Onan Transfer Switch

Cummins Power GenerationOnan PowerCommand™Transfer Switch

Onan Sales and Technical Training

Onan PowerCommand Transfer Switch Self-StudyPage i

Table of Contents

Lesson One: The New PowerCommand™ Transfer Switch ............................................. 1

Objectives .................................................................................................................................... 1

Overview of the New Transfer Switch .......................................................................................... 1

Progress Check............................................................................................................................. 7

Lesson Two: The New PowerCommand Transfer Switch Control................................. 10

Objectives ...................................................................................................................................10

Overview of Components of the New Control..............................................................................10

Overview of PCTS Control..........................................................................................................11

Control Packages.........................................................................................................................11

Control Features ..........................................................................................................................15

Control Options ...........................................................................................................................17

Interfaces.....................................................................................................................................19

Progress Check............................................................................................................................26

Lesson Three: How Onan Compares with the Competition ........................................... 29

Objectives ...................................................................................................................................29

Overview of Competitive Products ..............................................................................................29

Transfer Switch Level 1 Control Package ....................................................................................29

Positioning the PowerCommand Transfer Switch Level 1 Control ...............................................31

PowerCommand Transfer Switch Level 2 Control .......................................................................34

Positioning the PowerCommand Transfer Switch Level 2 Control ...............................................34

Transfer Switch Features Compared to Other Suppliers ...............................................................38

Progress Check............................................................................................................................42

Lesson Four: The PowerCommand Control Network .................................................... 44

Objectives ...................................................................................................................................44

The Opportunity for Network Solutions .......................................................................................44

Benefits of a Network Solution....................................................................................................45

Onan PowerCommand Transfer Switch Self-StudyPage ii

Opportunities in Healthcare Facilities............................................................................................46

Opportunities in Retail Markets ......................................................................................................49

Opportunities in Telecommunications ............................................................................................50

Connecting to the Network ..........................................................................................................51

Network Communication Module (NCM) Hardware....................................................................51

Network Communication Module Software........................................................................................53

Progress Check............................................................................................................................54

Lesson Five: InPower Service Tool .................................................................................. 56

Objectives ...................................................................................................................................56

Overview of the InPower Service Tool ........................................................................................56

InPower Transfer Switch Information ..........................................................................................58

Progress Check............................................................................................................................59

Lesson Six: Transfer Switch Selection ............................................................................. 61

Objectives ...................................................................................................................................61

Important Factors in the Selection of a Transfer Switch................................................................61

Case Studies ................................................................................................................................61

Appendix A: Digital Alpha Numeric Display................................................................... 67

Appendix B: Transfer Switch Network Input Variables................................................. 69

Appendix C: Transfer Switch Network Output Variables.............................................. 70

Appendix D: Information Monitored by InPower.......................................................... 72

Appendix E: Adjustments Available with InPower ....................................................... 73

Appendix F: Faults/Events History in InPower ............................................................. 75

Onan PowerCommand Transfer Switch Self-StudyPage iii

List of Figures and Tables

Figure 1-1: The OTPC .......................................................................................................... 2

Table 1-1: OTPC Features and Benefits ................................................................................ 3

Table 1-2: Onan’s Bypass Switch Features and Benefits ....................................................... 4

Table 2-1 Level 1 Transfer Switch Control Features and Benefits ....................................... 12

Table 2-2 Level 2 Control Features and Benefits................................................................. 14

Table 2-3: Features of the Operator Interface for Level 1 and Level 2 Control Options ....... 20

Figure 2-1: The OTPC Operator Panel ................................................................................ 22

Figure 2-2: The OTPC Front Panel...................................................................................... 23

Figure 3-1: Competition for the PowerCommand Transfer Switch Level 1 Control ............. 30

Table 3-1: PowerCommand Transfer Switch Level 1 Control Competitive Comparison...... 32

Table 3-1 (cont.): PowerCommand Transfer Switch Level 1 Control Competitive

Comparison................................................................................................................. 33

Figure 3-2: Competition for the PowerCommand Transfer Switch Level 2 Control ............. 34

Table 3-2: PowerCommand Transfer Switch Level 2 Control Competitive Comparison...... 35


Comparison................................................................................................................. 36


Comparison................................................................................................................. 37

Table 3-3: Comparison of Transfer Switch Features Provided by Major Suppliers .............. 39

Table 3-3 (cont.): Comparison of Transfer Switch Features Provided by Major Suppliers ... 40

Table 3-3 (cont.): Comparison of Transfer Switch Features Provided by Major Suppliers ... 41

Table 4-1: Profile of Candidates for PowerCommand Network........................................... 45

Table 4-2: Benefits of PowerCommand Network for the Healthcare Industry...................... 48

Table 4-3: Benefits of PowerCommand Network for the Retail Industry ............................. 49

Table 4-4: Benefits of PowerCommand Network for Telecommunications Industry........... 50

Figure 4-1: NCM Installed on PowerCommand Transfer Switch Level 2 Control................ 52

Onan PowerCommand Transfer Switch Self-StudyPage 1

Lesson One: The New PowerCommand™

Transfer Switch

Objectives After completing this lesson, you should be able to:

• Identify the products in the PowerCommand™ line

of transfer switch products.

• Recognize the difference among the transfer switch

products.

Overview ofthe NewTransfer

Switch

The PowerCommand OTPC and BTPC Transfer Switches

combine the field-proven OT and BT transfer switch

mechanisms with a new high-performance

microprocessor-based transfer switch control. The

control will be used on a number of transfer switch

products, providing consistent levels of performance, user

interface, and serviceability. As a result, the OTPC and

BTPC PowerCommand Transfer Switches keep many of

the benefits of their predecessors while adding

comparative advantage in terms of control, networking

capability and serviceability.

This lesson provides an overview of the PowerCommand

Transfer Switch family of products:

• OTPC Automatic Transfer Switch

• BTPC Bypass Isolation Transfer Switch

• PLTO Automatic Transfer Switch - Open Transition

• PLTH Closed Transition Transfer Switch

• PLTS Soft Loading Transfer Switch

• PowerCommand Network Communication Module

• Cummins Onan InPower™ Transfer Switch Service

Tool


OTPCOTPC

AutomaticAutomatic

TransferTransfer

SwitchSwitch

The OTPC Transfer Switch itself has not changed. It still

relies on the OTIII switch mechanism used in over

100,000 installations. The control, however, does

represent significant improvement over the PowerSentry

Control and over the competition’s microprocessor

controls now on the market. The next lesson deals

exclusively with the PowerCommand Transfer Switch

Control. See Table 1-1 for the features and benefits of the

OTPC. Figure 1-1 is a graphic representation of the

OTPC.

Figure 1-1: The OTPC

AUTOMATIC TRANSFERSWITCH

OPTIONAL BATTERY CHARGER

BAR GRAPHASSEMBLY

SWITCH PANEL

DIGITAL DISPLAY

RELAY ASSEMBLYPOWER MODULE

MOTOR DISCONNECT SWITCH

CONTROLLERBATTERIES

TB1

TB2


Table 1-1: OTPC Features and Benefits

Features BenefitsThree maintained positionsPreferredSource, Center, and Alternate Sourcepositions

Allows use as load shed equipment in parallelingsystems and allows programmed transitionfunctionality for transfer of motors, transformers,UPS, and other SCR equipment without disruption

Mechanical interlock Prevents source-to-source short circuit and meetscode requirement

Stored energy over center mechanism Provides uniformly fast operation of contacts onmaking and breaking regardless of electrical ormanual operation. Contacts cannot be ‘teased’,drawing dangerous arcs, during manual operation

Ampere ratings: From 40 to 3000 amperes Range of standard continuous ampere ratingscovers electrical distribution equipment ratings

Voltage ratings: Nine standard voltage ratingsfrom 120 to 600 VAC.

Covers all commonly used voltage rangesworldwide

Frequency rating: Dual rating for 50 and 60Hz.

Does not require special hardware to accommodate50 Hz applications

3 or 4 pole switch configurations Allows use on single-phase, three-phase solidneutral, and three-phase switched neutral systems

Optional neutral bar on 3 pole Allows application flexibility for 3-wire systemswithout a neutral conductor

Customer auxiliary contacts: Form C contactson normal and emergency side

Allows remote annunciation of transfer switchposition and control interface with auxiliaryequipment

Cu/Al mechanical pressure lugs Accommodates both types of cable materials.Mechanical pressure lugs are oversized to allowlarger cables when required for voltage drop, etc.

Bus connects Provides a provision for switchboard mounting andbus duct connection

Manual handles Permanently attached manual operating handlesprovide means for safe manual operation andservice operation with electrical operator disabled.Available on Onan transfer switches rated at 1000amps or less.

Motor disconnect switch Disables electrical operator for service and manualtransfer operation


BTPC BypassBTPC Bypass

IsolationIsolation

TransferTransfer

SwitchSwitch

The story of the BTPC is similar to the OTPC. The

BTPC retains the many benefits of the BT bypass switch

mechanism, while adding the new microprocessor

transfer switch control. Table 1-2 lists the bypass switch

features and associated benefits.

Table 1-2: Onan’s Bypass Switch Features and Benefits

Features Benefits

Combination automatic/manual bypass switch Combines OTIII, a mechanical bypass switch,and a drawout isolation mechanism into a singleunit

Non-load break Non-load break design allows switch bypass andisolation to either source without disruption to theload

Dual source bypass Can bypass to either source as long asacceptable power is available and the transferswitch is connected

Electro-mechanical interlock Prevents inadvertent bypassing to a dead source

Front panel bypass control Able to isolate and bypass load without openingcabinet

Center off position on bypass switch Controls speed of bypass to prevent out of phasemanual transfers

Safety shutters Drop into place as ATS is withdrawn to coverprimary disconnects

Safety shields Transparent Lexan shields cover all live partsincluding lugs

Extension rails Allow ATS to be rolled out of cabinet for easyoverhead lifting and removal after isolation


PLTO AutomaticPLTO Automatic

Transfer SwitchTransfer Switch

(Available 2000(Available 2000)

The PLTO is a breaker-based high amperage transfer

switch available with amperages from 800 to 3000.

Service Entrance rating is available as an option. The

PLTO uses a pair of insulated case breakers as the

switching mechanism. The PowerCommand Transfer

Switch control provides all sensing, control and user

interface functions. Further information on this new

product can be obtained from the Onan Switchgear and

Systems Group.

PLTH ClosedPLTH Closed

TransitionTransition


(Available 2000)(Available 2000)

The PLTH is a breaker-based paralleling transfer switch

that can connect to both sources for a 100-mSec transfer

time. A derivative of the Paralleling Load Transfer

Equipment (PLTE), the PLTH uses a pair of drawout

insulated case breakers as the switching mechanism. The

PowerCommand Transfer Switch Control provides all

sensing, control functions and operator interfaces. Service

Entrance rating is available as an option. Further

information on this new product is beyond the scope of

this training, contact the Onan Systems Group for

additional data.

PLTS SoftPLTS Soft

Loading TransferLoading Transfer

SwitchSwitch

(Available 2000)(Available 2000)

The PLTS is a breaker-based paralleling transfer switch

that can connect to both sources for a configured transfer

time period to allow load ramping. A derivative of the

PLTE Paralleling Load Transfer Equipment, the PLTS

uses a pair of drawout insulated case breakers as the

switching mechanism. The PowerCommand Transfer

Switch control provides all sensing, control (including

ramping) and operator interfaces. Service Entrance rating

is available as an option. A product specification sheet is

included with all sales tools. Again, further information

on this new product is beyond the scope of this training;

contact the Onan Systems Group.


PowerCommandPowerCommand

NetworkNetwork

CommunicationCommunication

Module (NCM)Module (NCM)

Onan transfer switches now have the capability to be

connected directly to the PowerCommand Network. The

Network Communication Module (NCM) allows the

transfer switch to talk to networked generator sets,

annunciators or any other LONMark compliant device.

Note: LonMark is the organization set up by Echelon to

create and define standards to promote interoperability

among LonWorks’ products. This allows one vendor’s

product to work with another vendor’s product without

requiring customization. Onan is a member of the

LonMark Interoperability Association and wrote the

Transfer Switch Standards.

The NCM is a digital board that can be ordered with the

transfer switch or added in the field. Lesson Four, “The

PowerCommand Control Network,” describes the

Network Communication Module in detail.

InPowerInPower


Service ToolService Tool

The Cummins Onan InPower Service Tool provides

improved service. Available on a standard laptop PC,

InPower provides configuration setup downloads, on-line

diagnostics, data analysis tools and real time monitoring.

Lesson Five describes this tool in detail.


Lesson One Progress Check

Answer the following questions based on information provided in the lesson. When finished,

check your responses against the answers shown following this progress check.

1. List the seven products that comprise the PowerCommand Transfer Switch family of

products.

________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

2. The OTPC Transfer Switch relies on the OTIII mechanism but the _______________

Control is replaced by the ________________ Control.

3. The is a breaker-based paralleling transfer switch that can connect to both

sources for a _________ transfer time. It uses a pair of ___________ ___________

________________ as the switching mechanism.

4. The allows

PowerCommand Transfer Switches to talk to networked generator sets, annunciators, or

any other compliant device.

5. List five features and the associated benefits of the OTPC transfer switch.

Features Benefits


Lesson One Progress Check (Cont.)

6. List five features and the associated benefits of the BTPC transfer switch.

Features Benefits


Answers to Lesson One Progress Check

1. The seven products comprising the PowerCommand Transfer Switch family of products

are:

• OTPC Automatic Transfer Switch

• BTPC Bypass Isolation Transfer Switch

• PLTO Automatic Transfer Switch - Open Transition

• PLTH Closed Transition Transfer Switch

• PLTS Soft Loading Transfer Switch

• PowerCommand Network Communication Module

• Cummins Onan InPower™ Transfer Switch Service Tool

2. The OTPC Transfer Switch relies on the OTIII mechanism but the PowerSentry Control

is replaced by the PowerCommand Control.

3. The PLTH is a breaker-based paralleling transfer switch that can connect to both sources

for a 100-mSec transfer time. It uses a pair of insulated case breakers as the switching

mechanism.

4. The Network Communication Module (NCM) allows PowerCommand Transfer Switches

to talk to networked generator sets, annunciators, or any other LONMark compliant

device.

5. Refer to Table 1-1 for a complete list of features and benefits for Onan’s OTPC transfer

switch.

6. Refer to Table 1-2 for a complete list of features and benefits for Onan’s BTPC transfer

switch.


Lesson Two: The New PowerCommand

Transfer Switch Control


• State the features, functions and benefits available

with the new PowerCommand Transfer Switch

Control.

• List the features of the Transfer Switch Level 1 and

Level 2 Control packages.

• Identify the various interfaces of the transfer switch

control.

Overview ofComponents

of the NewControl

This lesson addresses the features and functions of the

new PowerCommand Transfer Switch Control. The new

control represents a step-change improvement in transfer

switch control technology. This new microprocessor-

based control can be tailored for use with both basic

transfer switch applications and for more sophisticated

requirements such as load monitoring.

The lesson first covers the two levels of transfer switch

control options in detail. Next, the lesson describes the

three types of transfer switch control interfaces:

• Operator interface (covered in detail)

• Network interface via the Network Communications

Module (described in greater detail in Lesson Four)

• Cummins Onan InPower Software Service Tool

(discussed in greater detail in Lesson Five)

2. The New PowerCommand Transfer Switch Control


Overview ofPCTS Control

The PowerCommand Transfer Switch Control is a fully

featured microprocessor-based control with a choice of

two levels of option packages. All features, settings, and

adjustments are software enabled with no hardware

adjustments necessary. As a result, there are no

potentiometers to adjust or banks of dipswitches to set.

Adjustments can be downloaded from the InPower

service tool or made from the digital display.

A real-time clock provides data and time stamping of all

events, faults and generator exercise functions.

ControlPackages

Two levels of transfer switch control options are available

allowing flexibility for customers in determining the most

suitable level of control for a given application:

• Level 1 provides a basic level of sensing and control

with superior performance to other “value” switch

control packages.

• Level 2 provides more sensing options and additional

options for load monitoring and metering. Closed

transition functionality is available for PLTH and

PLTS.

Level 1 ControlLevel 1 Control

PackagePackage

The Level 1 Transfer Switch Control provides a basic

level of control for use with standby power applications.

See Table 2-1(next page) for a chart of the features and

benefits of the Level 1 control package.

2. The New PowerCommand Transfer Switch


Table 2-1: Level 1 Transfer Switch Control Features and Benefits

Features Benefits

Microprocessor-based control electronics Improved reliability and performance

PowerCommand network option Ability to access the PowerCommand network with asimple, and economical hardware upgrade

Local RS-232 serial port Allows quick configuration downloads, servicediagnostics, or data acquisition using a laptop PCand InPower software.

Software based trims and adjustments Reduced setup time, improved reliability and ease ofuse

Utility-to-generator applications Serves most common type of standby applications.

Over/under three-phase voltage sensing onutility, single phase over/undervoltagesensing on emergency, software adjustable

Provides an economical sensing package designedfor standby power applications

Frequency sensing on both sources, single-phase

Monitors variations in frequency on both sources

Start, transfer, retransfer, and stop timedelays, adjustable

Provides software adjustable time limits for the fourprimary transfer time delays

Programmed transition for inductive loadtransfer, software adjustable

Reliably transfers motors, transformers, UPS, andother SCR equipment without disruption or long termwear and tear damage

Programmable generator set exerciser Allows user-flexible scheduling of generator exerciseperiods. Exercise times can be set up on a multi-dayschedule, rather than limited to 1,2, or 4 weeks

Front panel test switch and time delay bypassswitch

Allows the operator to quickly enable a transfer,bypassing all time delays

Front panel LED indicators for: normalavailable/normal connected, emergencyavailable/emergency connected, not-in-auto,active test

Long-life LEDs provide at-a-glance source andtransfer switch status for quick summary of systemconditions

Front panel security key Disables front panel buttons and switches toprevents operation by unauthorized personnel

Optional digital display for front paneladjustments and monitoring

Provides convenient and quick access to reviewcurrent power and load conditions, makeadjustments, review events or check network status(if network option is used)



Level 2 ControlLevel 2 Control

PackagePackage

The Level 2 Transfer Switch Control accommodates a full

range of applications. As noted in the following summary

of features and benefits, it can be used not only for utility-

to-generator applications, but also for utility to utility and

generator-to-generator applications. It also provides:

• Three-phase voltage sensing of the emergency source

in contrast to the single phase undervoltage sensing

provided in the Level 1 control.

• Phase rotation and voltage imbalance sensing.

• The digital display panel is a standard part of this

package, where it is optional in the Level 1 control.

• The Level 2 control offers an optional load

monitoring package and a calendar-based

programmable generator set exerciser.

The BTPC transfer switch is available with the Level 2

control only.

See Table 2-2 (next page) for a chart of the features and

benefits of the Level 2 control package.



Table 2-2: Level 2 Control Features and Benefits

Features BenefitsMicroprocessor-based control electronics Improved reliability and performance

PowerCommand network option Ability to access the PowerCommand network with asimple, and economical hardware upgrade

Local RS-232 serial port Allows quick configuration downloads, service diagnostics,or data acquisition using a laptop PC and InPower software

Software based trims and adjustments Improved reliability, ease of use

Utility-to-generator, utility-to-utility, or generator-to-generator configurations

Accommodates a full range of applications

Over/under three-phase voltage sensing on bothsources, software adjustable

Provides complete sensing of the supply voltages forcritical applications

Frequency sensing on both sources, single-phase Monitors variations in frequency on both sources

Phase rotation and voltage imbalance sensing Safeguards against installation mistakes and severesingle-phase imbalance loading

Start, transfer, retransfer, and stop time delays,software adjustable

Provides software adjustable time limits for the four primarytransfer time delays

Programmed transition for inductive load transfer,software adjustable

Reliably transfers motors, transformers, UPS, and otherSCR equipment without disruption or long term wear andtear damage

Load monitoring package option Records the maximum load phase currents and neutralcurrent showing reserve capacity for future addition of load.Warns of excessive neutral current resulting from thirdharmonic non-linear loading or an unbalanced load

Programmable calendar-based generator setexerciser with specific date/time scheduling

Allows complete flexibility of scheduling generator exerciseperiods. Exercise times can be set up on a calendar basisto take advantage of plant shut-down, non-working days, orother scheduled opportunities

Digital display (standard with Level 2 control)provides front panel adjustments and monitoring

Provides convenient and quick access to review currentpower and load conditions, make adjustments, reviewevents; network status can be checked if network option isused

Front panel test switch and time delay bypassswitch

Allows the operator to quickly enable a transfer, bypassingall time delays

Front panel LED indicators for normal available/normalconnected, emergency available/emergencyconnected, not-in-auto, active test

Long-life LEDs provide at-a-glance source and transferswitch status for quick summary of system conditions

Front panel security key Disables front panel buttons and switches to preventoperation by unauthorized personnel

Analog LED bar graph meter option Allows at-a-glance confirmation of system status andanalog indication, voltage, current, frequency, KW andpower factor



ControlFeatures

This section provides a summary of the major features of

the PowerCommand Transfer Switch Control. Most

features can be enabled or disabled depending on

customer preference.

Real TimeReal Time

ClockClock

Both Level 1 and Level 2 controls include a real time

clock that keeps track of the date and time. This clock is

‘Y2K’ compliant and can be set to correct for daylight

savings time and leap years.

Time DelaysTime Delays Start Time Delay (TDES): A short time delay to prevent

the generator from starting during brief power

interruptions. This delay is adjustable from 0 to 15

seconds on the level 1 controls and from 0-120 sec on the

level 2 controls.

Transfer Time Delay (TDNE): This time delay allows

the generator to stabilize before the load is transferred. It

has an adjustable range of 0 – 120 seconds.

Retransfer Time Delay (TDEN): This delay begins after

source 1 voltage and frequency have returned to specified

values, allowing it to stabilize before load is transferred

back. It has an adjustable range of 0-30 minutes.

Stop Time Delay (TDEC): During this time delay, the

generator cools down at no load before stopping. This

delay is adjustable from 0 to 30 minutes.

Under-VoltageUnder-Voltage

SensingSensing

Both control levels include under-voltage sensors for both

source 1 and source 2. The Level 1 control includes 3-

phase sensing on Normal and single phase sensing on

Emergency. Level 2 provides 3-phase sensing on both

Normal and Emergency.



Over-VoltageOver-Voltage

SensingSensing

Both Control levels include over-voltage sensors for

source 1 and 2. The Level 1 control includes 3-phase

sensing on Normal and single phase sensing on

Emergency. Level 2 provides 3-phase sensing on both

Normal and Emergency.

FrequencyFrequency

SensingSensing

Both control levels include over- and under- frequency

sensing of Normal and Emergency.

Two-wireTwo-wire

StartingStarting

The generator start circuit uses a two-wire start control.

Three-wire starting is not supported in the

PowerCommand Control.

ProgrammedProgrammed

TransitionTransition

The PowerCommand Transfer Switch Control is available

in open transition mode with programmed transition as

standard on both Control Levels 1 and 2, but may be

turned on or off based on customer requirements.

Programmed transition stops the transfer switch in a

neutral position, disconnected from both sources, for an

adjustable time interval to allow inductive loads to decay.

ClosedClosedTransitionTransition

TransferTransfer

The PowerCommand Transfer Switch Control is available

in closed transition mode on two standard versions of

Paralleling Load Transfer Equipment—the PLTS and

PLTH.

The PLTH is capable of closing to both sources for

uninterrupted transfer of 100-mSec or less. The PLTS is

a soft loading transfer switch that can parallel both

sources and ramp up load over preset time duration.



ProgrammableProgrammable

GeneratorGenerator

ExerciserExerciser

Both control levels include a programmable generator

exerciser. Level 1 includes one programmable exercise

event that can set a repetitive exercise schedule of any

number of days. Level 2 allows up to 8 schedules

including repetitive sequences, exceptions (when the

customer does NOT want to exercise), and special dates

(could be off-peak hours, holidays, plant shutdowns, etc.).

Generator exercise can be set up to operate with or

without transferring load.

VoltageVoltage

ImbalanceImbalance

SensorSensor

Level 2 controls on 3-phase transfer switches include a

voltage imbalance sensor. The sensor indicates a source

failure when the deviation from average voltage is greater

than the user-specified value.

PhasePhase

RotationRotation

SensorSensor

Level 2 Controls on 3-phase transfer switches include a

phase rotation sensor to indicate a failure when source 1

and source 2 do not have the same phase.

Loss of SingleLoss of Single

Phase SensorPhase Sensor

Level 2 Control on 3-phase transfer switches can detect

the loss of a single phase on either source.

ControlOptions

This section provides a summary of the major options of

the PowerCommand Transfer Switch Control.

LoadLoad

MonitoringMonitoring

Load monitoring can be selected as an option with the

Level 2 control. The control senses the phase and neutral

currents, load voltages and power factor angles. The

control calculates KW, KVA and PF. All load

information is displayed on the digital display panel, or

can be displayed on the LED bargraph meters. The

control will also issue a warning when neutral currents

exceed user-specified values.



Relay SignalRelay Signal

ModuleModule

The Level 1 and Level 2 Relay Signal Modules includes

the following 8 form C relay contacts:

• Source 1 Connected

• Source 1 Available

• Source 2 Connected

• Source 2 Available

• Test Active

• ATS Not in Auto

• Elevator pre-Transfer

• Load Shed Active

The Level 2 version also includes the following for a total

of 11 Form C relay contacts:

• Fail to Close

• Fail to Synchronize

• Fail to Disconnect

Load ShedLoad Shed The Load Shed function is used to disconnect the load

from Source 2 in order to reduce demand on the generator

set for a period of time. When load shed is initiated, the

transfer switch is moved to the neutral position and

signals that the switch is ‘Not in Auto.’

LoadLoad

SequencerSequencer

OptionOption

Both the Level 1 and Level 2 controls can include up to 8

timed network variables to use for turning on loads in

sequence after a transfer, retransfer or both. The network

variables activate relays on the Network Digital I/O

Module (DIM). The Network Communications Module

(NCM) is required to use this option. The NCM will be

addressed in greater detail in Lesson 4.

Remote TestRemote Test

TransferTransfer

OptionOption

The transfer switch may be wired with a remote test

switch, which causes the switch to sense a simulated

utility power failure, initiate the transfer sequence and

transfer load to source 2 when it is available.



Float BatteryFloat Battery

ChargerCharger

OptionOption

The same 2 A and 10 A float chargers available on the

OTIII and BT are also available on the OTPC and BTPC.

The 2 A charger is designed for use at either 12 or 24

volts. The 10 A charger provides a choice of 12 or 24

volts.

AuxiliaryAuxiliary

Relay OptionRelay Option

The optional auxiliary relays provide contacts for

energizing external alarms, remote indicators and control

equipment such as louver motors or water pumps.

Interfaces The OTPC and BTPC offer several types of new or

improved interfaces including:

• High-visibility LED indicators

• A vacuum fluorescent digital display

• An analog LED bargraph meter option

The new network interface is the LONWorks-compliant

PowerCommand Network Communication Module

(NCM). The NCM allows the transfer switch to interface

with a PowerCommand system via the network. The

network will be adressed in greater detail in Lesson 4.

The Cummins Onan InPower Service Tool Interfaceprovides configuration download, on-line diagnostics,

data analysis tools, and real time monitoring using a

laptop PC. InPower will be discussed further in Lesson 5.

OperatorOperator

InterfaceInterface

The operator interface includes the following features:

• Basic interface panel

• Front panel security key option

• Digital alpha numeric display

• Analog LED bar graph metering

These features are illustrated and described in greater

detail on the following pages.



Table 2-3: Features of the Operator Interface for Level 1 and Level 2 Control Options

Features Level 1 Level 2

Basic interface panel Standard Standard

Front panel security key option Option Option

Digital alpha numeric display Option Standard

Analog bar graph meters Not available Option

Basic interface panel High-intensity LED indicator lamps designed for long lifeand easy reading in common lighting situations provide aquick summary of system conditions (see Figure 2-1).The interface panel is a standard feature on all OTPCtransfer switches. It contains six indicator lamps and threemembrane switches.

The control switches are tactile push buttons. These

lamps and switches include the following:

Lamps

Source 1 Available and Source 2 Available: Theseindicators are lit when the corresponding power sourcesare producing power. These indicators can be litsimultaneously.

Source 1 Connected: This indicator is lit when theautomatic transfer switch is in the normal position andSource 1 is supplying power to the load.

Source 2 Connected: This indicator is lit when theautomatic transfer switch is in the emergency position andSource 2 is supplying power to the load.

Not in Auto: For Genset–to–Utility configurations, theNot in Auto indicator lights when the genset On/Off/Autoswitch is not in the Auto position.

For Genset–to–Genset configurations, the Not in Autoindicator lights when On/Off/Auto switch on the non–preferred genset is not in the Auto position.

For Utility to Utility configurations, the Not in Autoindicator is not used.

Test/Exercise Active: The Test/Exercise Active indicatoris lit when the transfer switch has a test or exercise inprogress.



Switches

Test: The Test (Hold 2 Sec.) switch sends a start signal tothe generator set designated Power Source 2 and lightsthe Test/Exercise Active indicator. After the transfer timedelay, Source 2 starts and assumes the load provided thatthe With Load option is selected. Press the Test switchagain to end the test; the Test/Exercise Active indicatorgoes out and Source 1 resumes as the source of power.

Override: The Override switch terminates most systemtime delays. The Programmed Transition, Synch Check,and Engine Cool Down are not affected by this switch. Ifyou press this switch while the Transfer Inhibit input isalso active, the switch immediately transfers the load. Ifyou press this switch while the Re–Transfer Inhibit inputis active, the switch immediately retransfers the load.

Reset/Lamp Test:The Reset/Lamp Test switch turns onall control panel indicators.



Figure 2-1: The OTPC Operator Panel

Analog LEDBar GraphMetering

Basic InterfacePanel

Front PanelSecurityKey Option

Digital AlphaNumericDisplay



Front Panel SecurityKey Option

The option for a front panel security key can be used to

prevent activation of any commands to the front panel,

preventing unauthorized transfers or testing. Without the

security key only the Reset/Lamp Test Switch and

monitor functions of the digital display can be accessed.

Figure 2-2: The OTPC Front Panel

Front Panel SecurityKey Option



Digital Alpha NumericDisplay

The alphanumeric operator interface panel, a menu-driven

interface with a Main Menu, has six push buttons. The

Home button returns the operator to the Main Menu

screen and Previous Menu returns the panel to the

previous major menu. Four buttons are used for menu

navigation and input. You can find a detailed description

of the display menus in Section 4 of the Operator’s

Manual (962-0126).

The operator can use the digital alphanumeric display to

view detailed control information and to set up and

configure the control system using this display. It allows

two lines to appear with 20 characters for each line.

Information available on the panel is provided in

Appendix A.

Main Menu: The main menu system consists of three

top-level main 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.

Setup Menu: Before you can navigate the setup menus,

you must enter a password. When this information is

changed in any setup menu, you are prompted to either

save the changes or restore the old values.

A graphic of the menu structure is included in the file

tsmenu.PDF on your CD-ROM.



Analog Bar GraphMeters

A multi-function-metering package provides analog ACoutput metering for service to the loads. Bar GraphMeters are not available on Level 1 controls and areoptional on Level 2 controls. The bar graph metersinclude a 3-phase AC ammeter, a power meter, a powerfactor meter, a frequency meter, and a three phase ACvoltmeter:

AC Ammeter: The ammeter measures the line currentsof the load.

Power Meter: The power meter measures the real powerin percent of full load.

Power Factor Meter: The power factor meter measuresthe real power delivered to an inductive load.

Frequency Meter: This meter measures the outputfrequency of the selected power source in hertz.

AC Voltmeter: The voltmeter measures line–to–line andline to neutral voltages of the selected power source.

The vertical LED bar graph meters are consistent with

other PowerCommand products. The metering is color

coded as a percent of nominal conditions. Green is

normal. Amber indicates warning. Red indicates that

unacceptable conditions exist on the power supply fed

from the transfer switch. These meters provide

indications of system acceptability at a glance without

having to interpolate values from an analog dial.



Lesson Two Progress Check



1. Write in the interfaces that are available for each level of the transfer switch control

according to whether they are standard, optional or not available.


Standard Standard

Option Option

Option Standard

Not available Option

2. What are the major differences in source sensing between the Level 1 and Level 2

controls? (Check which are available for each level of transfer switch option.)

Sensing Parameters Level 1 Level 2

Voltage imbalance

Phase rotation

Undervoltage

Overvoltage

Frequency

Loss of single phase

3. Neutral current can be read using the __________ ___________ when the Level ___

control and _________ _____________ feature is selected.

4. Select the following that apply only to the Level 2 PowerCommand Transfer Switch

Control features:

a. Programmed transition for inductive load transfer, software adjustable

b. Utility-to-generator, utility-to-utility, or generator-to-generator configurations

c. Load monitoring package option

d. Programmable calendar-based generator set exerciser

e. Front panel test switch and override switch



5. Using the menu from the tsmenu.pdf file on your CD, trace the path for how you would

arrive at the number of transfers and order the following steps correctly, the first step as

number 1 and so on.

_____ Scroll to number of transfers

_____ Second main menu

_____ Statistics

_____ First main menu (more)

6. Only the Level 2 control includes a real-time clock for exerciser programming and event

logging.

_____ True

_____ False



Answers to Lesson Two Progress Check

1.


Basic interface panel Standard Standard

Front panel security key option Option Option

Digital alpha numeric display Option Standard

Analog bar graph meters Not available Option

2.

Sensing Parameters Level 1 Level 2

Voltage imbalance 4

Phase rotation 4

Undervoltage 4(3-phase normal, 1-

phase emergency)

4(3-phase normal, 3-

phase emergency)

Overvoltage 4(3-phase normal, 1-

phase emergency)

4(3-phase normal, 3-

phase emergency)

Frequency 4 4

Loss of single phase 4

3. Neutral current can be read using the digital display when the Level 2 control and load

monitoring feature is selected.

4. b,c,d. The Level 2 PowerCommand Transfer Switch Control is the only package to offer

utility-to-generator, utility-to-utility, or generator-to-generator configurations, a load

monitoring package option, and a programmable calendar-based generator set exerciser.

5. ___4__ Scroll to number of transfers

___2__ Second main menu

___3__ Statistics

___1__ First main menu (more)

6. False, both levels of control include a real-time clock.


Lesson Three: How Onan Compares with

the Competition


• Compare Onan’s transfer switch product line to that of the

competition.

• Explain the importance and benefits of selling Onan

transfer switches.

This lesson explains how to position both the transfer switch

levels 1 (basic level of control) and 2 (premium) control

packages with competitive offerings.

Even though the transfer switch market has a number of

competitors, only a handful constitutes the major sellers of

transfer switches in North America. These include the

following:

Overview ofCompetitive

Products• Onan

• Asco

• Russelectric

• Kohler

• Generac

• Zenith

TransferSwitch Level 1

ControlPackage

Industrial grade transfer switches generally share the same

basic features in terms of minimum performance:

• Listed to UL 1008 and CSA certified

• Electrically operated, mechanically held switch mechanism

• Mechanically interlocked to prevent uncontrolled closure

of both sources

• A full range of single phase and 3 phase voltages

• Fuse or breaker rated withstand and closing ratings

Customers looking for switches with a basic level of control

expect a good quality product and adherence to UL1008, CSA

and US National Electrical Code is assumed in even the most

basic transfer applications.

3. How Onan Compares with the Competition


The two primary basic transfer switches that can be compared

to the OTPC with Transfer Switch Control Level 1 are the

Asco 300 and the Zenith ZTG. Onan is not aware of any basic

switch that is available from Russelectric.

Less expensive switches than those we refer to as basic

switches are available, but they are usually deficient in either

quality or performance. Some specific examples are residential

switches such as WINCO and Generac.

Figure 3-1: Competition for the PowerCommand Transfer Switch Level 1 Control

Of prime consideration for the basic switches is the ability to

get a low price per amp and to obtain prompt delivery.

Customers are seeking reliable local service and often do not

have on-site maintenance expertise. Because these customers

depend heavily on factory service, the local reputation of the

distributor representative may influence the sale.

Asco 300Zenith ZTG with MX 100 Controls



Positioning thePowerCommandTransfer SwitchLevel 1 Control

The PowerCommand Transfer Switch Control packages are

positioned to compete across the range of transfer switch

products from basic to premium products.

The chart on the following pages (Table 3-1) compares the

features the PowerCommand Transfer Switch Level 1 Control

offers with those of competitive products.



Table 3-1: PowerCommand Transfer Switch Level 1 Control Competitive Comparison

PowerCommandTransfer SwitchLevel 1 Control

Asco 300 Zenith ZTG This is important because:

ControlPlatform

• Microprocessor-based

• Software-basedadjustment of transferswitch settings viaInPower Software oroptional Digital Display

• Password protection ofsettings


• Dipswitch adjustmentof settings


• Potentiometeradjustment of settings

• Dipswitch adjustments require lookup tablesto set.

• Potentiometers can be difficult to setbecause they require trial and error. Theycan also drift over time and temperature.

• Only Onan provides software basedadjustments set from the front panel display.

Sensing • 3-phaseover/undervoltagesensing normal. 1-phaseemergency

• Frequency sensing onboth sources

• 3-phase undervoltagesensing normal, 1-phase emergency

• Frequency sensing onemergency only

• 3-phase undervoltagesensing on normal, 1-phase emergency

• Frequency sensing onboth sources

• Only Onan offers a full sensing packageon the normal source.

Transfermodes

• Standard OpenTransition

• Programmed Transition


• In-Phase Monitor


• In-Phase Monitor

• Programmed Transitionavailable at added cost

• Only Onan offers Programmed Transitionas standard on every switch.

• Asco cannot offer Programmed Transitionon the 300 Series.

• Zenith requires an upgrade to a moreexpensive switch with a center off position.It cannot be upgraded in the field.

GeneratorsetExerciser

• Programmable exerciserallows exercise times setup on any daily intervalschedule from 1-225 days

• 7 day exerciser • 7 day exerciser • Only Onan provides this level offlexibility as standard. This means thata customer can select intervals of anynumber of days based on siterequirements and plant maintenancerequirements.



Table 3-1 (cont.): PowerCommand Transfer Switch Level 1 Control Competitive Comparison


Asco 300 Zenith ZTG This is important because:

ExternalInterfaces

• Basic panel (sourceavailable/ connectedindicators, test/ exercise/bypass buttons)

• Optional vacuumfluorescent digital display

• Optional Front PanelSecurity Key

• Panel with sourceavailable andconnected LEDs,exerciser switch, testswitch, and timedelay bypass switch

• Basic panel with sourceavailable and connectedand time delay timing LEDs

• Onan provides the option of adding avacuum fluorescent digital display.Other transfer switches do not providedisplays. Vacuum fluorescent displayshave better performance over extremetemperatures than LCD displays.

• The security key enables operation ofthe switch at the front panel preventingunauthorized personnel from initiating atransfer.

Network • LONWorks compliantnetwork interface

• SerialCommunicationsboard for use withPowerQuest.

None • All PowerCommand switches caninterface with other LONWorkscompliant devices allowing economicaladdition of transfer switch informationinto PowerCommand Systems andBuilding Automation networks.

Events • Sequenced eventrecording

• Optional network eventdisplay

None None • Only Onan provides time sequencedtransfer switch and network eventinformation at the digital display. Thiswill greatly improve troubleshooting andserviceability of the entire powersystem.

Options • Signal module

• Loadshed

• Load disconnectsignal

• Elevator pre-signal • Only the OTPC can move the entireload to a neutral position, disconnectedfrom both sources




At the upper end of the transfer switch market are those

businesses with a requirement for high reliability—central

office telecommunications, data centers, health care and critical

care facilities. These customers want products that enhance

total system reliability, and they are willing to pay for it.

Typically they require more sophisticated sensing and control

features and often incorporate the transfer switch into a more

elaborate back-up power scheme.

Figure 3-2: Competition for the PowerCommand Transfer Switch Level 2 Control

Positioning thePowerCommandTransfer SwitchLevel 2 Control

In addition to Onan, three suppliers make premium

switches—Asco, Russelectric and Zenith. As mentioned,

the Zenith business strategy to follow Asco limits their

comparative advantage, particularly in this high range of

product. As a result, we will focus on a comparison of

the Onan OTPC Transfer Switch Level 2 Control, the

Asco 7000 and Russelectric Model 2000 (see Table 3-2).

Asco 7000

Series


Onan PowerCommand Transfer Switch Self-Study Page 35

Table 3-2: PowerCommand Transfer Switch Level 2 Control Competitive Comparison

PowerCommand TransferSwitch Level 2 Control

Asco 7000 Russelectric 2000 This is important because:

Controlplatform


• Multi-language display

• Password protection ofsettings


• Voltage selectable

• Multi-language display

• Password protected


• Password protected

• Onan’s microprocessor isdesigned to be commonplatform that can directlycommunicate with otherPowerCommand productsfor applications worldwide

Sensing • 3-phase over/under voltagesensing on normal andemergency

• Under/over frequency onnormal and emergency

• Voltage imbalance sensing

• Phase rotation sensing

• Loss of single phasedetection

• 3-phase over/undervoltage sensing on-phasenormal and emergency

• Under/over frequency onnormal and emergency(+/- 0.2%)

• Voltage imbalancesensing

• Phase sequence sensing

• 3-phase over/under voltagesensing on normal andemergency

• Under/over frequency onnormal and emergency

• Phase sequence detection

• Voltage imbalance sensing

• Phase differentialmonitoring

• Onan provides a competitivesensing package designedto meet industryspecifications

Transfermodes

• Standard open transition

• Standard programmedtransition

• In-phase monitor withprogrammed transitionbackup (on the PLTO)

• Closed transition (on thePLTH)

• Closed transition withactive synchronization (onthe PLTS and PLTH)

• Optional bypass isolation(available on the BTPC)

• Standard opentransition

• Delayed transition(requires additionalswitch hardware)

• In-phase monitor

• Closed transition option

• Optional bypassisolation

• Standard open transition

• Delayed transition(requires additionalswitch hardware)

• Sync check (In-phasemonitor)

• Closed transition optionavailable

• Optional bypass isolation

• The OTPC and BTPC remainthe only switches on the marketthat can provide programmedtransition as standard. Onanhas also improved the in-phasemonitor by providing aprogrammed transition backup.The PLTS and PLTH canactively synchronize with aPCCII generator set.

3. How Onan Compares Against the Competition





Generatorsetexerciser

• Calendar-basedexerciser

• 1, 7 14 or 28 dayexerciser clock

• Calendar-based exerciser • The Onan calendar-based exerciseruses a real-time clock that allows upto 8 separate exercise programs tobe set up to accommodate plantmaintenance schedules, plantshutdowns, holidays, etc. The clockalso automatically corrects fordaylight savings and leap year.

Externalinterfaces

• Vacuum fluorescentdigital display

• Basic panel (sourceavailable/ connectedindicators, test/ exercise/bypass buttons)

• Optional digital LED bar-graph meter panel

• Front panel Security Key

• LCD digital display

• Touchpad programmingof features and settings

• LCD digital display

• Source connected LEDs

• Optional annunciationplate with sourceavailable, connected, notin auto, and audible alarm.

• Vacuum fluorescents provide highervisibility and better performance atextreme temperatures, especiallybelow –20C.

• Only Onan offers meters as apricebook option. The LED bargraph meters provide color-codedindication for at-a-glance visualdetermination of source and loadacceptability.

Network • Optional network board

• Lonworks compatible

• Transfer switch andgenerator set status fromnetwork

• Serial comm board (RS422/485 protocol) for usewith proprietaryPowerQuest

• Serial comm port(RS422/485 ModBus RTUprotocol) for use with BMSor Russel Scada system

• Onan’s network interface isdesigned to be LONMark compliant,allowing integration into buildingautomation systems.






Events/history

• Date/time stamped 50logged events

• Network eventinformation available atthe digital display

• Date/time stamp 99logged events

• Total ATS transfers

• ATS failures due tosource failure

• Total days of ATSoperation

• Total source availablehours

• Date/time stamped mostrecent 10 transfer events(numeric codes)

• Total each sourceavailable

• Total each sourceconnected

• Number of transferoperations to each source

• Onan provides more types of eventand history information to makediagnostics and record-keepingeasier.

Options • Signal module

• Loadshed

• Load power and loadcurrent monitoring

• Load sequencing via thenetwork

• Programmable loadshed • Loadshed • Only Onan senses source voltagecurrent, load, KW and PF in thetransfer switch. This means that theinformation is available from thetransfer switch and can be accessedusing InPower or communicatedacross the network from one device.Both Asco and Russelectric rely onseparate add-on load monitoringpackages.



TransferSwitch

FeaturesCompared to

OtherSuppliers

The following pages (Table 3-3) chart a comparison of

the features Onan’s transfer switches offer to those

available from other major suppliers. Understanding

exactly where Onan fits in this market is essential to

successfully positioning your products with customers.



Table 3-3: Comparison of Transfer Switch Features Provided by Major SuppliersFeature Onan Asco Russel Zenith Generac Kohler Why this is important:

Mechanically held switch • • • • • • Mechanically latched contacts help the switch withstand faults bylocking the contacts closed. Some switches can be manuallyoperated but not latched, so an improper service operation canleave the switch closed, but not latched. This can cause failure ofthe ATS.

Silver alloy contacts • • • • see note2

• Silver alloy provides better durability than pure silver.

Multiple leaf arc chutes • • • • see note3

• Arc chutes accelerate arc extinguishing and minimize contactwear on switching.

Quick-make, quick-breakmechanism

• • Prevents improper operation of the switch during serviceoperations. Makes switch safer to operate manually.

Programmed transition • seenote 2

• • see note1

seenote 2

Most effective way to deal with transfer of inductive loads.

Permanently attachedmanual operators

• • see note1

seenote 1

Permanent mounting helps prevent misoperation, loss of manualoperators. Safer manual operation.

Barriers over all liveparts, including lugs

• Barriers prevent direct inadvertent contact to dangerous voltagelevels.

Transparent barriers • • • Allows visual inspection of the switch mechanism without movingprotective covers.

Positive mechanicalinterlock

• seenote 3

• seenote 1

• seenote 1

Prevents accidental out of phase paralleling of sources, orenergizing a generator set that is shut down. Either can causeserious damage to the generator set.

True 4-pole(simultaneous) neutralswitching

• • Eliminates the danger of misoperation of neutral poles, which cancause operational and safety hazards.

Common Crossbar on 3-Pole and 4-PoleSwitches

• • • • Provides for synchronized opening of all contacts and minimizesthe possibility of transient switching overvoltages.



Table 3-3 (cont.): Comparison of Transfer Switch Features Provided by Major SuppliersFeature Onan Asco Russel Zenith Generac Kohler Why this is important:

Controls door-mounted • • • • • Door-mounting the control makes it more accessible, easier andsafer to work on.

Controls isolated fromswitch for service

• • • • Control disconnect plug allows isolation of the control for servicewithout interrupting power to loads.

Standard sensing andtiming in one controlpackage

• • Entire control system prototype-tested as system. Ease ofservice, availability of spares is improved.

One electronic control forall ratings

• • Improved reliability.

High voltage surge andnoise immunity

• • Control is resistant to voltage surges due to lightning and othertransient effects. If the voltage surge exceeds specifiedparameters, the Onan control will start the generator set andtransfer power, so customer knows failure has occurred, andproblem can be fixed.

Internal LED statuslamps

• Provides diagnostics and fault indicators to make service easier.LED’s designed to operate for the life of the control.

Control I/O isolated • Helps to protect the control from voltage surges and transientconditions that might damage the control.

Field adjustable,calibrated voltagesensors

• • • • Allows field modification of voltage conditions to suit the needs ofthe application. More reliable Indication of failed source.

Sensors on all phases ofboth sources

• Voltage sensors identical for both sources. Better partsavailability, easier service and calibration. Better protection forloads.

Service for entire powersystem from a singlesupplier

• Single source for technical information, product startup, service,warranty, parts.



Table 3-3 (cont.): Comparison of Transfer Switch Features Provided by Major SuppliersFeature Onan Asco Russel Zenith Generac Kohler Why this is important:

Can be networked withany transfer switchfrom any supplier

• Network is suitable for use in any building, even when switchesfrom several suppliers are in place. Minimizes costs of systemmonitoring.

Can be networked withany generator set fromany supplier

• Network is suitable for use in any building, even when equipmentfrom several suppliers are in place. Minimizes costs of systemmonitoring.

Non-Load breakbypass available

• • seenote 1

• No power interruption to critical loads when maintenance or serviceof switch is needed. Bypass switch is isolated from current surgesthat could damage it in day to day operation.

Bypass to any sourceat any time

• • Ease of operation. System is more reliable.

Bypass includes dead-source interlock

• • • • Prevents situation where system is connected to a source that isnot available.

Asco/Kohler Notes1. Switch can be manually operated to a new position without locking contacts in place. Or, could leave in neutral position and switch can’t recover.2. Model 300, 940 and 962 are not available with this feature. In phase monitor substituted.3. Closed transition transfer switches (Model 436) do not have mechanical interlock. Mechanical interlock is required on transfer switches by NFPA 99.4. Kohler can offer switch mechanisms that meet this requirement.Russelectric Notes:1. Russelectric has quoted non-load break bypass switches, but we have not seen any literature describing them. Standard product is a load break

bypass.Zenith Notes1. Switch can be manually operated to a new position without locking contacts in place.2. Zenith offers a closed transition transfer switch that does not include mechanical interlock. Mechanical interlock required by NFPA99.3. Mechanical interlock is required on transfer switches by NFPA 99.Generac Notes1. Switch can be manually operated to a new position without locking contacts in place.2. Silver contacts used on larger ATS models.3. Not available on switches rated 250VAC and lower4. Available only on switches rated 250VAC and lower



Lesson Three Progress Check



1. List three competitive advantages of the Onan Level 1 control versus the Asco 300.

2. List three competitive advantages of the Onan Level 2 control versus the Asco 7000.

3. The OTPC load monitoring option is integral to the Onan transfer switch. Explain the

competitive advantage over Russelectric and Asco.

4. Explain the importance of LONMark compliance.

5. Describe the importance of a single source supplier.



Answers to Lesson Three Progress Check

1. Refer to Table 3-1 for a comprehensive listing of the competitive advantages of the Onan

Level 1 control.

2. Refer to Table 3-2 for a comprehensive listing of the competitive advantages of the Onan

Level 2 control.

3. Only Onan senses source voltage current, load, KW and PF in the transfer switch. This

means that the information is available from the transfer switch and can be accessed

using InPower or communicated across the network from one device. Both Asco and

Russelectric rely on separate add-on load monitoring packages.

4. LONMark compliance is an industry standard that ensures compatibility with other

building maintenance systems.

5. A single source supplier offers many advantages. For example, service is more easily

arranged since only one vendor needs to be contacted. The system is more integrated; if

the design of one or more components change system integrity is preserved. The

components are designed originally to complement a systems approach.


Lesson Four: The PowerCommand Control

Network

Objectives After completing this section, you should be able to:

• Characterize the market for PowerCommand

Networks.

• Explain the features and benefits of adding transfer

switches to a PowerCommand Network.

• Describe the Network Communication Module

hardware and how to add the feature to an OTPC or

BTPC.

• Describe the types of information that can be sent and

received by the PowerCommand Transfer Switch.

TheOpportunityfor Network

Solutions

Let’s begin by looking at the type of facilities that can

benefit from a network solution. After examining key

market opportunities, the lesson continues on to explain

the key features and benefits of the transfer switch

Network Communication Module (NCM). The NCM is

the interface between the transfer switch and the network.

While the PowerCommand Network can be applied to

any generator set application, it is most ideal for those

companies with multiple buildings and sites and a large

number of generator sets to manage. The following

provides a profile of the type of plant to target for this

application and identifies the industries where you might

find customers with these types of needs. Keep in mind

that when new construction is being planned, the

opportunity for the PowerCommand Network is even

greater, because savings on installation and material costs

are easy to estimate in this early stage.

4. The PowerCommand Control Network


Table 4-1: Profile of Candidates for PowerCommand Network

Physical Plant Characteristics Examples of Industries

Life-safety code-driven buildings, such as single buildingsover 6 stories and facilities governed by NFPA 99 or 110

• Healthcare

• Hotels

• Commercial real estate

Generator sets in multiple buildings or installations on onesite

• Colleges and universities

• Correctional facilities

• Manufacturing plants

• Wastewater treatment facilities

• Some healthcare facilities

Multiple installations distributed over a wide area • Retail chains

• Public utilities

• Telecommunications

• Gas pipelines

• Some healthcare facilities

Benefits of aNetworkSolution

For these targeted customers, it is important to consider

the following benefits when evaluating a sales

opportunity. A network solution:

• Reduces or controls the cost of monitoring and

servicing standby power at all sites.

• Improves system reliability through improved

operations and maintenance.

• Is proactive in its automatic alarm notification to local

or distant technical personnel.

• Provides complete and convenient documentation of

operation, maintenance, and service.

• Is compliant with code requirements for record

keeping.

• Allows flexibility in adding or modifying facilities

and does so economically.

• Connects easily with building automation systems.



Now, take a closer look at specific markets that can

benefit from PowerCommand Network. The three

segments that will be examined in more detail further on

are as follows:

• Healthcare

• Retail

• Telecommunications

Opportunitiesin Healthcare

Facilities

The healthcare industry has particular stringent

requirements for power, because patients they treat often

depend on equipment for survival. Reliability is a critical

factor in their decision to buy any power system. This is

reinforced by building and National Fire Protection

Association (NFPA) codes, specifically those that apply

to healthcare facility construction:

• NFPA 110 defines the performance required of

emergency or standby power systems.

• NFPA 99 is the standard for healthcare facilities. It

tells how the testing and record-keeping requirements

of the emergency and standby power system are to be

met. It also specifies loads that must be transferred to

the generator. State and local building codes will

reference this code.

The Joint Commission on the Accreditation of Healthcare

Organizations (JAHCO), often referred to as the Joint

Commission, also influences requirements. It inspects

facilities every six months for accreditation renewal and

can be compared to professional licensing for the hospital

business.



JointJoint

CommissionCommission

RequirementsRequirements

The Joint Commission’s Accreditation Manual for

Hospitals references NFPA 99 and includes requirements

for documenting the maintenance and testing of the

emergency/standby power system during routine

operations.

The healthcare facility must inspect the emergency

standby power system weekly and exercise it monthly.

When the Joint Commission makes accreditation visits, it

reviews the records of these inspections and tests.

The monthly exercise is required to be performed for 30+

minutes at operating temperature at no less than 30% of

the generator rating.

You will find that the parameters monitored during

monthly exercising are displayed on PowerCommand

Control and can be monitored locally or remotely via a

PC.

The following table summarizes features and benefits of

the PowerCommand Network that benefit healthcare

operations. The table lists several features that address

Joint Commission requirements.



Table 4-2: Benefits of PowerCommand Network for the Healthcare IndustryPowerCommand Network Features Benefits to Healthcare Customers

PowerCommand Control design enhances reliablegenerator set startup

• Risk management

• Minimizes repair time and expense

Automatic alarm notificationDial-out capability for change-of-state, warning orshutdown conditions

• Greater flexibility because staff can circulatewithin or away from the facility

• Risk management because no need for humansto transfer alarm messages

PowerCommand software for Windows keepsrecords of system status and test performanceconveniently

• Low cost, convenient, compliance withaccreditation and code requirements

• Date/time stamp of events provide verification ofactual system performance

PowerCommand software for Windows permits localor remote monitoring and control. Localdistributorships can perform diagnostics from theirdistributorship.

• Saves time for the facility engineer

• Saves personnel costs: a few highly qualifiedindividuals monitor and control remotely, whileless qualified people do simpler on-site tasks

• Enhances system reliability through well-qualified technical service

PowerCommand Network uses logical connectionsrather than hardwiring between modules.

• Saves money on installation

• Saves money on future modification

Automatically records duration, load level, andoperating temperature conditions of generator setduring monthly exercise and whenever generator setruns for any reason (actual outage, testing afterrepairs, etc.)

• Operating personnel need not be present

• Events recording provides verification of actualsystem performance

Automatically collects all available generator setoperating data at user-defined intervals and storesdata in permanent record.

• Record may be viewed, downloaded or printed

• No manual transcription errors


Formats generator set operating data in standardprinted report.

• Meets documentation requirements of JAHCO

• Consistency of data

• Saves time for facility engineer

Records date and time intervals of automaticgenerator start-up and shutdown processes (duringexercise and actual outages)

• Meets data requirements of JAHCO


Records date and time intervals of automatictransfer switch tests and transfer switch position



Records automatic transfer switch operating data(current and voltage) on user-defined intervals andstores data in permanent record.



Automatic alarms notification to monitoring PC, vialocal network wiring and/or telephone modems toremote location, including automatic pagingcapability for unacknowledged alarms. Providesnear immediate notification from unattendedequipment whether running or not.





Opportunitiesin RetailMarkets

Retail facilities are realizing the growing importance of

emergency power for several reasons including:

• The need to protect public safety and avoid liability.

• Prevention of lost sales by enabling customer to keep

shopping during power outages.

• Prevention of losses due to theft or spoilage.

National chains benefit from PowerCommand Network’s

remote monitoring and automatic dial-up alarms, which

relieve the need for local expertise and help ensure

reliability at all locations. The following figure

summarizes benefits of PowerCommand Network for the

retail industry.

Table 4-3: Benefits of PowerCommand Network for the Retail Industry

PowerCommand Network Features Benefits to Retail Customers

• Remote monitoring and control of systemswith PowerCommand Network

• Reduces the need for on-site expertise.

• Skilled individuals at headquarters ordistributor can manage preventivemaintenance.

• Cummins/Onan distributors can providetechnical assistance.

• PowerCommand Network can be set up tonotify the distributor when service is needed.

• Technically qualified individuals are availablethrough Onan distributors

• Reliability of the standby power system underPowerCommand Network

• Ensures public safety, loss prevention and(with a 100% standby system) continuity ofoperations and revenue flow.

• Cost of system could be offset by customerbenefits

• Cost of standby system withPowerCommand Network may be offset byreduced time driving to sites, exercisinggenerator sets and recording information.



Opportunities inTelecommunica-

tions

Telecommunications has become a highly competitive

industry that includes regional operating companies,

which deliver telephone service over telephone lines,

operations that serve smaller areas, and cellular

companies that use radio equipment and sell

communications. All of these operations involve

dispersed locations that require a reliable power source.

With the remote monitoring and exercising of generator

sets available with the PowerCommand Network, a

qualified engineer at a central location can perform

diagnostics and send appropriate technicians to perform

the service, which is of tremendous value in convenience

and time. And because the loss of telephone service can

cost these companies as much as $10,000 per minute of

lost revenue, the increased reliability with

PowerCommand Network will provide even greater

value.

Table 4-4: Benefits of PowerCommand Network for Telecommunications IndustryPowerCommand Network Features Benefits to Telecomm Customers

PowerCommand Control design enhancesreliable generator set startup

• Maximizes reliability of standby powersystem, which in turn minimizes lostrevenue and supports life-criticalapplications such as 9-1-1 service.

Permits remote monitoring and control from acentral monitoring facility.

• Saves travel and personnel costs byallowing monitoring and control of multiplesites at a central location, requiring fewerskilled people to operate.

Automatic alarm notification. Dial-out capabilityfor change-of-state, warning or shutdownconditions

• Provides operational information to acentral monitoring point via modem forevaluation and dispatch by trainedpersonnel.

• Reduces travel and troubleshooting time byproviding key information before theservice technician leaves for the call.

Can communicate data necessary forevaluation of system status and testperformance

• Convenient method for system-wide testingand evaluation concerns.



Next the lesson examines how transfer switches interface

to the PowerCommand Network with hardware and

software components.

Connecting tothe Network

Incorporating transfer switches into a PowerCommand

network can provide powerful benefits to the customer.

As part of an integrated standby power system, the

transfer switch can start a generator set and monitor

conditions with reduced installation and wiring costs to

the facility. Building automation or SCADA systems can

use real time source and load data to maximize power

reliability, reduce facility energy costs and manage

emergency conditions.

NetworkCommunication

Module(NCM)

Hardware

Now we’ll examine the hardware interface of the transfer

switch with the network.

The Network Communication Module (NCM) provides a

LONWorks™ network interface to the OTPC and BTPC

Controls. The NCM uses the (existing) 78 KBPS twisted-

pair, transformer-coupled transceiver to interface to the

PowerCommand Network.

The NCM is an add-on daughter-board module to the

OTPC and BTPC Level 1 and Level 2 digital control

boards. It is connected to the OTPC and BTPC control

through a ribbon cable connector. The NCM requires two

three-volt lithium cells for back-up power during extended

power outages. Additional battery input is provided for

external (DC) power supplies.

The NCM is compatible with all existing PowerCommand

Network modules (CCM, DIM, and GCM). The NCM

provides remote communications, monitoring, and dial-

out to PowerCommand Network sites via modem (and

gateway) hardware. (See Figure 4-1 for the location of the

NCM.)



Figure 4-1: NCM Installed on PowerCommand Transfer Switch Level 2 Control

NetworkCommunicationsModule addedhere



NetworkCommunication

ModuleSoftware

The Network Communication Module operates by

sending defined packets of information out on the

network. These packets, called network variables, are

available to all devices residing on the network. Usually,

only specific types of devices are programmed to use

specific variables. LONMark compliance means that the

Onan network variables are formatted to the LONMark

standard and that all LONMark compliant devices can

recognize and use the information. As the author of the

LONMark transfer switch standard, Onan has ensured that

we meet the requirements for basic and optional network

variable information. We have additional network

variables that allow our generator sets, transfer switches

and other equipment to have an even tighter level of

integration. As the sole-source supplier of an emergency

power system, the network is a key advantage in terms of

system integration and improved reliability, service and

information to the end user.

The transfer switch network input and output variables are

detailed in Appendixes B and C. The charts define the

purpose of each variable and the types of equipment that

provide the inputs or can receive and use the inputs.



Lesson Four Progress Check



1. What advantage does the PowerCommand Control provide to healthcare facilities that

must inspect their emergency standby power systems weekly and exercise them monthly?

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

2. In the telecommunications industry where dispersed operations require a reliable power

source, what value does the PowerCommand Network provide?

_______________________________________________________________________

_______________________________________________________________________

3. Which of the following applies to the Network Communication Module (NCM)?

a. The NCM does not require back-up power.

b. It is compatible with two of the three existing PowerCommand Network modules.

c. It provides a LONWorks network interface to the OTPC and BTPC Controls.

d. It interfaces with the PowerCommand Network by a twisted-pair transformer-coupled

transceiver.

4. The Network Communication Module operates by sending defined packets of

information called _______________ __________________ out on the network.

5. _________________ _____________________means that the Onan network variables

are formatted to the standard and that all

compliant devices can recognize and use the information.



Answers to Lesson Four Progress Check

1. The parameters monitored during monthly exercising are displayed on the

PowerCommand Control and can be monitored locally or remotely via a PC.

2. A qualified engineer at a central location can perform diagnostics and send appropriate

technicians to perform any service required, which is of value in convenience and time.

3. c and d. It provides a LONWorks network interface to the OTPC and BTPC Controls

and it interfaces with the PowerCommand Network by a twisted-pair transformer-coupled

transceiver.

4. The Network Communication Module operates by sending defined packets of

information called network variables out on the network.

5. LONMark compliance means that the Onan network variables are formatted to the

LONMark standard and that all LONMark compliant devices can recognize and use the

information.


Lesson Five: InPower Service Tool


• List the products available with the InPower Service

Tool.

• Identify the tasks that can be performed on the

PowerCommand Transfer Switch using InPower.

• Describe the requirements for a personal computer

and how it is used with the InPower software.

• Explain the information that the InPower Service Tool

can monitor.

Overview ofthe InPower

Service Tool

As described in previous lessons, the PowerCommand

Transfer Switch microprocessor technology provides a

high level of sophistication in terms of monitoring

adjustment capability and record keeping. The most

effective way to use this technology is with the InPower

Service Tool.

Features ofFeatures of

InPowerInPower

InPower will transfer information between your laptop PC

and the PowerCommand Transfer Switch in a Windows-

based environment to perform the following tasks:

• Adjustments for trims and settings

• Monitoring of parameter values

• Display of faults and online access to the Fault

Information System (FIS). Note: The FIS online help

files are not available with InPower Verson 1.09.

• Test of inputs and outputs

• Strip chart for viewing and comparing selected

parameters

• Data logging

• Reporting and printing of parameter values

• Creation of a capture file of device parameter values

5. InPower Service Tool


This lesson concentrates on the information available

specifically for transfer switches. Other generic features

of InPower such as pull down menus and strip chart

functions are covered in separate training available on

InPower hardware and software. This lesson provides a

quick reference for getting started.

How InPowerHow InPower

WorksWorks

The PC running the software is connected to the transfer

switch by an RS-232 serial communications cable. This

serial cable is connected (COM) port on the service

PC with a DB9 connector. Both generator set and

transfer switch applications use a DB9 connector.

(Generator set applications can also use the 9-pin Deutsch

connector and connect via the engine harness.)

InPower uses a hardware security lock called a dongle,

which prevents unauthorized copying of the software and

unregistered access to a controller. The dongle must be

attached to the service PC curing InPower installation. It

stores the InPower product serial number and the

registration password. The registration password is

obtained by contacting the Cummins Service and Support

group. It can be entered by during the initial InPower

installation or by reinstalling InPower.

Minimum PCMinimum PC

RequirementsRequirements

The service PC that is used for this application must meet

the following requirements:

• Microsoft Windows 95, Windows 98, or Windows

NT 4.0 operating system

• An IBM PC or compatible with a minimum of

Pentium 300

• 32 to 64 megabytes of RAM and 75 megabytes free

hard drive space recommended

• Active matrix display

• Microsoft bus mouse or compatible pointing device



• 24X CD-ROM

• One free serial communications port

(COM1- COM 4)

• Parallel port

• Windows supported A4 printer (optional)

InPowerTransfer

SwitchInformation

InPower software for the PowerCommand transfer switch

has three sections of information:

• Monitor

• Adjustments

• Faults/Events

MonitorMonitor InPower can be used to monitor many parameters of the

PowerCommand transfer switch. See Appendix D for a

chart of information and parameters that InPower

monitors.

AdjustmentsAdjustments All adjustments can be made using InPower. While most

parameters can be reached from the Alphanumeric

Display, the Windows-based format will allow

adjustments to be made more quickly. See Appendix E

for the adjustments or set-ups that are available.

Faults/EventsFaults/Events The PowerCommand Transfer Switch keeps a rolling log

of the last fifty events or faults. It also keeps historical

statistics on each type of fault. This information can be

pulled up by InPower for diagnostics and reporting. See

Appendix F for the faults and event information that can

be obtained from the transfer switch using InPower.



Lesson Five Progress Check

1. True or False. The computer running InPower software must have one serial port and

two parallel ports available in order to run the application.

2. Identify the three sections of the InPower Service Tool:

3. InPower will tell the operator total number of voltage imbalance failures seen by the

transfer switch. What else will it tell the operator about Source undervoltage failure?

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

4. Name some of the tasks performed by InPower.

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

5. True or False. InPower is never required when an alphanumeric display is included in the

transfer switch.



Answers to Lesson Five Progress Check

1. False. The computer running InPower must have one communications port and one

parallel port available.

2. The InPower Service Tool has three sections of information:

• It can monitor information about the transfer switch.

• It can be used to make adjustments.

• It provides fault information.

3. For each type of fault or event, the system will tell the operator the:

• Event code

• Current status of event

• Time last occurred

• Total occurrences

• Dialout status (yes/no)

4. The following tasks will be performed by InPower:

• Adjustments for trims and settings

• Monitoring of parameter values

• Display of faults and online access to the Fault Information System. Note: The FIS

online help files are not available with InPower Verson 1.0.

• Test of inputs and outputs

• Strip chart for viewing and comparing selected parameters

• Data logging

• Reporting and printing of parameter values

• Creation of a capture file of device parameter values

5. False. InPower is required regardless of whether an alpha numeric display is included in

the transfer switch.


Lesson Six: Transfer Switch Selection


• Identify the primary factors to consider when

selecting a transfer switch.

• Review a specification for an automatic and a bypass

transfer switch.

ImportantFactors in

the Selectionof a Transfer

Switch

The proper selection of a transfer switch is based on a

number of factors. These include the following:

• Criticality of load

• Maintenance requirements

• Ampere rating of feeder circuit breaker/AIC of circuit

breaker

• Type of load

• 3-pole or 4-pole

• Voltage/frequency/three phase or single phase

• Indoor or outdoor

• Controls sophistication—sensing, interface and

communications capabilities

Case Studies The two following situations give you an opportunity to

decide how to handle a request that comes in from a

prospective customer. Read each case, then refer to

specification sheets as needed, and write a description of

what you would recommend to the prospect. Following

these exercises, you will find feedback on what would be

appropriate recommendations.

6. Transfer Switch Selection


Exercise 1:Exercise 1:

HospitalHospital

SettingSetting

A consulting engineer is doing design work for a hospital

and he has requested your help in selecting a switch. He

provides the following information:

• The load consists of life support and monitoring

equipment for the hospital’s new burn unit.

• The hospital’s chief facility engineer is concerned

about failure modes and minimizing extended

interruptions to the load under all circumstances.

• This switch will be located in the basement and the

generator set will be on the roof.

• The system is 277/480 volts with ground fault

protection on the service and feeder breakers.

• The feeder is 800 amps and the available fault current

is 65 KA.

What would you recommend? (Record your response

here.)




WastewaterWastewater

TreatmentTreatment

PlantPlant

An engineer has asked you to help select a switch for a

wastewater treatment plant. You learn the following:

• It is a wet, dirty environment.

• The customer wants to test the system unattended.

• The system’s voltage is 277/480 with ground fault

protection.

• There is a 600A feeder with an available fault current

of 65 KA.

• The steady-state load is 75% of the capacity of the

generator set KW rating. The load is lighting and

pumping equipment. The engineer does not want to

increase the size of the generator in order to keep the

project cost down.

• This is a water authority with multiple sites that they

want to monitor. They want to use Intellution

software to monitor all sites at a central location. All

other sites currently have Onan OTIII switches and

generator sets with PowerCommand controls.

What would you recommend? (Record your response

here.)

Turn to the following page and compare your

recommendations to the ones provided.



The following recommendations would be appropriate for

the settings described in each exercise.


PotentialPotential

SolutionSolution

For the hospital setting you can propose the following:

• This is a critical care facility. A burn unit will have a

large number of monitoring devices as well as other

equipment. Inductive loads are not an issue so

programmed transition is not required. If, at a later

date, new loads are added that may require

programmed transition, it is always included as

standard and can be enabled from the front panel

digital display.

• The facility engineer is concerned about maximizing

system reliability. Points to discuss would be:

♦ The bypass isolation feature allows service and

unloaded testing of the transfer switch without

interruption to the load.

♦ In the event of an emergency or unexpected

maintenance situation, the BTPC is a non-load-

break bypass capable of being safely transferred to

either live source at any time.

♦ In the event that the transfer switch does not

operate, the engineer can easily and reliably get

power to the load using the manual bypass

capability, which can be operated without opening

the cabinet.

♦ The switch can be serviced quickly and safely

while the load is bypassed.

• Transparent Lexan shields cover all live parts,

including lugs.

• Safety shutters close to prevent inadvertent contact

with the disconnected conductors.

• Extension rails allow the ATS to be rolled out of the

cabinet for easy removal.

• Load monitoring and bar graph metering are options



that will provide power and current data and at-a-

glance visual indications that the load is within rated

parameters.

• A network could be recommended, emphasizing that

the engineer could obtain generator set status and

event data at the transfer switch without going to the

roof.

• This switch will be located in the basement so a UL

Type 1 enclosure will be acceptable.

• With a 277/480-volt system with ground fault

protection, a four-pole switch would be

recommended. The four-pole switch eliminates a

parallel path for returning ground fault current on the

neutral. This ensures that the sensing for ground fault

protection is accurate.

• The feeder is 800 amps and the available fault current

is 65 KA, so the BTPC will meet these requirements.

Emphasize that every manufacturer’s circuit breaker

listed with our BTPC is individually reviewed and

endorsed by UL. This can make the engineer’s job

easier since the trip curves have already been

researched. This cannot be said of 3 cycle ratings,

because even if a transfer switch has a 3 cycle rating,

it is up to the engineer to confirm that the two devices

(transfer switch and breaker) are compatible.


PotentialPotential

SolutionSolution

For the water treatment plant, you want to make a

recommendation such as the following:

• Since the ground fault protection is only at the

service, a 3-pole, 277/480 VAC switch should be

proposed.

• Because central monitoring is required, networking

should be discussed, including Onan’s previous

experience with a variety of third party software

including Intellution.



• Because the customer wants to test the system

unattended, you can emphasize that exercise clocks

are always standard. Also emphasize that remote

testing can be done via the network from the central

monitoring facility.

• With a steady-state load at 75% of generator set and a

number of large motor loads, the engineer will want to

break up the load and stagger them onto the generator

set to minimize the inrush. This can be done in

several ways.

♦ Several transfer switches can be used with varying

transfer or programmed transition time delays to

start individual loads sequentially.

♦ Another method would be to use the network load

sequencing option. In this case, the transfer

switch would send signals to network I/O modules

with pre-configured delays for contact closures.

These would turn the motor loads on in a

prescribed order.

♦ Other options the engineer may want to consider

are time delay relays on the motor starters or the

use of a PLC to control the motor loads.

• Again, a 600-amp feeder with an available fault

current of 65 KA is appropriate for an OTPC 600.

And you will want to emphasize once more that every

manufacturer’s circuit breaker listed with our BTPC is

individually reviewed and endorsed by UL.

For a wet, dirty environment, this setting will require a

NEMA Type 4 enclosure that is suitable for “clean in

place.” If a customer requires a NEMA 4X (corrosion-

resistant), discuss providing an open construction switch

and arrange for a custom enclosure.


Appendix A: Digital Alpha Numeric Display

ControlDisplay

Summary Information

Source-1 andSource-2Information

• Voltage L1-L2, L2-L3, L3-L1

• Source frequency

• Source connected

• On-time

Setup • Sensors and setpoints

• Time delays

• Test

• Generator set exerciserStatistics • On time Source 1

• On time Source 2

• Average transition time

• Total transfers

• Total Source 1 failure

• Total Source 2 failure

• Control battery status

• Battery charger statusNetwork • Generator status for up to 16 networked generator sets

• Load sequencer for sequencing signals for up to eight loads“About”Information

• Version

• Date of manufacture

• Serial number

• PRODUCTION CODE

• ATS mode

• LONWorks Interface Module installed

• Relay Module installed

AC LoadMonitoring(Optional)

• AC volts (line to line and line to neutral)

• Frequency

• Current (amps)

• Rest power (kW)

• Apparent power (kVA)

• Power factor

• Neutral current

Digital Alpha Numeric Display


ControlDisplay

Detailed Information

Events • Fault event definitions

• Controller checksum error

• Low controller battery

• ATS fail to close: retransfer

• ATS fail to close: transfer

• ATS fail to disconnect

• Battery charger malfunction

• Network battery low

• Network communications error

• ATS common alarm (network only)

• Non-fault event definitions

• Source-1 connected

• Source-1 available

• Source-2 connected

• Source-2 available

• Emergency start-A

• Test start-A

• Emergency start-B

• Test start-B

• Time delay start-A (TDES-A)

• Time delay start-B (TDES-B)

• Time delay normal-to-emergency(TDNE)

• Time delay emergency-to-normal(TDEN)

• Time delay engine cool-down (TDEC)

• Time delay programmed transition(TDPT)

• Transfer pending (TDEL)

• Test in progress

• Exercise in progress

• Source-1 under-voltage failure

• Source-1 over-voltage failure

• Source-1 over/under frequency failure

• Source-1 voltage imbalance failure

• Source-1 loss of phase failure

• Source-2 under-voltage failure

• Source-2 over-voltage failure

• Source-2 over/under frequency failure


• Source-2 loss of phase failure

• Phase rotation failure

• Not in auto: ATS motor disconnected

• Not in auto: load shed

• Not in auto: transfer inhibit

• Not in auto: re-transfer inhibit

• Not in auto: ATS bypassed to Source-1

• Not in auto: ATS bypassed to Source-2

• Not in auto: common output (network)

• Service tool connected

• Closed transition transfer

• Synch enable output

• Speed adjust command (network)

• System fail to synchronize

• Load sequencer outputs (1-8)

• Network wink


Appendix B: Transfer Switch Network

Input VariablesNetwork Variable Description Used By

NviTestCmd Network Remote Test (w or w/o load) is used to allow another network device

to test the transfer switch

Master Control

NviStartCmd This input is used only for dual standby operation (both Source1 and Source2

are generator sets) where the ATS is made to 'appear' as a single generatorset. When true, the PowerCommand Transfer Switch Control will start one of

the backup generator sets.

PowerCommand

Transfer SwitchControl, ATS w/

Control

Communications

Module (CCM)

NviFaultResetCmd This input will clear or acknowledge the current ATS fault(s). Master Control

NviLoadShedCmd This input is used to instruct the ATS to shed and restore its load. Master,Power-

Command Control 1

(PCC1), PCC2

NviOverrideCmd This input is used to instruct the transfer switch to override (bypass) any delays

or inhibits, but not load shed.

Master Control

NviTransInhCmd This input is used to disable the ATS from transferring to Source2. Master Control

NviRetransInhCmd This input is used to disable the ATS from transferring back to Source1. Master Control

NviRelayControl1* PowerCommand for Windows uses this input to remotely shed and restore load

from the ATS.

PowerCommand for

Windows (PCW)

NviRelayControl2* PowerCommand for Windows uses this input to remotely inhibit transfer of the ATS. PCW

NviRelayControl3* PowerCommand for Windows uses this input to remotely test the ATS. PCW

NviRelayControl4* PowerCommand for Windows uses this input to override a transfer delay or inhibit. PCW

NviATSStatus This input is used to allow the transfer switch to view the status of other transfer

switches in the system. The input is limited to monitor a maximum of 16 transfer

switches. Information that can be viewed include: device name, auto/not-in-auto,

source connected, event code and type (fault, warning, inoperable), % rated load

current, KW, NFPA annunciation, extended annunciation

PowerCommand

Control Transfer

Switch Control, ATS

w/CCM

This input is used to allow the transfer switch to view the status of other

generator sets on the network. The input is limited to monitor 16 generator

sets. Information that can be viewed includes:

NviGenStatus

• Generator set name• Generator set type (PCC 1, 2, generator set with GCM)• Control position (off, run/manual)• Generator set state (stopped, start pending, warm-up-idle, running, cool

down – rated, cool down – idle)• Fault code and type (event, warning, derate, shutdown with cool down,

shutdown)• % rated KW• NFPA annunciation• Extended annunciation

PCC 1, 2, Generator

set w/CCM

nviSrc1Status This input is used to allow the transfer switch to view the status of Source1.

The input is limited to monitor a single generator set.

PCC 1, 2 Generator

set w/CCM

nviSrc2Status This input is used to allow the transfer switch to view the status of Source2.

The input is limited to monitor a single generator set.

PCC 1, 2, Generator

set w/CCM

NviMasterStatus This input is used to allow the generator set to view the status of the Master Control. The

input is limited to monitor a single Master Control.

Master Control

NviMasterACData This input is used to allow the generator set to view the AC load data at the Master

Control. The input is limited to a single Master Control.

Master Control

* Required for PowerCommand for Windows v1.10.


Appendix C: Transfer Switch Network

Output VariablesNetwork Variable Description Used By

NvoStartTypeB This output is only used with a PowerCommand Control 2 generatorset. This output is used to configure the PowerCommand Control 2generator set for emergency or non-emergency start. It will not start orstop the generator set.

PowerCommandControl 2 (PCC2)

NvoStartCmdB This output is used to start a generator set (when it is Source1) PCC 2,GeneratorCommunicationModule (GCM),Generator setw/CCM

NvoStartTypeA This output is only used with a PowerCommand Control 2 generatorset. This output is used to configure the generator set for emergencyor non-emergency start. It will not start or stop the generator set.

PCC 2

NvoStartCmdA This output is used to start a generator set (which is Source2). PCC 2, GCM,Generator setw/CCM

NvoSpeedAdjCmd Increase Source2 freq ('passive' parallel) PCC 2

NvoSyncEnableCmd Enable Source2 synchronizing PCC 2

nvoLoadInhCmd[9] These outputs are used to allow the PowerCommand Transfer Switch Controlto sequence the loading of either source. This allows the transfer switch toapply load ‘gently’ to a source, avoiding full step loading.

ATS, Relay

NvoTransPending This output is used to inform other devices on the network that apower source transfer is pending (to either source). This output isequivalent to the 'Elevator Signal'.

Elevator

NvoATSStatus This output is used to provide the current operating status of thistransfer switch for other devices on the network (PowerCommandControl 2 generator sets, PowerCommand Transfer Switch Controlsand Master Control).

Master, PCC 2,PowerCommandTransfer SwitchControl

NvoLoadACData Load: Hz, PF, kW, kVA, kVAR, V, A Master Control,Modbus

NvoSrcACData Source1 & 2: Hz, V Master Control,Modbus

nvoNFPA110Annun This output is used to annunciate the NFPA 110 states to the newannunciator (Source 1 connected, Source 2 connected, batterycharger malfunction).

NetworkAnnunciationModule (NAM)

NvoRemoteAnnun1 This output is used to annunciate the NFPA 110 states (Source 1connected, Source 2 connected, battery charger malfunction) to theold annunciator.

NAM (old)

Transfer Switch Network Output Variables


Network Variable Description Used By

This output is used to annunciate the extended transfer switch alarms tothe annunciator:

NvoExtendedAnnun

• Source1 Available


• Source1 Connected


• Test In Progress

• Load Shed

• Transfer Inhibit

• Retransfer Inhibit

• Fail To Close

• Fail To Disconnect

• Fail To Sync

• Slow Transfer

• Low ATS Battery

• Not In Auto

• Controller Error

• ATS Alarm

NAM

This output is used to annunciate a simplified transfer switch status tothe annunciator:

nvo8PointAnnun





• Test In Progress

• Load Shed

• Not In Auto

• ATS Alarm

NAM

This output is used to annunciate a 'short' generator set status to theannunciator:

nvo4PointAnnun





NAM

nvoFaultStatus This output is used to report the fault status of the transfer switch. Thisoutput is similar to a 'Common Alarm' output of a generator set.

NAM

nvoNotInAuto This output is used to report the readiness of the transfer switch. When the statefield is true, the transfer switch's front panel switch is not in the 'Auto' position.

NAM

nvoTestActive This output is used to report the transfer switch is performing a test orexercise. 'Test' refers to a manual test of the transfer switch while'exercise' refers to scheduled test.

NAM

nvoSrc1Available This output is used to report that Source1 is available for loading and it iswithin rated voltage and frequency.

NAM

nvoSrc2Available This output is used to report that Source2 is available for loading and iswithin rated voltage and frequency.

NAM

nvoSrc1Connected This output is used to report that Source-1 is connected to the load. PCC 2, NAM

nvoSrc2Connected This output is used to report that Source-2 is connected to the load. PCC 2, NAM

This output is used to provide the current ac data of the load.NvoACData*

• freq

• total_pf

• total_kva

• total_kw

• total_kvarvolts_ab

• volts_bc

• volts_ca

• volts_avolts_b

• volts_c

• amps_a

• amps_b

• amps_c

• percent_amps_a

• percent_amps_b

• percent_amps_c

Power-Command forWindows(PCW)

* Required for PowerCommand for Windows.


Appendix D: Information Monitored by

InPower

Information ParametersAbout the Controller • Name tag

• Control package level

• Software version

• Relay module connection

• Network module connection

• Load module connection

• Load shed enable

• Alphanumeric display enable

• Meter package enable

• Network module enable

• Battery status

Model Data • ATS serial number

• ATS model number

• Build date

• Nominal current

• Nominal voltage for Source-1

• Nominal voltage for Source-2

Load Data • Voltage V1N, V2N, V3N

• Voltage V12, V23, V31

• Frequency

• Amps L1, L2, L3, neutral

• Total KVA

• Total KW

• Power factor

Source-1 Data • Position

• Voltage L12, L23, L31

• Voltage L1N, L2N, L3N

• Frequency

• Run time

Source-2 Data • Position

• Voltage L12, L23, L31

• Voltage L1N, L2N, L3N

• Frequency

• Run time

Statistics • Run time for Source-1

• Run time for Source-2

• Average transfer time

• Number of transfers

• Total Source-1 failures

• Total Source-2 failures

• Control battery status

• Battery charger status

• Controller on-time

• Peak current

• Peak power

System • Transfer switch data for each ATS on network:

• Generator set data for each generator set on network:


Appendix E: Adjustments Available with

InPowerAdjustments Parameters

Controller Mode Application Configuration:• Utility to generator• Utility to utility• Generator set to generator set• TestRefresh:• Voltage sensing constants• Frequency sensing constantsSave: Permanently saves all changed variables

Exerciser Clock Set up:• Exercise programs 1-8• Exception programs 1-8

Real Time Clock Set Clock for:• Year• Month• Date• Day of the week• Hours• MinutesEnable/disable daylight savings feature

Nominal Voltage • Nominal voltage for Source-1 (line–line voltage for level 1 control, line–neutral for level 2 control)

• Nominal voltage for Source-2 (line–line voltage for level 1 control, line–neutral for level 2 control)

Nominal Current Nominal current (in amps) for all phasesNeutral Current • Warning current level for neutral current (in amps)

• Time delay for neutral current warning (seconds)NominalFrequency

• Source-1 nominal frequency• Source-2 nominal frequency

Source-1 Sensing • Single phase, 2-phase, or3-phase sensing

• Nominal voltage• Under voltage pick up setting• Under voltage dropout setting• Under voltage dropout time

delay• Over voltage sensor enable• Over voltage pickup setting• Over voltage dropout setting• Over voltage dropout time delay• Enable frequency sensing• Frequency sensor

• Nominal frequency of Source-1• Pick-up setting• Frequency sensor dropout setting• Frequency sensor dropout time

delay• Voltage imbalance sensor enable• Voltage imbalance sensor

dropout setting• Voltage imbalance sensor

dropout time delay setting• Loss of phase sensor enable• Phase rotation enable for

Source-1 and Source-2

Adjustments Available with InPower


Adjustments ParametersSource-2 Sensing • Single phase, 2-phase, or 3-

phase sensing• Nominal voltage• Under voltage pick up setting• Under voltage dropout setting• Under voltage dropout time

delay• Over voltage sensor enable• Over voltage pickup setting• Over voltage dropout setting• Over voltage dropout time delay• Nominal frequency of Source-1• Enable frequency sensing

• Frequency sensor pickup setting• Frequency sensor dropout setting• Frequency sensor dropout time

delay• Voltage imbalance sensor enable• Voltage imbalance sensor

dropout setting• Voltage imbalance sensor

dropout time delay setting• Loss of phase sensor enable• Phase rotation enable for Source-

1 and Source-2

Time Delays • Time delay engine start - A ( for U-G systems)• Time delay transfer from normal to emergency• Time delay retransfer from emergency to normal• Time delay programmed transition• Time delay engine cool-down - A (for U-G systems)• Time delay (elevator) pre-transfer signal• Time delay engine start – B (for G-G systems)• Time delay cool down – B (for G-G systems)• Changeover timer for generator-generator mode only• Over crank timer for generator-generator mode

VoltageAdjustment

• Source-1 V12, V23, V31• Source-1 V1N, V2N, V3N

• Source-2 V12, V23, V31• Source-2 V1N, V2N, V3N

CurrentAdjustment

• Load current L1, L2, L3, N• Nominal current

Power FactorAdjustment

• Phase 1 angle• Phase 2 angle• Phase 3 angle

Preferred Source Confirm preferred sourceFeature Enable • Alphanumeric display

• Bargraph meter• Loadshed• LONMark communications


Appendix F: Faults/Events History in

InPower

Faults/Events Information AvailableFaults Log of active faults:

• Controller checksum error

• Low controller battery• ATS fail to close: retransfer• ATS fail to close: transfer• ATS fail to charge (future)

• ATS Fail to Disconnect

• Battery charger malfunction• Network battery low• Network communications error• ATS common alarm

Event History Log Rolling list of last 50 events:• Source-1 connected

• Source-1 available• Source-2 connected• Source-2 available

• Emergency start A• Test start A• Emergency start B• Test start B

• Time delay start A (TDES-A)• Time delay start B (TDES-B)• time delay normal To emergency

(TDNE)• Time delay emergency to normal

(TDEN)• Time delay engine cool down

(TDEC)• Time delay programmed transition

(TDPT)• Transfer pending (TDEL)

• Test in progress• Exercise in progress• In-phase transfer active• Source-1 under voltage failure

• Source-1 over voltage failure• Source-1 Over/under frequency

failure


• Source-1 loss of phase failure• Source-2 undervoltage failure• Source-2 overvoltage failure

• Source-2 over/under frequency failure• Source-2 voltage imbalance failure• Source-2 loss of phase failure• Phase rotation failure

• Not in auto: ATS motor disconnected• Not in auto: load shed• Not in auto: transfer inhibit• Not in auto: retransfer inhibit

• Not in auto: ATS bypassed toSource-1

• Not in auto: ATS bypassed toSource-2

• Not in auto: common output• Service tool connected• Closed transition transfer

• Synch enable output• Speed adjust command• System fail to synchronize• Load sequencer outputs (1-8)

Event Records For each type of event or fault listed above:

• Event code• Current status of event• Time last occurred• Total occurrences

• Dialout status (yes/no)

Onan Transfer Switch

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