Product Manual B

ManualsBrandsCummins Power ManualsGenerator AccessoriesCummins OTEC Automatic Transfer Switch —600 Amps, 240 Volts, NEMA 1

English

Original Instructions 5-2019 0962-0617 (Issue 8)

InstallationInstallation ManualManual

Transfer Switch

40-1000 Amps

OTECA (Spec A)

OTECB (Spec A)

OTECC (Spec A)

OTECD (Spec A)

Summary of content (60 pages)

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Installation Manual Transfer Switch 40-1000 Amps OTECA (Spec A) OTECB (Spec A) OTECC (Spec A) OTECD (Spec A) English Original Instructions 5-2019 0962-0617 (Issue 8)
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Table of Contents 1. INTRODUCTION............................................................................................................................ 1.1 Installation Manual .................................................................................................................. 1.2 Transfer Switch Application .................................................................................................... 1.3 Transfer Switch Function .....................................................
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Safety Precautions This manual includes the following symbols to indicate potentially dangerous conditions. Read the manual carefully and know when these conditions exist. Then take the necessary steps to protect personnel and the equipment. DANGER This symbol warns of immediate hazards that will result in severe personal injury or death. WARNING This symbol refers to a hazard or unsafe practice that can result in severe personal injury or death.
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1 Introduction 1.1 Installation Manual This manual covers models produced under the Cummins®/Onan® and Cummins Inc. brand names. This manual provides information necessary for the installation of all product models and specs provided on the cover of this manual. 1.2 Transfer Switch Application Transfer switches are an essential part of a building's standby or emergency power system. The utility line (normal power), is backed up by a generator set (emergency power).
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1. Introduction No. 5-2019 Description No. Description 1 Utility (Normal Power) 4 Overcurrent Protective Device (Customer Supplied) 2 Overcurrent Protective Device (Customer Supplied) 5 Generator Set (Emergency Power) 3 Load FIGURE 1. LOAD TRANSFER SWITCH (TYPICAL FUNCTION) 1.4 Installation Overview These installation recommendations apply to typical installations. Whenever possible, these recommendations also cover factory designed options or modifications.
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5-2019 1. Introduction Application refers to the design of the complete standby power system that usually includes: • power distribution equipment • transfer switches • ventilation equipment • mounting pads • cooling systems • exhaust systems • fuel systems Each component must be correctly designed so the complete system functions as intended. Application and design is an engineering function generally done by specifying engineers or other trained specialists.
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1. Introduction 5-2019 FIGURE 2. CONTROL NAMEPLATE 1.6 How to Obtain Service When a product requires servicing, contact the nearest Cummins distributor. To locate the distributor, refer to www.cummins.com/support and select Distributor Locator. When contacting the distributor, always supply the complete model, specification, and serial number as shown on the nameplate. In the U.S.
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5-2019 1. Introduction When contacting the distributor, always supply the complete Model, Specification, and Serial Number as shown on the product nameplate. Outside the U.S. and Canada Refer to www.cummins.com/support and select Distributor Locator, or ask.powergen@cummins.com. 0962-0617 (Issue 8) 5 send an email to Copyright © 2019 Cummins Inc.
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2 Mounting 2.1 Location Requirements • Location in the existing electrical circuit varies with the application and the type of switch. • Location and wiring must comply with the contract drawings. • There must be a service disconnect in the commercial power line ahead of the transfer switch. • Choose a vibration-free mounting surface that supports the weight of the switch. • Avoid locations that are near flammable liquids or gases, or are hot, moist, or dusty.
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2. Mounting 5-2019 2. Anchors must be installed to an embedment depth, as recommended in the prequalification test report defined in Note 1. For IBC 2000 and IBC 2003 applications, the minimum embedment must be 8 times the anchor diameter. 3. Anchors must be installed in a minimum of 4000 PSI compressive strength normal weight concrete. Concrete aggregate must comply with ASTM C33.
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3 Wiring WARNING AC voltages and currents present an electrical shock hazard that can cause severe personal injury or death. Only trained and experienced personnel are to perform the following procedures. When installing conduit, observe the following precautions: 1. Before beginning conduit installation, cover the transfer switch to prevent accidental entry of metal chips. 2.
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3. Wiring No. 5-2019 Description No. Description 1 Optional Battery Charger 7 Transfer Switch Handles 2 Control Panel 8 Ground Lugs 3 Optional External Exercise Clock 9 TB2 4 TB1 10 Relay Assembly 5 Automatic Transfer Switch 11 J2 6 Power Transformer (600 Volt Units Only) 12 J1 FIGURE 3. COMPONENTS: 40, 70, 125 AMP (4-POLE) SWITCH Copyright © 2019 Cummins Inc.
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5-2019 No. 3. Wiring Description No. Description 1 J2 7 Power Transformer (600 Volt Units Only) 2 J1 8 Transfer Switch Handles 3 Control Panel 9 TB2 4 Optional External Exercise Clock 10 Ground Lugs 5 TB1 11 Optional Battery Charger 6 Automatic Transfer Switch 12 Relay Assembly FIGURE 4. COMPONENTS: 260 AMP SWITCH 0962-0617 (Issue 8) 11 Copyright © 2019 Cummins Inc.
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3. Wiring 5-2019 No. Description No. Description 1 Control Panel 8 Ground Lugs 2 Optional External Exercise Clock 9 TB2 3 TB1 10 Optional Battery Charger 4 Automatic Transfer Switch 11 J2 5 Neutral Bus Bar 12 J1 6 Transfer Switch Handles 13 Relay Assembly 7 Power Transformer (600 Volt Units Only) 14 Linear Actuator FIGURE 5. COMPONENTS: 300-600 AMP SWITCH (800-1000 AMP SIMILAR) Copyright © 2019 Cummins Inc.
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5-2019 3. Wiring 3.1 AC Connections TABLE 1.
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3. Wiring 5-2019 Set Screw Socket Size (Across Flats) Minimum Torque For Proper Operation 9/16 In 600 In-lbs (68 N•m) WARNING AC voltages and currents present an electrical shock hazard that can cause severe personal injury or death. Make sure that both AC power sources are disconnected. 6. Make sure that both AC power sources are disconnected. 7.
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5-2019 3. Wiring No. Description No. Description 1 Normal Lugs 5 Ground Lugs 2 Load Lugs 6 TB2 3 Neutral Lugs 7 TB1 4 Emergency Lugs FIGURE 7. 40-125 AMPERE, 3 POLE TRANSFER SWITCH TERMINAL ACCESS 0962-0617 (Issue 8) 15 Copyright © 2019 Cummins Inc.
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3. Wiring 5-2019 No. Description No. Description 1 Load Lugs 6 Emergency Lugs 2 Load Lug (4 Pole Only) 7 Ground Lugs 3 Neutral Lugs (3 Pole Only) 8 TB2 4 Remove Switch Cover for Lug Access 9 TB1 5 Emergency Lug (4 Pole Only) 10 Normal Lugs FIGURE 8. 300-1000 AMPERE, 3 AND 4 POLE TRANSFER SWITCH TERMINAL LUG ACCESS Copyright © 2019 Cummins Inc.
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5-2019 3. Wiring FIGURE 9. SECURE THE POWER CABLES 3.2 Control Connections Connections of standard and optional control wiring are made at terminal blocks TB1, TB2, and TB3; and directly at the (optional) auxiliary relays. TB1 is located near the top left side on the front of the transfer switch. TB2 is located below TB1, near the bottom left side of the transfer switch. TB3 and auxiliary relays are located on the DIN rail. 3.2.
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3. Wiring 5-2019 TABLE 3. WIRE SPECIFICATIONS Wire Size (AWG) Distance in Feet, One Way (Multiply by 0.3 for Meters) Column A Column B Column C Column D Column E 16 1000 90 - 50 - 14 1600 150 20 80 5 12 2400 225 30 125 10 10 4000 350 50 200 15 8 - 600 80 300 25 6 - 1000 125 500 40 Wire resistance must not exceed 0.5 ohm per line. Use stranded wire only. For connection to the screw terminal, strip the insulation back 3/8 inch (10 mm).
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5-2019 3. Wiring No. Description No. Description 1 GND 5 Remote test 2 2 6 Retransfer inhibit 3 B+ 7 Common 4 RMT 8 Transfer inhibit FIGURE 10. 3.2.3 TB2 CONNECTIONS Auxiliary Contacts Auxiliary contacts, used for external alarm or control circuitry, are available for the Source 1 (Normal) and Source 2 (Emergency) sides of the transfer switch. Connections for the auxiliary contacts can be made on terminal block TB1. The contacts have ratings of 10 amperes at 250 VAC.
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3. Wiring No. 5-2019 Description No. Description 1 Source 1 (normal) auxiliary switch 4 NC 2 Source 2 (emergency) auxiliary switch 5 COM 3 NO FIGURE 11. 3.2.4 TB1 CONNECTIONS Remote Test Input The transfer switch may be wired for a remote test input. The switch is used to start and stop manually initiated system tests. As with the control panel Test pushbutton, the remote test input can be configured to test with or without load.
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5-2019 3. Wiring No. Description No. Description 1 GND 5 Remote test 2 2 6 Transfer inhibit 3 B+ 7 Retransfer Inhibit 4 RMT 8 Common FIGURE 12. TB2 CONNECTIONS FOR REMOTE TEST TRANSFER NOTICE TB1 and TB2 will accept 22 AWG - 12 AWG wire with 3/8 inch (10 mm) strip. Torque to 9 in-lbs. 3.2.5 Transfer Inhibit Input To add transfer inhibit, connect a normally open, dry contact between terminals 6 and 8 of TB2.
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3. Wiring No. 5-2019 Description No. Description 1 GND 5 Remote Test 2 2 6 Transfer Inhibit 3 B+ 7 Load Shed (Optional) 4 RMT 8 Common FIGURE 13. TB2 CONNECTIONS FOR TRANSFER INHIBIT NOTICE TB1 and TB2 will accept 22 AWG - 12 AWG wire with 3/8 inch (10 mm) strip. Torque to 9 in-lbs. 3.2.6 Retransfer Inhibit Input To add retransfer inhibit, connect a normally open, dry contact between terminals 7 and 8 of TB2.
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5-2019 3. Wiring No. Description No. Description 1 GND 5 Remote Test 2 2 6 Transfer Inhibit 3 B+ 7 Retransfer Inhibit 4 RMT 8 Common FIGURE 14. TB2 CONNECTIONS FOR RETRANSFER INHIBIT NOTICE TB1 and TB2 will accept 22 AWG - 12 AWG wire with 3/8 inch strip (10 mm). Torque to 9 in-lbs. 3.2.7 Remote Override Input To add remote override, connect a normally open, dry contact between P4-2 on the back of the control panel and TB2-8.
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3. Wiring No. 5-2019 Description No. Description 1 GND 5 Remote Test 2 2 6 Transfer Inhibit 3 B+ 7 Retransfer Inhibit 4 RMT 8 Common FIGURE 15. CONNECTIONS FOR REMOTE OVERRIDE INPUT NOTICE TB1 and TB2 will accept 22 AWG - 12 AWG wire with 3/8 inch strip (10 mm). Torque to 9 in-lbs. 3.2.8 Auxiliary Relays and Elevator Relay Options Connections to the auxiliary and elevator relays are made directly to the relay terminals.
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5-2019 3. Wiring No. Description 1 Auxiliary relays 2 TB3 FIGURE 16. AUXILIARY RELAYS AND TB3 NOTICE TB1 and TB2 will accept 22 AWG - 12 AWG wire with 3/8 inch strip (10 mm). Torque to 9 in-lbs. TABLE 4.
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3. Wiring 5-2019 FIGURE 17. 3.2.9 RELAY TERMINALS Battery Charger Options When so equipped, a battery charger can be used for charging genset starting and control batteries. These chargers are current limiting and supply automatic constant voltages. When the battery approaches the full charge preset voltage, the charging current automatically tapers to zero amperes or to a steady-state load on the battery.
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5-2019 3. Wiring No. Description 1 2-Amp Charger 2 15-Amp (12 Volt), 12-Amp (24 Volt) Charger FIGURE 18. CURRENT BATTERY CHARGERS 3.2.9.1 2-Amp Battery Charger The 2-ampere battery charger {see Figure 19) has a 5 amp DC output circuit breaker switch on the front of the battery charger. The charger also includes a 5 amp AC fuse to protect the battery charger circuit. Under normal operating conditions, the Low Bat and AC Fail relays are energized and the High Bat relay is de-energized.
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3. Wiring 5-2019 FIGURE 19. No. 2-AMP POWERCOMMAND BATTERY CHARGER Description 1 Reset Button 2 Digital Display No. 3 FIGURE 20. Description LED Status Indicator 2-AMP CHARGER CONTROL PANEL Battery Charger Configuration - The RESET button on the control panel (see Figure 20 is used to configure the battery charger for the correct battery voltage. (More information on Setup menus is included in the Battery Charger Operator's Manual.) 3.2.9.
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5-2019 3. Wiring • The Reset button is used to select menu options and to clear fault messages. • The status LED is displays the appropriate color for the following conditions. ◦ Green - On solid indicates unit is charging ◦ Amber - On solid indicates Equalizing ◦ Red - On solid indicates a fault condition. The fault number is shown on the digital display. Optional Battery Temperature Sensor - A connector for an optional battery temperature sensor is located on the front of the battery charger.
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3. Wiring 5-2019 No. Description No. Description A 120, 208, and 240 VAC Battery Chargers 4 Fault Alarm Output Connector B 277, 380, 416, 480, and 600 VAC Battery Chargers 5 20 Amp DC Output Circuit Breaker Switch (Shown in "ON" Position) 1 Control Panel 6 Fuse Holders 2 Status LED 7 Optional Battery Temperature Sensor Connector 3 Circuit Breaker Guard FIGURE 22. 15/12-AMP POWERCOMMAND BATTERY CHARGERS 3.2.
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5-2019 3. Wiring The contacts are rated for 4 amperes at 120 VAC or 30 VDC. Connections to these contacts are made at terminals 41-42-43 (AC failure), 44-45-46 (high battery voltage), and 47-48-49 (low battery voltage) of TB3 (Figure 23). See Section 3.2 for the location of TB3 on the option panel. Use number 22 to number 12 AWG wire. For connection to the screw terminal, strip the insulation back 3/8 inch (10 mm). FIGURE 23. 3.
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Appendix A. Interconnect Diagrams and Outline Drawings Table of Contents Figure 24. 40-1200 Amp Typical Interconnection Diagram 630-2810 (Sheet 1 of 10) ............................ 35 Figure 25. 40-1200 Amp Typical Interconnection Diagram 630-2810 (Sheet 2 of 10) ............................ 36 Figure 26. 40-1200 Amp Typical Interconnection Diagram 630-2810 (Sheet 3 of 10) ............................ 37 Figure 27. 40-1200 Amp Typical Interconnection Diagram 630-2810 (Sheet 4 of 10) .......................
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5-2019 Appendix A. FIGURE 24. 0962-0617 (Issue 8) Interconnect Diagrams and Outline Drawings 40-1200 AMP TYPICAL INTERCONNECTION DIAGRAM 630-2810 (SHEET 1 OF 10) 35 Copyright © 2019 Cummins Inc.
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5-2019 Appendix A. FIGURE 26. 0962-0617 (Issue 8) Interconnect Diagrams and Outline Drawings 40-1200 AMP TYPICAL INTERCONNECTION DIAGRAM 630-2810 (SHEET 3 OF 10) 37 Copyright © 2019 Cummins Inc.
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5-2019 Appendix A. FIGURE 28. 0962-0617 (Issue 8) Interconnect Diagrams and Outline Drawings 40-1200 AMP TYPICAL INTERCONNECTION DIAGRAM 630-2810 (SHEET 5 OF 10) 39 Copyright © 2019 Cummins Inc.
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5-2019 Appendix A. FIGURE 30. 0962-0617 (Issue 8) Interconnect Diagrams and Outline Drawings 40-1200 AMP TYPICAL INTERCONNECTION DIAGRAM 630-2810 (SHEET 7 OF 10) 41 Copyright © 2019 Cummins Inc.
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5-2019 Appendix A. FIGURE 32. 0962-0617 (Issue 8) Interconnect Diagrams and Outline Drawings 40-1200 AMP TYPICAL INTERCONNECTION DIAGRAM 630-2810 (SHEET 9 OF 10) 43 Copyright © 2019 Cummins Inc.
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power.cummins.com Copyright © 2019 Cummins Inc. All rights reserved. Cummins, the "C" logo, PowerCommand, AmpSentry, and InPower are trademarks of Cummins Inc. Other company, product, or service names may be trademarks or service marks of others. Specifications are subject to change without notice.