL timer again after it senses
that the transfer switch has transferred. When the
Primarily used in elevator applications, this delay TDEL timer expires the second time, the control de-
sets a time to wait for an elevator pre-transfer sig- activates the elevator output. The Elevator Post

3-2
Transfer Delay is configurable to be enabled (On)
or disabled (Off) (default = Off).

3-3
 SENSORS TABLE 3-2. GENSET UNDERVOLTAGE AND
UNDERFREQUENCY SET POINTS
Utility Sensor
Description Set Point
The utility sensor monitors all phases of the utility Undervoltage Pickup
90%
for undervoltage conditions. Both the pickup and (% of Nominal)
dropout set points are adjustable. The set points Undervoltage Dropout
are listed in Table 3-1. Refer to Section 4 for infor- 75%
(% of Nominal)
mation on how to make adjustments.
Underfrequency Pickup
90%
(% of Nominal)
TABLE 3-1. UTILITY UNDERVOLTAGE SET
POINTS Underfrequency Dropout
85%
(% of Nominal)
Description Available Set Points
Undervoltage Pickup 95% Phase Check Sensor
(% of Nominal) 90% The phase check sensor can be enabled (set to
90% On) for applications that require a fast transfer of a
85% load between two live sources (both power source
Undervoltage Dropout available LEDs are lit). The phase check sensor
(% of Nominal) 80% determines when the relative phase difference
70% (less than 25 degrees and approaching 0) and the
frequency difference (less than 1 Hz) of the two
NOTE: If the utility undervoltage pickup is set at sources are within specified limits. When all condi-
90%, then the dropout has to be set lower tions are met, a transfer is initiated. If enabled, the
than 90%. phase check sensor is activated after all time de-
lays have expired, just before the transfer switch
transfers the load, and only when both sources are
Figure 3-1 illustrates how the pickup and dropout
available. Information on configuring the Phase
settings work.
Check On/Off function is included in Section 4.

Example using Default Settings Return to Programmed Transition

for Nominal Voltage of 240 VAC
This feature can be used in conjunction with the
Drop-out Pick-up Nominal
Setting Setting Setpoint phase check sensor. If, for some reason the two
(194V) (216V) (240V) sources do not fall within the specified limits of the
phase check sensor for a period of two minutes,
then the control bypasses the phase check sensor,
VOLTS returns to the Programmed Transition sequence of
operation, and transfers the load. If this feature is
85% of 90% of enabled, the programmed transition time delay
Nominal Nominal (TDPT) should be set greater than zero. The actual
setting depends on your load.

FIGURE 3-1. UNDERVOLTAGE SENSING AUTOMATIC OPERATION

Generator Sensor Automatic operation of the OTEC transfer switch

occurs unless:
The generator sensor is a single phase sensor that
 Power to the control is removed by disconnect-
monitors undervoltage and underfrequency condi-
ing the J1 connector
tions. All the pickup and dropout settings are fixed
and are not adjustable. The genset undervoltage  The slide switch located on the back of the
and underfrequency set points are listed in Table control panel is in the Configuration Mode
3-2. position

3-4
 MANUAL OPERATION b. Push the lower manual operator handle
down.
The transfer switch has operator handles for manu-
ally transferring the load (see Figure 3-2). Manual Retransfer - from the genset (Emergency)
operation must be performed by qualified person- to the utility (Normal):
nel under NO-LOAD CONDITIONS ONLY. Use the
a. Pull the lower manual operator handle up.
following procedure to manually transfer the load.
b. Push the upper manual operator handle
WARNING Manual operation of the transfer up.
switch under load presents a shock hazard that
can cause severe personal injury or death. Do NOTE: Remember that the transfer switch
not attempt to operate the switch manually transfers the load to the active power
when it is under load. Follow the “Safety Re- source. (If both power sources are
lated Work Practices” listed in NFPA 70E. available, it transfers the load to the
utility.)
6. Verify that the transfer switch is not under load.
WARNING Automatic transfer switch op-
7. Open the cabinet door of the automatic trans- eration results in rapid movement of the
fer switch. manual operator handles and presents a
hazard of severe personal injury. Keep
8. Remove power to the control by disconnecting hands clear of handles when switching
the J1 connector (see Figures 2-2 thru 2-5). back to automatic operation.

9. Transfer - from the utility (Normal) to the 10. To return to automatic operation, restore pow-
genset (Emergency): er to the control by reconnecting the J1 con-
nector.
a. Pull the upper manual operator handle
down. 11. Close the cabinet door.

UPPER
HANDLE

Transfer
Switch Han-
dles

LOWER
HANDLE

FIGURE 3-2. MANUAL OPERATION HANDLES

3-5
 PUSHBUTTON OPERATION  Stop the Utility Connected LED from flashing
as a result of a failure to connect to or discon-
The following describes operation of the three nect from the utility when commanded.
pushbuttons located on the control panel.  Stop the Genset Connected LED from flash-
ing as a result of a failure to connect to or dis-
Test Pushbutton connect from the genset when commanded.
The Test pushbutton is used to:  Cancel an active exercise period.
 Start a genset test. The Test LED flashes if the  Scroll through the control function values dur-
Test pushbutton is pressed and held for two ing configuration of the control panel.
seconds.
The Program Transition (TDPT), Elevator signal
 Terminate a genset test. The Test LED goes (TDEL), and Engine Cool Down (TDEC) time de-
out if the Test pushbutton is momentarily lays are not affected by pressing this pushbutton.
pressed.
 Scroll through the control functions during Set Exercise Pushbutton
configuration of the control panel.
This pushbutton is only used with the integrated ex-
More information on testing is included on the fol- erciser and only functions if the External Exercise
lowing pages. function is disabled (set to Off). Information on con-
figuring the control panel is included in Section 4.
Override Pushbutton The Set Exercise pushbutton is used to:
The Override pushbutton is used to:  Set a delayed repeat exercise period when the
pushbutton is pressed and held for five sec-
 Terminate the following system time delays:
onds.
− Time Delay Engine Start (TDES)  Start an immediate exercise period (that also
− Time Delay Normal to Emergency (TDNE) repeats) if the pushbutton is pressed momen-
tarily within ten seconds of starting the delayed
− Time Delay Emergency to Normal (TDEN) exercise period.
 Bypass the TDNE timer and transfer the load
immediately during an active Transfer Inhibit  Cancel the repeatable exercise periods if the
input. pushbutton is pressed and held for five sec-
onds.
 Bypass the TDEN timer and retransfer the load
immediately during an active Retransfer Inhib- More information on using the integrated exerciser
it input. is included on page 3−8.

3-6
 TEST WITH OR WITHOUT LOAD 2. Verify that the green Utility Connected LED on
the control panel is lit.
This feature allows a transfer switch operator to
test the transfer switch and generator power sys- 3. Verify that the green Utility Power Available
tem. The test is configurable to be with load or with- LED on the control panel is lit.
out load. A test with load initiates a load transfer. A
test without load just starts the generator and runs it 4. Press and hold the control panel Test pushbut-
without load. ton for two seconds or ground the Remote Test
input to initiate the Test. The Test LED flashes
1. Verify that the transfer switch is set to test with two times per second for two seconds, ac-
or without load, as desired (see Section 4). knowledging that the test was activated. Once
the test period starts, the Test LED stays on
2. Verify that the transfer switch is connected to continuously.
the utility and utility power is available.
5. The control simulates a utility power failure but
3. To start a test, press and hold the Test Push- the Utility Power Available LED remains lit as
button for two seconds or ground the Remote long as the utility is still available.
Test input.
6. The control starts the TDES timer. After the
4. To end the test, momentarily press the Test timer expires, the control de-energizes the
pushbutton or remove the ground from the Re- start relay, closing the start contact to signal
mote Test input. the generator to start.

NOTE: When ending a test with load, you can 7. When the generator output is acceptable (the
bypass the retransfer time delay Genset Power Available LED is lit) the control
(TDEN) and cause the immediate load starts the TDNE timer.
retransfer by pressing the Override
8. After the TDNE timer expires, the transfer
button. The generator stops after the
switch transfers to the genset (the Genset
engine cooldown time delay (TDEC).
Connected LED is lit).
Test With Load Sequence of Events 9. The control continues to run the generator with
the transfer switch connected to the genset un-
The following describes the sequence of events of til the control panel Test pushbutton is momen-
an OTEC transfer switch during a test with load. In tarily pressed or the ground is removed from
this example, TDPT is set to zero, the phase check the Remote Test input.
sensor is disabled, the Transfer Inhibit and Retran-
sfer Inhibit inputs are inactive, and TDEL is set to 10. After this action, the control starts the TDEN
zero. timer. The Test LED flashes twice per second
for two seconds to acknowledge the operation
The utility must be acceptable during the entire test and then the Test LED goes out.
event. Acceptability is determined by the active
source sensor (undervoltage sensor). If, at any 11. After the TDEN timer expires, the transfer
time, the undervoltage sensor determines that the switch retransfers back to the utility (the Utility
utility is not acceptable, the Test is terminated. Connected LED is lit).
Before a test can begin, the transfer switch must be 12. Once the transfer switch is connected to utility
connected to the utility power source and utility power, the control starts the TDEC timer.
power must be available.
13. After the timer expires, the control energizes
1. Verify that the transfer switch is set to test with the start relay, opening the start contact to sig-
load. nal the generator to stop.

3-7
Test Without Load Sequence of Events 3. Verify that the green Utility Power Available
LED on the control panel is lit.
The following describes the sequence of events of
an OTEC transfer switch during a test without load. 4. Press and hold the control panel Test pushbut-
In this sequence of events, the generator is started ton for two seconds or ground the Remote Test
and runs without load for the duration of the test. input. The Test LED flashes twice per second
for two seconds acknowledging that the test
A test must be started and ended by the same in- was activated. Once the test period starts, the
put. If a test is started with the front panel Test push- Test LED stays on continuously.
button, then it can only be ended with the pushbut-
5. The control de-energizes the start relay, clos-
ton. It cannot be ended with the Remote Test input.
ing the start contact to signal the generator to
If a test is started with the Remote Test input, it can-
start. When the genset starts and produces
not be ended with the front panel Test pushbutton.
power, the amber Genset Power Available
LED lights.
The utility must be acceptable during the entire test
event. Acceptability is determined by the active 6. The control continues to run the generator
source sensor (undervoltage sensor). If, at any without load until the control panel Test push-
time, the undervoltage sensor determines that the button is momentarily pressed or the ground is
utility is not acceptable, the Test is terminated. removed from the Remote Test input.
Before a test can begin, the transfer switch must be 7. After the control panel Test pushbutton is mo-
connected to the utility and utility power must be mentarily pressed or the ground is removed
available. from the Remote Test input, the control flashes
the Test LED twice per second for two seconds
1. Verify that the transfer switch is set to test with- to acknowledge the operation and then goes
out load. out.

2. Verify that the green Utility Connected LED on 8. The control energizes the start relay, opening
the control panel is lit. the start contact to signal the generator to stop.

3-8
 GENERATOR SET EXERCISER minutes and it repeats every 7, 14, 21, or 28 days
(default = 7 days) − see Section 4.
There are two exercise clock options, A049B864
and 0307−3053. Please refer to the appropriate The integrated exercise function cannot be used
section for further details on your model: Section unless the External Exercise function is disabled
3−12 for A049B864 and Section 3−30 for 0307− (set to Off).
3053. Before an exercise can begin, the transfer switch
must be connected to utility power and utility power
General Information must be available (the green Utility Connected and
Utility Power Available LEDs must be lit).
Run the generator for at least once each week with
at least 50% load (if possible). If you do not want to Power Loss Backup
use the exerciser, use the Test switch, to test the
generator set each week. If DC power is removed from the control panel, the
The control includes an integrated exerciser that is exercise clock uses a lithium battery to back up the
set by pressing the Set Exercise pushbutton. time setting. The battery is good for ten years and
In addition, there may also be an optional fully pro- doesn’t need to be serviced. The battery is at-
grammable external exerciser clock installed tached to the time chip on the control board.
and wired to a control input.
If both types of exercisers are available, only one If no exercise period is set, the Exercise LED is off
exerciser can operate at a time. The control (see Figure 2-1).
panel must be configured for the type of exerciser Setting the Integrated Exercise Period
being used. This is done by setting the
External Exerciser function ON or OFF. 1. Verify that the Exercise LED is off and the Ex-
ternal Exercise function is disabled (set to Off
− see Section 4). If the External Exercise func-
S If the integrated exerciser is used, the External tion is enabled, the integral exerciser is dis-
Exercise ON/OFF function must be set to abled.
OFF.
S If the external exerciser is used, the External 2. To set the exercise start time for a repeat exer-
Exercise ON/OFF function must be set to cise period, press and hold the Set Exercise
ON. pushbutton for 5 seconds. The Exercise LED
S If the external exerciser is factory−supplied, flashes at a rate of twice per second for 5 sec-
the External Exercise ON/OFF function is onds and then stays on when the exercise pe-
set to ON at the factory. riod is set. A delayed 20 minute exercise peri-
S If the external exerciser is not factory installed, od will start in 12 hours. At that time, the Exer-
the External Exercise ON/OFF function cise LED flashes at a rate of once per second
is set to OFF. during the entire exercise period. When the ex-
ercise period is over, the Exercise LED quits
flashing and remains on to signify that repeat
exercise periods are enabled.

Exercise With or Without Load 3. To start an immediate exercise period and

have it repeat, momentarily press the Set Ex-
The exercise with/without load configuration (see ercise pushbutton a second time within ten
Section 4) works with both types of exercisers (de- seconds of starting the delayed exercise peri-
fault = without load). When “With Load” is selected, od. Momentarily pressing and releasing the
the load is transferred to the genset. When “With- Set Exercise pushbutton a second time starts
out Load” is selected, the genset runs with no load an immediate 20 minute exercise period
for the duration of the exercise period. instead of waiting for 12 hours. The Exercise
LED flashes at a rate of once per second dur-
INTEGRATED EXERCISER ing the entire exercise period. When the exer-
cise period is over, the Exercise LED stops
This function is standard and is built into the con- flashing and remains on to signify that repeat
trol. With this exerciser, the exercise period is 20 exercise periods are enabled.

3-9
Canceling Repeat Exercise Periods 4. The Exercise LED stops flashing and remains
on to signify that repeat exercise periods are
With the control panel Exercise LED on steady, set (unless there are no repeat exercise peri-
press and hold the Set Exercise pushbutton for 5 ods). If there are no repeat exercise periods,
seconds. The Exercise LED flashes at a rate of the Exercise LED goes out.
twice per second for 5 seconds and then goes out
to signify that repeat exercise periods are can- Exercise With Load Sequence of Events
celled.
1. When an exercise period becomes active, the
Canceling An Active Exercise Period Exerciser LED flashes at a rate of once per
second.
Active exercise periods can be canceled by press-
ing the Override pushbutton on the control panel or 2. The control signals the generator to start.
by grounding the remote override input (P4-2) on
the back of the control panel. 3. When the generator output is acceptable, the
control transfers the load to the generator, fol-
Power Source Failure During An Active
lowing the configuration set points.
Exercise Period
4. After the exercise period has ended, the con-
If either power source fails during an active exer-
trol retransfers the load back to the utility, fol-
cise period, the control immediately terminates the
lowing the configured set points.
exercise and proceeds with the automatic mode of
operation. 5. Once the load is connected to utility power, the
Exercise Without Load Sequence of Events control runs the genset unload for the duration
of the cooldown timer (TDEC).
1. When an exercise period becomes active, the
Exerciser LED flashes at a rate of once per 6. After the TDEC timer expires, the control sig-
second. nals the genset to stop.

2. The control signals the generator to start and 7. Unless the repeat exercise periods have been
run for 20 minutes. canceled, the Exercise LED quits flashing and
remains on to signify that repeat exercise peri-
3. After the exercise period has ended, the con- ods are set. If the exerciser is not set up to re-
trol signals the generator to stop. peat exercises, the Exercise LED goes out.

3-10
EXTERNAL EXERCISER CLOCK OPTION
[TR 610 TOP2] (A049B864) The exercise clock has a built−in test feature that
can be used to initiate an exercise that has not
been programmed or cancel a programmed exer-
The optional external exercise clock includes a cise in process.
real−time clock that keeps track of the time and
date. The 7−DAY clock can be set for automatic NOTE: The clock includes a non−replaceable lithi-
changeover for summer/winter (daylight savings/ um battery with a life expectancy of at least ten
standard) time. The exercise clock can be used years power reserved is reduced with memory card
with 120V AC, 230−240V AC or 12−24 V AC or DC inserted (in battery mode). If the clock battery is
+ 10%/−15% operation. weak during a power failure, the clock will need to
Up to 56 programs are available to set exercise be replaced.
start and stop times. One program is required to
start an exercise period and a second one is re-
quired to stop an exercise period. :
FIGURE 13.1 EXTERNAL EXERCISE CLOCK

1
e 10
d
2f
ed 9
ds
3 e
ff d
dd f11
s4
2 d
2f
e s
d 8f
5
2f ed
2
ed d2
ds f2
6
f d7
e
d se
d
s2 fd
f
2f df
d
d 2d
s
2 2s
f
2 f
d
No. Description No. d
Description
2
2
2 −/+ push buttons
2
1 Time of DAY indicators 7 Used to increase/decrease values, to scroll
through menus and to select special functions.

Exercise state indicator OK button

2 8
(On/Off) Used to confirm selection

DATE
3 Time of DAY 9
(DAY, MONTH and YEAR)
DAY of week indicator Indicators of when exercises are scheduled for
4 10
(1 = MONDAY, 7 = Sunday) the current DAY.

Menu selection push button Dynamic display of the push button

5 Used to select one of four display modes or to 11
abort adjusting parameters

6 Obelisk Top2 Memory card slot

3-11
 FLASHES

INITIAL START−UP
menu. For example, if the user had made a mistake
When the time switch is removed from the packag- and pressed the OK button too quickly, the menu
ing all important settings have already been made. button enables returning to the previous selection
item.
Individual settings can be performed by selecting
and confirming. 5. Press the − or + push buttons until the correct
year is displayed and then press the OK push but-
1. The national language is being dis- ton. The MONTH is displayed.
played, use the − or + push buttons to scroll through
the available languages (English, Espanol, Fran-
cais, Portugal, Italiano or Deutsch).
FLASHES

6. Press the − or + push buttons until the correct

2. When the desired language is displayed, press month is displayed and then press the OK button.
the OK push button. The FORM DATE is displayed. The screen then shows the DAY value flashing.

FLASHES

7. Press the − or + push buttons until the correct

3. Press OK push button to display the DATE For- DAY is displayed and then press the OK push
mats. Button. The screen then shows the FORM TIME
menu.

4. Press − or + push buttons to select the desired

8. Press the OK push button. Press − or + push
date Format, then press the OK push button. The
buttons to select the desired Time Format.
YEAR is displayed.

NOTE: By pressing the ESC push button, i.e. the

menu button, it is possible to return to the previous
setting

3-12
 mode and screen displays the correct date and
time.

9. Press the OK push button when the desired

Time format is displayed. The screen then shows
the HOUR value flashing.
LCD LIGHTING (DISPLAY BACK LIGHT)
FLASHES
The LCD light (Display Back light) can be set to
”Always On” or ”Off after 1 Minute”.

*ALWAYS ON = background lighting is never

switched off
*OFF AFTER 1 MINUTE the background lighting
is switched off again 1 minute after the last time
10. Press the − or + push buttons until the correct
the pushbutton was pressed.
HOUR is displayed. Press the OK push button.
The screen then shows the MINUTE value-
flashing.
1. From the Home menu, press the Menu button.
FLASHES The PROGRAM menu is displayed.

11. Press the − or + push buttons until the correct

minute is displayed. Press the OK push button.
The screen 2. Press the + push button three times. The OP-
then shows the automatic summer/winter TIONS menu is displayed.
(SU−−WI USA) time changeover flashing.

3. Press the OK push button, then press +push but-

12. Press the − or + push buttons until the correct ton until LCD ILLUMINATION menu appears.
Summer/winter time changeover is displayed.
Press the OK
push button. The time switch is now in Auto

3-13
 USING THE MENU BUTTON

The Menu selection button is used to select four

display modes that have adjustable menus.

Time/DATE mode is used to set the correct DATE

and time. This mode can also be used to automati-
cally switch to the correct summer/winter time.

4. Press the OK push button to display the ALWAYS Program mode is used to set, review and clear ex-
ON menu. ercise start/stop times.

Manual mode is used to Permanent On/Off, Over-

ride exercise. This mode can be also used to set
holiday Program.

Options mode is used to enter a 4−digit code to

prevent changing settings by unauthorized person-
nel. This mode can also be used to switch On/Off
LCD−illumination (Display Back light)
NOTE: With OK push button a return is made to
When adjustments are completed, the Home menu
LCD illumination.
(Auto mode) is redisplayed. The Menu button can
also be used to abort adjusting parameters and re-
turn to the Home menu.

USING THE − / + PUSH BUTTONS

5. Press − push button to display the ”AFTER 1
MINUTE OFF” menu. Pressing the − or + push buttons are used to:

−Increase or decrease a parameter in an adjust-

able menu
−Select the next or previous menu.

Simultaneously pressing the − and + push buttons

is used to select special functions.

−Activate Manual Switching.

−Activate permanent switching.
−Cancelling manual/permanent switching.
6. Press the OK push button to return to LCD illumi-
nation menu. And then press Menu button twice to USING THE ’OK’ PUSH BUTTON
return to Home menu.
The OK push button is used to confirm the menu
selection or program adjustments you have made.
Upon pressing the OK push button, the next avail-
able menu is displayed and, if any program adjust-
ments were made, the changes are saved.

SETTING THE TIME, DATE WITH SUMMER/

WINTER TIME (DAYLIGHT SAVINGS TIME)
NOTE: In the battery mode (no mains) there is no The clock is programmed with the correct DATE
LCD lighting and central USA standard time and with the correct

3-14
daylight savings time settings. If it is necessary to
change these settings, the following describes how
to adjust the time and DATE and how to set the
clock to automatically switch to Summer/winter
time (Daylight savings time).
4. Press the OK push button to display the HOUR
menu.

FLASHES

5. Press the − or + push buttons to set the correct

hour. Press the OK push button to display the MIN-
1. Press the Menu push button on the exercise UTE menu.
clock. The Program menu is displayed.

FLASHES

2. Press the + push button. The Time/DATE menu

is displayed.
6. Press the − or + push buttons to set the correct
Minute. Press the OK push button to display the
TIME menu.

3. Press the OK push button to display the Time

menu.
7. Press the + push button. The SET DATE menu is
displayed.

3-15
 11. Press the − or + push buttons to set the correct
DAY. Press the OK push button to display the SET
DATE menu.

8. Press the OK push button to display the YEAR

menu.

FLASHES
12. Press the + push button. The Summer/Winter
(SU−−WI) menu is displayed.

9. Press the − or +push button to set the correct

YEAR. Press the OK push button to display the
MONTH menu.

13. Press the OK push button to display the World

Area menu.
FLASHES
It is possible to choose between 6 pre−set change-
over settings, use own changeover settings with 2
different methods, or switch off the automatic sum-
mer/winter time changeover using − or + push but-
tons.

FLASHES

10. Press the − or + push buttons to set the correct

MONTH. Press the OK push button to display the
DAY menu.

FLASHES
14. Press − or + push buttons to select one of the
world areas that has been programmed for auto-
matic time correction or else set up your own
changeover times. Then press OK push button to
activate and return to SU−WI menu.

NOTE: With the DAY light Savings Time program

set for North America,

3-16
* The first Sunday in April moves the time forward
one hour.

* The last Sunday in October moves the time back

one hour.

* If you wish to select one of the world areas (GB/

IRL/P, FIN/GR/TR, CDN, USA, IRAN, EUROPE
that has been programmed for automatic time
correction, press the + or −push buttons until the 16. Press the OK push button to display the menu
correct world area is selected. Then press OK but- for setting the MONTH when the summer change-
ton to activate and return to SU−WI menu. over will take place. Press the − or + push buttons
until the desired MONTH is displayed.

FLASHES

If you do not wish to set the clock for automatic

summer/winter changeover, press the − or + push
buttons. ”NO SU−WI” is displayed on the screen.
Press the OK button to return to the SU−WI menu.

FLASHES 17. Press the OK push button to display the menu

for setting the week when the Summer changeover
will take place. Press the − or + push buttons until
the desired week (1 to 5 [1 = first week, 4 = fourth
week, 5 = last week]) is displayed.

CODE COUNTRY NAME

GB GREAT BRITAIN
IRL IRELAND
FLASHES
FIN FINLAND
GR GREECE
TR TURKEY
CDN CANADA
UNITED STATES OF
USA
AMERICA
IRAN IRAN
EUROPE EUROPE
18. Press the OK push button to display the menu
for setting the week DAY of the week when summer
changeover will take place. Press the − or + push
buttons until the desired week day (1 to 7 [1 =
Monday, 7 = Sunday]) is displayed.
15. Press the − or + push buttons to display SU−WI
FREE RULE, and press OK push button to set up
your own changeover times.

3-17
 week, 5 = last
week]) is displayed.
FLASHES

FLASHES

WEEK TABLE
1 first week
2 second week
3 third week
4 fourth week
5 last week

NOTE: The starting time for the winter changeover

is the same time that was set previously.
19. Press the OK push button to display the menu
for setting the HOUR of the DAY when the summer
changeover will place. Press the − or + push but-
22. Press the OK push button followed by Menu
tons until the desired HOUR is displayed.
button twice. The Home menu is displayed.

FLASHES

SETTING EXERCISE START/STOP TIMES

NOTE: The starting time can be set for 1.00 to
22.00 for 24h format and 1.00 to 12.00 for 12h for- Up to 56 programs can be used to set exercise start
mat. and stop times. One program is required to start an
exercise period and a second one is required to
stop an exercise period.
20. Press the OK push button to display the menu
NOTE: If the Menu button is pressed before a Start/
for setting the month when the winter changeover
Stop program is saved, the word ”ABORT” is dis-
will take place. Press the − or + push buttons until
played on the screen. The program settings are lost
the desired MONTH is displayed.
and the new menu is displayed after two seconds
FLASHES or by pressing the OK button.

21. Press the OK push button to display the menu

for setting the week when the winter changeover
will take place. Press the − or + push buttons until
the desired week (1 thru 5 [1 = first week, 4 = fourth

3-18
1. From the Home menu, press the Menu button.
The PROGRAM menu is displayed.
5. With arrow push buttons − and + set the HOUR
for the switch−on (12:00 AM) and confirm with the
OK push button.

FLASHES

2. Press the OK push button. The NEW Program

menu is displayed. 6. With arrow push buttons − and + set the MIN-
UTES for the switch−on (00 minutes) and confirm
with the OK push button.

FLASHES

3. Press the OK push button. A brief fade−in now

occurs which is only for the programming of the free
memory locations. The number of available pro-
grammable time periods (maximum of 56) is tem-
porarily displayed. 7. With the arrow push buttons − and + select the
first weekday for the switching time (Monday =
DAY1) followed by confirmation with the OK push
button.

FLASHES

This fade−in can be prematurely ended by pressing

the OK push button

8. In order to copy the switching time to other week-

days confirm the COPY with the OK push button.
4. With the arrow push buttons − and + select chan-
nel status ON followed by confirmation using the
OK push button.

Flashes

NOTE: With the push buttons− and + it is possible

to change to SAVE if the switching time is only to be

3-19
performed on this weekday. Then press OK,
switching time would be saved ”individually” and 12. The New Program menu is redisplayed. The
a return to NEW would be made. switch−off time still has to be entered.
Press OK Push button.

FLASHES

9. To repeat an exercise more than once a week,

press the OK push button when the Copy menu is 13. Press the OK push button. A brief fade−in now
displayed. The Add ___DAY menu is displayed. occurs which is only for the programming of the free
The DAY after the DAY selected in step 7 is dis- memory locations. The number of available pro-
played. grammable time periods (maximum of 55) is tem-
porarily displayed.

FLASHES

10. Press the − or + push buttons to select the de- *This fade−in can be prematurely ended by press-
sired DAY of the week that an exercise is to begin. ing the OK push button.
Press the OK button.

14. Instead of a switch−on (On) the push button −

FLASHES and + must be selected for a switch−off (Off) and
confirm using the OK push button.

FLASHES

11. After the weekday SUNDAY, SAVE is offered

again. The switch−on timing of Monday at 12:00
AM has now been copied from Sunday. Confirm the
programming by pressing OK Push button. 15. Repeat steps 5 through 11 to set up the stop
time for your exercise.
FLASHES
16. Press the Menu button twice to return to the
Home menu.

NOTE: If there are any exercises scheduled for the

3-20
current DAY, those time period are indicated on the
screen.

SCHEDULED
EXERCISE

3. Press the + push button once. The Check menu

is displayed.

CHECKING THE PROGRAMS

The Check Program menus can be used to review

all set exercise start/stop times and, if necessary,
delete them.

NOTE: If the Menu button is pressed while viewing

start/stop programs, the Program Check function is 4. Press the OK push button. Now all programmed
aborted and the Home menu is redisplayed. switching times are displayed classified on the time
bar according to the time sequence starting with
the first weekday (e.g. MONDAY).
REVIEWING EXERCISE START/STOP
TIMES
FLASHES
All exercise start and stop exercise parameters can
be viewed from the Program Check menu. Normal-
ly, the starting time is followed by the ending time NOTE: If no exercise periods are set up, the mes-
for a programmed exercise. However, if a second sage ”EMPTY” is displayed. To return to the New
exercise period overlaps the time frame of the first Program menu, press the OK push button.
exercise period in the current DAY, two start times
are displayed, followed by two stop times.

1. From the Home menu, press the Menu button.

The Program menu is displayed.

5. Review additional set exercise periods and re-

turn to the Main menu.
* To exit the Check Programs function without re-
viewing all set exercise periods, press the − or +
push buttons until ”END” is displayed. Press the
OK button followed by menu button twice to return
to the Main menu.

2. Press the OK push button. The New Program MODIFYING EXCECISE START/STOP
menu is displayed. TIMES

It is possible to change exercise start/stop times

3-21
using the PROGRAM menu MODIFY.
FLASHES
1. From the Home menu, press the Menu button.
The Program menu is displayed.

6. Press − and + push buttons to modify the Min-

utes. Press OK push button to display MODIFY
BLOCK menu.

2. Press the OK push button. Press + push button

twice the MODIFY menu is displayed. FLASHES

7. Press + push button to modify the Switch−on

3. Press the OK push button. Now all programmed time day (MONDAY).
switching times are displayed classified on the time
bar according to the time sequence starting with
the first weekday (e.g. MONDAY). FLASHES

FLASHES

8. Press OK push button to return to MODIFY

menu.
4. Press OK push button to modify the MONDAY
switch−on time. The MODIFY HOUR menu is dis-
played.

FLASHES

9. Press + push button until the ”END” is displayed,

press OK button or with the MENU (ESC) push but-
ton the menu can be exited.

5. Press − and + push buttons to modify the HOUR. DELETING EXERCISE START/STOP TIMES
Press OK push button to display MODIFY MINUTE
menu. We can delete individual start and stop times.

3-22
1. From the Home menu, press the Menu button. 4. Press OK push button. The first switching time
The PROGRAM menu is displayed. saved for the first weekday is displayed

2. Press the OK push button. Press + push button

three times, the DELETE menu is displayed.
5. Press OK push button to display Delete block
menu.The entire switching time block (switch−on at
9:00 AM from Monday to Sunday) can be deleted:
DELETE BLOCK

Flashes

3. Press the OK push button. The SINGLE menu is

displayed.
6. Press the + push button to remove MONDAY
specifically from the block and delete it: DELETE
MONDAY.

Flashes

NOTE: In the DELETE submenu it is also possible

to select what is to be deleted. In addition to delet-
ing the switching times, it is also possible to select
the menu item DELETE ALL using + push button.
Here it is possible to jointly delete all saved switch-
ing commands for the selected channel.

3-23
 The exercise clock has a built−in test feature that
can be used to initiate an exercise that hasn’t been
programmed or cancel a programmed exercise in
7. Press the OK push button. The confirmation of process.
the delete procedure is displayed briefly followed
by an automatic return to the DELETE menu. The control panel Load/No Load function can be
set to test the genset with or without load, as de-
sired.

INITIATING AN EXERCISE

In the example shown below, ”Off” indicates that no

exercise is currently active.

8. Press the OK push button to delete the other

switching times.

1. With the Home menu displayed, simultaneously

press the −and + push buttons for approximately
one second. ”OVERRIDE” symbol is displayed on
the screen. In addition, ”Off” is switched to ”On” and
9. Press + push button until the ”END” is displayed. the exercise is initiated.

10. Press OK push button or with the MENU (ESC)

push button the menu can be exited.

2. To end the exercise, simultaneously press the −

and + push buttons for approximately one second.
The original Home menu is redisplayed and ”On” is
switched back to ”Off.”

INITIATING OR OVERRIDING AN
EXERCISE PROGRAM

3-24
 SELECTING PERMANENT ON/OFF MODE

The exercise clock has a permanent on/off mode

feature.

SELECTING PERMANENT ON/OFF MODE

OVERRIDING AN EXERCISE WITHOUT AN ACTIVE EXERCISE
In the example shown below, ”On” indicates that an In the example shown below, ”Off” indicates that no
exercise is currently active. exercise is currently active.

1. With the Home menu displayed, simultaneously

press the − and + push buttons for approximately
1. With the Home menu displayed, simultaneously
press the − and + push buttons for approximately
one second. ”OVERRIDE” symbol is displayed on three seconds. The OVERRIDE menu is first dis-
the screen. In addition, ”On” is switched to ”Off” and played and then the ”PERM On” symbol is dis-
the exercise is stopped. played on the screen. In addition, a continuous
band of segments is displayed on top of the screen
and ”Off” is switched to ”On.”

2. To restart the exercise, simultaneously press the

− and + push buttons for approximately one sec-
ond. The original Home menu is redisplayed and
”Off” is switched back to ”On.”

2. To switch to Permanent Off mode, press the −

and + push buttons for approximately three sec-
onds.”PERM Off” is displayed and ”On” is switched

3-25
back to ”Off.”

3. To return the clock to its original state, simulta- 2. To switch to Permanent On mode, press the −
neously press the − and + push buttons for approxi- and + push buttons for approximately three sec-
mately one second. The original Home menu is re- onds” PERM On” is displayed and ”Off” is switched
displayed. back to ”On.” In addition, a continuous band of seg-
ments is displayed on top of the screen.

SELECTING PERMANENT ON/OFF MODE

WITH AN ACTIVE EXERCISE 3. To return the clock to its original state, simulta-
neously press the − and + push buttons for approxi-
In the example shown below, ”On” indicates that an mately one second. The original Home menu is re-
exercise is currently active. displayed.

1. With the Home menu displayed, simultaneously ADDING A SECURITY CODE

press the − and + push buttons for approximately
three seconds. The Override menu is first dis- A 4−digit security code number can be entered to
played and then the ”PERM Off” symbol is dis- prevent unauthorized personnel from using the
played on the screen. clock. Once a security code has been set up, the
In addition, ”On” is switched to ”Off.” exercise clock is locked 75 seconds after the last
keystroke. It can only be operated again after the
correct PIN code is entered.

CAUTION: Once a PIN code has been activated

and the Reset button is pressed (See ”Resetting
the Timer” on the following page), the exercise tim-
er can no longer be activated without a valid PIN

3-26
code.

1. From the Home menu, press the Menu button. 4. Press the OK push button to display the NO PIN
The PROGRAM menu is displayed. menu.

FLASHES

NOTE: If NO PIN is selected and confirmed with the

2. Press the + push button three times. The OP- OK push button a return is made to PIN.
TIONS menu is displayed.

5. Press the − or + push buttons to display the WITH

PIN menu.

FLASHES

3. Press the OK push button, then press + push but-

ton until PIN menu appears.

6. Press the OK push button to display the CUR-

RENT PIN (here 0000). Continue with the OK push
button.

NOTE: If the − or + push buttons is pressed now,

the message ”END” is displayed. Press the OK
push button to return to the Home menu.
7. The NEW PIN appears on the display. The first
number flashes.

FLASHES

3-27
8. Press the − or + push buttons to enter the first If required please contact the Theben hotline.
digit of the PIN code and confirmed with the OK
push button. AFTER PROGRAMMING THE
EXERCISE CLOCK
9. After this, the second, third and fourth number of
the PIN code is stipulated. As soon as the fourth 1. Make sure the External Exercise function on the
number has been confirmed with the OK push but- transfer switch control panel is set to ”On”.
ton a return is made to the auto mode.
2. Place the generator set operation selector switch
IMPORTANT NOTE: The PIN number is immedi- in the Remote position.
ately valid and the time switch is locked by it.
3. Check the system for proper operation as de-
Additional information: ”Super PIN”
scribed in the Operator’s Manual.
o In time switch a super PIN code is stored individu-
ally for each device with which the time switch can RESETTING THE TIMER
be unlocked in spite of a set PIN. This super PIN
specific to each device ensures that the time switch The Reset button should only be used in cases of
can be unlocked again if the PIN code has been for- an emergency. Reset is achieved by pressing all 4
gotten. push buttons at the same time. By resetting, all
configuration settings (time format, 24 HOURs or
o The super PIN code is calculated from a special AM/PM, etc.) are maintained. DATE and time are
algorithm from the time switch device serial num- however deleted. The selection ”Keep program” or
ber.This serial number, specific to each device, can ”Delete program” is available. ”Delete program”
be seen on the right−hand side of the housing. must be confirmed separately. With ”Delete pro-
gram” all switching commands and the holiday pro-
o The super PIN software with the special algorithm gram are deleted.
is available from Theben AG.

3-28
 OPTIONAL EXTERNAL EXERCISER Up to 28 programs are available to set exercise
(0307−3053) start and stop times. One program is required to
start an exercise period and a second one is re-
The optional external exercise clock is a 7-day, quired to stop an exercise period.
24-hour clock that, when installed, can store and
execute several start/stop programs per day and
repeat exercise periods every week. It can be pro- The exerciser clock also has a built-in test feature
grammed to run exercise periods at different times that can be used to initiate a genset start and run
on different days. Unlike the integrated exerciser, cycle.
the external exercise can schedule an exercise pe-
riod for something other than 20 minutes.
The exerciser clock contains a lithium battery that
If the External Exercise function is enabled (set to is used as a backup power source. The battery is
On), then the integrated exerciser is disabled. not replaceable. When the clock is running off the
internal battery, three flashing dots are displayed
NOTE: After a period of inactivity, the clock enters between the hour and minute values (see Figure
sleep mode and turns off the display. To re- 3-3). Unless the clock battery fails, exercise pro-
activate the display, briefly press the Menu grams are stored and are not lost during a power
button. outage.
FLASHES

12 15 18 21 24

9 Auto

6
03 01 04
Off
3

0
. AM
11:30
1 2 3 4 5 6 7

FIGURE 3-3. INDICATOR OF CLOCK RUNNING The clock is programmed with the correct date and
OFF THE INTERNAL BATTERY central USA standard time and with the correct
daylight savings time settings. Programming the
Figure 3-4 illustrates the face of the exercise clock exerciser clock requires entering the exercise start
and provides information on the display and the and stop times and, if necessary, adjusting the time
function of the buttons. as described on the following pages.

3-29
 INDICATORS OF WHEN
DISPLAY MODE (AUTO, EXERCISES ARE SCHEDULED
PROG, , OR MAN) FOR THE CURRENT DAY

TIME OF DAY INDICATORS SPECIAL FUNCTION INDICATORS

12 15 18 21 24
= OVERRIDE ON/OFF
9 Auto = PERMANENT ON/OFF
EXERCISE STATE
6
03 01 04 DATE (MONTH, DAY, AND YEAR)
INDICATOR (ON/OFF) Off
SUMMER/WINTER
11:30AM
3
TIME OF DAY
CHANGEOVER INDICATOR
0
DAY OF WEEK INDICATOR = SUMMER
1 2 3 4 5 6 7
(1 = MONDAY, 7 = SUNDAY) = WINTER
ok BUTTON − USED TO
MENU SELECTION BUTTON − USED TO CONFIRM SELECTION
SELECT ONE OF FOUR DISPLAY MODES
OR TO ABORT ADJUSTING PARAMETERS
+/− BUTTONS − USED TO INCREASE/DECREASE
RESET BUTTON − USED ONLY IN CASE OF EMERGENCIES VALUES, TO SCROLL THROUGH MENUS, AND TO
TO DELETE INDIVIDUAL SETTINGS (SEE PAGE 3-45) SELECT SPECIAL FUNCTIONS

FIGURE 3-4. EXERCISE CLOCK FEATURES

3-30
Using the Menu Button to automatically switch to summer/winter time
(daylight savings time).
The Menu selection button is used to select three
display modes that have adjustable menus. 12 15 18 21 24

9 Auto
 The Clock mode ( ) is used to set the correct 01 01 03
6
date and time. This mode can also be used to Off
automatically switch to the correct summer/win-
ter time. See page 3-31.
3

0
12:00 PM
1 2 3 4 5 6 7
 The Program mode (Prog) is used to set (see
page 3-34), review (see page 3-37), and clear 1. Press the Menu button on the exercise clock.
exercise start/stop times (see pages 3-39 and The Program menu is displayed.
3-41).
FLASHES
 The Manual mode (Man) is used to enter a 12 15 18 21 24
4-digit code to prevent changing settings by un-
authorized personnel. See page 3-44. 9 Auto Prog Man

6 PROGRAM
When adjustments are completed, the Home menu 3
(Auto mode) is redisplayed (see Figure 3-4). The
0
Menu button can also be used to abort adjusting 1 2 3 4 5 6 7
parameters and return to the Home menu.
2. Press the + button. The Date/Time menu is
Using the +/− Buttons
displayed.
Pressing the + or − button is used to:
FLASHES
 Increase or decrease a parameter in an adjust- 12 15 18 21 24

able menu 9 Auto Prog Man

 Select the next or previous menu. 6 DAT/TIME

11:07 AM
3
Simultaneously pressing the + and − buttons is 0
used to select special functions. 1 2 3 4 5 6 7

 Initiate an exercise (see page 3-42)

3. Press the ok button to display the Year menu.
 Override an active exercise (see page 3-42)
12 15 18 21 24

 Select permanent on/off mode (see page 3-43) 9

6 YEAR
Using the ok Button FLASHES

20 03
3

The ok button is used to confirm the menu selec- 0

tion or program adjustments you have made. Upon 1 2 3 4 5 6 7

pressing the ok button, the next available menu is

displayed and, if any program adjustments were 4. Press the + or − button to set the correct year.
made, the changes are saved. Press the ok button to display the Month
menu.
Setting the Clock with Summer/Winter
Time (Daylight Savings Time) 12 15 18 21 24

9
The clock is programmed with the correct date and 6 MONTH
central USA standard time and with the correct FLASHES
03
3
daylight savings time settings. If it is necessary to
change these settings, the following describes how 0

to adjust the time and date and how to set the clock 1 2 3 4 5 6 7

3-31
5. Press the + or − button to set the correct “End” is displayed on the screen.
month. Press the ok button to display the Day Press the ok button to return to the
menu. Home menu.
12 15 18 21 24
12 15 18 21 24

9
9

DAY 6 END
6 FLASHES
FLASHES
11:09
3 AM
03.05
3
0
0
1 2 3 4 5 6 7
1 2 3 4 5 6 7

9. Press the ok button to display the No Summer/

6. Press the + or − button to set the correct day. Winter menu.
Press the ok button to display the Hour menu.
A small triangle is displayed above the as- 12 15 18 21 24

signed number in the display for the day of the 9

FLASHES
week (1 = Monday, 7 = Sunday). 6 NO SU/WI

11:10
12 15 18 21 24 3 AM
0
9

FLASHES 6 HOUR 1 2 3 4 5 6 7

10. Press the + or − button to display the With

11:08
3 AM
TRIANGLE
0
Summer/Winter menu.
1 2 3 4 5 6 7 12 15 18 21 24

7. Press the + or − button to set the correct hour. 9

FLASHES
A line is displayed on the screen indicating the 6 WITH S/W
hour of the day selected (the left side of the
11:10
3 AM
screen is for the first half of the day [AM] and 0
the top of the screen is for the second half of 1 2 3 4 5 6 7
the day [PM]). Press the ok button to display
the Minute menu. 11. Press the ok button to display the World Area
menu.
12 15 18 21 24
12 15 18 21 24
9

6 MINUTE FLASHES 9
FLASHES
6 USA/CAN
11:09
3 AM

11:10
3 AM
0
1 2 3 4 5 6 7 0
1 2 3 4 5 6 7

8. Press the + or − button to set the correct min-

12. Either select one of the world areas that has
ute. Press the ok button to display the Sum-
been programmed for automatic time correc-
mer/Winter menu.
tion or else set up your own changeover times.
12 15 18 21 24
NOTE: With the Daylight Savings Time pro-
9 gram set for North America,
FLASHES
6 SUM/WIN S The first Sunday in April
moves
11:09
AM
3
the time forward one hour.
0 S The last Sunday in October
1 2 3 4 5 6 7 moves the time back one
NOTE: If you do not wish to set the clock for hour.
automatic summer/winter changeover − If you wish to select one of the world areas
at this time, press the + or − button. (Europe, GP/P, SF/GR/TR, USA/CAN)

3-32
 that has been programmed for automatic 15. Press the ok button to display the menu for
time correction, press the + or − buttons setting the week when the Summer change-
until the correct world area is selected. Go over will take place. Press the + or − buttons
to step 19. until the desired week (1 thru 5 [1 = first week,
4 = fourth week, 5 = last week]) is displayed.
12 15 18 21 24
12 15 18 21 24
9
FLASHES
6 EUROPE 9

6 WEEK SU FLASHES
11:10
3 AM
0
3

0
06.01 AM

1 2 3 4 5 6 7
1 2 3 4 5 6 7

− If you wish to set up your own changeover 16. Press the ok button to display the menu for
times, continue with step 13. setting the hour of the day when the Summer
changeover will take place. Press the + or −
13. To set up your own changeover times, press buttons until the desired hour (1 thru 3) is dis-
the + or − buttons from the World Area menu played.
until the word “Free” is displayed.
12 15 18 21 24

12 15 18 21 24 9

9
6 HOUR
FLASHES FLASHES
FREE −−−−
01:
6 3 AM
0

11:10
3 AM
1 2 3 4 5 6 7
0
1 2 3 4 5 6 7
NOTE: The starting time can only be set for
1:00, 2:00, or 3:00 AM.
14. Press the ok button to display the menu for
17. Press the ok button to display the menu for
setting the month when the Summer change-
setting the month when the Winter change-
over will take place. Press the + or − buttons
over will take place. Press the + or − buttons
until the desired month is displayed.
until the desired month is displayed.
12 15 18 21 24 12 15 18 21 24

9 9

6 MONTH SU 6 MONTH WI
FLASHES FLASHES
3

0
01.01 AM 3

0
02.01 AM
1 2 3 4 5 6 7 1 2 3 4 5 6 7

3-33
18. Press the ok button to display the menu for 1. From the Home menu, press the Menu button.
setting the week when the Winter changeover The Program menu is displayed.
will take place. Press the + or − buttons until
the desired week (1 thru 5 [1 = first week, 4 =
FLASHES
fourth week, 5 = last week]) is displayed. 12 15 18 21 24

12 15 18 21 24
9 Auto Prog Man

9 6 PROGRAM
6 WEEK WI FLASHES 3

0
09.04 AM 0
1 2 3 4 5 6 7

1 2 3 4 5 6 7

NOTE: The starting time for the winter 2. Press the ok button. The New Program menu
changeover is the same time that is displayed.
was set in step 16.
19. Press the ok button. The Home menu is redis- 12 15 18 21 24

played and the appropriate summer/winter 9 Prog FLASHES

symbol is displayed. 6 NEW PROG
12 15 18 21 24 3

9 Auto 0

6
03 01 04 1 2 3 4 5 6 7
Off
3

0
11:12 AM 3. Press the ok button. The number of available
1 2 3 4 5 6 7 programmable time periods (maximum of 28)
is temporarily displayed.
Setting Exercise Start and Stop Times
12 15 18 21 24

Up to 28 programs can be used to set exercise start

9 Prog NUMBER OF
and stop times. One program is required to start an
FREE AVAILABLE
exercise period and a second one is required to 6
PROGRAMMABLE
stop an exercise period. TIME PERIODS
28
3

0
NOTE: If the Menu button is pressed before a
1 2 3 4 5 6 7
Start/Stop program is saved, the word
“Escape” is displayed on the screen. The
program settings are lost and the Home 4. The Starting Time (Time On) menu is dis-
menu is displayed after two seconds or played. Press the ok button.
by pressing the ok button.
12 15 18 21 24
12 15 18 21 24

9 Prog FLASHES 9 Prog

6 ESCAPE 6 TIME ON
On
3
3 FLASHES
0
0
1 2 3 4 5 6 7
1 2 3 4 5 6 7

3-34
5. The Hour menu is displayed. Press the + or − week, go to step 9. If you do wish to have the
buttons to set the desired exercise starting exercise repeat more than once a week, go to
hour (default = 12:00 AM). A line is displayed step 10.
on the screen indicating the hour of the day se-
lected (the left side of the screen is for the first 12 15 18 21 24

half of the day [AM] and the top of the screen 9 Prog FLASHES
is for the second half of the day [PM]). Press 6 COPY
the ok button. On

11:30 PM
3

12 15 18 21 24 0
1 2 3 4 5 6 7
9 Prog

6 HOUR 9. Press the + or − buttons. The Store menu is

On
displayed. Press the ok button. Go to step 13.
12:00AM
3

0
FLASHES 12 15 18 21 24
1 2 3 4 5 6 7

9 Prog FLASHES

6. The Minute menu is displayed. Press the + or 6 STORE

− buttons to set the desired exercise starting
11:30PM
3

minute. Press the ok button. 0

1 2 3 4 5 6 7
12 15 18 21 24

9 Prog 10. To repeat an exercise more than once a week,

6 MINUTE press the ok button when the Copy menu is
On displayed. The Add ___day menu is displayed.
11:30 PM
3
The day after the day selected in step 7 is dis-
0 played.
1 2 3 4 5 6 7
FLASHES
12 15 18 21 24

7. A menu is displayed for selecting the day of the 9 Prog FLASHES

week the exercise is to begin (default = 6 ADD TU
Monday). Press the + or − buttons to select the On

11:30 PM
3
desired day of the week. A small triangle is dis-
played above the assigned number in the dis- 0
1 2 3 4 5 6 7
play for the day of the week (1 = Monday, 7 =
Sunday). Press the ok button.
11. Press the + or − buttons to select the desired
12 15 18 21 24 day of the week that an exercise is to begin.
Press the ok button.
9 Prog FLASHES
6 MONDAY 12 15 18 21 24
On

11:30 PM
3 9 Prog FLASHES
0 6 ADD SA
1 2 3 4 5 6 7 On

11:30PM
3

8. The Copy menu is displayed. If you do not wish 0

to have the exercise repeat more than once a 1 2 3 4 5 6 7

3-35
12. Press the + or − buttons. The Store menu is 12 15 18 21 24
displayed. Press the ok button.
9 Prog NUMBER OF
6 FREE AVAILABLE
12 15 18 21 24
PROGRAMMABLE
TIME PERIODS
27
3
9 Prog FLASHES 0

6 STORE 1 2 3 4 5 6 7

11:30PM
3
15. The Ending Time (Time Off) menu is dis-
0
1 2 3 4 5 6 7
played. Press the ok button.
12 15 18 21 24

NOTE: After setting all days of the week that an 9 Prog

exercise is to be repeated, you can use 6 TIME OFF

Off
the + or − buttons to cycle through the 3 FLASHES
days and recheck the programs. When a 0
day that has a set program is redis- 1 2 3 4 5 6 7

played, it can be deleted. In the menu

shown below, press the ok button to de- 16. Repeat steps 5 thru 13 to set the stop time for
lete the displayed program. your exercise.

17. When the New Program menu is redisplayed,

12 15 18 21 24
press the + or − buttons until “End” is dis-
9 Prog FLASHES played.
6 DELETE MO
12 15 18 21 24

11:30 PM
3
9 Prog FLASHES
0
1 2 3 4 5 6 7 6 END
3

13. The New Program menu is redisplayed. 1 2 3 4 5 6 7

18. Press the ok button to return to the Home

12 15 18 21 24 menu.
9 Prog FLASHES NOTE: If there are any exercises scheduled for
6 NEW PROG the current day, those time periods are
3
indicated on the screen.
0 SCHEDULED
1 2 3 4 5 6 7
EXERCISES

12 15 18 21 24

14. Press the ok button to enter a time the exer- 9 Auto

cise is to end. The number of available pro- 03 01 04
6
grammable time periods is temporarily dis- Off
played. Please note that the number of avail-
11:30AM
3

able programmable time periods has now de- 0

creased by one. 1 2 3 4 5 6 7

3-36
Checking the Programs 12 15 18 21 24

The Check Program menus can be use to review all 9 Prog FLASHES
set exercise start/stop times and, if necessary, de- 6 MONDAY
lete them. 3

NOTE: If the Menu button is pressed while view- 0

1 2 3 4 5 6 7
ing start/stop programs, the Program
Check function is aborted and the Home NOTE: If no exercise periods are set up, the
menu is redisplayed. message “Empty” is displayed. To
return to the New Program menu,
Reviewing Exercise Start/Stop Times press the ok button.
All exercise start and stop exercise parameters can 12 15 18 21 24

be viewed from the Program Check menu. Normal- 9 Prog

ly, the starting time is followed by the ending time 6 EMPTY
for a programmed exercise. However, if a second
3
exercise period overlaps the time frame of the first
exercise period in the current day, two start times 0
1 2 3 4 5 6 7
are displayed, followed by two stop times.
5. Use the + or − buttons to select the day of the
1. From the Home menu, press the Menu button. week you wish to check. Press the ok button.
The Program menu is displayed. The starting time for the first exercise for the
FLASHES
selected day is displayed.
12 15 18 21 24 12 15 18 21 24

9 Auto Prog Man 9 Prog FLASHES

6 PROGRAM 6 NEXT
On
3

11:30PM
3

0 0
1 2 3 4 5 6 7 1 2 3 4 5 6 7

2. Press the ok button. The New Program menu NOTE: If a day does not have any set exer-
is displayed. cise periods, the screen below is dis-
played.
12 15 18 21 24
12 15 18 21 24
9 Prog FLASHES
9 Prog FLASHES
NEW PROG
6
6 NEXT
3

−−:−−PM
3
0
1 2 3 4 5 6 7 0
1 2 3 4 5 6 7

3. Press the + button once. The Check menu is 6. Press the ok button. The ending time for the
displayed. first exercise for the selected day is displayed.
12 15 18 21 24
12 15 18 21 24

9 Prog FLASHES FLASHES

9 Prog
6 CHECK 6 NEXT
Off
3

12:00AM
3
0
0
1 2 3 4 5 6 7
1 2 3 4 5 6 7

4. Press the ok button. The Monday menu is dis- 7. Press the ok button. The next exercise start
played. time is displayed. If the next start time is not on

3-37
 the day selected in step 5, the day of the week played. Press the ok button to return to
is indicated on the bottom of the screen. the Main menu.
12 15 18 21 24
12 15 18 21 24

9 Prog FLASHES
9 Prog FLASHES
6 NEXT 6 END
On INDICATES THAT AN 3

11:30PM
3
EXERCISE IS SET
0
0 FOR SATURDAY 1 2 3 4 5 6 7
1 2 3 4 5 6 7

NOTE: If an exercise period has been pro-

8. Review additional set exercise periods and re- grammed with a start time only, a continu-
turn to the Main menu. ous band of segments is displayed on the
left side and top of the screen showing
− To exit the Check Programs function with- the time of day the incomplete exercise
out reviewing all set exercise periods, period is set to begin. This band of seg-
press the + or − buttons until “END” is dis- ments is also displayed on any other ex-
played. Press the ok button to return to ercise periods scheduled for that day.
the Main menu.
12 15 18 21 24

12 15 18 21 24 9 Prog FLASHES
6 NEXT
9 Prog FLASHES On
END
3:00 AM
6 3
OFF
0

12:00AM
3
1 2 3 4 5 6 7
0
1 2 3 4 5 6 7
If an exercise period has been pro-
grammed with a stop time only, no spe-
− To review all set exercise periods, repeat cial indicator is displayed. The stop time
steps 6 and 7 until the word “END” is dis- is simply ignored.

3-38
Deleting Exercise Start/Stop Times 5. If necessary. use the + or − buttons to select
the day of the week that includes the exercise
While checking the programs, you can also delete ending time you wish to delete.
individual start and stop times.
12 15 18 21 24

12 15 18 21 24
9 Prog FLASHES
9 Prog FLASHES 6 FRIDAY
6 NEXT 3
On

11:30
3 PM 0
1 2 3 4 5 6 7
0
1 2 3 4 5 6 7
6. Press the ok button.
1. When an programmed exercise start time is
12 15 18 21 24
displayed, press the + or − buttons until “Clear”
is displayed. 9 Prog FLASHES
6 NEXT
12 15 18 21 24 Off

12:00AM
3
9 Prog FLASHES
0
6 CLEAR 1 2 3 4 5 6 7
On

11:30PM
3
7. Press the + or − buttons until “Clear” is dis-
0
1 2 3 4 5 6 7
played.
12 15 18 21 24
2. Press the ok button. The New Program menu
is redisplayed. 9 Prog FLASHES
6 CLEAR
12 15 18 21 24 Off

12:00AM
3
9 Prog FLASHES
0
6 NEW PROG 1 2 3 4 5 6 7

3
8. Press the ok button. The New Program menu
0 is redisplayed.
1 2 3 4 5 6 7

Individual or all exercise periods can also be

3. Press the + button once. The Check menu is cleared. For more information, see “Erasing (Clear-
displayed. ing) A Programmed Exercise Period” and “Erasing
(Clearing) All Exercise Periods” below.
12 15 18 21 24

9 Prog FLASHES Erasing (Clearing) A Programmed

6 CHECK Exercise Period
3 1. From the Home menu, press the Menu button.
0 The Program menu is displayed.
1 2 3 4 5 6 7
FLASHES
4. Press the ok button. The Monday menu is dis- 12 15 18 21 24
played.
9 Auto Prog Man

12 15 18 21 24 6 PROGRAM
9 Prog FLASHES 3

6 MONDAY 0
1 2 3 4 5 6 7
3

0 2. Press the ok button. The New Program menu

1 2 3 4 5 6 7
is displayed.

3-39
 12 15 18 21 24 12 15 18 21 24

9 Prog FLASHES 9 Prog FLASHES

6 NEW PROG 6 CLEAR
On

11:30PM
3 3

0 0
1 2 3 4 5 6 7 1 2 3 4 5 6 7

6. Press the ok button. The New Program menu

3. Press the + or − button until the Clear menu is is redisplayed.
displayed. 12 15 18 21 24

9 Prog FLASHES
12 15 18 21 24
6 NEW PROG
9 Prog FLASHES
3
6 CLEAR
0
3 1 2 3 4 5 6 7

0
1 2 3 4 5 6 7 7. Repeat steps 3 thru 6 to erase the stop time for
the exercise period erased above.

4. Press the + or − button until “Single“ is dis- 8. If necessary, repeat steps 3 thru 7 for any addi-
played. tional exercise periods that need to be erased.

9. When the New Program menu is redisplayed,

12 15 18 21 24
press the + or − buttons until the word “END”
9 Prog FLASHES is displayed.
6 SINGLE
12 15 18 21 24
3
9 Prog FLASHES
0
1 2 3 4 5 6 7 6 END
3

0
5. Press the ok button. The first exercise start 1 2 3 4 5 6 7

time of the week is displayed. To select a differ-

ent exercise start time, press the + or − buttons 10. Press the ok button to return to the Home
until the desired time is displayed. menu.

3-40
Erasing (Clearing) All Programmed 4. To clear all set exercise periods, press the + or
Exercise Periods − buttons until “All” is displayed. Press the ok
button.
1. From the Home menu, press the Menu button. 12 15 18 21 24
The Program menu is displayed.
9 Prog FLASHES
FLASHES 6 ALL
12 15 18 21 24 3

0
9 Auto Prog Man 1 2 3 4 5 6 7

6 PROGRAM
3 5. The word “Confirm” is displayed. To continue
0
clearing all exercise programs, press the ok
1 2 3 4 5 6 7 button. To abort clearing all exercise pro-
grams, press the + or − buttons.
2. Press the ok button. The New Program menu 12 15 18 21 24
is displayed. FLASHES
9 Prog

12 15 18 21 24
6 CONFIRM
3
9 Prog FLASHES
6 NEW PROG 0
1 2 3 4 5 6 7

0 6. The new program menu is redisplayed. Press

1 2 3 4 5 6 7 the + or − buttons until the word “END” is dis-
played.
3. Press the + or − buttons until the Clear menu
12 15 18 21 24
is displayed.
9 Prog FLASHES
12 15 18 21 24 6 END
9 Prog FLASHES 3

6 CLEAR 0
1 2 3 4 5 6 7
3

0
1 2 3 4 5 6 7
7. Press the ok button to return to the Home
menu.

3-41
Initiating or Overriding an Exercise 12 15 18 21 24

Program 9 Auto

6
03 01 04
Off
The exercise clock has a built-in test feature that
can be used to initiate an exercise that hasn’t been
3
2:58 PM
programmed or cancel a programmed exercise in 0
1 2 3 4 5 6 7
process.
Overriding an Exercise
The control panel Load/No Load function can be
set to test the genset with or without load, as de- In the example shown below, “On” indicates that an
sired. exercise is currently active.
12 15 18 21 24
Initiating an Exercise
9 Auto

03 01 04
In the example shown below, “Off” indicates that no 6
On
exercise is currently active. 3

0
2:50 PM
1 2 3 4 5 6 7
12 15 18 21 24

Auto
9
1. With the Home menu displayed, simulta-
03 01 04
6
Off neously press the + and − buttons for approxi-
mately one second. “Override” and a hand
3

0
2:50 PM symbol are displayed on the screen. In addi-
1 2 3 4 5 6 7 tion, “On” is switched to “Off” and the exercise
is stopped.
1. With the Home menu displayed, simulta- 12 15 18 21 24

neously press the + and − buttons for approxi- 9

mately one second. “Override” and a hand OVERRIDE
6
symbol are displayed on the screen. In addi- Off
tion, “Off” is switched to “On” and the exercise
is initiated.
3

0
2:50 PM
1 2 3 4 5 6 7

12 15 18 21 24
2. To restart the exercise, simultaneously press
9
OVERRIDE the + and − buttons for approximately one sec-
6
On ond. The original Home menu is redisplayed
and “Off” is switched back to “On.”
3

0
2:50 PM
12 15 18 21 24
1 2 3 4 5 6 7

9 Auto

6
03 01 04
2. To end the exercise, simultaneously press the On
+ and − buttons for approximately one second. 3
2:58 PM
The original Home menu is redisplayed and 0
1 2 3 4 5 6 7
“On” is switched back to “Off.”

3-42
Selecting Permanent On/Off Mode 12 15 18 21 24

9
The exercise clock has a permanent on/off mode PERM OFF
feature. 6
Off

Selecting Permanent On/Off Mode Without an

3

0
2:50 PM
Active Exercise 1 2 3 4 5 6 7

In the example shown below, “Off” indicates that no 3. To return the clock to its original state, simulta-
exercise is currently active. neously press the + and − buttons for approxi-
mately one second. The original Home menu
12 15 18 21 24 is redisplayed.
9 Auto

03 01 04 Selecting Permanent On/Off Mode With an

6
Off Active Exercise
3

0
2:50 PM In the example shown below, “On” indicates that an
1 2 3 4 5 6 7 exercise is currently active.
12 15 18 21 24
1. With the Home menu displayed, simulta-
neously press the + and − buttons for approxi- 9 Auto

mately two seconds. The Override menu is 6

03 01 04
On
first displayed and then the “Perm On” and the
hand/dot symbols are displayed on the
3

0
2:50 PM
screen. In addition, a continuous band of seg- 1 2 3 4 5 6 7
ments is displayed on the left side and top of
the screen and “Off” is switched to “On.” 1. With the Home menu displayed, simulta-
neously press the + and − buttons for approxi-
12 15 18 21 24
mately two seconds. The Override menu is
9 first displayed and then the “Perm Off” and the
6
OVERRIDE hand/dot symbols are displayed on the
Off screen. In addition, “On” is switched to “Off.”
3

0
2:50 PM 12 15 18 21 24
1 2 3 4 5 6 7
9
12 15 18 21 24
6
OVERRIDE
On
9

6
PERM ON
On
3

0
2:50 PM
3

0
2:50 PM 1 2 3 4 5 6 7

12 15 18 21 24
1 2 3 4 5 6 7
9

6
PERM OFF
2. To switch to Permanent Off mode, press the + Off
and − buttons for approximately two seconds. 3
2:50 PM
“Perm Off” is displayed and “On” is switched 0
1 2 3 4 5 6 7
back to “Off.”

3-43
 2. To switch to Permanent On mode, press the +
FLASHES
and − buttons for approximately two seconds.
“Perm On” is displayed and “Off” is switched 12 15 18 21 24

back to “On.” In addition, a continuous band of 9 Auto Prog Man

segments is displayed on the left side and top 6 MANUAL
of the screen.
3

12 15 18 21 24 0
1 2 3 4 5 6 7
9

6
PERM ON 3. Press the ok button to display the Pin menu.
On
3

0
2:50 PM 12 15 18 21 24

1 2 3 4 5 6 7 9 Man

6 PIN
3. To return the clock to its original state, simulta- 3
FLASHES
neously press the + and − buttons for approxi-
0
mately one second. The original Home menu 1 2 3 4 5 6 7
is redisplayed.
NOTE: If the + or − button is pressed now,
Adding A Security Code the message “End” is displayed.
Press the ok button to return to the
A 4-digit security code number can be entered to Home menu.
prevent unauthorized personnel from using the
12 15 18 21 24
clock.
9 Man
Once a security code has been set up, the exercise 6 END
clock is locked 90 seconds after the last keystroke.
3
It can only be operated again after the correct PIN
code is entered. 0
1 2 3 4 5 6 7

CAUTION Once a PIN code has been acti-

4. Press the ok button to display the No PIN
vated and the Reset button is pressed (see “Re-
menu.
setting the Timer” on the following page), the
exercise timer can no longer be activated with- 12 15 18 21 24
out a valid PIN code. The device must be re-
9
placed if the valid PIN code is lost. Man

6 NO PIN FLASHES
1. From the Home menu, press the Menu button. 3
The Program menu is displayed.
0
1 2 3 4 5 6 7
FLASHES
12 15 18 21 24 5. Press the + or − buttons to display the With
9 Auto Prog Man
PIN menu.
6 PROGRAM 12 15 18 21 24

3
9 Man
0
6 WITH PIN FLASHES
1 2 3 4 5 6 7
3

2. Press the + button twice. The Date/Time menu 0

is displayed, followed by the Manual menu. 1 2 3 4 5 6 7

3-44
 6. Press the ok button to display the PIN Number tion screens are displayed and the default na-
menu. tional language is flashed.
NOTE: If you choose not to enter a 4-digit 12 15 18 21 24
access code at this time, the only
way to exit Manual mode is to 9

press the reset (Res) button. 6 ENGLISH

12 15 18 21 24 3

0
9 Man
1 2 3 4 5 6 7
FLASHES PIN
6

0
0−.−− 2. If the incorrect language is being displayed,
use the + or − button to scroll through the avail-
1 2 3 4 5 6 7
able languages (English, Espanol, Francais,
Portugal, Italiano, or Deutsch).
7. Press the + or − buttons to enter the first digit
of your 4-digit access code. 3. When the desired language is displayed,
press the ok button. The year is displayed
8. Press the ok button. Then press the + or − but-
next.
tons to enter the second digit of your 4-digit ac-
cess code.
12 15 18 21 24

9. Repeat step 8 for the third and fourth digit of 9

your 4-digit access code. 6
YEAR

10. Press the ok button. The Home menu is then

redisplayed.
3

0
20 03
1 2 3 4 5 6 7

After Programming the Exerciser Clock

4. Press the + button until the correct year is dis-
1. Make sure the External Exercise function on played and then press the ok button. The
the transfer switch control panel is set to “On.” month is displayed next.
For more information, see Section 4.
12 15 18 21 24
2. Place the generator set operation selector
9
switch in the Remote position. MONTH
6

3. Check the system for proper operation as de-

scribed in the Operator’s Manual.
3
01
0
1 2 3 4 5 6 7
Resetting the Timer
The Reset button should only be used in cases of 5. Press the + or − button until the correct month
an emergency. Resetting the timer erases all ex- is displayed and then press the ok button. The
isting language, date, and time settings. There- screen then shows the day value flashing.
fore, that information will need to be reentered.
Upon pressing the Res button, the clock is set to 12 15 18 21 24

12:00 midnight, Wednesday, January 1, 2003. 9

However, scheduled exercise periods remain DAY
6
intact.
3
03.01
1. Use a pointed object to press the Res button 0
1 2 3 4 5 6 7
for approximately one second. Two informa-

3-45
6. Press the + or − button until the correct day is 7. Press the + or − button until the correct hour is
displayed. Press the ok button. The screen displayed. Press the ok button. The screen
then shows the hour value flashing. then shows the minute value flashing.
12 15 18 21 24

6
HOUR
3

0
12:00AM
1 2 3 4 5 6 7

3-46
4. Control Panel Configuration
The control panel can be used to configure ATS the rear side of the cabinet door presents a
functions. When in Configuration Mode, the value shock hazard that can cause severe personal
code for the various control functions can be modi- injury or death. Use extreme caution to avoid
fied. touching electrical contacts whenever the cab-
inet door is open.
The control panel has a series of eight LEDs that
display codes that indicate various control func- Battery power (DC power) must be available to
tions that can be configured. The first five LEDs dis- configure the control panel functions. AC power
play the function code and the last three LEDs dis- may be present but doesn’t have to be present to
play the value code for the displayed function (see configure the control panel. To check for DC power,
Figure 4-1). A listing of the control functions (includ- open the transfer switch door and place the ATS in
ing the function and value codes) is included in the Normal or Emergency position. The Utility Con-
Table 4-1. Additional information on these func- nected or Genset Connected LED should light.
tions is included in Section 3.
Configuration Mode is selected by operation of a
With the exception of the Test LED, the function small slide switch located on the back of the control
and value LEDs are not lit during automatic opera- panel. The switch is located near the bottom edge
tion (Automatic Mode). of the PCB (see Figure 4-2). The switch is partially
hidden to prevent accidental operation.
ACCESSING THE FRONT PANEL
CONFIGURATION EDITOR NOTE: The Configuration Mode can be entered
at any time, but once it is selected, all auto-
WARNING AC power within the cabinet and matic operation is suspended.

Test VALUE
FUNCTION INDICATOR
INDICATOR LEDS
LEDS

Control operation could be delayed by external source.

Exercise

Test Override Set Exercise

FIGURE 4-1. CONTROL PANEL

4-1
 TABLE 4-1. ADJUSTABLE TRANSFER SWITCH FUNCTIONS
FUNCTION FUNCTION CODE VALUE CODE VALUE (Default in bold italics) Pg Ref
Not Available f f f f f NA NA NA
TDES f f f f F f f f 0 Seconds (Disabled) 3-1
(Ti
(Time Delay
D l Engine
E i f f F 0.5 Second
Start)
f F f 1 Second
f F F 2 Seconds
F f f 3 Seconds
F f F 4 Seconds
F F f 6 Seconds
F F F 10 Seconds
TDNE f f f F f f f f 0 Seconds (Disabled) 3-1
(Ti
(Time D l Normal
Delay N l to f f F 1 Second
Emergency)
f F f 2 Seconds
f F F 3 Seconds
F f f 5 Seconds
F f F 30 Seconds
F F f 120 Seconds
F F F 300 Seconds
TDEN f f f F F f f f 0 Minutes (Disabled) 3-1
(Ti
(Time Delay
D l Emergency
E f f F 0.1 Minutes (For Testing)
to Normal)
f F f 5 Minutes
f F F 10 Minutes
F f f 15 Minutes
F f F 20 Minutes
F F f 25 Minutes
F F F 30 Minutes
TDEC f f F f f f f f 0 Minutes (Disabled) 3-1
(Ti
(Time Delay
D l Engine
E i f f F 0.1 Minutes (For Testing)
Cooldown)
f F f 5 Minutes
f F F 10 Minutes
F f f 15 Minutes
F f F 20 Minutes
F F f 25 Minutes
F F F 30 Minutes
TDPT f f F f F f f f 0 Seconds (Disabled) 3-2
(Ti
(Time Delay
D l Program
P f f F 0.5 Second
Transition)
f F f 1 Second
f F F 2 Seconds
F f f 3 Seconds
F f F 4 Seconds
F F f 6 Seconds
F F F 10 Seconds

4-2
 TABLE 4-1. ADJUSTABLE TRANSFER SWITCH FUNCTIONS (CONT.)
FUNCTION FUNCTION CODE VALUE CODE VALUE (Default in bold italics) Pg Ref
TDEL f f F F f f f f 0 Seconds (Disabled) 3-2
(Ti
(Time D l Elevator
Delay El f f F 1 Second
Signal)
f F f 2 Seconds
f F F 3 Seconds
F f f 5 Seconds
F f F 30 Seconds
F F f 120 Seconds
F F F 300 Seconds
Test With/Without
/ Load f f F F F f f f Without Load 3-7
f f F With Load
External Exercise On/Off
/ f F f f f f f f Off 3−8
f f F On
Exercise With/Without
/ f F f f F f f f Without Load
L d
Load f f F With Load
System
y Nominal Voltage
g f F f F f f f f Table 1 
T bl Selection
Table S l i f f F Table 2 
System
y Nominal Voltage
g f F f F F f f f 115 400
f f F 120 415
f F f 190 440
f F F 208 460
F f f 220 480
F f F 230 550
F F f 240 575
F F F 380 600
System
y Nominal f F F f f f f f 60 Hz
F
Frequency 50/60
0/60 Hz
H f f F 50 Hz
Single
g Phase/Three
/ f F F f F f f f Three Phase
Ph
Phase f f F Single Phase
Utilityy Undervoltage
g f F F F f f f f 90% 3-4
Pi k
Pickup f f F 95%
Utilityy Undervoltage
g f F F F F f f f 90% 3-4
D
Dropout f f F 85%
f F f 80%
f F F 70%
Phase Check On/Off
/ F f f f f f f f Off 3-4
f f F On
Return to Programmed
g F f f f F f f f Off 3-4
T
Transition
i i On/Off
O /Off f f F On
Elevator Post Transfer F f f F f f f f Off 3-2
D l On/Off
Delay O /Off f f F On
Exercise Repeat
p Interval F f f F F f f f Every 7 Days 3-9
f f F Every 14 Days
f F f Every 21 Days
f F F Every 28 Days

= THESE CONTROL FUNCTIONS ARE SET AT THE FACTORY AND SHOULD NOT REQUIRE ADJUSTING.

4-3
 MODIFYING THE CONFIGURATION 8. Slide the selector switch to the Configuration
Mode position, as described on page 4-1.
TDES is always the first function shown when
The control has been configured at the factory and entering Configuration Mode.
does not require additional adjustments (default
settings are shown in bold italics in Table 4-1). 9. Press the Test pushbutton to scroll through the
However, you may wish to adjust some of the set- various control function codes displayed with
tings for better performance. the first five LEDs (see Table 4-1). The black-
filled circles indicate which LEDs are lit for the
CAUTION Incorrect settings can result in the function and value codes listed.
transfer switch failing to operate correctly.
10. Once the desired function is selected, press
Only authorized trained personnel should the Override pushbutton to change the asso-
make changes to the control function settings. ciated value code displayed with the last three
External Exercise, System Nominal Voltage, LEDs.
System Nominal Frequency, and Single Phase/
Three Phase settings are made at the factory 11. When configuration is completed, return the
and should not require any additional adjust- selector switch back to the Automatic Mode
ments. position.

SWITCH IN SWITCH IN
AUTOMATIC CONFIGURATION
MODE MODE

FIGURE 4-2. NORMAL/CONFIGURATION MODE SELECTOR SWITCH

4-4
5. Troubleshooting
This section includes a description of the control WARNING AC power within the cabinet and
LED indicators, describes a typical transfer switch the rear side of the cabinet door presents a
sequence of events, and provides troubleshooting shock hazard that can cause severe personal
procedures. injury or death. Use extreme caution to avoid
touching electrical contacts with body, tools,
The troubleshooting procedure uses conditional jewelry, hair, clothes, etc. Remove power to the
schematics and symptoms to diagnose all possible door by disconnecting connector J1 and re-
problems. move power from the battery in the control pan-
el by disconnecting J2 (on the relay panel as-
ABOUT CUSTOMER INPUTS sembly) before removing and replacing com-
In applications with remote customer inputs, the ponents. The following procedures are to be
genset may start unexpectedly as a result of these performed only by technically trained and ex-
inputs. These symptoms may appear to be caused perienced personnel.
by the transfer switch control. Verify that the remote
input is not causing the symptom or isolate the con- CONTROL PANEL LED INDICATORS
trol from these inputs before troubleshooting the
control. The control panel located on the transfer switch en-
closure door contains six LED indicators. The indi-
WARNING Improper operation of the genera- cators provide some information about the current
tor set presents a hazard that can cause severe control status and may be helpful in troubleshoot-
personal injury or death. Observe all safety pre- ing the transfer switch. See Figure 5-1, Table 5-1
cautions in your generator set manuals. and Table 5-2.

TROUBLESHOOTING PAGE

Control Panel LED Indicators5-1

Sequence of Events . . . . . 5-4
Troubleshooting With Symptoms 5-10
Utility Power Failure . . . . . 5-11
Utility Power Is Restored . 5-14
Miscellaneous Troubleshooting Issues . . 5-17

5-1
 TEST
LED

Test

UTILITY
POWER GENSET
AVAILABLE POWER
Control operation could be delayed by external source.
LED AVAILABLE
Exercise LED

TEST Test Override Set Exercise GENSET

pushbutton CONNECTED
LED

UTILITY OVERRIDE SET EXERCISE EXERCISE

CONNECTED LED pushbutton pushbutton LED

FIGURE 5-1. CONTROL PANEL

TABLE 5-1. CONTROL PANEL LED INDICATORS

Indicator Definition
Utility (Normal) Power This indicator lights when the utility source voltage sensor has determined that Utility
Available power is available and is within acceptable voltage limits.
Utility (Normal) Connected 12. Lights constantly when the transfer switch is connected to the Utility.
13. Blinks once per second when the transfer switch has failed to connect to or
disconnect from the Utility when commanded.
14. Is off when the transfer switch is not connected to the Utility.
Genset (Emergency) This indicator lights when the generator source voltage sensor has determined that
Power Available generator power is within acceptable voltage and frequency limits.
Genset (Emergency) 15. Lights constantly when the transfer switch is connected to the Genset.
Connected 16. Blinks once per second when the transfer switch has failed to connect to or
disconnect from the Genset when commanded.
17. Is off when the transfer switch is not connected to the Genset.
Exercise The following describes the Exercise LED when an exercise is enabled.
18. Lights constantly when integrated repeat exercise periods have been set.
19. Blinks twice per second when the Set Exercise button is pressed and held to set
or cancel an integrated exercise period.
20. Blinks once per second when an integrated or external exercise period is active.
21. Is off when no integrated repeat exercise periods are set.
Test 22. This indicator blinks at two times per second rate during the two seconds that the
Test button is pressed to acknowledge that a test has been activated or when the
remote test input is grounded.
23. The indicator lights constantly during the test and goes out once the test is termi-
nated or normal power has failed.

5-2
 TABLE 5-2. CONTROL PANEL CONNECTIONS

CONNECTOR PIN # FUNCTION TYPE COMMENTS

P3 1 L3 Generator
3 L1 Generator
5 L3 Utility Voltage
V lt Sensor
S
75−600 Volts AC
Inputs
7 L2 Utility
9 L1 Utility

P4 1 Functional Earth Ground Common for remote inputs

2 Remote Override Connect to P4-1 to activate
3 Remote Test Connect to P4-1 to activate
4 External Exerciser Clock Connect to P4-1 to activate
5 Transfer Inhibit Inputs Connect to P4-1 to activate
6 Retransfer Inhibit Connect to P4-1 to activate
Connected to Utility Connect to P4-1 to activate when
7
(Normal) connected to utility power
Connected to Genset Connect to P4-1 to activate when
8
(Emergency) connected to the genset

P5 Grounded to energize open normal

1 Open Normal (Utility)
K2 relay
Grounded to energize close normal
2 Close Normal (Utility)
K3 relay
Open Emergency Grounded to energize open
3
(Genset) emergency K1 relay
Close Emergency Outputs Grounded to energize close
4
(Genset) emergency K3 relay
Grounded to energize elevator
5 Elevator Pretransfer
pretransfer relay
6 Genset Start Relay Dry contact closes (de-energizes) to
start the genset and is held open
7 Genset Start Relay (energized) to stop the genset
8 Ground Input (−) Battery
8 35 volts DC
8−35
9 B+ Input Connections

5-3
 SEQUENCE OF EVENTS 6. After the TDNE expires, the control enables
the Open Normal output by grounding P5-1,
The control executes a prescribed sequence of energizing the K2 relay coil.
events for all transfer switch operations.
7. The transfer switch moves to the Neutral posi-
Normal to Emergency Sequence of tion.
Events
NOTE: Auxiliary switch S5 on the transfer
The following describes the sequence of events for switch electrically breaks the signal to
an OTEC transfer switch during a normal (utility) the transfer switch operator and keeps
power failure. In this example, TDNE and TDPT the transfer switch in the Neutral posi-
are set higher than zero, TDEL is set to zero, and tion.
phase check is not enabled.
8. Auxiliary switch S3 removes the ground signal
Steps 1 thru 8 describe what normally happens from P4-7, signaling that the ATS has discon-
when the transfer switch is in the Normal position, nected from Normal; then the Utility Con-
utility power fails, and the switch transfers to the nected LED goes out.
Neutral position (see Figure 5-2). Steps 9 thru 12
describe what then normally happens when the 9. The control starts the time delay programmed
switch then moves from the Neutral position to the transition (TDPT) timer.
Emergency position (see Figure 5-3).
10. When the TDPT timer expires, both the Open
1. While the transfer switch is connected to the Normal (P5-1) and Close Emergency (P5-4)
utility (Normal position), utility power fails. The outputs are grounded, energizing K2 and K3
Utility Connected LED remains lit but the Utility relay coils to move the transfer switch from the
Power Available LED goes out. Neutral position to the Emergency position.
Auxiliary switch S8 breaks the signal.
2. The time delay engine start (TDES) begins.

3. When the TDES expires, K10 is de-energized 11. The load is transferred to the generator.
and the start contact closes P5-6 and P5-7,
sending a start signal to the generator. 12. Auxiliary switch S7 provides a ground signal to
P4-8, signaling that the ATS has transferred;
4. When the generator starts and produces pow- then the Genset Connected LED lights. The
er, the Genset Power Available LED lights. control then removes the ground signal from
the Open Normal (P5-1) and Close Emergen-
5. A time delay normal to emergency (TDNE) be- cy (P5-4) outputs, de-energizing relays K2 and
gins. K3.

5-4
Emergency to Normal Sequence of the transfer switch operator and keeps
Events the transfer switch in the Neutral posi-
tion.
The following describes the sequence of events for
an OTEC transfer switch that occur after the load 5. Auxiliary switch S7 removes the ground signal
has been transferred to the genset and then utility from P4-8, signaling that the ATS has discon-
power is restored. In this example, TDEN and nected from Emergency; then the Genset
TDPT are set higher than zero, TDEL is set to zero, Connected LED goes out.
and phase check is not enabled.
6. The control starts the TDPT timer.
Steps 1 thru 5 describe what normally happens
when the transfer switch is in the Emergency posi- 7. When the TDPT timer expires, the control
tion (connected to the genset), utility power returns, grounds both the Open Emergency (P5-3) and
and the switch transfers to the Neutral position (see Close Normal (P5-2) outputs, energizing K1
Figure 5-4). Steps 6 thru 10 describe what then nor- and K3 relay coils to move the transfer switch
mally happens when the switch then moves from from the Neutral position to the Normal posi-
the Neutral position to the Normal position (see Fig- tion. The load is transferred to the utility.
ure 5-5).
8. Auxiliary switch S3 provides a ground signal to
1. The utility returns. The Utility Power Available P4-7, signaling that the ATS has transferred;
LED lights. then the Utility Connected LED lights. The con-
trol then removes the ground signal from the
2. A time delay emergency to normal (TDEN) be-
Open Emergency (P5-3) and Close Normal
gins.
(P5-2) outputs, de-energizing relays K1 and
3. After the TDEN expires, the control grounds K3.
the Open Emergency output (P5-3), energiz-
ing K1 relay coil. 9. The control starts the time delay engine cool-
down (TDEC) timer.
4. The transfer switch moves to the Neutral posi-
tion. 10. When the TDEC timer expires, the P5-6 and
P5-7 contacts open, relay K10 opens, the gen-
NOTE: An auxiliary switch (S9) on the transfer erator stops running and the Genset Power
switch electrically breaks the signal to Available LED goes out.

5-5
This Page Intentionally Left Blank.

5-6
 ENERGIZED
CHANGING POSITION

LEGEND:

FOR A DESCRIPTION OF WHAT NORMALLY HAPPENS WHEN

THE TRANSFER SWITCH IS IN THE NORMAL POSITION, UTILITY
POWER FAILS, AND THE SWITCH TRANSFERS TO THE NEUTRAL
POSITION, SEE STEPS 1 THRU 8 ON PAGE 5-4.

FIGURE 5-2. TYPICAL CONDITIONAL SCHEMATIC − LOSS OF UTILITY POWER OCCURS, TRANSFER FROM UTILITY (SOURCE 1) TO NEUTRAL

5-7
 ENERGIZED
CHANGING POSITION

LEGEND:

FOR A DESCRIPTION OF WHAT NORMALLY HAPPENS

DESCRIBE WHEN THE SWITCH THEN MOVES FROM THE
NEUTRAL POSITION TO THE EMERGENCY POSITION, SEE
STEPS 9 THRU 12 ON PAGE 5-4.

FIGURE 5-3. TYPICAL CONDITIONAL SCHEMATIC − GENSET (SOURCE 2) AVAILABLE, TRANSFER FROM NEUTRAL TO THE GENSET

5-8
 ENERGIZED
CHANGING POSITION

LEGEND:

FOR A DESCRIPTION OF WHAT NORMALLY HAPPENS WHEN

THE TRANSFER SWITCH IS IN THE EMERGENCY POSITION
(CONNECTED TO THE GENSET), UTILITY POWER RETURNS,
AND THE SWITCH TRANSFERS TO THE NEUTRAL POSITION,
SEE STEPS 1 THRU 5 ON PAGE 5-5.

FIGURE 5-4. TYPICAL CONDITIONAL SCHEMATIC − UTILITY POWER RETURNS, TRANSFER FROM GENSET (SOURCE 2) TO NEUTRAL

5-9
 ENERGIZED
CHANGING POSITION

LEGEND:

FOR A DESCRIPTION OF WHAT NORMALLY HAPPENS WHEN

THE SWITCH THEN MOVES FROM THE NEUTRAL POSITION TO
THE NORMAL POSITION, SEE STEPS 6 THRU 10 ON PAGE 5-5.

FIGURE 5-5. TYPICAL CONDITIONAL SCHEMATIC − UTILITY POWER AVAILABLE, TRANSFER FROM NEUTRAL TO UTILITY (SOURCE 1)

5-10
This Page Intentionally Left Blank.

5-11
 TROUBLESHOOTING WITH SYMPTOMS age dependant (12 or 24 volts, depending on
the genset start battery).
Use the troubleshooting guide to help diagnose
transfer switch problems. It is divided into sections  If the switch is left connected to a DC power
based on the symptom. Common problems are source (for example, the genset start battery)
listed with their possible causes. Refer to the cor- but there is no AC power available, the control
rective action column for the appropriate test or ad- panel Connected LED for that power source
justment procedure. The section page number in will still be lit.
the right column lists the location of the test or ad-  The transfer, retransfer, and program transi-
justment procedure in the manual. tion relays (K1, K2, and K3) are pulsed and are
NOTE: In the schematics shown in this section, powered for only one second, or until an auxil-
“Source 1 Position” refers to the Normal iary contact (S3 or S7) changes state, and then
position on the transfer switch which is the power is removed (the relays are de-ener-
connected to the utility power source. gized). When a relay is being energized, there
“Source 2 Position” refers to the Emer- is an audible click.
gency position on the transfer switch  The software includes a motor retry function.
which is connected to the generator set. If the switch fails to transfer within one second,
Conditional schematics are used to highlight the power is removed and the software waits ten
circuit that is energized during the sequence of the seconds before trying again. After five at-
events. These conditional schematics are for a typ- tempts, the software quits trying and either the
ical transfer switch with options. Always refer to the Utility Connected LED or the Genset Con-
schematic and wiring diagram package that was nected LED flashes, depending on which part
shipped with the transfer switch for specific infor- of the switch circuit has failed. All operations
mation about its configuration. are then locked out until the software is reset
by pressing the Override pushbutton on the
Make a thorough inspection of the transfer switch control panel.
wiring to make sure that good wire harness and
ground connections are made. Correct wiring prob- Troubleshooting Warnings
lems before performing any test or replacing any
components. WARNING AC power within the cabinet and
the rear side of the cabinet door presents a
Transfer Switch Operation shock hazard that can cause severe personal
When troubleshooting the OTEC transfer switch, it injury or death. Use extreme caution to avoid
is important to remember the following: touching electrical contacts with body, tools,
jewelry, hair, clothes, etc. Remove power to the
 The control uses an auxiliary contact (S3 and door by disconnecting connector J1 and re-
S7) on either side of the switch to determine if move power from the battery in the control pan-
the switch has opened or closed. If the switch el by disconnecting J2 (on the relay panel as-
is bad, the control will continue to either open sembly) before removing and replacing com-
or close that side of the switch. ponents. The following procedures are to be
 The control supplies a grounding signal to pick performed only by technically trained and ex-
up the control relays (K1, K2, and K3). perienced personnel.
 All inputs are activated by applying a ground to WARNINGImproper operation of the genera-
the signal input. tor set presents a hazard that can cause severe
 The control operates over a DC voltage range personal injury or death. Observe all safety pre-
of 8 to 35 volts but the control relays are volt- cautions in your generator set manuals.

5-10
 UTILITY POWER FAILURE

UTILITY POWER (SOURCE 1) FAILS BUT THE GENSET DOES NOT START

WARNING AC power within the cabinet and the rear side of

the cabinet door presents a shock hazard that can cause se-
vere personal injury or death. Use extreme caution to avoid
touching electrical contacts with body, tools, jewelry, hair,
clothes, etc. Remove power to the door by disconnecting
connector J1 and remove power from the battery in the con-
trol panel by disconnecting J2 (on the relay panel assembly)
before removing and replacing components. The following
procedures are to be performed only by technically trained
and experienced personnel.
WARNING Improper operation of the generator set pres-
ents a hazard that can cause severe personal injury or
death. Observe all safety precautions in your generator set
manuals.
Section-
Problem Possible Cause Corrective Action
Page
Genset cranks but does There may be a genset problem. Check the fuel system. Refer to the
not start genset’s service manual.
Genset does not crank 1. A time delay engine start 1. Wait until the time delay (up to 3−1
(TDES) may be timing. 10 seconds) has expired, press
the Override pushbutton on the 3−5
control panel, or ground the
Override input.
2. There may not be a genset 2. Check for a genset start signal
start signal. (closed contact between P5-6
and P5-7).
3. The genset may be waiting for 3. Verify that the genset control is
a remote start command. set for Remote Start.
4. There may be defective wiring. 4a. Check the start circuit wiring
5-7
(see Figure 5-2).
4b. Check the wiring between the
ATS and the genset control.
5. There may be a defective bat- 5. Check the batteries and cable
tery or cables. connections.
6. The genset control may not be 6. Check the genset control for
functioning correctly. proper operation.

5-11
 GENSET IS RUNNING BUT THE ATS DID NOT TRANSFER TO THE GENSET
WARNING AC power within the cabinet and the rear side of
the cabinet door presents a shock hazard that can cause se-
vere personal injury or death. Use extreme caution to avoid
touching electrical contacts with body, tools, jewelry, hair,
clothes, etc. Remove power to the door by disconnecting
connector J1 and remove power from the battery in the con-
trol panel by disconnecting J2 (on the relay panel assembly)
before removing and replacing components. The following
procedures are to be performed only by technically trained
and experienced personnel.
WARNING Improper operation of the generator set pres-
ents a hazard that can cause severe personal injury or
death. Observe all safety precautions in your generator set
manuals.
Section-
Indicator Possible Cause Corrective Action
Page
Genset Avail- 1. There may be improper voltage at 1a. Check for proper genset voltage be-
able LED is off the voltage sensor inputs. tween P3-1 and P3-3. The voltage
must be higher than the genset volt-
age sensor pickup point.
1b. Check voltage sensing wiring be-
tween the control and the ATS.
2. There may be improper voltage 2. Check for proper genset voltage be-
between the ATS power terminals. tween ATS power terminals EA and
EC. Voltage must be higher than the
genset voltage sensor pickup point.
3. There may be improper voltage at 3a. Check for proper voltage at genset
the genset output terminals. output terminals. Voltage must be
higher than the genset voltage sen-
sor pickup point.
3b. Check the power circuit wiring be-
tween the ATS and the genset.
Genset Avail- 1. A time delay normal to emergency 1. Wait until the time delay (up to 300 3−1
able LED is on (TDNE) may be timing seconds) has expired, press the
Override pushbutton on the control 3−5
panel, or ground the Override input.
2. There may be an active transfer 2. Check for ground on P4-5. If pres- 3−5
inhibit. ent, remove the ground or press the
Override pushbutton.
3. A time delay elevator pre-transfer 3. Check for a ground on P5-5. If pres- 3−2
(TDEL) may be timing. ent either remove the ground or
else wait until the time delay (up to
300 seconds) has expired.

5-12
 GENSET IS RUNNING BUT THE ATS DID NOT TRANSFER TO THE GENSET (CONT.)
WARNING AC power within the cabinet and the rear side of
the cabinet door presents a shock hazard that can cause se-
vere personal injury or death. Use extreme caution to avoid
touching electrical contacts with body, tools, jewelry, hair,
clothes, etc. Remove power to the door by disconnecting
connector J1 and remove power from the battery in the con-
trol panel by disconnecting J2 (on the relay panel assembly)
before removing and replacing components. The following
procedures are to be performed only by technically trained
and experienced personnel.
WARNING Improper operation of the generator set pres-
ents a hazard that can cause severe personal injury or
death. Observe all safety precautions in your generator set
manuals.
Section-
Indicator Possible Cause Corrective Action
Page
Utility Con- The control was unsuccessful in its at- 1. Check the Open Normal circuit for a
nected LED is tempts to open the Normal side of the bad connection, open wire, or a
flashing ATS. After 5 attempts to move the ATS, faulty part.
the Utility Connected LED flashes, indi- 2. Check K2, S5, CB1, and the linear 5-7
cating that it failed to open. motor (see Figure 5-2).
To open Normal, the control grounds 3. Press the Override pushbutton to 3−5
P5-1 to energize K2 for 1 second and reset the control so it will try to open
monitors the Source 1 position input the Normal side of the ATS. Ob-
(P4-7) to see if auxiliary switch S3 serve what happens.
opens. If S3 doesn’t open, the control
de-energizes K2, waits 10 seconds, and
tries again. If S3 doesn’t open after the
fifth try, the Utility Connected LED
flashes and the control quits trying.
NOTE: The above description de-
scribes the operation if the pro-
grammed transition timer is set
higher than zero. If TDPT is set
to zero, the control grounds
both the P5-1 and P5-4 outputs
to energize the K2 and K3 re-
lays to transfer the ATS to
Emergency. If phase check is
enabled, then both K2 and K3
are also energized but not until
both sources are in phase.

5-13
 GENSET IS RUNNING BUT THE ATS DID NOT TRANSFER TO THE GENSET (CONT.)
WARNING AC power within the cabinet and the rear side of
the cabinet door presents a shock hazard that can cause se-
vere personal injury or death. Use extreme caution to avoid
touching electrical contacts with body, tools, jewelry, hair,
clothes, etc. Remove power to the door by disconnecting
connector J1 and remove power from the battery in the con-
trol panel by disconnecting J2 (on the relay panel assembly)
before removing and replacing components. The following
procedures are to be performed only by technically trained
and experienced personnel.
WARNING Improper operation of the generator set pres-
ents a hazard that can cause severe personal injury or
death. Observe all safety precautions in your generator set
manuals.
Section-
Indicator Possible Cause Corrective Action
Page
Genset Con- The control was unsuccessful in its at- 1. Check the Close Emergency circuit
nected LED is tempts to close the Emergency side of for a bad connection, open wire, or
flashing the ATS. After 5 attempts to move the faulty part.
ATS, the Genset Connected LED 2. Check K2, K3, S8, CB1, and the lin- 5-8
flashes, indicating that it failed to close. ear motor (see Figure 5-3).
To close Emergency, the control 3. Press the Override pushbutton to 3−5
grounds P5-1 and P5-4 to energize K2 reset the control so it will try to close
and K3 for 1 second and monitors the the Emergency side of the ATS. Ob-
Source 2 position input (P4-8) to see if serve what happens.
auxiliary switch S7 closes. If S7 doesn’t
close, the control de-energizes K2 and
K3, waits 10 seconds, and tries again. If
S7 doesn’t close after the fifth try, the
Emergency Connected LED flashes and
the control quits trying.

5-14
 UTILITY POWER IS RESTORED
UTILITY POWER IS RESTORED BUT THE SWITCH DOES NOT TRANSFER TO NORMAL
WARNING AC power within the cabinet and the rear side of
the cabinet door presents a shock hazard that can cause se-
vere personal injury or death. Use extreme caution to avoid
touching electrical contacts with body, tools, jewelry, hair,
clothes, etc. Remove power to the door by disconnecting
connector J1 and remove power from the battery in the con-
trol panel by disconnecting J2 (on the relay panel assembly)
before removing and replacing components. The following
procedures are to be performed only by technically trained
and experienced personnel.
WARNING Improper operation of the generator set pres-
ents a hazard that can cause severe personal injury or
death. Observe all safety precautions in your generator set
manuals.
Section-
Indicator Possible Cause Corrective Action
Page
Utility Power 1. There may be improper voltage at 1. Check for proper utility voltage be-
Available LED the voltage sensor inputs. tween P3-5, P3-7, and P3-9. Volt-
is off age must be higher than the utility
voltage sensor pickup point.
a. Check voltage sensing wiring
between the control and the
ATS.
b. Make sure the utility voltage
sensing pickup setting and drop-
2. There may be improper utility volt- out setting aren’t both set at
age between the ATS power termi- 90%.
nals. 2a. Check for proper utility power be-
tween ATS power terminals NA, NB,
and NC. Voltage must be higher
than the utility voltage sensor pickup
point.
2b. Check power circuit wiring between
the ATS and the upstream circuit
breaker.

5-15
 UTILITY POWER IS RESTORED BUT THE SWITCH DOES NOT TRANSFER TO NORMAL (CONT.)
WARNING AC power within the cabinet and the rear side of
the cabinet door presents a shock hazard that can cause se-
vere personal injury or death. Use extreme caution to avoid
touching electrical contacts with body, tools, jewelry, hair,
clothes, etc. Remove power to the door by disconnecting
connector J1 and remove power from the battery in the con-
trol panel by disconnecting J2 (on the relay panel assembly)
before removing and replacing components. The following
procedures are to be performed only by technically trained
and experienced personnel.
WARNING Improper operation of the generator set pres-
ents a hazard that can cause severe personal injury or
death. Observe all safety precautions in your generator set
manuals.
Section-
Indicator Possible Cause Corrective Action
Page
Utility Power 1. A time delay emergency to normal 1. Wait until the time delay (up to 30 3−1
Available LED (TDEN) may be timing. minutes) has expired, press the
is on Override pushbutton on the control
panel, or ground the Override input.
2. There may be an active retransfer 2. Check for ground on P4-6. If pres-
inhibit input. ent, remove the ground or press the
Override pushbutton.
3. A TDEL may be timing. 3. Check for a ground on P5-5. If pres-
ent, either remove the ground or
else wait until the time delay (up to
300 seconds) has expired.
4. A Phase Check may be enabled 4a. Check phase rotation
and the sources are not in phase. 4b. Check frequency differences be-
tween the two sources. Frequency
differences must be 1 Hz or less.
4c. Both sources may be at the exact
same frequency but not in phase.
The phase angle difference be-
tween the sources must be 25 de-
grees or less. Enable the “Returned
to Programmed Transition” function.
If the sources don’t meet the re-
quirements of in-phase for 2 min-
utes, then the control will transfer
the ATS in the programmed transi-
tion mode.

5-16
 UTILITY POWER IS RESTORED BUT THE SWITCH DOES NOT TRANSFER TO NORMAL (CONT.)
WARNING AC power within the cabinet and the rear side of
the cabinet door presents a shock hazard that can cause se-
vere personal injury or death. Use extreme caution to avoid
touching electrical contacts with body, tools, jewelry, hair,
clothes, etc. Remove power to the door by disconnecting
connector J1 and remove power from the battery in the con-
trol panel by disconnecting J2 (on the relay panel assembly)
before removing and replacing components. The following
procedures are to be performed only by technically trained
and experienced personnel.
WARNING Improper operation of the generator set pres-
ents a hazard that can cause severe personal injury or
death. Observe all safety precautions in your generator set
manuals.
Section-
Indicator Possible Cause Corrective Action
Page
Genset Con- The control was unsuccessful in its at- 1. Check the Open Emergency circuit
nected LED is tempts to open the Emergency side of for a bad connection, open wire, or
flashing the ATS. After 5 attempts to move the a faulty part.
ATS, the Emergency Connected LED 2. Check K1, S9, CB1, and the linear 5-9
flashes, indicating that it failed to open. motor (see Figure 5-4).
To open Emergency, the control 3. Press the Override pushbutton to 3−5
grounds P5-3 to energize K1 for 1 sec- reset the control so it will try to open
ond and monitors the Source 2 position the Emergency side of the ATS. Ob-
input (P4-8) to see if auxiliary switch S7 serve what happens.
opens. If S7 doesn’t open, the control
de-energizes K1, waits 10 seconds, and
tries again. If S7 doesn’t open after the
fifth try, the Genset Connected LED
flashes and the control quits trying.
NOTE: The above description de-
scribes the operation if the pro-
grammed transition timer is set
higher than zero. If TDPT is set
to zero, the control grounds
both the P5-2 and P5-3 outputs
to energize the K1 and K3 re-
lays to transfer the ATS to Nor-
mal. If phase check is enabled,
then both K1 and K3 are also
energized but not until both
sources are in phase.

5-17
 UTILITY POWER IS RESTORED BUT THE SWITCH DOES NOT TRANSFER TO NORMAL (CONT.)
WARNING AC power within the cabinet and the rear side of
the cabinet door presents a shock hazard that can cause se-
vere personal injury or death. Use extreme caution to avoid
touching electrical contacts with body, tools, jewelry, hair,
clothes, etc. Remove power to the door by disconnecting
connector J1 and remove power from the battery in the con-
trol panel by disconnecting J2 (on the relay panel assembly)
before removing and replacing components. The following
procedures are to be performed only by technically trained
and experienced personnel.
WARNING Improper operation of the generator set pres-
ents a hazard that can cause severe personal injury or
death. Observe all safety precautions in your generator set
manuals.
Section-
Indicator Possible Cause Corrective Action
Page
Utility Con- The control was unsuccessful in its at- 1. Check the Close Normal circuit for a
nected LED is tempts to close the Normal side of the bad connection, open wire, or faulty
flashing ATS. After 5 attempts to move the ATS, part.
the Utility Connected LED flashes, indi- 2. Check K1, K3, S4, CB1, and the lin- 5-10
cating that it failed to close. ear motor (see Figure 5-5).
To close Normal, the control grounds 3. Press the Override pushbutton to 3−5
P5-2 and P5-3 to energize K1 and K3 reset the control so it will try to close
for 1 second and monitors the Source 1 the Normal side of the ATS. Ob-
position input (P4-7) to see if auxiliary serve what happens.
switch S3 closes. If S3 doesn’t close,
the control de-energizes K1 and K3,
waits 10 seconds, and tries again. If S3
doesn’t close after the fifth try, the Utility
Connected LED flashes and the control
quits trying.

5-18
 SWITCH TRANSFERRED TO NORMAL BUT THE GENSET CONTINUES TO RUN
WARNING AC power within the cabinet and the rear side of
the cabinet door presents a shock hazard that can cause se-
vere personal injury or death. Use extreme caution to avoid
touching electrical contacts with body, tools, jewelry, hair,
clothes, etc. Remove power to the door by disconnecting
connector J1 and remove power from the battery in the con-
trol panel by disconnecting J2 (on the relay panel assembly)
before removing and replacing components. The following
procedures are to be performed only by technically trained
and experienced personnel.
WARNING Improper operation of the generator set pres-
ents a hazard that can cause severe personal injury or
death. Observe all safety precautions in your generator set
manuals.
Section-
Problem Possible Cause Corrective Action
Page
Genset did not 1. A time delay engine cooldown 1. Wait for the time delay (up to 30 3−1
shut down after (TDEC) may be timing. minutes) to expire.
the ATS has trans- 2. The genset may not have received 2. Check for a genset stop signal
ferred to Normal a stop signal. (open contact between P5-6 and
position P5-7).
3. The selector switch on generator 3. Check to see if the genset control
set control panel may not be in the is set for Remote Start.
correct position.
4. There may be defective wiring. 4. Check the start circuit wiring (see
5-9
Figure 5-4).
5. The genset control may not be op- 5. Check the genset control for prop-
erating correctly. er operation.

5-19
 MISCELLANEOUS TROUBLESHOOTING ISSUES

MISCELLANEOUS
WARNING AC power within the cabinet and the rear side of
the cabinet door presents a shock hazard that can cause se-
vere personal injury or death. Use extreme caution to avoid
touching electrical contacts with body, tools, jewelry, hair,
clothes, etc. Remove power to the door by disconnecting
connector J1 and remove power from the battery in the con-
trol panel by disconnecting J2 (on the relay panel assembly)
before removing and replacing components. The following
procedures are to be performed only by technically trained
and experienced personnel.
WARNING Improper operation of the generator set pres-
ents a hazard that can cause severe personal injury or
death. Observe all safety precautions in your generator set
manuals.
WARNING Ignition of explosive battery gasses can cause
severe personal injury. Do not smoke or cause any spark,
arc, or flame while servicing batteries.
Section-
Problem Possible Cause Corrective Action
Page
Genset running 1. The genset may not have received 1. Check for a genset stop signal
for no apparent a stop signal. (open contact between P5-6 and
reason P5-7).
2. The selector switch on generator 2. Check to see if the genset control
set control panel may not be in the is set for Remote Start.
correct position.
3. There may be defective wiring. 3. Check the start circuit wiring (see 5-9
Figure 5-4).
4. The genset control may not be op- 4. Check the genset control for prop-
erating correctly. er operation.

5-20
 MISCELLANEOUS (CONT.)
WARNING AC power within the cabinet and the rear side of
the cabinet door presents a shock hazard that can cause se-
vere personal injury or death. Use extreme caution to avoid
touching electrical contacts with body, tools, jewelry, hair,
clothes, etc. Remove power to the door by disconnecting
connector J1 and remove power from the battery in the con-
trol panel by disconnecting J2 (on the relay panel assembly)
before removing and replacing components. The following
procedures are to be performed only by technically trained
and experienced personnel.
WARNING Improper operation of the generator set pres-
ents a hazard that can cause severe personal injury or
death. Observe all safety precautions in your generator set
manuals.
WARNING Ignition of explosive battery gasses can cause
severe personal injury. Do not smoke or cause any spark,
arc, or flame while servicing batteries.
Section-
Problem Possible Cause Corrective Action
Page
Front panel test 1. The control is not set to Test With 1. Check the control setting to verify 3−6, 4-3
doesn’t transfer Load. that the Test With/Without Load
the load function has been set to With
2. The control is set to Test With Load Load.
but one of the following has oc- 2. If the control has been set to Test
curred. With Load,
a. The transfer time delay may 3−1
not have expired. a. The TDNE can be set for up to
300 seconds. If you do not wish
to wait until the time delay ex- 3−5
pires, press the Override push-
b. There may be an active trans- button.
fer inhibit. b. Check for ground on P4-5. If a
transfer inhibit is enabled, the 3−5
load transfer will not take place
until the Override pushbutton
on the control panel is pressed
or the transfer inhibit input is
c. There may be an active TDEL. disabled.
3−2
c. Check for a ground on P5-5. If
present, either remove the
ground or else wait until the
time delay has expired. The
TDEL can be set for up to 300
d. A phase check may be en- seconds.
3-4
abled. d. When the phase check function
is enabled, the genset does not
assume the load until both
sources are within acceptable
limits of the phase check sen-
sor.

5-21
 MISCELLANEOUS (CONT.)
WARNING AC power within the cabinet and the rear side of
the cabinet door presents a shock hazard that can cause se-
vere personal injury or death. Use extreme caution to avoid
touching electrical contacts with body, tools, jewelry, hair,
clothes, etc. Remove power to the door by disconnecting
connector J1 and remove power from the battery in the con-
trol panel by disconnecting J2 (on the relay panel assembly)
before removing and replacing components. The following
procedures are to be performed only by technically trained
and experienced personnel.
WARNING Improper operation of the generator set pres-
ents a hazard that can cause severe personal injury or
death. Observe all safety precautions in your generator set
manuals.
WARNING Ignition of explosive battery gasses can cause
severe personal injury. Do not smoke or cause any spark,
arc, or flame while servicing batteries.
Section-
Problem Possible Cause Corrective Action
Page
Remote test There is no contact between TB2-5 Close the contact to start a test. 2-8
doesn’t function and TB2-8.

Unit did not exer- 1. The selector switch on generator 1. Verify that the operation selector
cise. set control panel may not be in the switch on the generator set control
correct position. panel is set to the Remote posi-
2. Although the optional external ex- tion. 3−8, 4-4
erciser is installed, the External 2. If the optional external exerciser is
Exercise function may not be set installed, enter Configuration
to On. Mode and verify that the External
Exercise function on the control
panel has been set to On.
3. An exercise period may not be set 3. Check the Exercise LED on the
or is set but not yet started. control panel to see if it is lit.
3−8,
a. If the Exercise LED is not lit, no 3-29
exercise period has been set.
Refer to the exerciser program-
ming procedure for information
on setting an exercise.
b. If the Exercise LED is lit but not
flashing, the exercise period
has not yet started. Integrated
exercisers do not display exer-
cise start and stop times. If the 3-37
optional external exerciser is
enabled, check the exercise
clock to see when an exercise
is scheduled.
4. There may be genset problems. 4. Try starting the generator set using
its start-stop controls. If it does not
crank, check the starting batteries
and cable connections. If it cranks
but does not start, check the fuel
supply.

5-22
 15/12 AMP BATTERY CHARGER Fault Alarm Output Connector
TROUBLESHOOTING AND FAULTS
The battery charger includes a fault output relay
The 15/12-amp battery charger includes one set of that is activated (contacts close) when faults occur.
Form B alarm contacts (corresponding to the status The contacts are rated at 2 amps/30 VDC. This fea-
LED on the control panel). When red, this LED indi- ture can be used by wiring a fault indicator to the
cates a fault condition. The control panel also dis- fault alarm output connector located on the front of
plays the fault codes listed in Table 5-4. the battery charger (see Figure 2-17). A 2-pin plug
connector (323−1678−02) is shipped with the
When a fault occurs, the red fault LED lights and a 15/12-amp transfer switch battery charger.
brief description of the fault and the numeric fault
code is displayed on the digital display (see Fig- FIGURE 5-6.
ure 5-7). To correct the fault, find the fault code
number in Table 5-4 and take the suggested cor-
rective actions. If the problem persists, call an au-
thorized Cummins Power Generation distributor for
help.

Clearing Faults
Most displayed faults are cleared by removing the
fault. However, faults 379 − OVER CURR, 442 −
HIGH BATT VOLT, and 9115 − BATT FAIL can only
be cleared by cycling completely through the Setup
RESET DIGITAL LED STATUS
menus or by powering down the charger after the
BUTTON DISPLAY INDICATOR
fault is corrected. (More information on Setup me-
nus is included in the Battery Charger Operator’s FIGURE 5-7. 15/12-AMP CHARGER CONTROL
Manual.) PANEL

5-23
 TABLE 5-3. TABLE 5-4. BATTERY CHARGER TROUBLESHOOTING USING FAULT CODES

WARNING Some battery charger service procedures present hazards that can result in se-
vere personal injury or death. Only trained and experienced personnel may perform service.
WARNING Ignition of explosive battery gasses can cause severe personal injury. Do not
smoke or cause any spark, arc, or flame while servicing batteries.
Fault Description Possible Cause Solution
379 − OVER Output Overload Output current is excessive. Cycle through the Setup
CURR Charger control may be menus to try and clear the
failing. fault. If the fault returns, the
charger control may have
failed.
441 − LOW BATT Low Batteryy 1.No battery connected. Connect the battery.
VOLT V l
Voltage 2.Output breaker is in the Verify the output breaker is
“Off” (down) position. in “On” (up) position.
3.A 12V battery is con- Attach a 24V battery or set
nected but the charger is the charger for 12V
set for 24V charging. charging.
4.Battery can no longer Replace the battery.
maintain charge.
5.The wire between the Check the wire.
charger and the battery is
loose or broken.

442 − HIGH BATT High Battery 1.A 24V battery is con- Attach a 12V battery or set
VOLT Voltage nected but the charger is the charger for 24V
set for 12V charging. charging.
2.Large load dump may Cycle through the Setup
have caused momentary menus to clear the fault and
voltage rise. restart charging.

2331 − LOW AC Low Input Voltage AC input voltage is more Check level of input voltage.
VOLT than 10% below nominal Charger will not operate with
rated voltage. voltage 10% or more below
nominal.
2358 − HIGH AC High Input Voltage AC input voltage is more Check level of input voltage.
VOLT than 10% above nominal Charger will not operate with
rated voltage. voltage 10% or more above
nominal.
2263 − HIGH BATT Battery Temp 1.Battery’s ambient temper- Move the battery into a
TEMP above 55 degrees ature is too high. cooler location. Charger will
C automatically begin charging
(For installations again after the battery
that include the temperature lowers.
optional battery
temperature 2.Possible shorted cells Replace the battery.
sensor) within the battery is caus-
ing an excessive battery
temperature increase.

5-24
 TABLE 5-3. TABLE 5-4. BATTERY CHARGER TROUBLESHOOTING USING FAULT CODES (CONT.)
WARNING Some battery charger service procedures present hazards that can result in se-
vere personal injury or death. Only trained and experienced personnel may perform service.
WARNING Ignition of explosive battery gasses can cause severe personal injury. Do not
smoke or cause any spark, arc, or flame while servicing batteries.
Fault Description Possible Cause Solution
2544 − OVER Charger is 1.Charger’s ambient tem- Move the charger to a
TEMP overheating perature is too high. cooler location. The charger
will automatically begin
charging again after the
internal temperature lowers.
2.Charger’s internal cooling Verify that the charger’s air
fan is blocked, failed, or inlets on the side of the
air inlets are covered. charger are not blocked and
nothing is interfering with fan
rotation.
9115 − BATT FAIL Unrecoverable The battery can no longer Replace the battery and
battery hold a charge or has been cycle through the Setup
damaged excessively due to menus to clear the fault.
extremely deep discharge.
NOTE: Faults 379 (OVER CURR), 442 (HIGH BATT VOLT), and 9115 (BATT FAIL) can only be cleared:
. By disconnecting the charger harness plug,
. By cycling completely through the Setup menus,
or
. By recycling the power.

Battery Charger Fails to Charge

WARNING AC power
within the cabinet and For 120, 208, and 240 VAC battery chargers, verify
the rear side of the that the two 10 amp AC circuit breaker switches
cabinet door presents have not been tripped (are in the up position). If the
a shock hazard that circuit breakers are in the “On” position, call your
can cause severe per- dealer or distributor.
sonal injury or death.
Use extreme caution
to avoid touching For 277, 380, 416, and 600 VAC battery chargers,
electrical contacts check the battery charger fuse(s). Replace, if nec-
whenever the cabinet essary, with fuses of the correct rating. Fuse am-
door is open. pere ratings are shown on the charger faceplate. If
the fuse is OK, call your dealer or distributor.

WARNING Ignition of
explosive battery
gases can cause se-
vere personal injury.
Battery Loses Charge
Do not smoke or
cause any spark or Battery charger float voltage could be too low (if
flame while servicing equipped with battery charger). Call your dealer or
batteries. distributor.

5-25
Troubleshooting placement fuses are listed in the battery charger
Operator’s Manual.
Most troubleshooting issues result in fault codes
that are displayed on the battery charger’s digital WARNING Voltages within the charging sys-
display (see Table 5-4). Overload conditions or tem present an electrical shock hazard that can
equipment failures may require additional trouble- cause severe personal injury or death. Discon-
shooting (see Table 5−9). nect all sources of AC and DC power from the
battery charger before servicing.
Loss of AC Power
5. Disconnect the battery charger from AC power
When there is a loss of power, the battery charger and the battery.
relay contacts announce this fault as an AC power
loss. Since the charger is no longer powered, noth- 6. Unscrew the fuse holders from the front of the
ing is displayed on the digital display. battery charger.

7. Check the fuses and replace the blown

Replacing Fuses fuses(s).
When replacing a blown fuse on battery charger 8. Reinstall the fuse holders.
models that use them, be sure to use a fuse of the
same rating and type. Do not use fuses of a higher 9. Reconnect the battery charger to AC power
rating. Fuses must be UL and CSA certified. Re- and reconnect the charger to the battery.

5-26
 BATTERY CHARGER TROUBLESHOOTING PROCEDURES
WARNING AC power within the cabinet and the rear side of
the cabinet door presents a shock hazard that can cause se-
vere personal injury or death. Some battery charger service
procedures present hazards that can result in severe per-
sonal injury or death. The following procedures are to be
performed only by trained and experienced personnel. Use
extreme caution to avoid touching electrical contacts when
the cabinet door is open. Do not wear jewelry or loose cloth-
ing. Stand on a dry, non-conductive surface such as a rub-
ber mat or wooden platform. Before removing or replacing
components, remove power to the door by disconnecting
connectors J1(removes power to the door) and J2 (removes
power from the battery in the control panel) (both connec-
tors are on the relay panel assembly)
WARNING Improper operation of the generator set pres-
ents a hazard that can cause severe personal injury or
death. Observe all safety precautions in your generator set
manuals.
WARNING Ignition of explosive battery gasses can cause
severe personal injury. Do not smoke or cause any spark,
arc, or flame while servicing batteries.
Problem Possible Cause Corrective Action
No DC Output 3.Tripped DC circuit breaker. 1.Correct the possible overload and
reset the circuit breaker.
4.Blown AC fuse(s) (277, 380, 416, 2.Correct the possible overload and
480, and 600 VAC battery chargers). replace the fuse(s), as described be-
5.Tripped AC circuit breaker(s) (120, low.
208, and 240 VAC battery chargers). 3.Correct the possible overload and
reset the circuit breaker.
Low DC Output 1.Faulty battery 1.Replace the battery.
2.Charger failure 2.Call a service representative.
High DC Output Charger failure Call a service representative.

5-27
This Page Intentionally Left Blank.

5-29
6. Transfer Switch Service
This section covers the removal and replacement  If there is an external battery charger, discon-
procedures for the transfer switch assembly. nect it from its AC power source. Then discon-
nect the set starting battery negative [−] cable.
SWITCH ASSEMBLY
REMOVAL/REPLACEMENT PROCEDURE WARNING The transfer switch presents a
shock hazard that can cause severe personal
There are four separate switch assemblies. Each injury or death unless all AC power is removed.
assembly corresponds to a particular current Disconnect all sources of AC power to the
range. The four current range groups are: transfer switch before servicing. Be sure to set
40-70-125 amperes, 150-225-260 amperes, the generator set operation selector switch to
300-400-600 amperes, and 800-1000 amperes. Stop, disconnect the battery charger from its
AC power source, and disconnect the starting
For servicing purposes, each transfer switch as- battery negative [−] cable.
sembly can be separated into the following compo-
nents: RECONNECTING AC POWER
(WHEN FINISHED)
 Linear Actuator
 Block and Crossbar Assembly After all service procedures are completed:
 Auxiliary Switches  Connect the negative (−) battery cable to the
starting battery. If applicable, connect the bat-
A separate section covers the removal and re- tery charger to its AC power source.
placement procedures for each major component
 Reconnect utility power (Normal) and genset
within a particular range.
power (Emergency).
DISCONNECT AC POWER  Set the operation selector switch on the genset
to in the Remote position.
Before beginning any service procedure:
WARNING AC power within the cabinet and
 Turn the operation selector switch on the gen- the rear side of the cabinet door presents a
erator to Stop. (The selector switch is located shock hazard that can cause severe personal
on the generator set control panel.) injury or death. Use extreme caution to avoid
 Disconnect all sources of AC power from touching electrical contacts whenever the cab-
the transfer switch. inet door is open.

6-1
 LINEAR ACTUATOR REMOVAL AND 4. Pry the capacitor(s) loose from the bracket.
REPLACEMENT (40 TO 125 AMPERES) Remove the end cap and disconnect the red
and white actuator leads from the capacitor
Set the operation selector switch on the generator and the black lead from circuit breaker. Note
control panel to Stop. Disconnect both power the lead connections to the capacitor termi-
sources from the transfer switch. If there is an nals.
external battery charger, disconnect it from AC
power. Then disconnect the genset starting battery 5. Remove the socket head capscrews and lock
(negative [−] lead first). washers that secure the actuator to the block
assemblies (Figure 6-2). Note the ground wire
WARNING AC power within the cabinet pres-
connection to the lower left capscrew.
ents an electrical shock hazard that can cause
severe personal injury or death. Disconnect all
sources of AC power from the transfer switch 6. Disengage the actuator rod from the switch
before servicing. handle and remove the actuator from the block
assembly.
The following procedures cover the removal and
replacement of the linear actuator for 40- to 7. Remove one of the hex head capscrews and
125-ampere switches. lock washers that secure the rod end assem-
bly to the actuator rod.
Removing Actuator
CAUTION Electric Shock Hazard 8. Remove the rod end assembly from the actua-
Capacitors are considered stored energy tor rod (Figure 6-1) and slide the rod out of the
and present an electrical shock hazard that actuator.
can cause personal injury.
Make sure all capacitors are safely and ful- Replacing Actuator
ly discharged before working on equip-
ment. 1. Insert the actuator rod into the replacement
actuator motor from the side opposite the
1. Open the transfer switch cabinet door.
ground brush (Figure 6-1). Install the rod end
2. Loosen and remove the four machine screws assembly and tighten the capscrew to 70−75
(with flat washers) that secure the plastic in-lbs (7.9−8.5 NSm).
switch cover to the switch base, and lift it off.
2. Position the actuator motor on the block as-
3. Separate the actuator lead wires from the rest semblies so the load wires are at the bottom,
of the wiring harness. Remove wire ties as re- and fit the rod assembly into the handle of the
quired. closed switch assembly.

ACTUATOR GROUND ROD END

ROD BRUSH ASSEMBLY

HEX HEAD CAPSCREW

WITH LOCK WASHER

FIGURE 6-1. LINEAR ACTUATOR (40 TO 125 AMPERES, 3 POLE TRANSFER SWITCHES ONLY)

6-2
 1

ACTUATOR
ROD

LINEAR A A
ACTUATOR

ROD END
ASSEMBLY

2
TERMINAL
BRACKET

GROUND
CONNECTION
1 1

1 TORQUE TO 25−30 IN-LBS (2.8−3.4 NSm).

2 TORQUE TO 70−75 IN-LBS (7.9−8.5 NSm).

VIEW A−A

FIGURE 6-2. TRANSFER SWITCH COVER (40 TO125 AMPERES, 3 POLE TRANSFER SWITCHES ONLY)
3. Secure the actuator motor to the block assem- lock washers (4). Be sure to reconnect the
blies using socket head capscrews (4) and ground wire to the lower left screw (Figure

6-3
 6-2). Tighten capscrews to 25−30 in-lbs BLOCK AND CROSS-BAR ASSEMBLY
(2.8−3.4 NSm). REMOVAL AND REPLACEMENT
(40 TO 125 AMPERES, THREE POLE
CAUTION Use care when removing the TRANSFER SWITCHES ONLY)
block and cross-bar assembly from the
base. Carefully disengage the cross-bar Set the operation selector switch on the generator
from the auxiliary switch assembly to control panel to Stop. Disconnect both power
avoid cracking the switches.Do not over- sources from the transfer switch. If there is an
tighten screws or the switch can be dam- external battery charger, disconnect it from AC
aged. power. Then disconnect the genset starting battery
(negative [−] lead first).
4. Connect the black actuator lead wire to the cir- WARNING AC power within the cabinet pres-
cuit breaker, and connect the red and white ac- ents an electrical shock hazard that can cause
tuator lead wires to the following capacitor ter- severe personal injury or death. Disconnect all
minals: sources of AC power from the transfer switch
before servicing.
Red Lead Wire - Connect to capacitor C1,
The following procedures cover the removal and
Terminal 1.
replacement of the block and crossbar assemblies
for 40- to 125-ampere switches.
White Lead Wire - If one capacitor, connect
to capacitor C1, Terminal 2. If two capaci- Removing the Block and Cross-Bar
tors, connect to capacitor C2, Terminal 2. Assembly (Normal or Emergency)
1. Remove the linear actuator as described in the
Transfer switches for voltage ranges 347,
Linear Actuator Removal and Replacement
380/416, 440/480 and 480 use two capacitors
(C1 and C2) wired together in series. A single
section for 40 to 125 ampere switches. Follow
jumper wire is placed between terminal 2 on C1 steps 1-6 in the Removing Actuator section.
and Terminal 1 on C2.
2. Remove the round head machine screws and
flat washers that secure the interlock bar to the
5. Replace the capacitor end cap(s) and install interlock arms (see Figure 6-3) and remove
the capacitor(s) in the bracket(s). Use wire ties the interlock bar.
to hold actuator lead wires in place.
3. Disconnect the control wiring leads from the
jumper bus bars.
6. Check transfer switch operation and align-
ment of the actuator rod by manually opening 4. Remove the hex head machine screws, ring
and closing both the Source 1 (Normal) and terminals, flat washers, lock washers, and nuts
Source 2 (Emergency) switch assemblies. that secure the jumper bus bars (see Fig-
ure 6-3) to the load bus bars.
7. Place the plastic switch cover in position and
secure with machine screws (4) and flat wash- 5. Remove the hex head machine screws and
spring washers that secure the jumper bus
ers (4). Tighten to 25−30 in-lbs (2.8−3.4 NSm)
bars to the block assemblies, and lift off the
torque.
jumper bus bars.

8. Connect the starting battery (negative [−] lead 6. Remove the control wiring leads from the pow-
last). If applicable, connect the battery charger er source terminals (Figure 6-4).
to AC power. Reconnect utility and genset
power. Set the operation selector switch to 7. Loosen the lug terminal screws and remove
Auto (or Remote). the power source supply wires from the lug ter-
minals.

9. Test the switch for proper operation and close 8. Remove the two round head machine screws,
the cabinet. lock washers, and flat washers that secure the

6-4
 block assembly to the base; and carefully re- 7. Install the jumper bus bars and secure to the
move the assembly. switch assemblies with hex head machine
screws and spring washers. Tighten to 25−30
CAUTION Use care when removing the in-lbs (2.8−3.4 NSm) torque.
block and cross-bar assembly from the
base. Carefully disengage the cross-bar 8. Secure the jumper bus bars to each load bus
from the auxiliary switch assembly to bar using a hex head machine screw, ring ter-
avoid cracking the switches. minal, flat washer, lock washer, and nut. Tight-
Replacing the Block and Cross-Bar en to 25−30 in-lbs (2.8−3.4 NSm) torque.
Assembly
9. Connect the control wiring leads to the corre-
1. Clean all current-carrying surfaces with a wire sponding jumper bus bar terminal. Control
brush. wires are marked LOAD A,B,C.

2. Hold the block assembly in position on the

10. Apply thread sealant (blue Loctite 242, Onan
base and check the alignment of the auxiliary
part number 518−0309) to the threads of the
switch lever. When the main switch contacts
interlock bar machine screws. Install the inter-
are closed, the auxiliary switch lever must be
lock bar and secure to each interlock arm with
aligned vertically, as shown in Figure 6-3.
a round head machine screw and flat washer.
Move the auxiliary switch lever as required to
Tighten to 15−20 in-lbs (1.7−2.3 NSm) torque.
get correct alignment.

3. Secure the block assembly to the base with 11. Attempt to close both sides of the transfer
round head machine screws (2), lock washers switch. The interlock assembly must hold one
(2), and flat washers (2). Tighten the screws to side open so that only one side closes at a
25−30 in-lbs(2.8−3.4 NSm). time.

4. Install the power source supply wires and se- 12. Replace the linear actuator as described in
curely tighten the lug terminals. Linear Actuator Removal And Replacement
section for 40- to 125-ampere switches. Fol-
5. Connect the control wiring leads to the corre-
low steps 2 through 8 in the Replacing Actua-
sponding power source terminals. Control
tor section. Apply a thin coat of lubricant (Onan
wires are marked NORM A,B,C or EMER
part number 524−0157) to the slot in the han-
A,B,C for identification.
dle.
6. Apply a thin coat of joint compound between
the mating surfaces of the jumper bus bars, 13. Test the switch for proper operation and close
braided strap connector, and load bus bars. the cabinet.

6-5
 INTERLOCK LOAD BUS
2 BAR BARS

JUMPER 1 1
BUS BAR

JUMPER
BUS BAR

LOAD BUS
BAR
VIEW C−C VIEW D−D

1 TORQUE TO 25−30 IN-LBS (2.8−3.4 NSm).

2 TORQUE TO 15−20 IN-LBS (1.7−2.3 NSm).

FIGURE 6-3. SWITCH ASSEMBLY (40 TO 125 AMPERES, 3 POLE TRANSFER SWITCHES ONLY)

6-6
 POWER SOURCE
LEAD TERMINAL

CONTROL WIRING
TERMINAL

FIGURE 6-4. CONTROL WIRING TERMINALS (40 TO 125 AMPERES, 3 POLE TRANSFER SWITCHES ONLY)

6-7
 AUXILIARY SWITCH REMOVAL AND bracket (Figure 6-5); and lift out the four
REPLACEMENT (40 TO 125 AMPERES, switches, insulating barriers, and switch lever.
THREE POLE TRANSFER SWITCHES
ONLY) Replacing Auxiliary Switch Assembly

Set the operation selector switch on the generator 1. Place the auxiliary switch lever in the bracket
control panel to Stop. Disconnect both power as shown in Figure 6-5. Note that the end of the
sources from the transfer switch. If there is an lever with the octagonal hole must engage the
external battery charger, disconnect it from AC transfer switch cross bar when the auxiliary
power. Then disconnect the genset starting battery switch assembly is installed.
(negative [−] lead first)..
2. Install the auxiliary switches (4) and insulating
WARNING AC power within the cabinet pres-
barriers (5) in the bracket, and secure with hex
head machine screws (2) and nuts (2).Tighten
ents an electrical shock hazard that can cause
to 10−15 in-lbs (1.1−1.7 NSm) torque. Note
severe personal injury or death. Disconnect all
that each switch must be assembled so the
sources of AC power from the transfer switch
side with two terminals (Figure 6-5) is facing in-
before servicing.
ward, toward the other auxiliary switch.
The following procedures cover the removal and
replacement of the auxiliary switch for 40- to 3. Manually close the contacts that will be
125-ampere switches. coupled to the auxiliary switch lever.

4. Hold the auxiliary switch assembly in position

Removing Auxiliary Switch Assembly on the base and check the alignment of the
auxiliary switch lever. When the transfer switch
1. Open the transfer switch cabinet door. is closed, the auxiliary switch must be aligned
as shown in Figure 6-5. Move the auxiliary le-
2. Loosen and remove the four machine screws ver as required to get the correct alignment.
(with flat washers) that secure the plastic
switch cover to the switch base, and lift it off. 5. Secure the bracket to the base using the hex
head machine screws and tighten to 25−30 in-
3. Loosen the two machine screws that secure lbs (2.8−3.4 NSm) torque.
the terminal bracket to the base. Move the ter-
minal bracket to allow access to the auxiliary 6. Install control wiring leads on the correspond-
switches. ing switch terminals. Leads are marked with
terminal numbers (S2/N0, S7/NC, S9/C, etc..)
4. Remove the control wiring leads from the aux- for identification. Refer to Figure 6-5 for identi-
iliary switch terminals (Figure 6-5). fication of the auxiliary switch terminals.

5. Remove the hex head machine screws that 7. Place the terminal bracket in position on the
secure the auxiliary switch assembly bracket base and secure it with hex head machine
to the base. screws. Tighten to 25−30 in-lbs (2.8−3.4 NSm).

6. Disengage the auxiliary switch lever from the 8. Place the plastic switch cover in position and
transfer switch crossbar and lift out the auxilia- secure with machine screws (4) and flat wash-
ry switch assembly. ers (4). Tighten to 25−30 in-lbs (2.8−3.4 NSm).

CAUTION Use care when removing the 9. Connect the starting battery (negative [−] lead
block and cross-bar assembly from the last). If applicable, connect the battery charger
base. Carefully disengage the cross-bar to AC power. Reconnect utility and genset
from the auxiliary switch assembly to power. Set the operation selector switch to
avoid cracking the switches. Auto (or Remote).

7. Remove the hex head machine screws and 10. Test the switch for proper operation and close
nuts that secure the auxiliary switches to the the cabinet.

6-8
 SIDE WITH TWO
TERMINALS

SWITCH LEVER IN
CLOSED POSITION

NORMAL SIDE EMERGENCY SIDE

INSULATING
BARRIERS

MACHINE
SCREWS
1

AUXILIARY
SWITCH LEVERS

BRACKETS

1 TORQUE TO 10−15 IN-LBS (1.1−1.7 NSm).

FIGURE 6-5. AUXILIARY SWITCHES (40 TO 125 AMPERES, 3 POLE TRANSFER SWITCHES ONLY)

6-9
 LINEAR ACTUATOR REMOVAL AND to the switch assemblies (Figure 6-6), and lift
REPLACEMENT (150 TO 260 AMPERES out the spacers (4) and barriers (2).
TRANSFER SWITCHES AND 40 TO 125
AMPERES, FOUR POLE TRANSFER 7. Disengage the actuator rod from the switch
SWITCHES) handle and remove the actuator from the
switch assembly.
Set the operation selector switch on the generator
control panel to Stop. Disconnect both power 8. Remove one of the hex head capscrews and
sources from the transfer switch. If there is an lock washers that secure the rod end assem-
external battery charger, disconnect it from AC bly to the end of the actuator rod.
power. Then disconnect the genset starting battery
(negative [−] lead first). 9. Remove the rod end assembly from the actua-
tor rod (Figure 6-6) and slide the rod out of the
WARNING AC power within the cabinet pres- actuator motor.
ents an electrical shock hazard that can cause
severe personal injury or death. Disconnect all Replacing Actuator
sources of AC power from the transfer switch
before servicing. 10. Insert the actuator rod into the replacement
actuator motor (Figure 6-7). Hold the actuator
The following procedures cover the removal and ground brush up slightly to allow passage of
replacement of the linear actuator for 150- to the actuator rod. Install the rod end assembly
260-ampere switches. and tighten capscrew to 70−75 in-lbs (7.9−8.5
NSm).
Removing Actuator
CAUTION Electric Shock Hazard 11. Hold the actuator motor in position over the
Capacitors are considered stored energy switch assemblies so the lead wires are at the
and present an electrical shock hazard that bottom, and fit the rod assembly into the han-
can cause personal injury. dle of the closed switch assembly.
Make sure all capacitors are safely and ful-
ly discharged before working on equip- 12. Secure the actuator motor to the switch as-
ment. semblies using hex head capscrews (4), lock
washers (4), flat washers (4), barriers (2), and
1. Open the transfer switch cabinet door. spacers (4). Tighten the capscrews to 25−27
in-lbs (2.8−3.0 NSm).
2. Loosen and remove the two self-locking nuts
and two machine screws (with flat washers) 13. Connect the black actuator lead wire to the cir-
that secure the plastic switch cover to the cuit breaker, and the red and white actuator
switch base, and lift off the cover. (Figure 6-6) lead wires to the following capacitor terminals:

3. Separate the actuator lead wires from the rest RED LEAD  Capacitor C1, Terminal 1
of the wiring harness; remove wire ties as re- WHITE  One capacitor,
quired. LEAD Capacitor C1, Terminal 2.
4. Pry the capacitor(s) loose from the bracket.  Two capacitors,
Remove the end cap and disconnect the red Capacitor C2, Terminal 2.
and white actuator lead wires from the capaci-
tor terminals. Transfer switches for voltage ranges 347,
380/416, and 440/480 use two capacitors (C1
5. Disconnect the black actuator wire from the and C2) wired together in series. A single jump-
circuit breaker and disconnect the ground wire er wire is placed between terminal 2 on C1 and
from the end of the actuator. terminal 1 on C2.

6. Remove the hex head capscrews, flat wash- 14. Replace the capacitor end cap(s) and install
ers, and lock washers that secure the actuator the capacitor(s) in the bracket(s).

6-10
 1

ROD END
ASSEMBLY
LINEAR
ACTUATOR
ACTUATOR
ROD
BARRIER 2

TERMINAL
BRACKET
SPACER 3
3

VIEW A−A
1 TORQUE TO 70−75 IN-LBS (7.9−8.5 NSm).
2
TORQUE TO 25−27 IN-LBS (2.8−3.0 NSm).
3
TORQUE TO 25−30 IN-LBS (2.8−3.4 N-m).

FIGURE 6-6. TRANSFER SWITCH COVER (150 TO 260 AMPERES TRANSFER SWITCHES AND 40 TO 125
AMPERES, 4 POLE TRANSFER SWITCHES)

6-11
15. Connect the ground wire to the end of the ac- (2), and self-locking nuts (2). Tighten to 25−30
tuator. Use wire ties to hold the actuator lead in-lbs (2.8−3.4 NSm) torque.
wires in place with the wiring harness.
18. Connect the starting battery (negative [−] lead
16. Check operation of the transfer switch and last). If applicable, connect the battery charger
alignment of the actuator rod by manually to AC power. Reconnect utility and genset
opening and closing both the Normal and power. Set the operation selector switch to
Emergency switch assemblies. Auto (or Remote).
17. Place the plastic switch cover in position and 19. Test the switch for proper operation and close
secure with machine screws (2), flat washers the cabinet.

6-12
 GROUND
BRUSH

FIGURE 6-7. LINEAR ACTUATOR

(150 TO 260 AMPERES TRANSFER SWITCHES AND 40 TO 125 AMPERES, 4 POLE TRANSFER SWITCHES)

6-13
 BLOCK AND CROSS-BAR ASSEMBLY the jumper bus bar/load bus bar/load lug sup-
REMOVAL AND REPLACEMENT (150 TO port block assembly.
260 AMPERES TRANSFER SWITCHES
26. Remove the control wiring leads from the pow-
AND 40 TO 125 AMPERES, FOUR POLE
er source terminals.
TRANSFER SWITCHES)
27. On 4-pole switches (Figure 6-9): Before the
Set the operation selector switch on the generator block and cross-bar assembly can be re-
control panel to Stop. Disconnect both power moved, the neutral block assembly must be
sources from the transfer switch. If there is an loosened and pivoted slightly out of the way.
external battery charger, disconnect it from AC
power. Then disconnect the genset starting battery 1. Remove the two machine screws that se-
(negative [−] lead first). cure the arc chute cover. Remove the cov-
er and the arc chute.
WARNING AC power within the cabinet pres- 2. Remove the hex head capscrew, terminal
ents an electrical shock hazard that can cause ring, spring washer, and load lug that se-
severe personal injury or death. Disconnect all cure the neutral jumper bus bar. Remove
sources of AC power from the transfer switch the neutral jumper bus bar.
before servicing.
3. Remove the two Phillips screws and the
The following procedures cover the removal and spacer that secure the source lug side of
replacement of the block and cross-bar assemblies the neutral block.
for 150- to 260-ampere switches. 4. Pivot the neutral block slightly away from
the block and cross-bar assembly.
Removing the Block and Cross-Bar
Assembly (Normal or Emergency) CAUTION Use care when removing the
block and cross-bar assembly from the
20. Loosen the lug terminal screws and remove base. Carefully disengage the cross-bar
the power source supply wires from the lug ter- from the auxiliary switch assembly to
minals. avoid cracking the switches.Use care
when removing the block and cross-bar as-
21. Remove the linear actuator as described in the sembly from the base.
Linear Actuator Removal and Replacement
section for 150- to 260-ampere switches. Fol- 28. Remove the remaining hex head capscrews
low steps 1 through 7 in the Removing Actua- that secure the block and cross-bar assembly
tor section. to the base, and carefully remove the assem-
bly.
22. Remove the hex head capscrews, lock wash-
ers, and flat washers that secure the interlock 29. Remove the two threaded hex spacers from
bar to the interlock arms (Figures 6-8 and 6-9), the back of each block assembly and save for
and remove the interlock bar. reuse.

23. Remove the round head machine screws and 30. On 4-pole switches (Figure 6-9): With a
mounting plate that secure the handle assem- screwdriver, dig the glue out of the cavity in the
bly to the switch assembly, and lift off the han- base of the neutral block. Remove the ma-
dle assembly. chine screw that secures the neutral block,
and remove the neutral block.
24. Disconnect the control wiring leads from the
jumper bus bars. 31. Remove the two round head machine screws
that secure the interlock arm to the block and
25. Remove the hex head capscrews and spring cross-bar assemblies, and lift off the interlock
washers that secure the A, B, and C jumper arm.
bus bars to the block and cross-bar assem-
blies. Remove the two Phillips head screws 32. Remove the hex head capscrews, ring termi-
and the two hex head capscrews that secure nals, spring washers, and lug terminals from
the load lug support block. Carefully remove the block and cross-bar assembly.

6-14
 JUMPER LOAD BUS NEUTRAL
BUS BARS BARS BAR

2
INTERLOCK
ARM
INTERLOCK
2 4
1 4 BAR

1 TORQUE TO 25−30 IN-LBS (2.8−3.4 NSm).

2
TORQUE TO 10−12 FT-LBS (13.6−16.3 NSm).
3
TORQUE TO 15−20 IN-LBS (1.7−2.3 NSm).
4
TORQUE TO 70−75 IN-LBS (7.9−8.5 NSm).

FIGURE 6-8. 3-POLE SWITCH ASSEMBLY (150 TO 260 AMPERES)

6-15
 JUMPER LOAD BUS
BUS BARS BARS

2
2

INTERLOCK
ARM
2
1 INTERLOCK 4
4 BAR

1 TORQUE TO 25−30 IN-LBS (2.8−3.4 NSm).

2
TORQUE TO 10−12 FT-LBS (13.6−16.3 NSm).
3
TORQUE TO 15−20 IN-LBS (1.7−2.3 NSm).
4
TORQUE TO 70−75 IN-LBS (7.9−8.5 NSm).

FIGURE 6-9. 4-POLE SWITCH ASSEMBLY (40 TO 260 AMPERES)

6-16
Replacing Block and Cross-Bar Assembly 40. Clean the current-carrying surfaces of the
jumper bus bars and load bus bars with a wire
33. Install the lug terminals on the block and cross- brush.
bar assembly and secure with hex head caps-
crews, ring terminals, and spring washers. 41. Install the A, B, and C jumper bus bar/load bus
Tighten to 10−12 ft-lbs (13.6−16.3 NSm). bar/load lug support block assembly. Secure
to the block and cross-bar assemblies with hex
34. Install the interlock arm and secure with the head capscrews and spring washers. Tighten
two round head capscrews. Tighten the to 10−12 ft-lbs (13.6−16.3 NSm) torque. Se-
screws to 15−20 in-lbs (1.7−2.3 NSm) torque. cure the load lug support block with the four
screws. Tighten to 70−75 in-lbs (7.9−8.5 NSm)
35. Install the two threaded hex spacers in the torque.
back of the block and cross-bar assembly.
42. Connect the control wiring leads to the corre-
36. On 4-pole switches (Figure 6-9): Secure the sponding jumper bus bar terminals. Control
neutral block with the machine screw that was wires are marked LOAD A, B, C, N.
removed from the center hole. Tighten to
70−75 in-lbs (7.9−8.5 NSm). Fill the cavity in 43. Place the handle assembly in position on the
the block with adhesive silicone to completely block and cross-bar assembly and secure with
cover the screw head. Pivot the neutral block the two machine screws and mounting plate.
to permit placement of the block and cross-bar Tighten to 15−20 in-lbs (1.7−2.3 NSm) torque.
assembly. Apply a thin coat of lubricant (Onan part num-
ber 524−0157) to the slot in the handle.
37. Secure the block and cross-bar assembly to
the base with the hex head capscrews. Tight- 44. Apply thread sealant (blue Loctite 242, Onan
en to 70−75 in-lbs (7.9−8.5 NSm) torque. part number 518−0309) to the threads of the
interlock bar capscrews. Install the interlock
38. On 4-pole switches (Figure 4-9): bar and secure to each interlock arm with a hex
1. Pivot the neutral block back to its correct head capscrew, lock washer, and flat washer.
position. Tighten to 70−75 in-lbs (7.9−8.5 NSm) torque.
2. Secure the neutral block with the two Phil- 45. Attempt to close both sides of the transfer
lips screws and the spacer. Tighten to switch. The interlock assembly must hold one
70−75 in-lbs (7.9−8.5 NSm) torque. side open so that only one side closes at a
3. Secure the neutral jumper bus bar with time.
the hex head capscrew, terminal ring,
spring washer, and load lug. Tighten to 46. Replace the linear actuator as described in the
10−12 ft-lbs (13.6−16.3 NSm) torque. Linear Actuator Removal and Replacement
section for 150- to 260-ampere switches. Fol-
4. Position the neutral block arc chute and low steps 2 through 9 in the Replacing Actua-
cover. Secure the arc chute cover with the tor section.
two machine screws. Tighten to 25−30 in-
lbs (2.8−3.4 NSm) torque. 47. Install the power source supply wires and se-
curely tighten the lug terminals to the torque
39. Connect the control wiring leads to the corre- value specified on the plastic cover.
sponding power source terminals. Control
wires are marked NORM A,B,C,N or EMER 48. Test the switch for proper operation and close
A,B,C,N for identification. the cabinet.

6-17
 AUXILIARY SWITCH REMOVAL AND 55. Remove the hex head capscrews and nuts
REPLACEMENT (150 TO 260 AMPERES that secure the auxiliary switches to the brack-
TRANSFER SWITCHES AND 40 TO 125 ets (Figure 6-10), and lift out the four auxiliary
AMPERES, FOUR POLE TRANSFER switches and insulating barriers.
SWITCHES) Replacing Auxiliary Switch Assembly
Set the operation selector switch on the generator 56. Install the insulating barriers (5) and auxiliary
control panel to Stop. Disconnect both power switches (4) in the brackets and secure with
sources from the transfer switch. If there is an hex head machine screws (2) and nuts (2).
external battery charger, disconnect it from AC
Tighten to 10−15 in-lbs (1.1−1.7 NSm). Note
power. Then disconnect the genset starting battery
that each switch must be assembled so the
(negative [−] lead first).
side with two terminals faces inward (Figure
WARNING AC power within the cabinet pres- 6-10) when the auxiliary switch assembly is
ents an electrical shock hazard that can cause installed on the base.
severe personal injury or death. Disconnect all
57. Hold the auxiliary switch assembly in position
sources of AC power from the transfer switch
on the base (the side with two terminals must
before servicing.
face inward) and secure the bracket to the
The following procedures cover the removal and base using the hex head machine screws.
replacement of the auxiliary switch assembly for Tighten to 25−30 in-lbs (2.8−3.4 NSm) torque.
150- to 260-ampere switches.
58. Install the control wiring leads on the corre-
Removing Auxiliary Switch Assembly sponding switch terminals. Leads are marked
with the terminal numbers (S2/NO, S5/NC,
49. After disconnecting all sources of AC power, S7/C, etc..) for identification. Refer to Figures
open the transfer switch cabinet door. 6-8, 6-9, and 6-10 for identification of auxiliary
switch terminals.
50. Loosen and remove the two self-locking nuts
and the two machine screws (with flat wash- 59. Place the terminal bracket in position on the
ers) that secure the plastic switch cover to the base and secure it with the hex head machine
switch base, and lift off the cover. screws. Tighten to 25−30 in-lbs (2.8−3.4 NSm).

51. Remove the three machine screws that secure 60. Place the plastic switch cover in position and
the terminal bracket (Figure 6-6) to the base. secure with machine screws, flat washers, and
Move the terminal bracket to allow access to self-locking nuts. Tighten to 25−30 in-lbs
the auxiliary switches. (2.8−3.4 NSm) torque.

52. Remove the control wiring leads from the aux- 61. Connect the starting battery (negative [−] lead
iliary switch terminals (Figure 6-10). last). If applicable, connect the battery charger
to AC power. Reconnect utility and genset
53. Remove the hex head machine screws that power. Set the operation selector switch to
secure the auxiliary switch assembly bracket Auto (or Remote).
to the base.
62. Test the switch for proper operation and close
54. Lift out the auxiliary switch assembly. the cabinet.

6-18
 NO

TORQUE TO 10−15 IN-LBS

(1.1−1.7 NSm).
NC

COM

BARRIERS

FIGURE 6-10. AUXILIARY SWITCH (150 TO 260 AMPERES TRANSFER SWITCHES AND 40 TO 125 AM-
PERES, 4 POLE TRANSFER SWITCHES)

6-19
 LINEAR ACTUATOR REMOVAL AND 69. Disengage the actuator rod from the switch
REPLACEMENT (300 TO 600 AMPERES) handle and remove the actuator from the
switch assembly.
Set the operation selector switch on the generator
control panel to Stop. Disconnect both power 70. Remove one of the hex head capscrews and
sources from the transfer switch. If there is an lock washers that secure the rod end assem-
external battery charger, disconnect it from AC bly to the end of the actuator rod.
power. Then disconnect the genset starting battery
(negative [−] lead first). 71. Remove the rod end assembly (Figure 6-11)
and slide the actuator rod out of the actuator
WARNING AC power within the cabinet pres- motor.
ents an electrical shock hazard that can cause
severe personal injury or death. Disconnect all Replacing Actuator
sources of AC power from the transfer switch
before servicing. 72. Insert the actuator rod into the replacement
actuator motor (Figure 6-12). Hold the actua-
The following procedures cover the removal and tor ground brush up slightly to allow passage
replacement of the linear actuator for 300- to of the actuator rod. Install the rod end assem-
600-ampere switches. bly and tighten capscrew to 70−75 in-lbs
(7.9−8.5 NSm).
Removing Actuator
73. Hold the actuator motor in position over the
CAUTION Electric Shock Hazard switch assemblies so the lead wires are at the
Capacitors are considered stored energy bottom and fit the rod assembly into the handle
and present an electrical shock hazard that of the closed switch assembly.
can cause personal injury.
Make sure all capacitors are safely and ful- 74. Secure actuator motor to switch assemblies
ly discharged before working on equip- using hex head capscrews (4), lock washers
ment. (4), flat washers (8), and spacers (4). Tighten
capscrews to 25−27 in-lbs (2.8−3.0 NSm).
63. Open the transfer switch cabinet door.
75. Connect the black actuator lead wire to the cir-
64. Loosen and remove the four machine screws cuit breaker, and the red and white actuator
that secure the plastic switch cover to the lead wires to the following capacitor terminals:
transfer switch, and lift off the cover (Figure
6-11). RED LEAD  Capacitor C1, Terminal 1
WHITE  One capacitor,
65. Separate the actuator lead wires from the rest LEAD Capacitor C1, Terminal 2.
of the wiring harness; remove wire ties as re-  Two capacitors,
quired. Capacitor C2, Terminal 2.

66. Pry the capacitor(s) loose from the bracket.

Transfer switches for voltage ranges 347,
Remove the end cap and disconnect the red
380/416, and 440/480 use two capacitors (C1
and white actuator lead wires from the capaci- and C2) wired together in series. A single jump-
tor terminals. er wire is placed between terminal 2 on C1 and
terminal 1 on C2.
67. Disconnect the black actuator lead from the
circuit breaker and the ground wire from the 76. Replace the capacitor end cap(s) and install
end of the actuator. the capacitor(s) in the bracket(s).

68. Remove the hex head capscrews, flat wash- 77. Connect the ground wire to the end of the ac-
ers, and lock washers that secure the actuator tuator. Use wire ties to hold actuator lead wires
to the switch assemblies (Figure 6-11). in place with the rest of the wiring harness.

6-20
 ACTUATOR
ROD CAPSCREW
1

ROD END
ASSEMBLY

LINEAR
ACTUATOR

ACTUATOR
2 CAPSCREW

BARRIER

TERMINAL
BRACKET

VIEW A−A

1 TORQUE TO 70−75 IN-LBS (7.9−8.5 NSm).

2
TORQUE TO 25−27 IN-LBS (2.8−3.0 NSm).
3
TORQUE TO 25−30 IN-LBS (2.8−3.4 NSm).

FIGURE 6-11. TRANSFER SWITCH COVER (300 TO 600 AMPERES)

78. Check the operation of the transfer switch and opening and closing both the Normal and
the alignment of the Actuator rod by manually Emergency switch assemblies.

6-21
79. Install the plastic switch cover on the switch to AC power. Reconnect utility and genset
with the four screws. Tighten to 25−30 in-lbs power. Set the operation selector switch to
(2.8−3.4 NSm). Auto (or Remote).

80. Connect the starting battery (negative [−] lead 81. Test the switch for proper operation and close
last). If applicable, connect the battery charger the cabinet.

ACTUATOR
ACTUATOR
ROD
MOTOR
GROUND
BRUSH

WHITE

RED
BLACK

FIGURE 6-12. LINEAR ACTUATOR (300 TO 600 AMPERES)

6-22
 BLOCK AND CROSS-BAR ASSEMBLY 86. Remove the control wiring leads from the pow-
REMOVAL AND REPLACEMENT er source terminals.
(300 TO 600 AMPERES)
87. Remove the lug terminal screws and the pow-
er supply wires from the lug terminals. Re-
Set the operation selector switch on the generator
move the lug mounting screws and then re-
control panel to Stop. Disconnect both power
move the solder-less lugs from the switch as-
sources from the transfer switch. If there is an
semblies.
external battery charger, disconnect it from AC
power. Then disconnect the genset starting battery 88. Remove the hex head capscrews, ring termi-
(negative [−] lead first). nals, spring washers, flat washers, lock wash-
ers, and nuts that secure the jumper bus bars
WARNING AC power within the cabinet pres- to the load bus bars.
ents an electrical shock hazard that can cause
severe personal injury or death. Disconnect all 89. Remove the hex head capscrews and spring
sources of AC power from the transfer switch washers that secure the jumper bus bars to the
before servicing. block assemblies, and lift off the jumper bus
bars.
The following procedures cover the removal and
replacement of the block and cross-bar assemblies 90. Remove the four screws, lock washers, and
for the 300- to 600-ampere switches. flat washers that secure the block and cross-
bar assembly to the base. On 4-pole
Removing the Block and Cross-bar switches, remove the screw that secures the
Assembly (Normal or Emergency) small bearing bracket to the neutral block (Fig-
ure 6-14). Remove the block and cross-bar as-
82. Remove the linear actuator as described in the sembly. Save the bearing bracket and screw
Linear Actuator Removal and Replacement for reuse.
section for 300- to 600-ampere switches.
CAUTION Use care when removing the
83. Remove the hex head capscrews, lock wash- block and cross-bar assembly from the
ers, and flat washers that secure the interlock base. Carefully disengage the cross-bar
bar to the interlock arm (Figures 6-13 and from the auxiliary switch assembly to
6-14), and remove the interlock bar. avoid cracking the switches.
91. On 4-pole switches (Figure 6-14): Remove
84. Disconnect the control wiring leads from the the four screws that secure the block and con-
jumper bus bars. tact assembly to the base, and lift off the block
and contact assembly.
85. Remove the round head shoulder screws and
lock washers that secure the handle assembly 92. Remove hex head capscrew and lock washer
to the block and cross-bar assembly, and lift off that secure the interlock arm assembly to the
the handle assembly. block assembly and lift off the interlock arm.

6-23
 INTERLOCK INTERLOCK 2 INTERLOCK 1
ARM BAR ARM

BLOCK AND
CROSSBAR
1 ASSEMBLY

LUG
TERMINALS

JUMPER 3
BUS BAR

LOAD BUS
JUMPER
BAR
BUS BAR

1 TORQUE TO 70−75 IN-LBS (7.9−8.5 NSm).

2
TORQUE TO 10−12 FT-LBS (13.6−16.3 NSm).
3
TORQUE TO 25−30 IN-LBS (2.8−3.4 NSm).

FIGURE 6-13. 3-POLE SWITCH ASSEMBLY (300 TO 600 AMPERES)

6-24
 INTERLOCK INTERLOCK 2 3 3 INTERLOCK
ARM BAR ARM 1

NEUTRAL
BLOCK AND
1 CROSSBAR
ASSEMBLY

BLOCK AND
CROSSBAR
ASSEMBLY

LUG
TERMINALS

JUMPER
BUS BAR 3

JUMPER
LOAD BUS
BUS BAR
BAR

1 TORQUE TO 70−75 IN-LBS (7.9−8.5 NSm).

2
TORQUE TO 10−12 FT-LBS (13.6−16.3 NSm).
3
TORQUE TO 25−30 IN-LBS (2.8−3.4 NSm).

FIGURE 6-14. 4-POLE SWITCH ASSEMBLY (300 TO 600 AMPERES)

6-25
Replacing the Block and Cross-bar tween the current-carrying surfaces. Tighten
Assembly (Normal or Emergency) to 70−75 in-lbs (7.9−8.5 NSm).

93. Install interlock arm on block assembly using 99. Install the actuator handle on the block assem-
capscrew and lock washer (Figures 6-13 and bly with the shoulder screws and lock washers.
6-14). Torque to 70−75 in-lbs (7.9−8.5 NSm). Tighten to 25−30 in-lbs (2.8−3.4 NSm). Apply
a thin coat of lubricant (Onan part number
524−0157) to the slot in the handle.
94. On 4-pole switches (Figure 6-13): Secure
the block and contact assembly to the base us- 100.Connect the power source supply wires to the
ing the four screws removed in step 10 above. lug terminals. Tighten the lug terminals to the
Tighten the screws to 25−30 in-lbs (2.8−3.4 torque value silkscreened on the transfer
NSm). Place the bearing bracket (removed in switch cover.
step 9) in position on the end of the cross-bar
assembly. 101.Connect the control wiring leads to the power
source terminals. Control wires are marked
95. Install the block and cross-bar assembly on NORM A, B, C or EMER A, B, C.
the transfer switch base (with screws, lock
washers, and flat washers), carefully engag- 102.Connect the control wiring leads to the jumper
ing auxiliary switches. Tighten to 70−75 in-lbs bus bars. Control wires are marked LOAD A,
(7.9−8.5 NSm). On 4-pole switches, tighten the B, C for identification.
bearing bracket screw to 25−30 in-lbs (2.8−3.4
NSm). 103.Apply thread sealant (blue Loctite 242, Onan
part number 518−0309) to the threads of the
96. Clean the current-carrying surfaces of the interlock bar capscrews. Install the interlock
block assembly and the lug terminals with a bar and secure to each interlock arm with a hex
wire brush. Install the lug terminals with the head capscrew, lock washer, and flat washer.
round head screws and lock washers. Tighten Tighten to 70−75 in-lbs (7.9−8.5 NSm).
to 70−75 in-lbs (7.9−8.5 NSm).
104.Attempt to close both sides of the transfer
switch. The interlock assembly must hold one
97. Secure the jumper bus bars to the block as-
side open so that only one side closes at at
sembly with the capscrews and spring wash-
time.
ers. Make sure the mating surfaces have a
coating of electrical joint compound. Tighten 105.Replace the linear actuator as described in the
the capscrews 10−12 ft-lbs (13.6−16.3 NSm). Linear Actuator Removal and Replacement
section for 300- to 600-ampere switches. Fol-
98. Secure the load bus bars to the jumper bus low steps 2 through 9 in the Replacing Actua-
bars with the capscrews, lock washers, flat tor section.
washers, spring washers, ring terminals, and
nuts (Figures 6-13 and 6-14). Be sure to apply 106.Test the switch for proper operation and close
a thin coat of electrical joint compound be- the cabinet.

6-26
 AUXILIARY SWITCH REMOVAL AND 108.Loosen and remove the four machine screws
REPLACEMENT (300 TO 600 AMPERES) that secure the plastic switch cover to the
transfer switch, and lift off the cover.
Set the operation selector switch on the generator
control panel to Stop. Disconnect both power 109.Loosen and remove the four machine screws
sources from the transfer switch. If there is an that secure the terminal bracket (Figure 6-11)
external battery charger, disconnect it from AC to the base. Move the terminal bracket to allow
power. Then disconnect the genset starting battery access to the base.
(negative [−] lead first).
110.Remove the control wiring leads from the aux-
WARNING AC power within the cabinet pres- iliary switch terminals (Figure 6-15).
ents an electrical shock hazard that can cause
severe personal injury or death. Disconnect all 111. Close the transfer switch to the side you are
sources of AC power from the transfer switch working on and remove the hex head machine
before servicing. screws that secure the auxiliary switch assem-
The following procedures cover the removal and bly bracket to the base.
replacement of the auxiliary switch assembly for
300- to 600-ampere switches. 112.Lift out the auxiliary switch assembly.

Removing Auxiliary Switch Assembly 113.Remove the hex head machine screws and
nuts that secure the auxiliary switches to the
107.After disconnecting all sources of AC power, bracket (Figure 6-15) and lift out the auxiliary
open the transfer switch cabinet door. switches and insulating barriers.

NO

TORQUE TO 10−15 IN-LBS

(1.1−1.7 NSm).
NC

COM

BARRIERS

FIGURE 6-15. AUXILIARY SWITCH (300 TO 600 AMPERES)

6-27
Replacing Auxiliary Switch Assembly with the terminal numbers (S2/N0, S5/NC,
S7/C, etc..) for identification. Refer to Figures
114.Install the insulating barriers (5) and auxiliary 6-13, 6-14, and 6-15 for identification of the
switches (4) in the brackets, and secure with auxiliary switch terminals.
hex head machine screws (2) and nuts (2). 117.Place the terminal bracket in position on the
Tighten to 10−15 in-lbs (1.1−1.7 NSm). Note base and secure it with the hex head machine
that each switch must be assembled so the screws. Tighten to 25−30 in-lbs (2.8−3.4 NSm).
side with two terminals faces inward (Figures
6-13, 6-14, and 6-15) when the auxiliary switch 118.Place the plastic cover in position and secure
assembly is installed on the base. with the hex head screws and flat washers.
Tighten to 25−30 in-lbs (2.8−3.4 NSm).
115.Hold the auxiliary switch assembly in position
119.Connect the starting battery (negative [−] lead
on the base (the side with two terminals must
last). If applicable, connect the battery charger
face inward) and secure the bracket to the
to AC power. Reconnect utility and genset
base with the hex head machine screws.
power. Set the operation selector switch to
Tighten to 25−30 in-lbs (2.8−3.4 NSm).
Auto (or Remote).
116.Install the control wiring leads on the corre- 120.Test the transfer switch for proper operation
sponding switch terminals. Leads are marked and close the cabinet.

6-28
 LINEAR ACTUATOR REMOVAL AND 127.Disconnect the black actuator lead wire from
REPLACEMENT (800 AND 1000 the circuit breaker and the ground wire from
AMPERES) the end of the actuator.

128.Remove the hex head capscrews, flat wash-

Set the operation selector switch on the generator
ers, and lock washers that secure the actuator
control panel to Stop. Disconnect both power
to the switch assemblies (Figure 6-16) and lift
sources from the transfer switch. If there is an
out the spacers and actuator motor.
external battery charger, disconnect it from AC
power. Then disconnect the genset starting battery
Replacing Actuator
(negative [−] lead first).
129.Hold the actuator motor and spacers (4) in
WARNING AC power within the cabinet pres- position over the switch assemblies with the
ents an electrical shock hazard that can cause lead wires at the bottom.
severe personal injury or death. Disconnect all
sources of AC power from the transfer switch 130.Secure the actuator motor to the switch as-
before servicing. semblies using hex head capscrews (4), lock
washers (4), and flat washers (4). Tighten the
The following procedures cover the removal and capscrews to 70−75 in-lbs (7.9−8.5 NSm).
replacement of the linear actuator for 800- and
1000-ampere switches. 131.Connect the black actuator lead wire to the cir-
cuit breaker, and the red and white actuator
Removing Actuator lead wires to the following capacitor terminals:
CAUTION Electric Shock Hazard RED LEAD  Capacitor C1, Terminal 1
Capacitors are considered stored energy WHITE  One capacitor,
and present an electrical shock hazard that LEAD Capacitor C1, Terminal 2.
can cause personal injury.
Make sure all capacitors are safely and ful-  Two capacitors,
ly discharged before working on equip- Capacitor C2, Terminal 2.
ment.
White Lead Wire - Connect to capacitor C2 -
121.Open the transfer switch cabinet door. Terminal 2.

122.Remove a hex head capscrew, flat washer, Transfer switches for voltage ranges 347,
and lock washer that secures one of the rod 380/416, and 440/480 use two capacitors (C1
and C2) wired together in series. A single jump-
end assemblies to the end of the actuator rod.
er wire is placed between terminal 2 on C1 and
terminal 1 on C2.
123.Remove the rod end assembly (Figure 6-16)
and slide the actuator rod out of the actuator Transfer switches for voltage ranges 115,
motor. 190/200, 208, and 220/240 use two capacitors
(C1 and C2) wired in parallel. Two jumper wires
124.Loosen and remove the twelve machine are used. One is placed between terminal 1 on
screws (with flat washers) that secure the C1 and terminal 1 on C2. The other is placed be-
tween terminal 2 on C1 and terminal 2 on C2.
three plastic switch covers to the switch base,
and lift off the switch covers (Figure 6-16). 132.Replace the capacitor end cap(s) and install
the capacitor(s) in the bracket(s).
125.Separate the actuator lead wires from the rest
of the wiring harness; remove the wire ties as 133.Connect ground wire to the end of the actuator.
required. Use wire ties to hold the actuator lead wires in
place with the rest of the wiring harness.
126.Pry the capacitors loose from the brackets.
Remove the end cap and disconnect the red 134.Place the plastic switch covers in position and
and white actuator lead wires from the capaci- secure with machine screws and flat washers.
tor terminals. Tighten to 25−30 in-lbs (2.8−3.4 NSm) torque.

6-29
 ACTUATOR
ROD

LINEAR
ACTUATOR

ROD END
ASSEMBLY

2 ACTUATOR
ROD CAPSCREW

2
ACTUATOR
CAPSCREW

SPACER
1

1 TORQUE TO 25−30 IN-LBS (2.8−3.4 NSm).

2 VIEW A−A
TORQUE TO 70−75 IN-LBS (7.9−8.5 NSm). 115−240V 347−480V
PARALLEL SERIES

FIGURE 6-16. TRANSFER SWITCH COVER (800 - 1000 AMPERES)

135.Insert the actuator rod into the replacement
actuator motor (Figure 6-17). Hold the actua-
6-30
 tor ground brush up slightly to allow passage opening and closing both the Normal and
of the actuator rod. Emergency switch assemblies.

136.Secure the rod end assembly to the actuator 138.Connect the starting battery (negative [−] lead
rod with the hex head capscrew, flat washer, last). If applicable, connect the battery charger
and lock washer. Tighten the capscrew to to AC power. Reconnect utility and genset
70−75 in-lbs (7.9−8.5 NSm). Fit rod assembly power. Set the operation selector switch to
into the handle of the closed switch assembly. Auto (or Remote).

137.Check the operation of the transfer switch and 139.Test the switch for proper operation and close
the alignment of the actuator rod by manually the cabinet.

ROD END
ASSEMBLY ACTUATOR
ACTUATOR
ROD
MOTOR
GROUND
BRUSH

RED

WHITE

BLACK
CAPSCREW
WITH LOCK
WASHER

FIGURE 6-17. LINEAR ACTUATOR (800 - 1000 AMPERES)

6-31
 BLOCK AND CROSS-BAR ASSEMBLY 145.Remove hex head capscrews, spring wash-
REMOVAL AND REPLACEMENT ers, and bushings that secure the jumper bus
(800 AND 1000 AMPERES) bars to the switch assemblies. Lift off the jump-
er bus bars. (The neutral pole on the 4-pole
Set the operation selector switch on the generator switches does not have a bushing at this con-
control panel to Stop. Disconnect both power nection.)
sources from the transfer switch. If there is an
external battery charger, disconnect it from AC 146.Remove the control wiring leads from the pow-
power. Then disconnect the genset starting battery er source terminals.
(negative [−] lead first).
147.Loosen lug terminal screws and remove pow-
WARNING AC power within the cabinet pres- er source supply wires from the lug terminals.
ents an electrical shock hazard that can cause
severe personal injury or death. Disconnect all 148.With a screwdriver, dig the glue out of the insu-
sources of AC power from the transfer switch lator cups that cover and insulate the block as-
before servicing. sembly mounting screws.

The following procedures cover the removal and 149.Remove hex head capscrews and flat washers
replacement of the block and cross-bar assemblies that secure the block assemblies (Figures
for 800- and 1000-ampere switches. 6-18 and 6-19) to the base, and lift off the block
assemblies (note where spacers are used).
Removing the Block and Cross-bar
Assembly (Normal or Emergency)  On 3-pole switches, the A-phase block on
the Normal side and C-phase block on the
140.Remove the linear actuator as described in the Emergency side have a spacer under
Linear Actuator Removal and Replacement their outer mounting tabs. On 4-pole
section for 800- and 1000-ampere switches. switches, the A-phase block on the Nor-
mal side and neutral block on the Emer-
141.Lift the arc chute covers off the arc chutes.
gency side have this spacer. Make certain
142.Remove the hex head capscrews, lock wash- that you install new block assemblies with
ers, and flat washers that secure the interlock the spacers in their original positions.
bar to the interlock arm (Figures 6-18 and
6-19); and remove the interlock bar.  The block assemblies are not identical.
The A- and C-phase blocks, and the neu-
143.Disconnect the control wiring leads from the tral block on 4-pole switches, are different
jumper bus bars. from the B-phase block. Refer to parts
manual and part numbers stamped on re-
144.Remove hex head capscrews, ring terminals placement block assemblies to make cer-
and spring washers that secure jumper bus tain that you install new block assemblies
bars (Figures 6-18 and 6-19) to load bus bars. in their correct positions.

6-32
150.Remove round machine screws, lock wash- 153.Remove shoulder screws and self-locking
ers, and flat washers that secure arc chutes nuts that secure the two halves of the handle
(Figures 6-18 and 6-19) to block assemblies; assembly together. Remove the shoulder
and lift out arc chutes, barriers, and spacers. screws and lock washers that secure the han-
Discard arc chute barriers and spacers. dle assembly to the block and cross-bar as-
151.Remove the Allen head capscrews and lug ter- sembly. Slide the two halves of the handle
minals from the block assemblies. apart and remove them.

152.Remove the hex head capscrews and flat 154.Remove the two round head machine screws
washers that secure the cross-bar assembly that secure the interlock arm to the cross-bar
to the base, and lift off the cross-bar assembly. assembly, and lift of the interlock arm.
CAUTION Use care when removing the
block and cross-bar assembly from the
base. Carefully disengage the cross-bar
from the auxiliary switch assembly to
avoid cracking the switches.Use care
when removing the block and cross-bar as-
sembly from the base.

6-33
 INTERLOCK CROSSBAR
ARM 3 ASSEMBLY
3 5 INTERLOCK
BAR

BLOCK 3 JUMPER 2
ASSEMBLY BUS BAR

ARC 1
2 CHUTE
6 ARC
CHUTE
4 BARRIER

ARC
CHUTE
SPACER

LOAD BUS
SPACER JUMPER
BAR
BUS BAR

1 TORQUE TO 15−20 IN-LBS (1.7−2.3 NSm). 4 TORQUE TO 28−33 FT-LBS (40.0−44.7 NSm).
2 5
TORQUE TO 25−30 IN-LBS (2.8−3.4 NSm). TORQUE TO 18−20 FT-LBS (24.4−27.1 NSm).
3 6
TORQUE TO 70−75 IN-LBS (7.9−8.5 NSm). TORQUE TO 10−12 FT-LBS (13.6−16.3 NSm).

FIGURE 6-18. 3-POLE SWITCH ASSEMBLY (800 - 1000 AMPERES)

6-34
 INTERLOCK CROSSBAR
ARM 3 ASSEMBLY INTERLOCK
3 5 BAR

3 JUMPER 2
BUS BAR
BLOCK
ASSEMBLY 1

2 ARC
ARC
6 CHUTE
CHUTE
4 BARRIER
ARC
CHUTE
SPACER

LOAD BUS JUMPER

SPACER BUS BAR
BAR

1 TORQUE TO 15−20 IN-LBS (1.7−2.3 NSm). 4 TORQUE TO 28−33 FT-LBS (40.0−44.7 NSm).
2 5 TORQUE TO 18−20 FT-LBS (24.4−27.1 NSm).
TORQUE TO 25−30 IN-LBS (2.8−3.4 NSm).
3 6
TORQUE TO 70−75 IN-LBS (7.9−8.5 NSm). TORQUE TO 10−12 FT-LBS (13.6−16.3 NSm).

FIGURE 6-19. 4-POLE SWITCH ASSEMBLY (800 - 1000 AMPERES)

6-35
Replacing the Block and Cross-bar mal side and the neutral block on the
Assembly (Normal or Emergency) Emergency side have this spacer. Make
certain that you install new block assem-
155.Install the interlock arm on the cross-bar as- blies with the spacers in their original posi-
sembly and secure with the round head ma- tions.
chine screws. Tighten the screws to 15−20 in-
lbs (1.7−2.3 NSm) torque.  The block assemblies are not identical.
The A- and C-phase blocks, and the neu-
156.Apply a thin coat of lubricant (Onan part num- tral block on 4-pole switches, are different
ber 524−0157) to the slot in the handle. Place than the B-phase block. Refer to the parts
the handle assembly in position on the switch manual and the part numbers stamped on
assembly and secure with the shoulder the replacement block assemblies to
screws, lock washers, and locknuts. Tighten to make certain that you install new block as-
25−30 in-lbs (2.8−3.4 NSm). semblies in their correct positions.

157.Secure the cross-bar assembly to the base 161.Fill the insulator cups that cover and insulate
with the hex head capscrews (4), lock washers the block assembly mounting screws with
(4), and flat washers (4). Tighten to 70−75 in- adhesive silicone to completely cover the
lbs (7.9−8.5 NSm) torque. washers and screw heads.

158.Apply a thin coat of glyptol between the arc 162.Install the power source supply wires and se-
chute spacers and the arc chute barrier. Place curely tighten the lug terminals to 10−12 ft-lbs
the arc chute spacers (2), arc chute barrier, (13.6−16.3 NSm) torque.
and arc chute in position on each block assem-
163.Connect the control wiring leads to the power
bly; and secure with round head machine
source terminals. Control wires are marked
screws (2), lock washers (2) and flat washers
NORM A,B,C or EMER A,B,C for identifica-
(2). Tighten to 15−20 in-lbs (1.7−2.3 NSm)
tion.
torque.
164.Apply a thin coat of electric joint compound be-
159.Apply a thin coat of electrical joint compound tween the mating surfaces of the jumper bus
between the mating surfaces of the block as- bars, the braided strap connectors, and load
sembly and the lug terminals. Install the lug bus bars.
terminals on the block assemblies and secure
with the Allen head capscrews. Tighten to 165.Install the jumper bus bars and secure to the
28−33 ft-lbs (40.0−44.7 NSm) torque. switch assemblies with hex head capscrews,
spring washers, and bushings. (The neutral
160.Place each block assembly in position on the pole on 4-pole switches does not have a bush-
base and secure with the hex head capscrews ing at this connection.) Tighten to 18−20 ft-lbs
and flat washers. Refer to Figures 4-18 and (24.4−27.1 NSm) torque.
4-19 to determine where the spacers are re-
quired. Tighten the capscrews to 70−75 in-lbs 166.Secure the jumper bus bars to the load bus
(7.9−8.5 NSm) torque. bars with hex head capscrews, ring terminals,
and spring washers. Tighten to 10−12 ft-lbs
 On 3-pole switches, the A-phase block on (13.6−16.3 NSm) torque.
the Normal side and the C-phase block on
the Emergency side have a spacer under 167.Connect the control wiring leads to the jumper
their outer mounting tabs. On 4-pole bus bars. Control wires are marked LOAD
switches, the A-phase block on the Nor- A,B,C for identification.

6-36
168.Apply thread sealant (blue Loctite 242, Onan The following procedures cover the removal and
part number 518−0309 is recommended) to replacement of the auxiliary switch assembly for
the threads of the interlock bar capscrews. 800- and 1000-ampere switches.
Install the interlock bar and secure to each in-
terlock arm with a hex head capscrew, lock Removing Auxiliary Switch Assembly
washer, and flat washer. Tighten to 70−75 in-
lbs (7.9−8.5 NSm).
173.Open the transfer switch cabinet door.
169.Place the arc chute covers in position over the
arc chutes. 174.Remove the hex head capscrew, flat washer,
and lock washer that secures one of the rod
170.Attempt to close both sides of the transfer end assemblies to the end of the actuator rod.
switch. The interlock assembly must hold one
side open so that only one side closes at at 175.Remove rod end assembly (Figure 6-16) and
time. slide the actuator rod out of the actuator motor.
171.Replace the linear actuator as described in the
Linear Actuator Removal and Replacement 176.Loosen and remove the twelve machine
section for 800- and 1000-ampere switches. screws (with flat washers) that secure the
Follow steps 2 through 10 in the Replacing Ac- three plastic switch covers to the switch base,
tuator section. and lift off the switch covers (Figure 6-16).

172.Test the switch for proper operation and close 177.Remove the hex head machine screws that
the cabinet. secure the terminal bracket to the base. Move
the bracket to the side to allow access to the
AUXILIARY SWITCH REMOVAL AND auxiliary switch terminals.
REPLACEMENT (800 AND 1000
AMPERES) 178.Remove the control wiring leads from the aux-
iliary switch terminals (Figure 6-20).
Set the operation selector switch on the generator
control panel to Stop. Disconnect both power
sources from the transfer switch. If there is an 179.Close the transfer switch to the side you are
external battery charger, disconnect it from AC working on and remove the hex head machine
power. Then disconnect the genset starting battery screws that secure auxiliary switch assembly
(negative [−] lead first). brackets to the base. Lift out the auxiliary
switch assembly.
WARNING AC power within the cabinet pres-
ents an electrical shock hazard that can cause 180.Remove round head machine screws, flat
severe personal injury or death. Disconnect all washers, and nuts that secure the auxiliary
sources of AC power from the transfer switch switches to bracket (Figure 6-20); and lift out
before servicing. the auxiliary switches and insulating barriers.

6-37
Replacing Auxiliary Switch Assembly 185.Place the plastic covers in position and secure
them with machine screws and flat washers.
181.Install the insulating barriers and auxiliary Tighten to 25−30 in-lbs (2.8−3.4 NSm) torque.
switches in the brackets and secure with hex
head capscrews (2) and nuts (2). Note that
186.Insert the actuator rod into the replacement
each switch must be assembled so the side
actuator motor. Hold the actuator ground
with two terminals faces inward (Figure 6-20)
brush up slightly to allow passage of the actua-
when the auxiliary switch assembly is
tor rod.
installed.

182.Install the auxiliary switch assembly on the 187.Secure the rod end assembly to the actuator
base and secure the bracket to the base using rod with the hex head capscrew, flat washer,
the hex head machine screws. Tighten to and lock washer. Tighten capscrew to 70−75
25−30 in-lbs (2.8−3.4 NSm) torque. in-lbs (7.9−8.5 NSm). Fit the rod assembly into
the handle of the closed switch assembly.
183.Install control wiring leads on switch terminals.
The leads are marked with the terminal num-
188.Connect the starting battery (negative [−] lead
bers (S2/N0, S5/NC, S7/C, etc..) for identifica-
last). If applicable, connect the battery charger
tion. Refer to Figures 6-18, 6-19, and 6-20 for
to AC power. Reconnect utility and genset
identification of the auxiliary switch terminals.
power. Set the operation selector switch to
184.Place terminal bracket in position on base and Auto (or Remote).
secure it with the hex head machine screws
(4). Tighten to 25−30 in-lbs (2.8−3.4 NSm) 189.Test the transfer switch for proper operation
torque. and close the cabinet.

NO

TORQUE TO 10−15 IN-LBS

(1.1−1.7 NSm).
NC

COM

BARRIERS

FIGURE 6-20. AUXILIARY SWITCH (800 - 1000 AMPERES)

6-38
7. Schematics

SCHEMATIC PAGE
Typical Interconnection Diagram 630−2810 (Sheet 1 of 9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Typical Interconnection Diagram 630−2810 (Sheet 2 of 9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Typical Interconnection Diagram 630−2810 (Sheet 3 of 9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Typical Interconnection Diagram 630−2810 (Sheet 4 of 9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Typical Interconnection Diagram 630−2810 (Sheet 5 of 9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Typical Interconnection Diagram 630−2810 (Sheet 6 of 9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Typical Interconnection Diagram 630−2810 (Sheet 7 of 9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Typical Interconnection Diagram 630−2810 (Sheet 8 of 9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Typical Interconnection Diagram 630−2810 (Sheet 9 of 9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Typical Wiring Diagram 630−2766 (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Typical Wiring Diagram 630−2766 (Sheet 2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Typical Wiring Diagram 630−2766 (Sheet 3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Typical Wiring Diagram 630−2766 (Sheet 4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Typical Wiring Diagram 630−2768 (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Typical Wiring Diagram 630−2768 (Sheet 2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Typical Wiring Diagram 630−2768 (Sheet 3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Typical Wiring Diagram 630−2768 (Sheet 4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

7-1
THIS PAGE LEFT INTENTIONALLY BLANK

7-2
40−1000 AMP TYPICAL INTERCONNECTION DIAGRAM (REVISION: G) (SHEET 1 OF 12)

7-3
40−1000 AMP TYPICAL INTERCONNECTION DIAGRAM (REVISION: G) (SHEET 2 OF 12)

7-4
40−1000 AMP TYPICAL INTERCONNECTION DIAGRAM (REVISION: G) (SHEET 3 OF 12)

7-5
40−1000 AMP TYPICAL INTERCONNECTION DIAGRAM (REVISION: G) (SHEET 4 OF 12)

7-6
40−1000 AMP TYPICAL INTERCONNECTION DIAGRAM (REVISION: G) (SHEET 5 OF 12)

7-7
40−1000 AMP TYPICAL INTERCONNECTION DIAGRAM (REVISION: G) (SHEET 6 OF 12)

7-8
40−1000 AMP TYPICAL INTERCONNECTION DIAGRAM (REVISION: G) (SHEET 7 OF 12)

7-9
40−1000 AMP TYPICAL INTERCONNECTION DIAGRAM (REVISION: G) (SHEET 8 OF 12)

7-10
40−1000 AMP TYPICAL INTERCONNECTION DIAGRAM (REVISION: G) (SHEET 9 OF 12)

7-11
40−1000 AMP TYPICAL INTERCONNECTION DIAGRAM (REVISION: G) (SHEET 10 OF 12)

7-12
40−1000 AMP TYPICAL INTERCONNECTION DIAGRAM (REVISION: G) (SHEET 11 OF 12)

7-13
40−1000 AMP TYPICAL INTERCONNECTION DIAGRAM (REVISION: G) (SHEET 12 OF 12)

7-14
 THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
SCHEMATIC AND WIRING DIAGRAM
PACKAGE THAT WAS SHIPPED WITH THE
TRANSFER SWITCH.

No. 630-2766 Sh 1 of 4
Rev. D
Modified 5/2007

40−600 AMP TYPICAL WIRING DIAGRAM (SHEET 1 OF 4)

7-15
 THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
SCHEMATIC AND WIRING DIAGRAM
PACKAGE THAT WAS SHIPPED WITH THE
TRANSFER SWITCH.

No. 630-2766 Sh 2 of 4
Rev. D
Modified 5/2007

40−600 AMP TYPICAL WIRING DIAGRAM (SHEET 2 OF 4)

7-16
 THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
SCHEMATIC AND WIRING DIAGRAM
PACKAGE THAT WAS SHIPPED WITH THE
TRANSFER SWITCH.

No. 630-2766 Sh 3 of 4
Rev. D
Modified 5/2007

40−600 AMP TYPICAL WIRING DIAGRAM (SHEET 3 OF 4)

7-17
 THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
SCHEMATIC AND WIRING DIAGRAM
PACKAGE THAT WAS SHIPPED WITH THE
TRANSFER SWITCH.

No. 630-2766 Sh 4 of 4
Rev. D
Modified 8/2010

40−600 AMP TYPICAL WIRING DIAGRAM (SHEET 4 OF 4)

7-18
 THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
SCHEMATIC AND WIRING DIAGRAM
PACKAGE THAT WAS SHIPPED WITH THE
TRANSFER SWITCH.

No. 630-2768 Sh 1 of 4
Rev.C
Modified 11/2004

40−1000 AMP TYPICAL INTERCONNECTION DIAGRAM (Sheet 1 of 4)

7-19
 THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
SCHEMATIC AND WIRING DIAGRAM
PACKAGE THAT WAS SHIPPED WITH THE
TRANSFER SWITCH.

No. 630-2768 Sh 2 of 4
Rev. C
Modified 11/2004

40−1000 AMP TYPICAL INTERCONNECTION DIAGRAM (Sheet 2 of 4)

7-20
 THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
SCHEMATIC AND WIRING DIAGRAM
PACKAGE THAT WAS SHIPPED WITH THE
TRANSFER SWITCH.

No. 630-2768 Sh 3 of 4
Rev. C
Modified 11/2004

40−1000 AMP TYPICAL INTERCONNECTION DIAGRAM (Sheet 3 of 4)

7-21
 THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
SCHEMATIC AND WIRING DIAGRAM
PACKAGE THAT WAS SHIPPED WITH THE
TRANSFER SWITCH.

No. 630-2768 Sh 4 of 4
Rev.C
Modified 11/2004

40−1000 AMP TYPICAL INTERCONNECTION DIAGRAM (Sheet 4 of 4)

7-22
This Page Intentionally Left Blank.

7-23
This Page Intentionally Left Blank.

7-24
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Specifications are subject to change without notice.