Upload
shashiraj-shettigar
View
461
Download
66
Embed Size (px)
DESCRIPTION
ATS OM - OTPC Installation - Cummins
Citation preview
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 1/154
InstallationInstallation ManualManual
Generator Set
40-4000 Amps
OTPCA (Spec A)
OTPCB (Spec A)
OTPCC (Spec A)
OTPCD (Spec A)
OTPCE (Spec A-C)
OTPCF (Spec A-B)
OTPCG (Spec A-B)
OTPCH (Spec A-B)OTPCJ (Spec A)
EnglishOriginal Instructions 5-2013 962-0618 (Issue 6
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 2/154
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 3/154
Table of Contents
1. INTRODUCTION............................................................................................................................ 1
1.1 Installation Manual.................................................................................................................. 1
1.2 Transfer Switch Application .................................................................................................... 1
1.3 Transfer Switch Function ........................................................................................................ 2
1.4 Utility-to-Genset Operation ..................................................................................................... 3
1.5 Utility-to-Utility Operation ........................................................................................................ 3
1.6 Generator-to-Generator Operation ......................................................................................... 3
1.6.1 Prime Power (Plant to Plant) Operation....................................................................... 3
1.6.2 Dual Stand-By Operation............................................................................................. 6
1.7 Control Level 1 and Level 2.................................................................................................... 9
1.8 Installation Overview............................................................................................................. 10
1.8.1 Application and Installation ........................................................................................ 10
1.8.2 Safety Considerations................................................................................................ 101.9 Model Identification ............................................................................................................... 10
1.10 How to Obtain Service ........................................................................................................ 11
2. MOUNTING.................................................................................................................................. 13
2.1 Location ................................................................................................................................ 13
2.2 Wall Mounting ....................................................................................................................... 13
2.3 Open Construction ................................................................................................................ 16
2.4 Seismically Certified Installations.......................................................................................... 18
3. WIRING........................................................................................................................................ 21
3.1 Dual Standby System - Genset-To-Genset Installations ...................................................... 21
3.2 Prime Power (Plant to Plant) System - Genset-To-Genset Installations .............................. 213.3 Dual Standby System - Genset-To-Genset Installations ...................................................... 22
3.4 Recommended Compression Lugs (OTPCE Spec D).......................................................... 22
3.5 AC Connections .................................................................................................................... 23
3.5.1 Converting Transfer Switch Phase Setting ................................................................ 26
3.6 Control Connections ............................................................................................................. 31
3.6.1 Connecting the Transfer Switch to a Genset............................................................. 32
3.6.2 Auxiliary Contacts ...................................................................................................... 33
3.6.3 Remote Start-Stop Connections ................................................................................ 33
3.6.4 Remote Test Feature................................................................................................. 34
3.6.5 Transfer Inhibit ........................................................................................................... 34
3.6.6 Load Shed Option...................................................................................................... 34
3.6.7 Auxiliary Relays Option.............................................................................................. 35
3.6.8 Relay Module Option ................................................................................................. 36
3.6.9 Battery Charger Options ............................................................................................ 38
3.6.10 Battery Charger Alarm Contacts Option .................................................................. 41
3.6.11 Network Connections............................................................................................... 42
3.7 Voltage Sensing Wiring (Level 2 Control Only) .................................................................... 42
962-0618 (Issue 6) i
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 4/154
Table of Contents 5-2013
3.8 Transfer Switches in Fire Pump Circuit Applications............................................................ 43
3.8.1 Required Transfer Switch Features ........................................................................... 44
3.8.2 Location...................................................................................................................... 45
3.8.3 Isolating Switch .......................................................................................................... 45
3.8.4 Supervision ................................................................................................................ 45
3.8.5 Separate ATS for Auxiliaries...................................................................................... 45
3.9 Shorting Bar Removal........................................................................................................... 453.10 Inspection and Cleanup ...................................................................................................... 46
4. SETUP AND ADJUSTMENTS ..................................................................................................... 47
4.1 Before Adjusting.................................................................................................................... 47
4.1.1 Install J1 and J2 ......................................................................................................... 47
4.1.2 Install Digital Module and Network Communications Module Batteries .................... 47
4.1.3 Connect the Battery (Utility to Genset and Genset to Genset ApplicationsOnly) ............................................................................................................................ 47
4.1.4 Connect AC Line Power............................................................................................. 47
4.2 Digital Display Menu ............................................................................................................. 53
4.2.1 Main Menu ................................................................................................................. 534.2.2 Setup Menu................................................................................................................ 53
4.2.3 Navigation .................................................................................................................. 53
4.3 Voltage and Frequency Sensing........................................................................................... 66
4.3.1 Under-Voltage Sensing.............................................................................................. 66
4.3.2 Over-Voltage Sensing................................................................................................ 66
4.3.3 Frequency Sensing .................................................................................................... 67
4.3.4 Voltage Imbalance Sensing ....................................................................................... 68
4.3.5 Phase Rotation Sensing ............................................................................................ 68
4.3.6 Loss of Single Phase Sensing................................................................................... 68
4.4 Sync Check Sensor .............................................................................................................. 73
4.4.1 Active Sync Feature................................................................................................... 734.4.2 Speed Adjust.............................................................................................................. 74
4.5 POWER COMMAND TIME DELAYS ................................................................................... 76
4.5.1 Start Time Delay (TDES, TDES-A, and TDES-B)...................................................... 76
4.5.2 Stop Time Delay (TDEC, TDEC-A, and TDEC-B) ..................................................... 76
4.5.3 Transfer Time Delay (TDNE) ..................................................................................... 76
4.5.4 Retransfer Time Delay (TDEN).................................................................................. 76
4.6 Programmable Generator Exerciser ..................................................................................... 81
5. CHECKOUT ............................................................................................................................... 113
5.1 STARTING TEST (UTILITY-TO-GENSET MODE)............................................................. 113
5.2 TEST TRANSFER WITH LOAD ......................................................................................... 1135.3 CONTROL LED INDICATORS AND SWITCH ................................................................... 114
5.3.1 LED Indicators.......................................................................................................... 114
5.3.2 Exerciser Enable/Disable Switch ............................................................................. 114
6. START-UP CHECKLIST ............................................................................................................ 117
6.1 SETUP USING THE DIGITAL DISPLAY............................................................................ 117
6.1.1 Setting Exercise(s)................................................................................................... 117
ii 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 5/154
5-2013 Table of Contents
6.1.2 Setting the Unit to Test With or Without Load ......................................................... 118
6.1.3 Saving the Settings and System Verification........................................................... 118
6.1.4 Features................................................................................................................... 118
6.2 SETUP USING INPOWER ................................................................................................. 118
6.2.1 Setting Exercise(s)................................................................................................... 118
6.2.2 Setting the Unit to Test With or Without Load ......................................................... 119
6.2.3 Saving the Settings and System Verification........................................................... 1196.2.4 Features................................................................................................................... 119
6.2.5 About InPower Service Tool .................................................................................... 120
6.2.6 About Network Applications and Customer Inputs .................................................. 120
7. WIRING CONSIDERATIONS FOR CLOSED TRANSITION TRANSFER SWITCHES............. 121
7.1 Re-transfer and transfer inhibit functions............................................................................ 121
7.2 Fail to disconnect................................................................................................................ 122
APPENDIX A. INTERCONNECT AND CONNECTION DIAGRAMS.............................................. 125
962-0618 (Issue 6) iii
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 6/154
Table of Contents 5-2013
This page is intentionally blank.
iv 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 7/154
Safety Precautions
This manual includes the following symbols to indicate potentially dangerous conditions. Read the manualcarefully and know when these conditions exist. Then take the necessary steps to protect personnel andthe equipment.
DANGER
This symbol warns of immediate hazards that will result in severe personal injury or death.
WARNING
This symbol refers to a hazard or unsafe practice that can result in severe personal injury or death.
CAUTION
This symbol refers to a hazard or unsafe practice that can result in personal injury or product 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 severepersonal injury or death. Read and follow these suggestions.
Keep the transfer switch cabinet closed and locked. Make sure only authorized personnel have the cabinetand operational keys.
Due to the serious shock hazard from high voltages within the cabinet, all service and adjustments to thetransfer switch must be performed only by an electrician or authorized service representative.
Whenever closed transition is used, approval in parallel with the local electric utility must be obtained.
GENERAL PRECAUTIONS
Place rubber insulative mats on dry wood platforms over metal or concrete floors when working on anyelectrical equipment. Do not wear damp clothing (particularly wet shoes) or allow skin surfaces to be dampwhen 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 drugthat makes the operation of equipment unsafe.
UTILITY-TO-GENSET OR GENSET TO GENSET APPLICATIONS
If the cabinet must be opened for any reason:
1. Move the operation selector switch on the generator set to Stop.
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 extremecaution due to the danger of shock hazard.
962-0618 (Issue 6) v
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 8/154
Safety Precautions 5-2013
UTILITY-TO-UTILITY APPLICATIONS
If the cabinet must be opened for any reason, remove AC power to the automatic transfer switch. If theinstructions require otherwise, use extreme caution due to the danger of shock hazard.
WARNING
INCORRECT SERVICE OR REPLACEMENT OF PARTS CAN RESULT IN DEATH, SEVERE PERSONAL INJURY,
AND/OR EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST BE QUALIFIED TO PERFORM ELECTRICAL AND/OR MECHANICAL SERVICE.
vi 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 9/154
1 Introduction
1.1 Installation Manual
This manual covers models produced under the Cummins®/Onan® and Cummins Power Generation brand names.
This manual provides information necessary for installation of an OTPC transfer switch. This is
an open transition (OT) transfer switch with a PowerCommand (PC) control. It is capable of
executing Open Transition with Sync Check, Programmed Transition, and Closed Transition
transfer modes.
An Open Transition with Sync Check executes an OT when both sources of power are within
specified tolerances of frequency, voltage, and relative phase difference. If both sources meet
the tolerances, a fast transfer occurs.
A Programmed Transition executes an OT by disconnecting the load from the source of
power, pausing in the neutral position of the transfer switch (between switched positions) to
allow transient currents from the load to diminish, and then the load is switched to the other source.
A Closed Transition executes a load transfer by momentarily paralleling both sources (a
maximum of 100ms) before switching sources.
1.2 Transfer Switch Application
Transfer switches are an essential part of a building's standby or emergency power system.
Power Source 1 (Normal), commonly the utility line, is backed up by Power Source 2
(Emergency), often a generating set. The transfer switch automatically switches the electrical
load from one source to the other.
The load is connected to the common of the transfer switch (Figure 1). Under normal
conditions, the load is supplied with power from Source 1 (as illustrated). If Source 1 is
interrupted, the load is transferred to Source 2. When Source 1 returns, the load is retransferred
to Source 1. The transfer and retransfer of the load are the two most basic functions of a
transfer switch.
962-0618 (Issue 6) 1
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 10/154
1. Introduction 5-2013
FIGURE 1. LOAD TRANSFER SWITCH (TYPICAL FUNCTION)
1.3 Transfer Switch Function
Automatic transfer switches, capable of automatic operation without operator intervention,
perform the basic function of transferring the load to the available source. The controller
monitors each source for allowable voltage and frequency range. Transfer switches may interact
with any of the Lon-Mark™ devices.
• Genset
• Master Controller
• Annunciator Panel
• Circuit Breaker
2 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 11/154
5-2013 1. Introduction
1.4 Utility-to-Genset Operation
In utility-to-genset applications, the transfer switch performs the following functions:
1. Senses the interruption of the Source 1 power.
2. Sends a start signal to the generator set (Source 2).
3. Transfers the load to the Source 2.
4. Senses the return of Source 1.
5. Retransfers the load to Source 1.
6. Sends a stop signal to the generator set.
1.5 Utility-to-Utility Operation
In utility-to-utility applications, the transfer switch performs the following functions:
1. Senses the interruption of the Source 1 power.
2. Transfers the load to the Source 2.
3. Senses the return of Source 1.
4. Retransfers the load to Source 1.
Level 2 controllers can control a two-utility configuration for prime power. One utility is
designated the preferred source. The control automatically transfers the load between the two
utilities and detects alarm conditions. The exercise routine is not available in this configuration.
The operator can select either source as the preferred source. See the Digital Display Menu
System section.
1.6 Generator-to-Generator OperationIn genset-to-genset applications, there are two possible configurations, as shown in Figure 3.
• Prime Power - Two gensets provide all of the power (utility power is not available).
• Dual Standby - Two gensets are used to back up utility power.
1.6.1 Prime Power (Plant to Plant) Operation
In prime power applications, utility power is not available. The system includes one transfer
switch and two gensets (see Figure 3). One genset is always running and supplying power to
the load while the other genset is the backup genset. An external power supply is not needed in
this application.
1.6.1.1 Preferred Source Selection
Under normal operation, one genset is designated as the preferred source and supplies power
to the load. The second genset is the backup power source. If the preferred genset fails, the
backup genset starts and the transfer switch transfers the load to the backup genset.
At any time, the PC service tool or the Test sub-menu (see Figure 2) can be used to designate
either genset (Source 1 or Source 2) as the preferred genset. The Preferred Source menu is
included in the Test submenus (see Figure 57).
962-0618 (Issue 6) 3
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 12/154
1. Introduction 5-2013
If the user manually changes the preferred source setting so that the backup genset becomes
the preferred genset, the transfer switch transfers the load to the new preferred genset when it
becomes available. The unit that is carrying the load is always considered the preferred source.
The control doesn't automatically select which source is considered preferred.
FIGURE 2. PREFERRED SOURCE SUBMENU
FIGURE 3. GENERATOR-TO-GENERATOR CONFIGURATION IN PRIME POWER AND DUAL
STANDBY MODES
4 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 13/154
5-2013 1. Introduction
1.6.1.2 Automatic Changeover
The transfer switch can be set up to change the preferred source automatically by enabling the
changeover timer. The Time Delay submenus under Setup or the PC service tool can be used
to enable the changeover timer and specify a changeover delay time period (see Figure 4). The
Changeover menus are included in the Time Delay submenus (see Figure 53 through Figure
56).
The automatic changeover timer automatically changes the preferred source and transfers the
load to the new preferred genset after a TDEN time delay. After the transfer is complete, the
control initiates a cool-down period (TDEC) on the old preferred genset before shutting it down.
The old preferred genset is now the new backup genset. The changeover timer is now timing for
the next changeover and the cycle continues as long as the changeover timer is enabled.
FIGURE 4. CHANGEOVER SUBMENUS
1.6.1.3 Prime Power Wiring A permanent start jumper is installed in the transfer switch and is shipped from the factory in the
prime power mode. Verify that the jumper (TB3-57 to TB3-59) is installed (see Appendix A ).
1.6.1.4 System Startup
To set up a system for prime power operation:
1. Place the motor disconnect switch in the Off position, and both generator selector switches
into the OFF position.
2. Place the transfer switch in the Source 1 position.
3. Place the Off-Manual-Auto selector switch on the Source 1 genset control in the Auto
position. The genset will start and supply power to the load (the load will be energized andTDECa may be timing).
4. Use the PC Service tool or the Test sub-menu to set this genset as the preferred source.
5. Wait for TDECa to finish timing.
6. Place the Off-Manual-Auto selector switch on the Source 2 genset control in the Auto
position.
7. Place the motor disconnect switch in the Auto position.
962-0618 (Issue 6) 5
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 14/154
1. Introduction 5-2013
8. If desired, use the Time Delay sub-menus under Setup or use the PC Service tool to
enable the changeover timer and specify a changeover delay time period.
1.6.1.5 Testing the System by Turning Off the Preferred Source
1. With the preferred source genset running and supplying power to the load, place the
genset control Off-Manual-Auto selector switch in the Off position. The backup genset
should start and run. After the voltage and frequency are at acceptable levels, the transfer switch should transfer
the load to the backup genset.
2. Place the genset control Off-Manual-Auto selector switch on the preferred genset back in
the Auto position. The preferred genset should start and run.
After the voltage and frequency levels are at acceptable levels, the transfer switch should
transfer the load back to the preferred genset.
After the transfer is complete, the control initiates a cool-down period (TDEC) on the
backup genset and it should stop.
1.6.1.6 Testing the System by Changing the Designated Preferred Source
1. With the preferred source genset running and supplying power to the load, use the PC
Service tool or the Test sub-menu to change the preferred source. The new preferred
source should start and run.
After the voltage and frequency are at acceptable levels, the transfer switch should transfer
the load to the new preferred source.
After the transfer is complete, the control initiates a cool-down period (TDEC) on the old
preferred source and it should stop.
2. Use the PC Service tool or the Test sub-menu to change the preferred source back to the
original genset. The original genset should start and run.
After the voltage and frequency levels are at acceptable levels, the transfer switch shouldtransfer the load back to the original genset.
After the transfer is complete, the control initiates a cool-down period (TDEC) on the
backup genset and it should stop.
1.6.2 Dual Stand-By Operation
In dual stand-by applications, utility power is available. The system includes two transfer
switches (a Master ATS and a Slave ATS) and two gensets (see Figure 3). Utility power
supplies power to the load and both gensets are backup gensets.
Under normal operation, the utility is supplying power to the load through the lead transfer
switch. The lead transfer switch is a utility-to-genset switch. The two gensets are connected to
the genset-to-genset transfer switch. The load side of this switch is connected to the genset sideof the lead transfer switch.
Upon loss of utility power to the lead transfer switch, a signal is sent to the genset-to-genset
transfer switch to start the preferred genset. When the lead transfer switch senses generator
voltage, it transfers the load to that genset. If the preferred genset fails to start, a signal is sent
to the backup genset to start. The PC Service tool or the Test sub-menu on the genset-to-
genset transfer switch can be used to set the preferred source.
6 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 15/154
5-2013 1. Introduction
If the Stand-By Start is inactive, upon initial power–up (or reset), or during software initialization,
the transfer switch control will not start either genset. When a Stand-By Start command is
received by the Slave ATS from a Master ATS (or other device), the preferred genset
immediately starts. If the preferred genset does not start, a time delay engine start (TDES) is
initiated and the control starts the backup genset. The load is connected to the genset when it
becomes available.
If the preferred genset becomes available while the backup genset is active, a time delayretransfer (TDEN) period is initiated and the load is retransferred back to the preferred genset. A
time delay cool-down (TDEC) period is initiated before turning off the backup genset. When the
Stand-By Start becomes deactivated, a TDEC period is initiated and the active generator is
turned off.
1.6.2.1 Preferred Source Selection
Under normal operation, one genset is designated as the preferred source and the second
genset is designated as the backup power source. If both the utility power and the preferred
genset fails, the backup genset starts and the genset-to-genset transfer switch transfers the
load to the backup genset.
At any time, the PC service tool or the Test sub-menu (see Figure 57) on the genset-to-gensettransfer switch can be used to designate either genset (Source 1 or Source 2) as the preferred
genset. If the preferred genset is changed and the backup genset becomes the preferred
genset, the transfer switch transfers the load to the new preferred genset if it is needed and
when it becomes available.
1.6.2.2 Alternating Preferred Source
In an attempt to keep the running time equally distributed between both gensets, the control can
be set to alternate between the gensets when utility power fails. The selected preferred genset
starts with the first power outage. The second power outage starts the backup genset, which
now becomes the preferred genset. Upon subsequent outages, the preferred genset alternates.
If the preferred genset becomes available while the backup genset is active, a time delay
retransfer (TDEN) period is initiated and the load is retransferred back to the preferred genset. Atime delay cool-down (TDEC) period is initiated before turning off the backup genset. When the
Stand-By Start becomes deactivated, a TDEC period is initiated and the active generator is
turned off.
Only utility outages and tests or exercises initiated at the lead transfer switch result in the
gensets being alternated. The designated preferred genset will not change if it fails and the
backup genset takes over the load. This alternating preferred source can only be enabled with
the PC Service tool. When enabled, a genset can be designated as the preferred source for a
maximum of two weeks. Time adjustments can be made in one-hour increments.
1.6.2.3 Control Voltage
A dual stand-by configuration requires an external 12-24 VDC power supply to keep the genset-to-genset control active. An optional Battery Kit is available, or the genset starting batteries can
be used. See drawing 630-2024 for connection details.
1.6.2.4 Dual Stand-By Wiring
For dual stand-by applications, the jumper (TB3-57 to TB3-59) must be removed.
962-0618 (Issue 6) 7
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 16/154
1. Introduction 5-2013
1.6.2.5 System Startup
To set up a system for dual stand-by operation:
1. Place the motor disconnect switch on both transfer switches in the Off position.
2. Connect both transfer switches to the Source 1 side.
3. Make sure the Off-Manual-Auto selector switch on both gensets is in the Off position.
4. Make sure the genset-to-genset transfer switch is being powered by an external DC supply.
5. Press the Lamp Test/Reset button on the genset-to-genset transfer switch. If all of the front
panel lights come on, the control is running properly.
6. Use the PC Service tool or the Test sub-menu on the genset-to-genset transfer switch to
set the Source 1 genset as the preferred source.
7. Energize utility power to the lead transfer switch. The load is energized and a time delay
(TDECa) begins.
8. Wait for TDECa to finish timing.
9. Set the time delay engine start (TDESa) to zero on the lead transfer switch.
10. Set the time delay engine stop (TDECa) to zero on the lead transfer switch.
11. If desired, use the PC Service tool to enable the alternating preferred source.
12. Place the motor disconnect switch in the Auto position on both transfer switches.
1.6.2.6 Testing the System by Removing Utility Power and Turning Off thePreferred Genset
1. With the utility supplying power to the load and neither genset running, turn off the utility
circuit breaker feeding the load transfer switch. The preferred genset should start and run.
After the voltage and frequency are at acceptable levels, the lead transfer switch should
transfer the load to the preferred genset.
2. Place the Off-Manual-Auto selector of the preferred genset (running) control in the Off
position.
The preferred genset should stop and the backup genset should start and run.
After the voltage and frequency are at acceptable levels, the genset-to-genset transfer
switch should transfer the load to the backup genset.
3. Place the Off-Manual-Auto selector switch on the preferred genset back to the Auto
position. The preferred genset should start and run.
After the voltage and frequency are at acceptable levels, the genset-to-genset transfer
switch should transfer the load to the preferred genset. The backup genset should stop
after the time delay engine cool-down (TDECa) is completed.
4. Turn on the utility circuit breaker feeding the lead transfer switch.
After the voltage and frequency are at acceptable levels, the lead transfer switch should
transfer the load back to the utility. The preferred genset should stop after the time delay
engine cool-down (TDECb) is completed.
8 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 17/154
5-2013 1. Introduction
1.6.2.7 Testing the System with Alternating Preferred Source Enabled:
1. With the utility supplying power to the load and neither genset running, turn off the utility
circuit breaker feeding the lead transfer switch. The preferred genset should start and run.
After the voltage and frequency are at acceptable levels, the lead transfer switch should
transfer the load to the preferred genset.
2. Restore utility power.
After the voltage and frequency are at acceptable levels, the lead transfer switch should
transfer the load back to the utility. The preferred genset should stop after the time delay
engine cool-down is completed.
3. Turn off utility power. The backup genset should now be the preferred genset and should
start and run.
After the voltage and frequency are at acceptable levels, the genset-to-genset transfer
switch should transfer to the new primary genset.
After the lead transfer switch senses the proper voltage and frequency levels, the lead
transfer switch should transfer the load to the genset.
4. Restore utility power.
After the voltage and frequency are at acceptable levels, the lead transfer switch should
transfer the load back to the utility. The new preferred genset should stop after the time
delay engine cool-down is completed.
The gensets will alternately start upon subsequent power outages, system tests, or
exercises initiated by the lead transfer switch.
1.7 Control Level 1 and Level 2
Two controls are available. The type of power source switched and the desired features
determine the control levels available. The Table 1 lists the applications that are available witheach control.
TABLE 1. AVAILABLE CONTROL LEVELS
Power Sources Level 1 Level 2
Genset-to-Utility X X
Genset-to-Genset X
Utility-to-Utility X
The control board level can be viewed, using the digital display (see Figure 5). This menu is
included in the About submenus (see Figure 76 through Figure 79).
FIGURE 5. CONTROL LEVEL SUBMENU
962-0618 (Issue 6) 9
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 18/154
1. Introduction 5-2013
1.8 Installation Overview
These installation recommendations apply to typical installations. Whenever possible, these
recommendations also cover factory designed options or modifications. However, because of
the many variables in any installation, it is not possible to provide specific recommendations for
every situation. If there are any questions not answered by this manual, contact your nearest
Cummins/Onan distributor for assistance.
1.8.1 Application and Installation
Installations must be carefully planned and correctly installed for proper operation. This involves
two essential elements: application and installation.
Application refers to the design of the complete standby power system that usually includes
power distribution equipment, transfer switches, ventilation equipment, mounting pads, cooling
exhaust, and fuel systems. Each component must be correctly designed so the complete
system functions as intended. Application and design is an engineering function generally done
by specifying engineers or other trained specialists. Specifying engineers are normally
responsible for the design of the complete standby system and for selecting the materials and
products required.Installation refers to the actual set-up and assembly of the standby power system. The
installers set up and connect the various components of the system as specified in the system
design plan. The complexity of the standby system normally requires the special skills of
qualified electricians, plumbers, sheetmetal workers, etc. to complete the various segments of
the installation. This is necessary so all components are assembled using standard methods
and practices.
1.8.2 Safety Considerations
The transfer switch has been carefully designed to provide safe and efficient service when
properly installed, maintained, and operated. However, the overall safety and reliability of the
complete system depends on many factors outside the control of the manufacturer. To avoidpossible safety hazards, make all mechanical and electrical connections to the transfer switch
exactly as specified in this manual. All systems external to the transfer switch must comply with
all applicable codes. Make certain all required inspections and tests have been completed and
all code requirements have been satisfied before certifying the installation is complete and ready
for service.
1.9 Model Identification
Identify your model by referring to the Model and Specification number as shown on the
nameplate. Electrical characteristics are shown on the lower portion of the nameplate, which is
located on the cabinet door.
If it is necessary to contact a dealer or distributor regarding the transfer switch, always give the
complete Model, Specification, and Serial number as listed on the nameplate. This information
is necessary to properly identify your unit among the many types manufactured.
10 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 19/154
5-2013 1. Introduction
1. OTPC - Open Transition PowerCommand® Control.
2. Ampere Rating:
A = 40, 70, 125
B = 150, 225, 260
C = 300, 400, 600
D = 800, 1000
E = 1200
F = 1600
G = 2000
H = 3000
J = 4000
3. Assigned spec number - issued for each specific combination of accessories, voltages,
frequency and standards codes. This number is only repeated for standard product.
4. Specification letter - advances with production modification.
1.10 How to Obtain Service
When the transfer switch requires servicing, contact your nearest Cummins Power Generation
distributor. Factory-trained Parts and Service representatives are ready to handle all your
service needs.
To contact your local Cummins Power Generation distributor in the United States or Canada,call 1-800-888-6626 (this automated service utilizes 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.
Typically, our distributors are listed under:
Generators-Electric,
Engines-Gasoline or
Engines-Diesel, or Recreational Vehicles-Equipment,
Parts and Service.
For outside North America, call Cummins Power Generation, 1-763-574-5000, 7:30 AM to 4:00PM, Central Standard Time, Monday through Friday. Or, send a fax to Cummins Power
Generation using the fax number 1-763-574-8087.
When contacting your distributor, always supply the complete Model, Specification, and Serial
Number as shown on the generator set nameplate.
Copyright© 2006 Cummins Power Generation. All rights reserved.
Cummins, Onan, and PowerCommand are registered trademarks of Cummins Inc.
962-0618 (Issue 6) 11
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 20/154
1. Introduction 5-2013
This page is intentionally blank.
12 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 21/154
2 Mounting
2.1 Location
The location of the transfer switch in the existing electrical circuit varies with the application andthe type of entrance switch. The location and wiring must comply with the contract drawings.
There must be a service disconnect in the commercial power line ahead of the transfer switch.
A typical installation is shown in Figure 6. Cabinet dimensions and weights are listed in Table 2
and Table 2.
Choose a vibration-free mounting surface that supports the weight of the switch. Avoid locations
that are near flammable liquids or gases, or are hot, moist, or dusty.
WARNING
An electrical arc occurs during transfer that can ignite a flammable atmosphere, resulting insevere personal injury or death. The switch must not be located near batteries, fuel tanks,
solvents, or other sources of flammable liquids or gases, or in areas sharing ventilation withsuch sources.
2.2 Wall Mounting
1. Make sure that the wall where the ATS switch is to be mounted is suitable to hold firmly the
weight and size of the transfer switch, within a reasonable safety factor.
2. Check the location to be sure no wires or plumbing, gas, or exhaust lines run behind the
wall.
3. Make sure that all anchorage fasteners used to bolt the switch to wall are strong enough to
withstand the switch weight and its vibration during operation, within a reasonable safetyfactor.
4. Install two mounting bolts in the wall for the top cabinet mounting keyholes.
5. With the shipping box standing so that the cabinet is upright, carefully remove the top and
sides of the box.
WARNING
Improper lifting can cause severe personal injury. Have sufficient manpower for lifting and mounting the cabinet.
6. Raise the cabinet and mount it on the two mounting bolts in the wall.
7. Install two bottom mounting bolts, but do not tighten them. (Do not remove the cabinet
support until all bolts are installed).
8. Push the cabinet against the wall. If the cabinet does not align flush against the wall, shim
the mounting bosses as required.
9. When the switch is installed on the wall, the switch cabinet should be squared up before
final fastener tightening. Make sure the installed ATS is square, level, and plumb upon
completion of the installation.
962-0618 (Issue 6) 13
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 22/154
2. Mounting 5-2013
10. Tighten all mounting bolts.
TABLE 2. APPROXIMATE NEMA 1 CABINET DIMENSIONS
Switch Current Height Width Depth With Door WeightRating
Closed Open
40, 70, & 125 (Three 27 in 20.5 in 12 in 31.5 82 lbPole Switches Only) 686 mm 521 mm 305 mm 800 mm 37 kg
40, 70 & 125 (Four 35.5 in 26 in 16 in 41 in 165 lbPole Switches) and 902 mm 660 mm 406 mm 1042 mm 75 kg150 & 225 (Three andFour Pole Switches)
260 43.5 in 28.5 in 16 in 43 in 170 lb
1105 mm 724 mm 406 mm 1093 mm 77 kg
300, 400, & 600 54 in 25.5 in 18 in 42 in 225 lb
1372 mm 648 mm 457 mm 1067mm 102 kg
800 (Open and 68 in 30 in 19.5 in 48.5 in 360 lbProgrammed 1727 mm 762 mm 495 mm 1232 mm 163 kg
Transition) & 1000(Open andProgrammedTransition) - Spec A
1000 (Closed 75 in 36 in 21.5 in 54 in 450 lbTransition) & 1200 - 1905 mm 915 mm 546 mm 1372 mm 204 kgSpec C
1000 (Closed 75 in 36 in 21.5 in 54 in 450 lbTransition) & 1200 1905 mm 915 mm 546 mm 1372 mm 204 kg(Closed Transition) -Spec D
1200 (Open and 90 in 39 in 27.5 in 65 in 730 lbProgrammed 2286 mm 991 mm 698 mm 1644 mm 331 kgTransition) - Spec D
1600 & 2000 90.0 in 36.0 in 48 in 84 in 1100 lb
2286 mm 915 mm 1219 mm 2134 mm 499 kg
3000 90.0 in 36.0 in 48 in 84 in 1250 lb
2286 mm 915 mm 1219 mm 2134 mm 567 kg
4000 90.0 in 47.0 in 60 in 106 in 1870 lb
2286 mm 1193.8 1524 mm 2692.4 mm 848 kg
TABLE 3. APPROXIMATE NEMA 3R AND 4 CABINET DIMENSIONS
Switch Current Height Width Depth with Door WeightRating
Closed Open
40, 70, & 125 (Three 34 in 26.5 in 12.5 in 36.5 in 125 lbPole Switches Only) 864 mm 673 mm 318 mm 927 mm 57 kg
40, 70 & 125 (Four 42.5 in 30.5 in 16 in 44 in 215 lbPole Switches) and 1080 mm 775 mm 406 mm 1118 mm 97 kg150 & 225 (Three andFour Pole Switches)
14 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 23/154
5-2013 2. Mounting
Switch Current Height Width Depth with Door WeightRating
Closed Open
260 46 in 32 in 16 in 46 in 225 lb
1168 mm 813 mm 406 mm 1168 mm 102 kg
300, 400, & 600 59 in 27.5 in 16.5 in 41.5 in 275 lb
1499 mm 699 mm 419 mm 1054 mm 125 kg
800 (Open and 73.5 in 32.5 in 19.5 in 49.5 in 410 lbProgrammed 1867 mm 826 mm 495 mm 1257 mm 186 kgTransition & 1000(Open andProgrammedTransition) - Spec A
1000 (Closed 75 in 36 in 19.5 in 55 in 450 lbTransition) & 1200 - 1905 mm 915 mm 495 mm 1397 mm 204 kgSpec C
1000 (Closed 75 in 36 in 19.5 in 55 in 450 lbTransition) & 1200 1905 mm 915 mm 495 mm 1397 mm 204 kg(Closed Transition) -Spec D
1200 (Open and 90 in 39 in 27.5 in 65 in 730 lbProgrammed 2286 mm 991 mm 698 mm 1644 mm 331 kgTransition) - Spec D
1600 & 2000 90 in 32.5 in 51.0 in 79 in 1100 lb
2286 mm 826 mm 1295 mm 2007 mm 499 kg
3000 90 in 38.0 965 mm 51.0 in 84.5 in 1250 lb
2286 mm 1296 mm 2146 mm 567 kg
4000 90.0 in 47.0 in 61.25 in 107.25 in 1870 lb
2286 mm 1193.8 1555.75 mm 2724 mm 848 kg
962-0618 (Issue 6) 15
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 24/154
2. Mounting 5-2013
FIGURE 6. TYPICAL WALL-MOUNT INSTALLATION
2.3 Open Construction
Use a cabinet of the required NEMA type. The door should be secured and have safety
warnings required to meet all applicable codes. The minimum cabinet size is 90 in (H) x 39 in
(W) x 25 in (D).
The outline drawings supplied with the transfer switch provide outline dimensions for mountingthe transfer switch components inside the cabinet. Page one of the outline drawing shows the
dimensions of the control plate typically mounted on the back side of the front door. Page two
shows the cutout needed and proper mounting so the touch pad and optional key switch are
visible through the front of the door.
Refer to the Wiring Section for electrical connections.
16 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 25/154
5-2013 2. Mounting
FIGURE 7. TYPICAL OPEN CONSTRUCTION
962-0618 (Issue 6) 17
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 26/154
2. Mounting 5-2013
2.4 Seismically Certified Installations
Seismically certified transfer switch installations (feature code A080-7) have special
requirements, as defined by IAA-VMC (Independent Approval Agency, the VMC Group).
1. The design of post-installed anchors in concrete used for the component anchorage is
prequalified for seismic applications in accordance with ACI 355.2 and documented in a
report by a reputable testing agency (for example, the Evaluation Service Report issued bythe international Code Council).
2. Anchors must be installed to an embedment depth, as recommended in the prequalification
test report defined in Note 1. For IBC 2000 and IBC 2003 applications, the minimum
embedment must be 8 times the anchor diameter.
3. Anchors must be installed in a minimum of 4000 PSI compressive strength normal weight
concrete. Concrete aggregate must comply with ASTM C33. Installation in structural
lightweight concrete is not permitted unless otherwise approved by the structural engineer
of record.
4. Anchors must be installed to the maximum torque specification, as recommended by the
anchor manufacturer.
5. Anchors must be installed in the locations specified on the Installation Outline Drawings or
on Seismic Requirements Installation Drawing 0179-5288.
6. Wide washers must be installed at each anchor location between the anchor head and the
equipment for tension load distribution. Wide steel washers must be Series W of American
National Standard Type A plain washers (low carbon steel washers), ANSI B18.22.1- 1965,
R1975, with the washer sizes specified on drawing 0179-5288 (Switch Installation, Seismic
Requirements, sheet 2 of 3).
7. Concrete floor slab and concrete housekeeping pads must be designed and rebar-
reinforced for seismic applications, in accordance with ACI 318.
8. All housekeeping pad thicknesses must be designed in accordance with the prequalification
test report, as defined in Note 1 or a minimum of 1.5 times the anchor embedment depth,whichever is largest.
9. All housekeeping pads must be dowelled or cast into the building structural floor slab and
designed for seismic application, as per SCI 318 and as approved by the structural
engineer of record.
10. Wall mounting equipment must be installed to a rebar-reinforced structural concrete wall
that is seismically designed and approved by the engineer of record to resist the added
seismic loads from components being anchored to the wall.
11. Floor mounted equipment (with or without a housekeeping pad) must be installed to a
rebar-reinforced structural concrete floor that is seismically designed and approved by the
engineer of record to resist the added seismic loads from components being anchored to
the floor.
12. When installing to a floor or wall, rebar interference must be considered.
13. Attaching seismic certified equipment to any floor or wall, other than those constructed of
structural concrete and designed to accept the seismic loads from said equipment, is not
permitted by this specification.
14. Attaching seismic certified equipment to any floor constructed of light weight concrete over
steel decking is not permitted by this specification.
18 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 27/154
5-2013 2. Mounting
15. Attaching seismic certified equipment to any concrete block walls or cinder block walls is
not permitted by this specification.
For special switch installation requirements, see written and tabulated seismic
requirements listed on drawing 0179-5288.
The installation of the seismically certified switch should be overseen by the installation project
structural engineer of record.
The Site Specific Requirements listed on page one of the “Seismic Certificate of Compliance"
should be filled out by the installation project structural engineer of record.
Drawing 0179-5288 and the Seismic Certificate of Compliance for transfer switch and seismic
installation requirements are included in the literature package of each seismically certified
switch with feature code A080-7.
962-0618 (Issue 6) 19
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 28/154
2. Mounting 5-2013
This page is intentionally blank.
20 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 29/154
3 Wiring
Refer to Figure 28 thru Figure 32 for component locations.
WARNING
AC voltages and currents present an electrical shock hazard that can cause severe personal injury or death. Only qualified personnel are to perform the following procedures.
When installing conduit, observe the following precautions:
1. Before beginning conduit installation, cover the transfer switch to prevent accidental entry
of metal chips.
2. Install at least 2 feet (610 mm) of flexible conduit between the rigid conduit and generator
set to absorb vibration.
3. Run control circuit wiring in separate conduit from the AC wiring; otherwise, induced
currents could cause operational problems within the switch. If using non-metallic conduits,
be sure to use shielded cable. Cutouts can be made through the top, bottom, or sides of the cabinet. (Refer to the switch outline drawings in Appendix A.)
CAUTION
Installation debris can cause equipment failure and damage. Use extreme care to keep drill chips and filings out of the relays, contacts, and other parts of the automatic transfer switchwhen mounting or connecting conduit. Screwdrivers should be used carefully to prevent damage to components.
3.1 Dual Standby System - Genset-To-Genset
InstallationsGenset-to-genset installations that include a dual standby system are typically installed with a
control battery and battery charger. Refer to the interconnection drawings included with your
transfer switch. A typical interconnection drawing for this type of installation is included at the
back of this manual.
3.2 Prime Power (Plant to Plant) System - Genset-To-Genset Installations
Prime Power Wiring - A permanent start jumper is installed in the transfer switch and is
shipped from the factory in the prime power mode. Verify that the jumper (TB3-57 to TB3-59) isinstalled.
962-0618 (Issue 6) 21
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 30/154
3. Wiring 5-2013
3.3 Dual Standby System - Genset-To-GensetInstallations
Genset-to-genset installations that include a dual standby system are typically installed with a
control battery and battery charger. A DC power supply is required for dual standby systems.
Refer to the interconnection drawings included with your transfer switch. A typical
interconnection drawing for this type of installation is included at the back of this manual.
Control Voltage - A dual stand-by configuration requires an external 12-24 VDC power supply
to keep the genset-to-genset control active. An optional Battery Kit is available, or the genset
starting batteries can be used. See Appendix A for connection details.
Dual Stand-By Wiring - For dual stand-by applications, the jumper (TB3-57 to TB3-59) must be
removed (see Appendix A).
3.4 Recommended Compression Lugs (OTPCE Spec D)
Tables Table 4 through Table 7 list recommended compression lugs in sizes 500, 600, and 750
MCM for the OTPCE Spec D switch.
TABLE 4. COMPRESSION LUGS FROM ILSCO
750 MCM 600 MCM 500 MCM
CRA-750L2 CRA-600L2 CRA-500L2
2ACL-750 2ACL-600 2ACL-500
2IACL-750 2IACL-600 2IACL-500
CRA-xxxL2 represents long barrel copper compression lugs.
2ACL-xxx represents aluminum compression lugs.
2IACL-xxx represents narrow tang aluminum compression lugs.
TABLE 5. COMPRESSION LUGS FROM THOMAS & BETTS (COLOR-KEYED)
750 MCM 600 MCM 500 MCM
54223 54289 54286
60278 60275 60273
60278N 60278N 60278N
54xxx represents short barrel two hole lugs.
60xxx represents two hole lugs - 90° C.
60xxxN represents range taking narrow tongue single barrel lugs. The 60278N lug is from 500 to 750 MCM.
TABLE 6. COMPRESSION LUGS FROM THOMAS & BETTS ( BLACKBURN)
750 MCM 600 MCM 500 MCM
LCN75 LCN600 LCN500
ATL502 ATL6002 ATL5002
22 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 31/154
5-2013 3. Wiring
LCN represents long barrel 2-hole mount copper lugs.
ATL represents 2-hole aluminum lugs.
TABLE 7. COMPRESSION LUGS FROM BURNDY
750 MCM 600 MCM 500 MCM
YA39-2LN YA36-2LN YA34-2LN
YA39-2N YA36-2N YA34-2N
YA44L-2NTC-FX - YA38L-2NTC-FX
YAG44L-2NTC-LD - YAG38L-2NTC-LD
YA44-2N-FXB - YA38-2N-FXB
YA39A5 and YA39AM2 YA36A3 YA34A3
YAxx-2LN represents standard length barrel copper compression terminal.
YAxx-2N represents long barrel uninsulated copper compression terminal.
YAxxL-2NTC-FX represents standard length barrel copper compression terminal for flexible and extra flexible copper cables.
YAGxxL-2NTC-LD represents standard length barrel lead plated copper compression terminal.YAGxx-2N-FXB represents long barrel copper compression terminal belled entry for flexible and extra flexible copper cables.
YAxxAx and YAxxAMx represent 2-hole and 4-hole uninsulated aluminum compression terminal.
3.5 AC Connections
Perform wiring in the following sequence:
1. Test the operation of the generator set from its own controls.
2. Stop the generator set and remove the negative lead from the cranking battery to prevent
starting.
WARNING
Failure to prevent the generator set from starting before wiring procedures are performed presents a shock hazard that can cause severe personal injury or death. Disconnect generator set battery (negative (-) terminal first) before proceeding.
3. Connect conductors of sufficient size (see contract drawings) to carry rated current from
the line, load, and generator set directly to the transfer switch terminals, which are marked
A, B, and C (A, B, C, and N on 4-pole switches). A neutral bar with lugs is standard on 3-
pole switches.
On transfer switches with a bar graph display, in order to measure the current, the load
cables must each pass through a current transformer (Figure 8). Transfer switches areshipped with current transformer (CT) wires (white wire = X1, black wire = X2) connected to
the terminal block (TB4) with the polarity mark facing the transfer switch. When wiring the
power cables to the transfer switch, be sure the cables pass thru the CTs, and make sure
all CTs are facing the same direction with the polarity marks facing the transfer
switch.
Table 9 gives the type and maximum conductor size the transfer switch accepts. Figure 10
through Figure 13 show transfer switch source and load connections.
962-0618 (Issue 6) 23
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 32/154
3. Wiring 5-2013
TABLE 8.
FIGURE 8. CURRENT TRANSFORMER WIRING
TABLE 9. TERMINAL LUG CAPACITY FOR COPPER OR ALUMINUM CONDUCTORS
Switch Current Rating Wires per Phase Size Range of Wires
40/70/125 Source 1 12 AWG-2/0 Cu-Al
40/70/125 Load & Neutral 1 14 AWG-2/0 Cu-Al
150/225 1 6 AWG-300 MCM Cu-Al
260 1 6 AWG-400 MCM Cu-Al
300/400 2 3/0 AWG-250 MCM Cu-Al
1 3/0 AWG-600 MCM Cu-Al
600 2 250-500 MCM Cu-Al
800 (Open and Programmed 4 250-500 MCM Cu-AlTransition)/1000 (Open andProgrammed Transition) - Spec A
1000 (Closed Transition)/1200 Spec C 4 2 AWG-600 MCM Cu-Al
1000 (Closed Transition)/1200 (Closed 4 2 AWG-600 MCM Cu-AlTransition) Spec D
1200 (Open and Programmed 4 2 AWG-600 MCM Cu-Al
Transition) - Spec D (standard - mechanical lugs)4-1/0-750 MCM Cu-Al
(optional - mechanical lugs)
500 MCM Cu-Al
(optional - mechanical lugs)
600 MCM Cu-Al
(optional - compression lugs)
750 MCM Cu-Al
(optional - compression lugs)
24 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 33/154
5-2013 3. Wiring
Switch Current Rating Wires per Phase Size Range of Wires
1600/2000 8 2 AWG-600 MCM Cu-Al (lugsoptional)
1600/2000 8 2 AWG-750 MCM Cu-Al (lugsoptional)
3000 8 2 AWG-600 MCM Cu-Al (lugs
optional)
3000 8 2 AWG-750 MCM Cu-Al (lugsoptional)
4000 12 2 AWG-600 MCM Cu-Al (lugsoptional)
4000 12 2 AWG-750 MCM Cu-Al (lugsoptional)
4. On 120-volt switches, connect the hot side to the (A) lug and the neutral side to the Neutral
lug. On 240-volt single phase switches, connect the two hot lines to the A- and C-lugs and
the Neutral line to the Neutral lug.
5. Connect power cables to the load terminals. Tighten the lugs as indicated in Table 10.
TABLE 10. LUG TORQUES
Set Screw Socket Size (Across Flats) Minimum Torque For Proper Operation
3/16 In 80 In-lbs (9 N•m)
1/4 In 200 In-lbs (23 N•m)
5/16 In 275 In-lbs (31 N•m)
3/8 In 375 In-lbs (43 N•m)
1/2 In 500 In-lbs (57 N•m)
9/16 In 600 In-lbs (68 N•m)
6. Make sure that both AC power sources are disconnected.
WARNING
AC voltages and currents present an electrical shock hazard that can cause severe personal injury or death. Make sure that both AC power sources are disconnected.
7. For 800-1000 amp transfer switches used on a circuit capable of delivering 50,000 amps @
600 volts, wrap the line cables together with nominal 1/2-inch nylon rope, or rope having a
minimum tensile strength of 4200 pounds, at five inches from the line terminals with four
wraps (see Figure 9). This is not required for 1000 amp Closed Transition switches.
962-0618 (Issue 6) 25
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 34/154
3. Wiring 5-2013
FIGURE 9. SECURING THE POWER CABLES
3.5.1 Converting Transfer Switch Phase SettingConverting a transfer switch from single-phase to three-phase operation or from three-phase to
single-phase operation is a three-step procedure:
CAUTION
Incorrect placement of transformer jumper wires can cause damage to the control when power isapplied. To perform this conversion procedure correctly, refer to and comply with the schematicsand wiring diagrams that were shipped with the transfer switch.
1. Disconnect both AC power sources.
WARNING
AC voltages and currents present an electrical shock hazard that can cause severe personal injury or death. Make sure that both AC power sources are disconnected.
2. Stop the generator set and remove the negative lead from the cranking battery to prevent
starting.
WARNING
Failure to prevent the generator set from starting before wiring procedures are performed presents a shock hazard that can cause severe personal injury or death. Disconnect generator set battery (negative (-) terminal first) before proceeding.
3. Place the transformer jumper wires (on the Power Module board) in the appropriate
configuration. See Figure 10 through Figure 13. Refer to the service manual and to the
schematic and wiring diagram package.
4. Set the appropriate Phase parameter with the digital menu system (see Section Chapter 4)
when it is available or the PC service tool.
26 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 35/154
5-2013 3. Wiring
FIGURE 10. 40- TO 125-AMPERE TRANSFER SWITCH TERMINAL ACCESS
962-0618 (Issue 6) 27
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 36/154
3. Wiring 5-2013
FIGURE 11. 1200-AMPERE TRANSFER SWITCH TERMINAL LUG ACCESS (CLOSED TRANSITION)
28 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 37/154
5-2013 3. Wiring
FIGURE 12. 1200-AMPERE TRANSFER SWITCH TERMINAL LUG ACCESS (OPEN AND
PROGRAMMED TRANSITION)
962-0618 (Issue 6) 29
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 38/154
3. Wiring 5-2013
FIGURE 13. 1600- TO 3000-AMPERE TRANSFER SWITCH TERMINAL LUG ACCESS
30 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 39/154
5-2013 3. Wiring
3.6 Control Connections
Connections of standard and optional control wiring are made at terminal blocks TB1, TB2, TB3,
and Relay Module; and directly at the (optional) auxiliary relays ( Figure 14).
TB1 is located near the top left side on the front of the transfer switch. TB2 is located below
TB1, near the bottom left side of the transfer switch. TB3 and auxiliary relays are located inside
the cabinet on the DIN rail (see Table 11).
FIGURE 14. CONTROL WIRING CONNECTIONS
TABLE 11. DIN RAIL LOCATIONS
Model (Amps) Cabinet Type Location
OTPC 40-1000 A All Types Inside, upper left wall
OTPC 1200 Amps All Types Upper left side
OTPC 1600-4000 A Type 1 Left side of cabinet
OTPC 1600-4000 A Type 3R, 4, 12 Right side of cabinet
962-0618 (Issue 6) 31
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 40/154
3. Wiring 5-2013
3.6.1 Connecting the Transfer Switch to a Genset
WARNING
AC voltages and currents present an electrical shock hazard that can cause severe personal injury or death. Disconnect the AC power source.
Wire size depends on the distance and the type of battery charger installed. Refer to Table 12
to determine the wire size required.
• All leads to TB2 use Column A.
• If the transfer switch is not equipped with a battery charger, use Column A for all wires.
• If the transfer switch is equipped with a 2-Amp charger, use Column B for B+ and GND.
Use Column A for all other wires.
• If the transfer switch is equipped with a 10-Amp charger, use Column C for B+ and GND.
Use Column A for all other wires.
• If the genset is equipped with an annunciator, use Column A for wires to the annunciator.
TABLE 12. WIRE SPECIFICATIONS
Distance in Feet, One Way (Multiply by 0.3 for Meters)Wire Size (AWG)
Column A Column B Column C
16 1000 125 25
14 1600 200 40
12 2400 300 60
10 4000 500 100
Wire resistance must not exceed 0.5 ohm per line. Use stranded wire only. For connection to
the screw terminal, strip the insulation back 3/8 inch (10 mm).Remote starting (for Cummins Power Generation water-cooled generator sets only) uses
terminals B+, GND (ground), and RMT of terminal block TB2 (Figure 16). Connect these
terminals to like terminals on the generator set. Refer to Interconnect Wiring diagram shipped
with the switch. A jumper is shipped with the transfer switch and is in a small envelope attached
to TB2.
• For PCC 3100 and PCC 2100 genset controls, install a jumper between TB2-1 and TB2-2
for ground-to-start connection.
• For Detector 12 genset controls, install a jumper between TB2-2 and TB2-3 for B+ start.
• For PCC 3200 and PCC 1301 genset controls requiring a dry contact start, do not install a
jumper.
Be sure to check the Interconnect Wiring diagram shipped with the transfer switch.
For network wiring instructions, refer to the PowerCommand Network and Operator's Manual
(PN 900-0366 for TP-78 networks or 900-0529 for FT-10 networks).
32 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 41/154
5-2013 3. Wiring
3.6.2 Auxiliary Contacts
Auxiliary contacts, used for external alarm or control circuitry, are available for the Source 1
(Normal) and Source 2 (Emergency) sides of the transfer switch. Connections for the auxiliary
contacts can be made on terminal block TB1 (Figure 15). The contacts have ratings of 10
amperes at 250 VAC. Figure 15 shows the normally open and normally closed positions of the
auxiliary contacts with the transfer switch in the neutral position. Moving the transfer switch to
Normal or Emergency actuates the corresponding auxiliary contacts.
Use number 22 to number 12 AWG stranded wire. For connection to the screw terminal, strip
the insulation back 3/8 inch (10 mm).
FIGURE 15. TERMINAL BLOCK TB1
3.6.3 Remote Start-Stop ConnectionsUse number 18 to number 12 AWG stranded wire. Resistance must not exceed 0.5 ohm per
line. Stranded wire is recommended. For connection to the screw terminal, strip the insulation
back 3/8 inch (10 mm).
Remote starting (for Onan water-cooled generator sets only) uses terminals B+, GND (ground),
and RMT of terminal block TB2 (Figure 16). Connect these terminals to like terminals on the
generator set. Refer to your generator set wiring diagrams.
Connect the supplied jumper between terminals 1 and 2 for PowerCommand control systems.
Connect the jumper between terminals 2 and 3 for Detector Control systems. Do not use the
jumper for all other systems.
962-0618 (Issue 6) 33
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 42/154
3. Wiring 5-2013
FIGURE 16. TB2: START CONNECTIONS, REMOTE TEST, AND TRANSFER INHIBIT
3.6.4 Remote Test Feature
The transfer switch can be remotely activated by using an external switch. Closure of a set of
contacts (switch) across the remote test transfer input and common causes the transfer switch
to sense a (simulated) utility power failure and send a start/run signal to the generator set. The
load is transferred to the generator set when generator set power becomes available. (Refer to
the Service manual.)
To a remote test switch, connect normally open contacts (from a test switch) to terminals 5 and
8 of TB2 (Figure 16).
Use number 22 to number 12 AWG stranded wire (maximum resistance of 4 ohms per line). For
connection to the screw terminal, strip the insulation back 3/8 inch (10 mm).
3.6.5 Transfer Inhibit
To add transfer inhibit, connect normally open contacts to terminals 6 and 8 of TB2 ( Figure 16).
In systems that have multiple closed transition transfer switches the transfer inhibit function
should be used to make sure that multiple switches don't transfer at the same time. Refer to the
section on closed transition ATS considerations.
In systems that have multiple closed transition transfer switches the retransfer inhibit function
should be used to make sure that multiple switches don't transfer at the same time. Refer to thesection on closed transition ATS considerations.
Use number 22 to number 12 AWG stranded wire. For connection to the screw terminal, strip
the insulation back 3/8 inch (10 mm).
3.6.6 Load Shed Option
To add a load shed control, connect normally open contacts across terminals 7 and 8 of TB2.
34 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 43/154
5-2013 3. Wiring
Load shed is initiated by the closing of contacts across terminals 7 and 8 of TB2. When the load
shed function is initiated, the switch is moved from the Source 2 position to the neutral position.
When load shedding is in effect, a return of Source 1 utility power causes immediate retransfer
to Source 1. If the load shed signal is removed before Source 1 returns, the switch transfers
back to Source 2 if the Source 2 is available.
NOTICE TB1 and TB2 will accept 22 AWG - 12 AWG wire with 3/8 inch (10 mm) strip. Torque to 9 in-lbs.
3.6.7 Auxiliary Relays Option
Connections to the auxiliary relays are made directly to the relay terminals. Figure 14shows the
location of the Auxiliary Relays on the options panel. The terminals accept wire sizes from one
number 18 AWG stranded wire to two number 12 AWG stranded wires. For connection to the
screw terminal, strip the insulation back 3/8 inch (10 mm).
There are two types of auxiliary relay coils (12 VDC and 24 VDC).
Table 13lists several auxiliary relay options.
All relays have two normally open and two normally closed contacts that are rated for 6
amperes at 600 VAC (Figure 17).
TABLE 13. AUXILIARY RELAY
24 Vdc Coil Installed, Not Wired
24 Vdc Coil Emergency Relay
24 Vdc Coil Normal Relay
24 Vdc Coil Genset Run Relay
12 Vdc Coil Installed, Not Wired
12 Vdc Coil Emergency Relay
12 Vdc Coil Normal Relay
12 Vdc Coil Genset Run Relay
962-0618 (Issue 6) 35
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 44/154
3. Wiring 5-2013
FIGURE 17. AUXILIARY RELAY TERMINALS
3.6.8 Relay Module Option
The Relay Module provides nine sets of form C contacts and two sets of normally open contacts
that are rated for 2 Amps at 30 VDC or 0.60 Amps at 120 VAC. Two sets of form C contacts and
one set of normally open contacts is reserved for future use. Connections to these relays are
made at J14 and J15 on the Relay Module. The Relay Module is located on the left inside wall
of the transfer switch enclosure.
The Source 1 and Source 2 Connected relays are energized when their respective power
sources are available, ready to produce power, and connected to the load.
NOTICE The following image shows all relay contacts as de-energized.
The Source 1 and Source 2 Available relays are energized when their respective power sources
are producing power.
The Test/Exercise relay is energized when the system is in test or exercise mode.
The Elevator Pre-Transfer relay is energized during the elevator signal time delay. The relay
contacts are used to provide a warning that a transfer or retransfer is about to occur.
The ATS Not-In-Auto relay is energized when any one of the following is active:
• Motor Disconnect Switch in OFF position
• Transfer Inhibit
• Retransfer Inhibit
• Load Shed
• P12 is disconnected from Power Module
The Load Shed relay is active when a load shed signal is given between TB2-7 and TB2-8.
36 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 45/154
5-2013 3. Wiring
The Fail to Disconnect relay is active when the transfer switch remains connected to both
sources for more than 100 msec during a closed transition transfer. It should be wired to the
shunt trip of the breaker feeding the ATS on either the normal or the emergency side. Refer to
the section on closed transition ATS wiring considerations.
NOTICE
TB1 and TB2 will accept 22 AWG - 12 AWG wire with 3/8 inch (10 mm) strip. Torque to 9in-lbs.
TABLE 14. RELAY MODULE CONTACTS (ALL SHOWN AS DE-ENERGIZED)
Relay NO COM NC
Source 1 Connected J14-1 J14-2 J14-3
Source 2 Connected J14-4 J14-5 J14-6
Source 1 Available J14-7 J14-8 J14-9
Source 2 Available J14-10 J14-11 J14-12
Test/Exercise Active J14-13 J14-14 J14-15
ATS Not-In-Auto J15-1 J15-2 J15-3
Elevator Pre-Transfer J15-4 J15-5 J15-6
Not Used J15-7 J15-8 J15-9
Not Used J15-10 J15-11 J15-12
Not Used J15-13 J15-14 X
Load Shed J15-15 J15-16 X
FIGURE 18. OPTIONAL RELAY MODULE
962-0618 (Issue 6) 37
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 46/154
3. Wiring 5-2013
3.6.9 Battery Charger Options
Battery chargers are used with utility-to-genset and genset-to-genset applications. When so
equipped, a battery charger can be used for charging genset starting and control batteries.
These chargers are current limiting and supply automatic 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. A float-charge battery charger regulates its charge voltage to continuously charge without
damage to 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 19). One battery charger is rated for 2 amperes
at 12 or 24 VDC. The other battery charger is rated for 15 amperes at 12 VDC or 12 amperes at
24 VDC.
FIGURE 19. CURRENT BATTERY CHARGERS
3.6.9.1 2-Amp Battery Charger
The 2-ampere battery charger (see Figure 20) has a 5 amp DC output circuit breaker switch on
the front of the battery charger. The charger also includes a 5 amp AC fuse to protect the
battery charger circuit.
Under normal operating conditions, the Low Bat and AC Fail relays are energized and the High
Bat relay is de-energized. In response to a Low Bat or AC Fail condition, the appropriate
normally energized relay (Low Bat or AC Fail) drops out. In response to a High Bat condition,
the normally de-energized High Bat relay is energized.Control Panel - The 2-amp charger control panel includes a digital display, a RESET button, and
an LED status indicator (see Figure 21).
• The 2-line x 16-character digital display displays menus and faults.
• The RESET button is used to select menu options and to clear fault messages.
• The status LED displays the appropriate color for the following conditions.
• Green - Onsolid indicates unit is charging
38 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 47/154
5-2013 3. Wiring
• Red - On solid indicates a fault condition. The fault number is shown on the digital
display.
Battery Charger Configuration - The RESET button on the control panel (see Figure 21) is used
to configure the battery charger for the correct battery voltage. (More information on Setup
menus is included in the Battery Charger Operator's Manual.)
FIGURE 20. 2-AMP POWERCOMMAND BATTERY CHARGER
FIGURE 21. 2-AMP CHARGER CONTROL PANEL
3.6.9.2 15/12-Amp Battery Charger
There are two types of 15/12-amp PowerCommand battery chargers (see Figure 22). All 15/12-
amp battery chargers have a 20 amp DC circuit breaker switch on the front of the batterycharger. 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 23).
• The 2-line x 16-character digital display displays menus and faults.
962-0618 (Issue 6) 39
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 48/154
3. Wiring 5-2013
• The Reset button is used to select menu options and to clear fault messages.
• The status LED is displays the appropriate color for the following conditions.
• Green - Onsolid indicates unit is charging
• Amber - Onsolid indicates Equalizing
• Red - On solid indicates a fault condition. The fault number is shown on the digital
display.
FIGURE 22. 15/12-AMP POWERCOMMAND BATTERY CHARGERS
40 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 49/154
5-2013 3. Wiring
FIGURE 23. 15/12-AMP CHARGER CONTROL PANEL
3.6.9.2.1 Optional Battery Temperature Sensor
Optional Battery Charger Sensor - A connector for an optional battery temperature sensor is
located on the front of the battery charger. When used to monitor battery temperature, theoptional battery temperature sensor is connected from the battery charger to the positive
terminal of the battery. A fault message (fault code 2263) is displayed if the battery temperature
is too high (reaches 131 degrees F (55 degrees C)).
Battery Charger Configuration - The RESET button on the control panel (see Figure 23) is used
to configure the battery charger. (More information on Setup menus is included in the Battery
Charger Operator's Manual.)
• Battery Voltage and Type - The battery charger must be correctly configured, using the
Setup menus, for the correct battery voltage and type before it is connected to the battery.
The battery voltage can be set for 12 or 24 VDC (default = 12 VDC). The battery type can
be set for Lead-Acid, Gel, or AGM batteries (default = Lead-Acid).
NOTICE
A factory installed battery charger is set up for the proper DC battery voltage requested onthe production order, with the Lead-Acid battery type selected as the default.
• Battery Equalization - Battery equalization is available for lead-acid batteries that are
completely charged, using the Equalize Battery screen in the Setup menus. When battery
equalization is in process, the LED status indicator turns amber.
3.6.10 Battery Charger Alarm Contacts Option
The optional 10-ampere battery charger can include three sets of form C relay contacts, as an
additional option.
Under normal operating conditions, the Low Bat and AC Fail relays are energized and the High
Bat relay is de-energized. In response to a Low Bat or AC Fail condition, the appropriate
normally energized relay (Low Bat or AC Fail) drops out. In response to a High Bat condition,
the normally de-energized High Bat relay is energized.
The contacts are rated for 4 amperes at 120 VAC or 30 VDC. Connections to these contacts are
made at terminals 41-42-43 (AC failure), 44-45-46 (high battery voltage), and 47-48-49 (low
battery voltage) of TB3 (Figure 24). See Figure 14 for the location of TB3 on the option panel.
962-0618 (Issue 6) 41
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 50/154
3. Wiring 5-2013
Use number 22 to number 12 AWG stranded wire. For connection to the screw terminal, strip
the insulation back 3/8 inch (10 mm).
The Level 1 and Level 2 Digital Modules have an input dedicated to monitor the AC Line failure
on the battery charger. This input is located at J27-23 and activated when grounded. (As of this
printing, this input is only available at J27-23.)
FIGURE 24. BATTERY CHARGER ALARM CONTACTS AND NETWORK CONNECTIONS
3.6.11 Network Connections
For installations that include a PowerCommand network module, connect stranded twisted pair
network cable to the left side of terminals 51 and 52 on TB3. The network module is located on
the left side of the digital module.
3.7 Voltage Sensing Wiring (Level 2 Control Only)
The transfer switch is wired at the factory for a 4-wire, 3-phase Wye configuration with grounded
neutral. If this transfer switch is being connected to a Delta power system or a Wye without a
grounded neutral, modify the wiring as follows:
1. Disconnect the neutral sensing wires marked TB12-7 and TB14-7.
NOTICE Leave the short jumpers as they are.
2. Insulate the terminals and secure them to the harness with a wire tie.
42 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 51/154
5-2013 3. Wiring
No. Description No. Description
1 Power module 3 Remove wire from TB 12-7
2 Remove wire from TB 14-7
FIGURE 25. OPTIONAL DELTA CONFIGURATION JUMPER
3.8 Transfer Switches in Fire Pump Circuit Applications
The following image shows the typical fire pump controller/transfer switch arrangement for
transfer switches in the range of 40 to 1000 Amp.
962-0618 (Issue 6) 43
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 52/154
3. Wiring 5-2013
No. Description No. Description
1 Source 1 (normal) 9 Fire pump feeder breaker
2 Fire pump service disconnect 10 Source 2 (generator)
3 Upstream overcurrent device (fuse or circuit breaker) 11 Alternate source
4 Pump room 12 Generator feeder breaker
5 Transfer switch 13 Normal source
6 Fire pump motor 14 To other loads
7 Fire pump controller 15 Pump room
8 Isolating switch
FIGURE 26. TYPICAL FIRE PUMP CONTROLLER AND TRANSFER SWITCH ARRANGEMENT
3.8.1 Required Transfer Switch Features1. An OTPC with Level 2 control (one ATS per fire pump)
2. Programmed transition
3. Phase sequence monitor
4. Momentary Test Switch (on cabinet door)
5. UL type 4 or 12 cabinet
44 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 53/154
5-2013 3. Wiring
3.8.2 Location
The transfer switch and Source 2 (generator) isolating switch must be located in the fire pump
room.
3.8.3 Isolating Switch
The contractor must furnish and install a lockable isolating switch, with auxiliary contacts, on theSource 2 (generator) side of the ATS.
3.8.4 Supervision
The isolating switch auxiliary contacts must be connected to the ATS controls to prevent
generator set starting when the isolating switch is open. Refer to the site interconnection
drawing.
3.8.5 Separate ATS for Auxiliaries
A separate ATS must supply all pump room auxiliaries.
3.9 Shorting Bar Removal
The current transformers are shorted during shipment. The shorting bar in terminal block TB4
connects all outputs to ground. The shorting bar must be removed in order for current metering
to function. To remove the shorting bar from the center of TB4:
1. Remove the protective cover.
2. Loosen all the the shorting bar screws and lift it out of the terminal block.
3. Reinstall the protective cover. Save the shorting bar for reuse.
962-0618 (Issue 6) 45
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 54/154
3. Wiring 5-2013
No. Description No. Description
1 Mounting plate 4 Shorting bar
2 Current module 5 Protective cover
3 Terminal and terminal block (TB4) 6 Jumper wires
FIGURE 27. SHORTING BAR REMOVAL
3.10 Inspection and Cleanup
Inspect all wiring to be certain that:
• Wiring does not interfere with switch operation.
• Wiring is not damaged as door opens and closes.
• Wiring does not contact sharp or abrasive surfaces.
• No wiring is left loose and unconnected.
After mounting and wiring the cabinet, clean the interior with a vacuum cleaner to remove any
chips, filings, or dirt from the cabinet interior and components.
The installation is not yet complete.
Do not energize the transfer switch until instructed to do so in Sections 4 and 5.
46 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 55/154
4 Setup and Adjustments
After the transfer switch is installed, the control settings can be adjusted. Setup and adjustment
procedures can be performed using the Digital Display. If the transfer switch is not equipped
with the Digital Display you must use the PC service tool to view and change parameters. Refer
to the InPower™ User's Guide for details on using the PC service tool.
4.1 Before Adjusting
4.1.1 Install J1 and J2
WARNING
AC power in the cabinet and the rear side of the cabinet door presents a shock hazard that cancause severe personal injury or death. Use extreme caution to avoid touching electrical contactswhen the cabinet door is open. Do not wear long hair, damp clothing, or jewelry.
Install connectors J1 and J2 when all wiring is complete.
4.1.2 Install Digital Module and Network CommunicationsModule Batteries
The digital module and the optional network communication module each require two batteries.
These batteries are included with the transfer switch. Install the batteries in the two battery
holders on the module(s). Orient batteries according to the polarity marks on the battery
holders.
4.1.3 Connect the Battery (Utility to Genset and Genset to
Genset Applications Only)Make sure that the RUN switch on the generator is in the STOP position and connect the
battery (negative [-] lead last). If applicable, reconnect the external battery charger.
WARNING
Ignition of explosive battery gases can cause severe personal injury. Do not smoke or cause any arc, spark, or flame while servicing batteries.
4.1.4 Connect AC Line Power
If the transfer switch main contacts are not closed to the Source 1 (Normal) power source side,
manually close the transfer switch to the Source 1 side. Then connect AC line power to theautomatic transfer switch. The Source 1 Available and Source 1 Connected lamps should light.
962-0618 (Issue 6) 47
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 56/154
4. Setup and Adjustments 5-2013
FIGURE 28. INTERIOR/COMPONENTS: 40-125 AMP SWITCH
48 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 57/154
5-2013 4. Setup and Adjustments
FIGURE 29. INTERIOR/COMPONENTS: 1200 AMP SWITCH (CLOSED TRANSITION)
962-0618 (Issue 6) 49
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 58/154
4. Setup and Adjustments 5-2013
FIGURE 30. INTERIOR/COMPONENTS: 1200 AMP SWITCH (OPEN AND PROGRAMMED
TRANSITION)
50 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 59/154
5-2013 4. Setup and Adjustments
FIGURE 31. INTERIOR/COMPONENTS: 1600-4000 AMP SWITCH (TYPE 1 CABINET)
962-0618 (Issue 6) 51
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 60/154
4. Setup and Adjustments 5-2013
FIGURE 32. INTERIOR/COMPONENTS: 1600-4000 AMP SWITCH (TYPE 3R CABINET)
52 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 61/154
5-2013 4. Setup and Adjustments
4.2 Digital Display Menu
This section describes the Digital Display Menu System and navigation through the menus. The
menus display status information, events, and setup menus. Setup menus contain parameters
with adjustable values. The descriptions in this section include ranges for the parameters and
default values. The Digital Display is an option with Level 1 controls and is standard with Level 2
controls. See Figure 33.The Digital Display Menu System is a 2-line by 20-character graphical display screen and six
buttons. The screen or menu displays status information, parameters, events and messages.
The buttons change screens and parameters. Two buttons have names: Home and Previous
Menu. These buttons are used for navigation. Messages include navigational indicators for the
other four buttons.
4.2.1 Main Menu
The main menu system consists of three top-level menus that list vertical menus (or sub-
menus). The sub-menus display status information. This information cannot be changed in the
main menus. The main menus contain eight sub-menus including the Setup Menus.
4.2.2 Setup Menu
To change setup parameters, you must enter a password (574); however, you can bypass the
password and examine, but not change (read only), current parameter settings. When
parameters are changed in any setup menu, you are prompted to either save the changes or
restore the old values.
4.2.3 Navigation
Refer to Figure 83 through Figure 88 at the end of this section for an overview of menu
navigation. These illustrations can also be used to locate a submenu and determine how to
access it.
962-0618 (Issue 6) 53
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 62/154
4. Setup and Adjustments 5-2013
FIGURE 33. CABINET WITH OPTIONS
54 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 63/154
5-2013 4. Setup and Adjustments
FIGURE 34. NAVIGATION
962-0618 (Issue 6) 55
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 64/154
4. Setup and Adjustments 5-2013
FIGURE 35. MAIN MENUS
56 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 65/154
5-2013 4. Setup and Adjustments
FIGURE 36. SOURCE 1 AND 2 SUBMENUS
962-0618 (Issue 6) 57
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 66/154
4. Setup and Adjustments 5-2013
FIGURE 37. LOAD SUBMENUS
58 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 67/154
5-2013 4. Setup and Adjustments
FIGURE 38. STATISTICS SUBMENUS (PRIOR TO SOFWARE VERSION 1.12)
962-0618 (Issue 6) 59
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 68/154
4. Setup and Adjustments 5-2013
FIGURE 39. STATISTICS SUBMENUS (STARTING WITH SOFTWARE VERSION 1.12)
60 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 69/154
5-2013 4. Setup and Adjustments
FIGURE 40. EVENTS SUBMENUS
962-0618 (Issue 6) 61
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 70/154
4. Setup and Adjustments 5-2013
FIGURE 41. PASSWORD SUBMENUS
62 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 71/154
5-2013 4. Setup and Adjustments
FIGURE 42. SETUP DESCRIPTION
962-0618 (Issue 6) 63
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 72/154
4. Setup and Adjustments 5-2013
FIGURE 43. CHANGING SETUP PARAMETERS (SOFTWARE VERSIONS PRIOR TO 1.12)
64 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 73/154
5-2013 4. Setup and Adjustments
FIGURE 44. CHANGING SETUP PARAMETERS (STARTING WITH SOFTWARE VERSION 1.12)
962-0618 (Issue 6) 65
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 74/154
4. Setup and Adjustments 5-2013
4.3 Voltage and Frequency Sensing
4.3.1 Under-Voltage Sensing
All controls include under-voltage sensors for Source 1 and Source 2. When a sensor detects a
low voltage condition over a specified time period, it initiates a transfer. When the source
voltage returns to an acceptable value again, the sensor initiates a retransfer.These parameters are adjustable. The under-voltage sensing range for a falling voltage (drop-
out) is 75 to 98% of the pick-up voltage setting. The default value is 90%. The pick-up range for
a rising voltage is 85 to 100% of the nominal voltage setpoint. The default value is 90%. The
adjustable range for the time delay period is 0.1 to 1.0 seconds in 0.1 second increments. The
default delay time is 0.5 second. These values are set with the PC service tool or the digital
display. See Figure 45 for an example using the default values. Refer to Figure 48 through
Figure 51 for information on how to set up those values using the digital display.
FIGURE 45. UNDER-VOLTAGE SENSING
4.3.2 Over-Voltage Sensing
All controls include over-voltage sensors for Source 1 and Source 2 that can be disabled and
not used. When a sensor detects a high voltage condition over a specified time period (delay), it
initiates a transfer. When the source voltage falls to an acceptable value again, the sensor
initiates a retransfer.
These parameters are adjustable. The over-voltage sensing range (drop-out) for a rising voltage
is 105 to 135% of the nominal voltage setpoint. The default value is 110%. The pick-up range
for a falling voltage is 95 to 100% of the drop-out setting. The default value is 95%. The
adjustable range for the delay time period is 0.5 to 120.0 seconds in 1 second intervals. The
default delay time is 3.0 seconds. The over-voltage sensing feature is enabled by default. These
values are set with the PC service tool or the digital display. See Figure 46 for an example
using the default values. Refer to Figure 48 through Figure 51 for information on how to set up
those values using the digital display.
66 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 75/154
5-2013 4. Setup and Adjustments
FIGURE 46. OVER-VOLTAGE SENSING
4.3.3 Frequency Sensing
All controls include frequency sensors for Source 1 and Source 2 that can be disabled and not
used. When a sensor detects a high or low frequency condition over a specified delay time
period, it initiates a transfer. When the frequency returns to an acceptable value again, the
sensor initiates a retransfer.
These parameters are adjustable. The nominal frequency can be set between 45.0 and 60.0 Hz
in 0.1 Hz increments. The default frequency is 60 Hz. The acceptable frequency bandwidth
(pick-up) is ±5 to ±20% of the nominal frequency setpoint. The default value is 10%. The drop-
out frequency is 1 to 5% beyond the pick-up. The default value is 1%. The range for the delay
time period is 0.1 to 15 seconds. The default delay time is 1.0 second. The frequency sensing
feature is enabled by default. These values are set with PC service tool or the digital display.
See Figure 47 for an example using the default values. Refer to Figure 48 or Figure 51 for
information on how to set up those values using the digital display.
FIGURE 47. FREQUENCY SETTING
962-0618 (Issue 6) 67
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 76/154
4. Setup and Adjustments 5-2013
4.3.4 Voltage Imbalance Sensing
Three phase Level 2 controllers include a voltage imbalance sensor for both Source 1 and
Source 2. This feature informs the operator when there is significant voltage imbalance between
the phases of Source 1 or Source 2. This feature is used for equipment protection.
A voltage imbalance is typically caused by severe single phase loading. The sensor indicates a
failure when the maximum deviation from the average voltage is greater than a user-specifiedvalue between 2 and 10 % (drop-out) of the average voltage in 1% increments. The pickup
value is fixed at 10% of the drop-out. The time delay for the imbalance sensor drop-out is
adjustable (2-20 seconds).
This sensor can be enabled using the PC service tool or the digital display Setup submenus.
This sensor is inactive for single phase systems and indicates no failures. To prevent nuisance
faults, the setting can be increased up to 10 % of the nominal voltage. Refer to Figure 48 or
Figure 51 for information on how to set up those values using the digital display.
4.3.5 Phase Rotation Sensing
Three phase Level 2 controllers include a phase rotation sensor. This feature monitors the
phase rotation of the source opposite from the connected source. When the alternate source isout of phase rotation with the connected source, transfer is inhibited. This generally occurs on
new installations or after storm damage or generator rewiring. This feature protects against
equipment damage by preventing transfer to a source that is out of phase. This feature is
required in fire pump applications.
CAUTION
Level 1 controls do not support three-phase sensing on Source 2. Do not select the three-phaseoption for the Source 2 Sensing adjustment with Level 1 controls, even if the system is three phase. This setting will prevent Source 2 from becoming available.
Both voltage sources have to be applied in order to check phase rotation. Generally, a power
source may become out of phase rotation in new installations, after a storm, or when there isgenerator rewiring.
This feature is enabled by default. To disable it, see Figure 48 or Figure 48.
4.3.6 Loss of Single Phase Sensing
Three phase Level 2 controllers include a loss of single phase sensor. This feature initiates a
transfer from a source that has lost a single phase and prevents a transfer to a source that has
lost a single phase. This is generally caused by a single phase to line ground or open. The
controller indicates a fault when the relative phase angle between any line-to-line phase angle
drops to less than 90°. This feature is mainly used to protect three phase devices, such as
motors.
To enable this sensor, see Figure 48 or Figure 50. This sensor is inactive for single phase
systems and indicates no failures.
68 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 77/154
5-2013 4. Setup and Adjustments
FIGURE 48. SETUP GROUP 1 - SENSOR SUBMENUS (SOFTWARE VERSIONS PRIOR TO 1.12)
962-0618 (Issue 6) 69
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 78/154
4. Setup and Adjustments 5-2013
FIGURE 49. SETUP GROUP 1 - SENSOR SUBMENUS (SOFTWARE VERSIONS PRIOR TO 1.12)
(CONTINUED)
70 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 79/154
5-2013 4. Setup and Adjustments
FIGURE 50. SETUP GROUP 1 - SENSOR SUBMENUS (STARTING WITH SOFTWARE VERSION 1.12)
962-0618 (Issue 6) 71
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 80/154
4. Setup and Adjustments 5-2013
FIGURE 51. SETUP GROUP 1 - SENSOR SUBMENUS (STARTING WITH SOFTWARE VERSION 1.12)
(CONTINUED)
72 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 81/154
5-2013 4. Setup and Adjustments
4.4 Sync Check Sensor
If enabled, the Sync Check sensor overrides programmed transition whenever transferring
between two live sources. If only one power source is available, programmed transition
overrides the Sync Check sensor.
The Sync Check sensor is disabled on BTPC transfer switches. The transfer switch mode
setting can be changed with the InPower service tool or with the digital display (see Figure 52)when it is available.
Sync Check is used to determine when both sources of power are within specified tolerances of
frequency, voltage, and relative phase difference. If both sources are within this range, a fast
transfer occurs.
Synchronicity parameters are adjustable. The frequency bandwidth range is from 0.1 and 1.0
Hz. The default value is 1.0 Hz. The frequency difference between the sources must be equal to
or less than the set value in order for transfer to occur. The voltage window is from 5 and 25
volts. The default value is 10 volts. The average voltage difference between the two sources
must be equal to or less than the set value in order for transfer to occur. The manual offset
range is from -25 to +25 milliseconds. The default value is 0 milliseconds. The transfer switch
controller measures non-programmed transition transfer times from one source to another. Ittakes into account relay coils and solenoids energizing. These values can be set with the
InPower service tool or with the digital display (see Figure 52) when it is available.
Another feature included with controls that have a Sync Check sensor is the Return to
Programmed Transition. If the two sources fail to synchronize within two minutes, a Failed to
Synchronize event occurs and the ATS will not transfer. However, if the Return to Programmed
Transition feature is enabled, the control reverts the ATS to the programmed transition mode
and executes an open transition. This feature is enabled by default and can be changed with
the InPower service tool or with the digital display (see Figure 52) when it is available.
4.4.1 Active Sync Feature
When the transfer switch is configured to transfer in closed transition mode it is recommendedto use the active sync feature. When the active sync feature is enabled,
the transfer switch control can send a Sync Enable command to the genset to synchronize with
the utility. This command is activated just before the Sync Check sensor is activated. When the
genset control receives a Sync Enable command and detects the Source 1 bus voltages, the
genset control automatically synchronizes its speed and phase to match the Source 1 bus. The
Sync Check sensor monitors both sources. When they are synchronized, a transfer or retransfer
command is initiated.
To use the Active Sync feature, it must first be enabled. The Active Sync feature can be
enabled with the InPower service tool or the digital display (see the Active Sync sub-menu in
Figure 52).
When the Active Sync feature is enabled, the control runs an Active Sync Time Delay (if greater than 0) and sends the Sync Enable command to the genset. The Active Sync Time Delay is
used to check the stability of the system before transferring to the other source. The two
sources must remain synchronized for this period of time period before a transfer command is
given. The Active Sync Time Delay is adjustable from 0 to 5 seconds in 0.1 second increments
(default = 0.5 seconds). The Active Sync Delay timer can be set with the InPower service tool or
the digital display (see Figure 52). The active sync feature may be used with a non-paralleling
genset control as well as a paralleling control. A non-paralleling genset control will not
962-0618 (Issue 6) 73
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 82/154
4. Setup and Adjustments 5-2013
synchronize the genset to the utility but enabling the active sync feature will impose the active
sync time delay so that the two source must remain synchronized for the set time period
maximizing the reliability of the transfer. When using a non-paralleling genset with this feature it
is recommended to set the generator set frequency to 0.1 Hz higher than the utility to make sure
that the generator set will come into sync with the utility.
4.4.2 Speed AdjustIf a PowerCommand transfer switch and a non-paralleling genset are networked together, the
transfer switch control can send a Speed Adjust command to the genset to increase its speed
just enough to increase its frequency by 0.5 Hz. The command is activated just before the Sync
Check sensor is activated. It is used when the genset takes a long time to drift in sync with the
utility. This increases the number of “in-phase" opportunities to satisfy the Sync Check sensor.
Speed Adjust is always enabled unless the Active Sync is enabled. The genset must be
capable of reacting to a Speed Adjust command. This feature is only available if a
PowerCommand network is installed.
74 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 83/154
5-2013 4. Setup and Adjustments
FIGURE 52. SYNC CHECK SUBMENUS (STARTING WITH SOFTWARE VERSION 1.20.250)
962-0618 (Issue 6) 75
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 84/154
4. Setup and Adjustments 5-2013
4.5 POWER COMMAND TIME DELAYS
4.5.1 Start Time Delay (TDES, TDES-A, and TDES-B)
This delay is adjustable from 0 to 15 seconds in 1 second increments on Level 1 controls and
from 0 to 120 seconds in 1 second increments on Level-2 controls. The default value is
3 seconds for both. This brief time delay prevents generator set starting during short power interruptions. Timing starts the moment of Source 1 power interruption. If the duration of
interruption exceeds the delay time, the control system signals the generator set to start. The
value is set with PC service tool or the digital display.
For genset-to-genset applications, TDES-A is the start time delay to start Power Source 2
genset and TDES-B is the start time delay to start Source 1 genset.
4.5.2 Stop Time Delay (TDEC, TDEC-A, and TDEC-B)
This delay is adjustable from 0 to 30 minutes in 1 minute increments. The default value is 10
minutes. It begins timing when the load is retransferred to Source 1. At the end of the delay, the
stop signal is sent to the generator set. During this time delay, the generator set cools down at
no load before stopping. The value is set with PC service tool or the digital display.For genset-to-genset applications, TDEC-A is the stop time delay to stop Power Source 2
genset and TDEC-B is the stop time delay to stop Source 1 genset.
4.5.3 Transfer Time Delay (TDNE)
This delay begins when Source 2 (typically the generator) voltage and frequency reach the
settings of the control. After the delay, the transfer switch transfers the load to Source 2. This
brief time delay allows the generator set to stabilize before the load is applied. It has an
adjustable range of 0 to 120 seconds in 1 second increments. The default value is 10 seconds.
The value is set with the PC service tool or the digital display.
4.5.4 Retransfer Time Delay (TDEN)This delay begins the moment Source 1 line voltage and frequency return to specified values.
After the delay, the transfer switch can retransfer the load to Source 1. The delay allows the
Power Source 1 to stabilize before retransfer. It has an adjustable range of 0 to 30 minutes in 1
minute increments. The default value is 10 minutes. The value is set with PC service tool or the
digital display.
76 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 85/154
5-2013 4. Setup and Adjustments
FIGURE 53. SETUP GROUP 2 - TIME DELAY SUBMENUS (SOFTWARE VERSIONS PRIOR TO 1.12)
962-0618 (Issue 6) 77
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 86/154
4. Setup and Adjustments 5-2013
FIGURE 54. SETUP GROUP 2 - TIME DELAY SUBMENUS (SOFTWARE VERSIONS PRIOR TO 1.12)
(CONTINUED)
78 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 87/154
5-2013 4. Setup and Adjustments
FIGURE 55. SETUP GROUP 2 - TIME DELAY SUBMENUS (STARTING WITH SOFTWARE VERSION
1.12)
962-0618 (Issue 6) 79
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 88/154
4. Setup and Adjustments 5-2013
FIGURE 56. SETUP GROUP 2 - TIME DELAY SUBMENUS (STARTING WITH SOFTWARE VERSION
1.12) (CONTINUED)
80 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 89/154
5-2013 4. Setup and Adjustments
FIGURE 57. SETUP GROUP 2 - TEST SUBMENUS
4.6 Programmable Generator Exerciser
Level 1 controllers include one programmable generator exercise event and Level 2 controllers
include eight programmable generator events and eight programmable exceptions. These
events are generally programmed to be recurring. They can be programmed from the PC
service tool or the digital display. All controllers have a push-button switch on the digital module
that enables and disables the exerciser clock. See the Digital Display Menu System section for
details on setting the clock.
For utility-to-genset configurations, the exerciser clock initiates genset start and run cycles at
specified intervals for specified durations. This clock is not used in utility-to-utility or genset-to-
genset configurations.
962-0618 (Issue 6) 81
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 90/154
4. Setup and Adjustments 5-2013
FIGURE 58. SETUP GROUP 2 - EXERCISER SUBMENUS (SOFTWARE VERSIONS PRIOR TO
1.5.190)
82 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 91/154
5-2013 4. Setup and Adjustments
FIGURE 59. SETUP GROUP 2 - EXERCISER SUBMENUS (SOFTWARE VERSIONS PRIOR TO
1.5.190) (CONTINUED)
962-0618 (Issue 6) 83
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 92/154
4. Setup and Adjustments 5-2013
FIGURE 60. SETUP GROUP 2 - EXERCISE SUBMENUS (STARTING WITH SOFTWARE VERSION
1.5.190)
84 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 93/154
5-2013 4. Setup and Adjustments
FIGURE 61. SETUP GROUP 2 - EXERCISE SUBMENUS (STARTING WITH SOFTWARE VERSION
1.5.190) (CONTINUED)
962-0618 (Issue 6) 85
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 94/154
4. Setup and Adjustments 5-2013
FIGURE 62. SETUP GROUP 2 - EXERCISE EXCEPTIONS SUBMENUS (STARTING WITH
SOFTWARE VERSION 1.5.190)
86 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 95/154
5-2013 4. Setup and Adjustments
FIGURE 63. SETUP GROUP 2 - EXERCISE EXCEPTIONS SUBMENUS (STARTING WITH
SOFTWARE VERSION 1.5.190) (CONTINUED)
962-0618 (Issue 6) 87
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 96/154
4. Setup and Adjustments 5-2013
FIGURE 64. SETUP GROUP 2 - EXERCISE SUBMENUS (STARTING WITH SOFTWARE VERSION
1.12)
88 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 97/154
5-2013 4. Setup and Adjustments
FIGURE 65. SETUP GROUP 2 - EXERCISE SUBMENUS (STARTING WITH SOFTWARE VERSION
1.12) (CONTINUED)
962-0618 (Issue 6) 89
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 98/154
4. Setup and Adjustments 5-2013
FIGURE 66. SETUP GROUP 2 - EXERCISE EXCEPTIONS SUBMENUS (STARTING WITH
SOFTWARE VERSION 1.12)
90 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 99/154
5-2013 4. Setup and Adjustments
FIGURE 67. SETUP GROUP 2 - EXERCISE EXCEPTIONS SUBMENUS (STARTING WITH
SOFTWARE VERSION 1.12) (CONTINUED)
962-0618 (Issue 6) 91
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 100/154
4. Setup and Adjustments 5-2013
FIGURE 68. SETUP GROUP 2 - EXERCISE SUBMENUS (STARTING WITH SOFTWARE VERSION
1.13.244)
92 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 101/154
5-2013 4. Setup and Adjustments
FIGURE 69. SETUP GROUP 2 - EXERCISE SUBMENUS (STARTING WITH SOFTWARE VERSION
1.13.244) (CONTINUED)
962-0618 (Issue 6) 93
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 102/154
4. Setup and Adjustments 5-2013
FIGURE 70. SETUP GROUP 2 - EXERCISE EXCEPTIONS SUBMENUS (STARTING WITH
SOFTWARE VERSION 1.13.244)
94 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 103/154
5-2013 4. Setup and Adjustments
FIGURE 71. SETUP GROUP 2 - EXERCISE EXCEPTIONS SUBMENUS (STARTING WITH
SOFTWARE VERSION 1.13.244) (CONTINUED)
962-0618 (Issue 6) 95
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 104/154
4. Setup and Adjustments 5-2013
FIGURE 72. SETUP GROUP 3 - MODE SUBMENU (PRIOR TO SOFTWARE VERSION 1.20.250)
FIGURE 73. SETUP GROUP 3 - MODE SUBMENU (STARTING WITH SOFTWARE VERSION 1.20.250)
96 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 105/154
5-2013 4. Setup and Adjustments
FIGURE 74. SETUP GROUP 3 - CLOCK SUBMENUS
962-0618 (Issue 6) 97
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 106/154
4. Setup and Adjustments 5-2013
FIGURE 75. SETUP GROUP 3 - SEQUENCER SUBMENUS
98 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 107/154
5-2013 4. Setup and Adjustments
FIGURE 76. THIRD MAIN MENU - ABOUT SUBMENUS (SOFTWARE VERSIONS PRIOR TO 1.20.250)
962-0618 (Issue 6) 99
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 108/154
4. Setup and Adjustments 5-2013
FIGURE 77. THIRD MAIN MENU - ABOUT SUBMENUS (SOFTWARE VERSIONS PRIOR TO 1.20.250)
(CONTINUED)
100 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 109/154
5-2013 4. Setup and Adjustments
FIGURE 78. THIRD MAIN MENU - ABOUT SUBMENUS (STARTING WITH SOFTWARE VERSION
1.20.250)
962-0618 (Issue 6) 101
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 110/154
4. Setup and Adjustments 5-2013
FIGURE 79. THIRD MAIN MENU - ABOUT SUBMENUS (STARTING WITH SOFTWARE VERSION
1.20.250) (CONTINUED)
102 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 111/154
5-2013 4. Setup and Adjustments
FIGURE 80. THIRD MAIN MENU - SYSTEM SUBMENUS
962-0618 (Issue 6) 103
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 112/154
4. Setup and Adjustments 5-2013
FIGURE 81. THIRD MAIN MENU - ACTIVE TD SUBMENUS (SOFTWARE VERSIONS PRIOR TO 1.12)
104 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 113/154
5-2013 4. Setup and Adjustments
FIGURE 82. THIRD MAIN MENU - ACTIVE TD SUBMENUS (STARTING WITH SOFTWARE VERSION
1.12)
962-0618 (Issue 6) 105
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 114/154
4. Setup and Adjustments 5-2013
FIGURE 83. MENU SYSTEM MAP - PRIOR TO SOFTWARE VERSION 1.5.190
106 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 115/154
5-2013 4. Setup and Adjustments
FIGURE 84. MENU SYSTEM MAP - STARTING WITH SOFTWARE VERSION 1.5.190
962-0618 (Issue 6) 107
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 116/154
4. Setup and Adjustments 5-2013
FIGURE 85. MENU SYSTEM MAP - STARTING WITH SOFTWARE VERSION 1.8.204
108 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 117/154
5-2013 4. Setup and Adjustments
FIGURE 86. MENU SYSTEM MAP - STARTING WITH SOFTWARE VERSION 1.12
962-0618 (Issue 6) 109
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 118/154
4. Setup and Adjustments 5-2013
FIGURE 87. MENU SYSTEM MAP - STARTING WITH SOFTWARE VERSION 1.13.244
110 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 119/154
5-2013 4. Setup and Adjustments
FIGURE 88. MENU SYSTEM MAP - STARTING WITH SOFTWARE VERSION 1.20.250
962-0618 (Issue 6) 111
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 120/154
4. Setup and Adjustments 5-2013
This page is intentionally blank.
112 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 121/154
5 Checkout
If the transfer switch is equipped with a Digital Display, use it to checkout the switch. Refer to
Section 4 for setup details. If the switch is not equipped with a Digital Display, use the the LED
indicators located on the Digital Module mounted on the inside of the transfer switch enclosure
door. See Figure 89.
WARNING
AC power within the cabinet and the rear side of the cabinet door presents a shock hazard that can cause severe personal injury or death. Use extreme caution to avoid touching electrical contacts whenever the cabinet door is open.
WARNING
Improper operation of the generator set presents a hazard that can cause severe personal injury or death. Observe all safety precautions in your generator set Operation and Installationmanuals.
5.1 STARTING TEST (UTILITY-TO-GENSET MODE)
1. Move the selector switch on the engine control to Run. The generator set should start and
run.
2. Move the selector switch to Remote. The generator set should stop.
5.2 TEST TRANSFER WITH LOAD
1. Set the Test With/Without Load variable to the With Load value. Use the Digital Display
Menu System or PC Service Tool.
The Test With/Without Load variable must be set to the With Load value in order totest with load.
2. Press and hold the Test switch for 2 seconds. With the appropriate time delays, the
generator set should start and the load should be transferred to the generator. The Source
2 Available lamp lights when the generator output is sensed. The Source 2 Connected
lamp lights to indicate that transfer has occurred.
3. Check the operation of the Bar Graph Meters (if equipped) on the cabinet door.
4. Press the Test switch. The transfer switch should retransfer load to Source 1 and stop the
generator set after any time delays. The Source 1 Available lamp lights immediately. The
Source 1 Connected lamp lights to indicate that retransfer has occurred.
5. Set the Test With/Without Load variable to the value you want to use for genset exercising.
962-0618 (Issue 6) 113
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 122/154
5. Checkout 5-2013
5.3 CONTROL LED INDICATORS AND SWITCH
5.3.1 LED Indicators
The digital module located on the inside of the switch enclosure door contains ten LED
indicators. The indicators provide some information about the current control status. These
indicators may be helpful in troubleshooting the transfer switch when the Digital Display is notavailable. See Figure 89 and Table 15.
5.3.2 Exerciser Enable/Disable Switch
The Exerciser Enable/Disable switch (Figure 89) enables the control to exercise the genset
during future scheduled exercise periods and lights the Exerciser Enabled indicator or disables
the scheduled exercise period and turns the indicator off. The operator can also enable and
disable the exerciser from the Digital Display, when it is available or from the PC Service Tool.
FIGURE 89. LED LOCATION ON DIGITAL MODULE (SHOWN ON THE 40 TO 125 AMP SWITCH)
114 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 123/154
5-2013 5. Checkout
TABLE 15. DIGITAL MODULE LED INDICATORS
Indicator Definition
Status Blinks at 1/2 Hz rate when the controller has power and the program is running withouterror. This indicator flashes the event code of an active event until the event isacknowledged with the Reset switch on the front panel. This indicator is sometimesreferred to as the heart beat because it blinks constantly when the controller does not
have an active event.
S1 Available Lights when Power Source 1 has acceptable voltage and frequency limits. Thisindicator lights when the Source 1 Available indicator on the control panel lights.
S2 Available Lights when Power Source 2 has acceptable voltage and frequency limits. Thisindicator lights when the Source 2 Available indicator on the control panel lights.
Start A/TDES-A1. Lights constantly when the control has commanded Source 2 to start
2. Blinks at 1/2 Hz rate during the time delay to engine start (TDESa)
Start B/TDES-B This indicator is only used for genset-to-genset applications when Source 1 is agenerator not a utility.
1. Lights constantly when the control has commanded Source 1 to start
2. Blinks at 1/2 Hz rate during the time delay to engine start (TDESb)Retransfer/TDEN
1. Lights when the control energizes the Retransfer relay
2. Blinks at 1/2 Hz rate during the time delay to retransfer (TDEN)
Transfer/TDNE1. Lights when the control energizes the Transfer relay
2. Blinks at 1/2 Hz rate during the time delay to transfer (TDNE)
Sync-Check Blinks at 1-second rate when the in-phase sensor is active (maximum of 120 seconds).
TDPT Time Delay Programmed Transition
Blinks at 1/2 Hz rate during the programmed transition time delay
Exerciser Enabled Lights when the Exerciser clock is enabled and blinks during an exercise period. Thesmall switch next to the indicator enables and disables the exerciser. The operator can
also enable and disable the exerciser from the Digital Display when it is available.
962-0618 (Issue 6) 115
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 124/154
5. Checkout 5-2013
This page is intentionally blank.
116 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 125/154
6 Start-up Checklist
NOTICE
Power must be available to the unit in order to perform this checklist.
This start-up checklist provides the steps necessary to complete a typical setup. It also includes
information on setting up a programmed exercise.
The transfer switch control is programmed at the factory with the voltage, frequency, and
options listed on the nameplate. Make sure the application matches the nameplate values.
Check the remote start connections before powering up the transfer switch.
• Verify that the remote start connections are correct for your application. For more
information on jumper placement, refer to the interconnection diagram shipped with the
unit.
• For Level 2 controls with 3-wire, 3-phase Delta applications, refer to the interconnection
diagram shipped with the unit.
The transfer switch is released with the appropriate calibration and settings that allow the unit to
function properly without any additional adjustments.
The clock must be set in order to maintain an accurate log of events and exercises. In addition,
you may wish to set exercise periods and set the transfer switch to test with or without load
(default = Without Load).
A setup can be done using the digital display or InPower™.
6.1 SETUP USING THE DIGITAL DISPLAY
• If the unit is equipped with a security key switch on the front door, place the switch in the
Program position.
NOTICE
No changes can be made unless this key switch is in the Program position.
• Using the digital display, navigate to the Setup sub-menu and enter the password (574).
6.1.1 Setting Exercise(s)
• Navigate to the Exercise sub-menus and set exercise(s):
• [ ] Select “Enabled" to enable the exercise feature.
• [ ] Select “Enabled" to enable an exercise.
• [ ] Select a day between Sunday and Saturday.
• [ ] Enter the time of day the exercise cycle is to begin (hr = 0-23, mn = 0-59).
• [ ] Set the duration the exercise cycle will run (hr = 0-23, mn = 0-59).
• [ ] Enter the number of weeks between each exercise (interval) (0 = one time only, 1
= once a week, 2 = once every two weeks, 52 = once every 52 weeks).
962-0618 (Issue 6) 117
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 126/154
6. Start-up Checklist 5-2013
• [ ] Select whether or not you want the exercise to run the generator(s) with or without
a load. The default is “Without Load."
NOTICE
Exercise exceptions are also available through the digital display menus. For more information,see the Operator's Manual . Exercise exceptions can be cancelled in the “Cancl Active Excpts"sub-menu (change from “Normal" to “Cancel").
6.1.2 Setting the Unit to Test With or Without Load
• Navigate to the Test sub-menu and set the Test Switch to Test With or Without Load:
• [ ] Select whether or not you want your transfer switch to test “With" or “Without
Load." The default is “Without Load."
6.1.3 Saving the Settings and System Verification
• Before exiting the Setup sub-menus, save the changes made to the control settings by
pressing the Home button, then selecting Save on the menu.• Next, verify that the transfer switch is operating properly.
• [ ] Check to make sure the correct time is displayed.
• [ ] View the “Next Exercise In" sub-menu to verify that a time is displayed.
• [ ] Do a complete system check, including simulating a power outage. For more
information about operation, see the Operator Manual.
6.1.4 Features
Loss of phase detection and voltage imbalance sensing are disabled at the factory. Before
enabling them, see the Operator's Manual to review the feature descriptions.
CAUTION
Level 1 controls do not support three-phase sensing on Source 2. Do not select the three-phaseoption for the Source 2 Sensing adjustment with Level 1 controls, even if the system is three phase. This setting will prevent Source 2 from becoming available.
6.2 SETUP USING INPOWER
6.2.1 Setting Exercise(s)
• Navigate to the Adjustments→ Feature Enable folder.
• [ ] Select “Enabled" to enable an exercise.
• [ ] Select the “Save Adjustments" icon.
• Navigate to the Adjustments→ Exerciser Clock folder.
• [ ] Enable Program 1.
• [ ] Select a start day between Sunday and Saturday.
118 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 127/154
5-2013 6. Start-up Checklist
• [ ] Set the time the exercise cycle is to begin (hr = 0-23, mn = 0-59).
• [ ] Set the duration of the exercise cycle (hr = 0-23, mn = 0-59).
• [ ] Enter an interval that the exercise cycle will repeat (0 = one time only, 1 = once a
week, 2 = once every two weeks, 52 = once every 52 weeks).
• [ ] Select whether or not you want the exercise to run the generator(s) with or without
a load. The default is “Without Load."
• [ ] Select the “Save Adjustments" icon.
NOTICE
The Reset Exerciser Repeat Count feature, in the Controller Mode folder, can be used to changea repeat interval. Switch the setting from “False" to “True" for the new interval to take effect. Thesetting will automatically switch back to “False" again.
NOTICE
Exercise exceptions are available through the Adjustments → Exceptions folder. Refer to theInPower User's Guide for more information.
6.2.2 Setting the Unit to Test With or Without Load
• Navigate to the Test→ Setup folder.
• [ ] Set the Test Switch to test “With" or “Without Load." The default is “Without Load."
• [ ] Select the “Save Adjustments" icon.
6.2.3 Saving the Settings and System Verification
• To store your settings in a capture file, select the Device" pull-down menu and select
“Capture to file."
• Next, verify that the transfer switch is operating properly.
• [ ] Do a complete system check, including simulating a power outage. For more
information about the operation, see the Operator Manual.
• [ ] Review settings.
6.2.4 Features
Loss of phase detection and voltage imbalance sensing are disabled at the factory. Before
enabling them, see the Operator's Manual to review the feature descriptions.
CAUTIONLevel 1 controls do not support three-phase sensing on Source 2. Do not select the three-phaseoption for the Source 2 Sensing adjustment with Level 1 controls, even if the system is three phase. This setting will prevent Source 2 from becoming available.
962-0618 (Issue 6) 119
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 128/154
6. Start-up Checklist 5-2013
6.2.5 About InPower Service Tool
The InPower service tool can be used to test the transfer switch using functions, including
Remote Test, Transfer Inhibit, Retransfer Inhibit, etc. InPower, when used improperly, can
cause symptoms like warnings and shutdowns that appear to be a defective control. When
these problems occur, always verify that a Test feature was not left enabled with InPower.
Always disable test features before disconnecting InPower.
6.2.6 About Network Applications and Customer Inputs
In applications with networks and remote customer inputs, these inputs may cause unexpected
genset or transfer switch operation. These symptoms may appear to be caused by the transfer
switch control. Verify that the remote input is not causing the symptom or isolate the control
from these inputs before troubleshooting the control.
120 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 129/154
7 Wiring Considerations for ClosedTransition Transfer Switches
There are two functions that should be used with closed transition transfer switches: The
transfer and re-transfer inhibit functions should be used to prevent two switches fromtransferring at the same time and the fail to disconnect output of the relay signal module should
be wired to the shunt trip of one of the breakers feeding the ATS to prevent extended paralleling
of the two sources.
7.1 Re-transfer and transfer inhibit functions
In applications with more than one closed transition ATS, the transfer and re-transfer inhibit
functions should be used to prevent multiple transfer switches from transferring at the same
time. For example to prevent two switches from re-transferring from the genset to the utility at
the same time wire the normally closed contact that indicates the first ATS is connected to the
normal source into the retransfer inhibit input of the transfer switch that is intended to transfer
second. Ground the common aux contact on the first switch so that the re-transfer inhibit inputon the second switch is grounded when the first transfer switch is not connected to the normal
source. This will inhibit the second switch from beginning its retransfer sequence (including all
time delays) until after the first transfer switch has transferred back to the normal source. A
similar wiring scheme can be used when transferring to the emergency source so that only one
switch transfers at a time. Switch position indicators are available on the relay signal module
which is included with all Cummins closed transition ATSmodels. Figure 90 and Figure 91
illustrate how this can be done with all of Cummins’ closed transition transfer switch models.
FIGURE 90. BTPC 1600-3000, CHPC
962-0618 (Issue 6) 121
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 130/154
7. Wiring Considerations for Closed Transition Transfer Switches 5-2013
FIGURE 91. BTPC 125-1200, 4000, OTPC 1000-4000
7.2 Fail to disconnect
The Fail to Disconnect relay is active when the transfer switch remains connected to both
sources for more than 100 msec during a closed transition transfer. It should be wired to the
shunt trip of the breaker feeding the ATS on either the normal or the emergency side. The fail todisconnect relay is located on the relay signal module. See Figure 92.
122 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 131/154
5-2013 7. Wiring Considerations for Closed Transition Transfer Switches
FIGURE 92. BREAKER SHUNT TRIP
962-0618 (Issue 6) 123
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 132/154
7. Wiring Considerations for Closed Transition Transfer Switches 5-2013
This page is intentionally blank.
124 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 133/154
Appendix A. Interconnect and ConnectionDiagrams
Table of ContentsFigure 93. 1200 Amp Typical Interconnection Diagram (sheet 1 of 10) ................................................ 127
Figure 94. 1200 Amp Typical Interconnection Diagram (sheet 2 of 10) ................................................ 128
Figure 95. 1200 Amp Typical Interconnection Diagram (sheet 3 of 10) ................................................ 129
Figure 96. 1200 Amp Typical Interconnection Diagram (sheet 4 of 10) ................................................ 130
Figure 97. 1200 Amp Typical Interconnection Diagram (sheet 5 of 10) ................................................ 131
Figure 98. 1200 Amp Typical Interconnection Diagram (sheet 6 of 10) ................................................ 132
Figure 99. 1200 Amp Typical Interconnection Diagram (sheet 7 of 10) ................................................ 133
Figure 100. 1200 Amp Typical Interconnection Diagram (sheet 8 of 10) .............................................. 134
Figure 101. 1200 Amp Typical Interconnection Diagram (sheet 9 of 10) .............................................. 135
Figure 102. 1200 Amp Typical Interconnection Diagram (sheet 10 of 10) ............................................ 136
Figure 103. Typical Interconnection Diagram - Generator-to-Generator, Plant-to-Plant (sheet 1 of 4) .................................................................................................................................................................. 137
Figure 104. Typical Interconnection Diagram - Generator-to-Generator, Plant-to-Plant (sheet 2 of 4) .................................................................................................................................................................. 138
Figure 105. Typical Interconnection Diagram - Generator-to-Generator, Plant-to-Plant (sheet 3 of 4) .................................................................................................................................................................. 139
Figure 106. Typical Interconnection Diagram - Generator-to-Generator, Plant-to-Plant (sheet 4 of 4) .................................................................................................................................................................. 140
Figure 107. Typical Interconnection Diagram - Generator-to-Generator, Dual Standby System (sheet 1of 4) .............................................................................................................................................................. 141
Figure 108. Typical Interconnection Diagram - Generator-to-Generator, Dual Standby System (sheet 2of 4) .............................................................................................................................................................. 142
Figure 109. Typical Interconnection Diagram - Generator-to-Generator, Dual Standby System (sheet 3of 4) .............................................................................................................................................................. 143
Figure 110. Typical Interconnection Diagram - Generator-to-Generator, Dual Standby System (sheet 4of 4) .............................................................................................................................................................. 144
962-0618 (Issue 6) 125
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 134/154
Appendix A. Interconnect and Connection Diagrams 5-2013
This page is intentionally blank.
126 962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 135/154
5-2013 Appendix A. Interconnect and Connection Diagra
FIGURE 93. 1200 AMP TYPICAL INTERCONNECTION DIAGRAM (SHEET 1 OF 10)
962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 136/154
Appendix A. Interconnect and Connection Diagrams 5
FIGURE 94. 1200 AMP TYPICAL INTERCONNECTION DIAGRAM (SHEET 2 OF 10)
128 962-0618 (Is
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 137/154
5-2013 Appendix A. Interconnect and Connection Diagra
FIGURE 95. 1200 AMP TYPICAL INTERCONNECTION DIAGRAM (SHEET 3 OF 10)
962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 138/154
Appendix A. Interconnect and Connection Diagrams 5
FIGURE 96. 1200 AMP TYPICAL INTERCONNECTION DIAGRAM (SHEET 4 OF 10)
130 962-0618 (Is
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 139/154
5-2013 Appendix A. Interconnect and Connection Diagra
FIGURE 97. 1200 AMP TYPICAL INTERCONNECTION DIAGRAM (SHEET 5 OF 10)
962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 140/154
Appendix A. Interconnect and Connection Diagrams 5
FIGURE 98. 1200 AMP TYPICAL INTERCONNECTION DIAGRAM (SHEET 6 OF 10)
132 962-0618 (Is
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 141/154
5-2013 Appendix A. Interconnect and Connection Diagra
FIGURE 99. 1200 AMP TYPICAL INTERCONNECTION DIAGRAM (SHEET 7 OF 10)
962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 142/154
Appendix A. Interconnect and Connection Diagrams 5
FIGURE 100. 1200 AMP TYPICAL INTERCONNECTION DIAGRAM (SHEET 8 OF 10)
134 962-0618 (Is
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 143/154
5-2013 Appendix A. Interconnect and Connection Diagra
FIGURE 101. 1200 AMP TYPICAL INTERCONNECTION DIAGRAM (SHEET 9 OF 10)
962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 144/154
Appendix A. Interconnect and Connection Diagrams 5
FIGURE 102. 1200 AMP TYPICAL INTERCONNECTION DIAGRAM (SHEET 10 OF 10)
136 962-0618 (Is
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 145/154
5-2013 Appendix A. Interconnect and Connection Diagra
FIGURE 103. TYPICAL INTERCONNECTION DIAGRAM - GENERATOR-TO-GENERATOR, PLANT-TO-PLANT (SHEET 1 OF 4)
962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 146/154
Appendix A. Interconnect and Connection Diagrams 5
FIGURE 104. TYPICAL INTERCONNECTION DIAGRAM - GENERATOR-TO-GENERATOR, PLANT-TO-PLANT (SHEET 2 OF 4)
138 962-0618 (Is
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 147/154
5-2013 Appendix A. Interconnect and Connection Diagra
FIGURE 105. TYPICAL INTERCONNECTION DIAGRAM - GENERATOR-TO-GENERATOR, PLANT-TO-PLANT (SHEET 3 OF 4)
962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 148/154
Appendix A. Interconnect and Connection Diagrams 5
FIGURE 106. TYPICAL INTERCONNECTION DIAGRAM - GENERATOR-TO-GENERATOR, PLANT-TO-PLANT (SHEET 4 OF 4)
140 962-0618 (Is
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 149/154
5-2013 Appendix A. Interconnect and Connection Diagra
FIGURE 107. TYPICAL INTERCONNECTION DIAGRAM - GENERATOR-TO-GENERATOR, DUAL STANDBY SYSTEM (SHEET 1 OF 4)
962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 150/154
Appendix A. Interconnect and Connection Diagrams 5
FIGURE 108. TYPICAL INTERCONNECTION DIAGRAM - GENERATOR-TO-GENERATOR, DUAL STANDBY SYSTEM (SHEET 2 OF 4)
142 962-0618 (Is
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 151/154
5-2013 Appendix A. Interconnect and Connection Diagra
FIGURE 109. TYPICAL INTERCONNECTION DIAGRAM - GENERATOR-TO-GENERATOR, DUAL STANDBY SYSTEM (SHEET 3 OF 4)
962-0618 (Issue 6)
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 152/154
Appendix A. Interconnect and Connection Diagrams 5
FIGURE 110. TYPICAL INTERCONNECTION DIAGRAM - GENERATOR-TO-GENERATOR, DUAL STANDBY SYSTEM (SHEET 4 OF 4)
144 962-0618 (Is
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 153/154
7/21/2019 ATS OM - OTPC Installation - Cummins
http://slidepdf.com/reader/full/ats-om-otpc-installation-cummins 154/154