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English

Original Instructions 8-2018 A056K730 (Issue 4)

OwnerOwner ManualManual

Transfer Switch

RA Series

100A (Spec B)

200A (Spec B)

400A (Spec A)

Summary of content (102 pages)

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Owner Manual Transfer Switch RA Series 100A (Spec B) 200A (Spec B) 400A (Spec A) English Original Instructions 8-2018 A056K730 (Issue 4)
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Table of Contents 1. IMPORTANT SAFETY INSTRUCTIONS ....................................................................................... 1.1 Warning, Caution, and Note Styles Used in This Manual ..................................................... 1.2 General Information ................................................................................................................ 1.2.1 Safety Precautions ...................................................................................................
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Table of Contents 8-2018 5.2 Hardware Torque Specifications........................................................................................... 5.3 Switch Removal and Replacement Procedure ..................................................................... 5.3.1 Disconnect AC Power ................................................................................................ 5.3.2 Transfer Switch Assembly Removal .......................................................................... 5.3.
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1 IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS. This manual contains important instructions that should be followed during installation and maintenance of the generator set and batteries. Safe and efficient operation can be achieved only if the equipment is properly operated and maintained. Many accidents are caused by failure to follow fundamental rules and precautions. 1.
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1. IMPORTANT SAFETY INSTRUCTIONS 8-2018 DANGER This symbol warns of immediate hazards that will result in severe personal injury or death. WARNING This symbol refers to a hazard or unsafe practice that can result in severe personal injury or death. CAUTION This symbol refers to a hazard or unsafe practice that can result in personal injury or product or property damage. 1.2.
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8-2018 1.3.1 1. IMPORTANT SAFETY INSTRUCTIONS AC Supply and Isolation NOTICE Local electrical codes and regulations (for example, BS EN 12601:2010 Reciprocating internal combustion engine driven generating sets) may require the installation of a disconnect means for the generator set, either on the generator set or where the generator set conductors enter a facility. NOTICE The AC supply must have the correct over current and earth fault protection according to local electrical codes and regulations.
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2 Introduction 2.1 Owner Manual This manual covers models produced under the Cummins® brand names. This manual provides information necessary for operation, installation, and service of RA Series transfer switches. This manual also includes parts information. This is an open transition transfer switch which does not include an integral automatic transfer switch (ATS) control. With an open transition switch, there is never a time when both sources are supplying power to the load.
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2. Introduction 2.2 8-2018 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). The transfer switch switches the electrical load from one source to the other. The load is connected to the common of the ATS (Figure 5). Under normal conditions, the load is supplied with power from the utility (as illustrated).
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8-2018 2. Introduction 4. Transfers the load to the generator set 5. Senses the return of utility power 6. Sends utility available signal to generator set 7. Receives retransfer command from generator set control 8. Retransfers the load to the utility The transfer switch design is intended to signal when the utility voltage is not present and when it returns. The utility sense relay coil will energize or stay energized at voltages other than nominal.
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2. Introduction 8-2018 The nameplates for the RA Series transfer switches are located inside the cabinet in the following locations: • RA 100A/200A transfer switches: On the upper right side (see Figure 7 and Figure 8).
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2. Introduction 2.5 8-2018 Manufacturing Facilities U.S. and CANADA EMEA, CIS EMEA, CIS Cummins Inc. 1400 73rd Ave. NE Minneapolis, MN 55432 USA Cummins Inc. Columbus Avenue Manston Park Manston, Ramsgate Kent CT12 5BF United Kingdom Cummins Inc.
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8-2018 2. Introduction • Recreational Vehicles-Equipment, or • Parts and Service If it is necessary to contact a distributor regarding the transfer switch, always give the complete Model and Serial number. This information is necessary to properly identify your unit among the many types manufactured. WARNING Removing the front door will expose the operator to hazardous voltage. Ensure that both sources are de-energized and locked out prior to removing the door.
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8-2018 2. Introduction FIGURE 13. 2.6 RA 400A SERVICE ENTRANCE MODEL Installation Overview These installation recommendations apply to typical installations. Whenever possible, these recommendations also cover factory designed options or modifications. However, because of the many variables in any installation, it is not possible to provide specific recommendations for every situation. If there are any questions not answered by this manual, contact your nearest Cummins Inc. distributor for assistance.
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2. Introduction 2.6.1 8-2018 Application and Installation Installations must be carefully planned and correctly installed for proper operation. This involves two essential elements: application and installation. Application refers to the design of the complete standby power system that usually includes power distribution equipment, transfer switches, ventilation equipment, mounting pads, cooling systems, exhaust systems, and fuel systems.
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3 Installation 3.1 Installation - Mounting 3.1.1 Introduction Proper storage, installation, operation, and maintenance helps to increase the life of the transfer switch. Installation is to be done only by licensed certified electricians. WARNING AC power within the cabinet presents a shock hazard that can cause severe personal injury or death. Incorrect installation, service, or parts replacement can result in severe personal injury, death, and/or equipment damage.
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3. Installation 8-2018 There must be a service disconnect in the commercial power line ahead of the transfer switch. Typical installations of a transfer switch are shown in Figure 17 on page 25 and Figure 19 on page 27. Cabinet dimensions and weights are listed in Table 2 on page 27. 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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8-2018 3. Installation NOTICE Service entrance (SE) model transfer switches are rated service entrance equipment. The main bonding jumper is factory installed in the connected position between the Neutral assembly and Ground stud on the cabinet. By installing a transfer switch as shown in the figure below, the main bonding jumper should be removed or moved from a connected position to a disconnected position No. Description No.
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3. Installation 8-2018 No. Description No. Description 1 Utility Source 5 Generator Source 2 Circuit Breaker 6 All Loads 3 Transfer Switch 7 Main Breaker Panel 4 Circuit Breaker FIGURE 16. TOTAL COVERAGE SYSTEM (NON-SERVICE ENTRANCE MODEL) Copyright © 2018 Cummins Inc.
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8-2018 3. Installation No. Description No. Description 1 Cummins Standby Generator 3 Automatic Transfer Panel 2 Service Entrance Box 4 Main Breaker Panel FIGURE 17. A056K730 (Issue 4) TYPICAL WALL-MOUNT INSTALLATION OF NON-SERVICE ENTRANCE MODELS 25 Copyright © 2018 Cummins Inc.
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3. Installation 8-2018 No. Description No. Description 1 Utility Source 5 Generator Source 2 Circuit Breaker 6 All Loads 3 Transfer Switch 7 Main Breaker Panel 4 Circuit Breaker FIGURE 18. Copyright © 2018 Cummins Inc.
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8-2018 3. Installation No. Description 1 Cummins Standby Generator 2 Automatic Transfer Panel FIGURE 19. No. 3 Description Main Breaker Panel TYPICAL WALL-MOUNT INSTALLATION OF SERVICE ENTRANCE MODELS TABLE 2. APPROXIMATE CABINET DIMENSIONS Switch Current Rating Height Width Depth Weight 100 Amp NSE 24.0 in (619 mm) 17.0 in (433 mm) 7.1 in (181 mm) 33 lb (15 kg) 200 Amp NSE 27.1 in (688 mm) 18.2 in (463 mm) 7.1 in (181 mm) 46 lb (21 kg) 100 and 200 Amp SE 23.3 in (591 mm) 19.
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3. Installation 8-2018 No. Description 1 Ground Lugs 2 Bonding Jumper 3 FIGURE 20. 3.1.5 No. Description Extra Ground MAIN BONDING JUMPER Mounting Method RA Series transfer switches are mounted to a wall. Follow the appropriate set of mounting instructions and refer to the outline drawings in Appendix C for installation dimensions, specifications, and mounting hole patterns.
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8-2018 3. Installation WARNING Improper lifting can cause severe personal injury. Have sufficient manpower for lifting and mounting the cabinet. 7. Remove the transfer switch from the box and remove the plastic covering. WARNING Unit will not be stable when supported only by bottom bolts. Additional support is required to keep unit vertical while top bolts are installed. 8. Raise the cabinet and mount it on the two mounting bolts in the wall. Provide support for the cabinet during installation.
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3. Installation 3.2.1 8-2018 AC Connections RA Series transfer switches are supplied with screw type terminals for the Utility, Generator, Load, and Neutral power connections. Either copper or aluminum cables can be used for AC connections. Connect the Utility, Generator, Load, and Neutral conductors to the clearly marked terminals on the transfer switch. Use a wire brush to remove any surface oxides from the cables. Verify that all connections are correct before tightening the lugs.
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8-2018 3. Installation TABLE 4.
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3. Installation No. 8-2018 Description No. Description 1 TB4 3 Socket 2 Utility Sense Relay 4 Control Relay FIGURE 21. CONTROL WIRING CONNECTIONS 3.2.2.2 Connecting the Transfer Switch to the Generator WARNING AC voltages and currents present an electrical shock hazard that can cause severe personal injury or death. Disconnect the AC power source. Make sure the generator set is not running and cannot be started.
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8-2018 3. Installation The transfer switches require a combination of genset battery (B-) and (B+) for control wiring depending on whether the genset is a PC1.1 control model or an air-cooled model (C13N6H, C17N6H, C20N6H). See Interconnect Wiring Diagram for pictorial representation. 1. N/C or N/O Utility Source Available Indicators: (B-) present when Utility Source is available (TB4-2). (B-) present when Utility Source is unavailable (TB4-1). 2.
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3. Installation 8-2018 NOTICE The mechanism is shipped in the Utility side position. For service entrance transfer switches, the circuit breaker is shipped in the Off position. Copyright © 2018 Cummins Inc.
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4 Troubleshooting 4.1 Introduction This section describes troubleshooting issues, as well as the sequence of events for transfer switch operations that do not include a controller. 4.2 Troubleshooting Procedures for Experienced Service Personnel This section describes a typical transfer switch sequence of events, and provides detailed troubleshooting procedures for experienced service personnel. The troubleshooting procedures use conditional schematics and symptoms to diagnose all possible problems.
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4. Troubleshooting 4.2.2 8-2018 Generator-to-Utility Sequence of Events The following steps describe what normally happens when the transfer switch is connected to the generator, utility power returns, and the switch moves from the Generator position to the Utility position. 1. The utility returns. 2. The generator control receives a ground (B-) signal from the TB4-2 utility sense relay. 3.
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8-2018 4.2.5 4. Troubleshooting Troubleshooting for Transfer Switches For information on the generator controller indicator fault signals, refer to the generator service manual. The tables below list troubleshooting issues for RA Series transfer switches. WARNING AC power within the cabinet and the rear side of the cabinet door presents a shock hazard that can cause severe personal injury or death.
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4. Troubleshooting 8-2018 TABLE 7. TROUBLESHOOTING THE TRANSFER SWITCH (PROBLEM #1) Problem The transfer switch failed to transfer to the generator Possible Cause Corrective Action 1. The K1 relay coil may not have received a signal from the controller. 2. K1 relay may malfunction. 3. There may be a defective wire. 4. The switch mechanism solenoid may be burnt out. 5. There may be loose or broken parts within the switch mechanism. 6. The jumper may not have been installed (air-cooled models). 7.
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8-2018 4. Troubleshooting TABLE 8. TROUBLESHOOTING THE TRANSFER SWITCH (PROBLEM #2) Problem The transfer switch failed to transfer to the utility Possible Cause Corrective Action 1. The Utility source may not be present. 2. The K2 relay is faulty — used to detect if utility voltage is present. 3. The K1 relay coil may still be receiving control signal. 4. K1 relay may malfunction. 5. There may be a defective wire. 6. The switch mechanism solenoid may be burnt out. 7.
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4. Troubleshooting 8-2018 TABLE 9. TROUBLESHOOTING THE TRANSFER SWITCH (PROBLEM #3) Problem Possible Cause Corrective Action Transfer switch signal failure 1. No feedback to indicate switch position either on Utility or Generator side. 2. The ASW or BSW limit switch may be faulty. 1. Check the wiring connection and verify the signal. 2. Replace the limit switch. Copyright © 2018 Cummins Inc.
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5 Transfer Switch Service 5.1 Introduction This section covers the removal and replacement procedures for transfer switch components. NOTICE For servicing purposes, each transfer switch assembly is removed and replaced as a single component; there are no serviceable sub-components. 5.2 Hardware Torque Specifications Unless otherwise stated, use the following recommendations when torquing hardware: TABLE 10.
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5. Transfer Switch Service 8-2018 WARNING If the cabinet must be opened for any reason, disconnect AC power to the automatic transfer switch. If the instructions require otherwise, use extreme caution due to the danger of shock hazard. WARNING Ignition of explosive battery gases can cause severe personal injury. Do not smoke or cause any spark, arc, or flame while servicing batteries.
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8-2018 5. Transfer Switch Service • Loosen and remove the two screws, nuts, and washers securing the bracket at the load side (top) of the switch. • Remove the switch and bottom bracket from the cabinet. d. Mark the busbar of each phase of the Utility/Generator and Load. Then remove all of the busbars from the old switch. CAUTION Mounting the busbar in the wrong direction may increase the risk of a short to ground. Mount the busbar with the long end toward the breaker. e.
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5. Transfer Switch Service 5.3.3 8-2018 Transfer Switch Replacement CAUTION Carefully follow all hardware torque requirements to avoid damage to parts. 1. RA 100A/200A transfer switch replacement only: a. Install the busbars on the new switch in accordance with the markings. Make sure that the long end of the busbar is connected to the breaker. b. Use the hardware that was previously removed to install the new switch in the cabinet. Torque the M6 nuts to 50 in-lbs (5.6 Nm). c.
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8-2018 5. Transfer Switch Service WARNING Ignition of explosive battery gases can cause severe personal injury. Do not smoke or cause any spark, arc, or flame while servicing batteries. WARNING Batteries emit hydrogen, a highly explosive gas. Thoroughly ventilate the battery compartment before connecting battery cables. Connect the negative (-) cable (s) first to reduce the risk of arcing. 3. Reconnect utility power (Normal) and generator set power (Emergency). 4.
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5. Transfer Switch Service No. 8-2018 Description No. Description 1 Hex Head Screw 5 Ring Terminal 2 Ring Terminal 6 Hex Head Screw 3 Hex Head Screw 7 Switch Mechanism 4 Hex Head Screw 8 Cabinet FIGURE 22. INTERIOR COMPONENTS FOR RA 100A/200A NON-SERVICE ENTRANCE MODELS Copyright © 2018 Cummins Inc.
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8-2018 5. Transfer Switch Service No. Description No. Description 1 Switch Mechanism 5 Ring Terminal Detail (Shown from Bottom View) 2 M8 Bolts and Washers 6 M6 Screws and Lock Washers 3 Cabinet 7 M6 Nuts 4 M6 Bolts FIGURE 23. A056K730 (Issue 4) INTERIOR COMPONENTS FOR RA 400A NON-SERVICE ENTRANCE MODELS 47 Copyright © 2018 Cummins Inc.
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5. Transfer Switch Service No. 8-2018 Description No. Description 1 Hex Head Screws 7 Hex Head Screws 2 Busbar 8 Cabinet 3 Hex Head Screw 9 Ring Terminal 4 Busbars 10 Hex Nut 5 Hex Nut 11 Switch Mechanism 6 Circuit Breaker 12 Busbars FIGURE 24. INTERIOR COMPONENTS FOR RA 100A/200A SERVICE ENTRANCE MODELS Copyright © 2018 Cummins Inc.
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8-2018 5. Transfer Switch Service No. Description No. Description 1 Busbar, Bonding Jumper 9 Plastic Barrier 2 Busbar, Neutral 10 Breaker Mounting Bracket 3 Busbar, Ground 11 Circuit Breaker 4 Cabinet 12 3/8-16 Hardware 5 M8 Bolts 13 M6 Hardware 6 Switch Mechanism 14 M8 Bolts 7 3/8-16 Hardware 15 Ring Terminal Detail (Shown from Bottom View) 8 #10-32 Hardware 16 M6 Hardware FIGURE 25.
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5. Transfer Switch Service 5.4 8-2018 Limit Switch Replacement Procedure WARNING The transfer switch presents a shock hazard that can cause severe personal injury or death. Before beginning installation, remove all sources of AC power. If a generator provides emergency power, move the generator operation selector switch to Stop, disconnect AC line power, disconnect the battery charger from its AC power source, and disconnect the starting battery, negative (–) lead first. 1.
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8-2018 5. Transfer Switch Service c. Restore AC power to the automatic transfer switch. d. Move the operation selector switch on the generator to the Remote (or Auto) position. No. Description 1 Mounting Hardware 2 Limit Switches FIGURE 26. A056K730 (Issue 4) No. 3 Description Transfer Switch RA112N3, RA212N3, RA112S3, AND RA212S3 TRANSFER SWITCH REMOVAL 51 Copyright © 2018 Cummins Inc.
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8-2018 5. Transfer Switch Service No. Description No. 1 Transmission Shaft 2 Switch Position Indicators Red ON or Green OFF FIGURE 28. A056K730 (Issue 4) 3 Description Transfer Switch Manual Operation Handle RA112N3, RA212N3, RA112S3, AND RA212S3 MANUAL OPERATION HANDLE 53 Copyright © 2018 Cummins Inc.
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8-2018 5.5 5. Transfer Switch Service Control Relay (K1) Replacement Procedure WARNING The transfer switch presents a shock hazard that can cause severe personal injury or death. Before beginning installation, remove all sources of AC power. If a generator provides emergency power, move the generator operation selector switch to Stop, disconnect AC line power, disconnect the battery charger from its AC power source, and disconnect the starting battery (negative [-] lead first). 1.
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5. Transfer Switch Service No. 8-2018 Description 1 Relay 2 Clip 3 FIGURE 30. 5.6 No. Description Base CONTROL RELAY INSTALLATION Circuit Breaker Replacement Procedures These procedures are only for RA Series service entrance transfer switches. WARNING The transfer switch presents a shock hazard that can cause severe personal injury or death. Before beginning installation, remove all sources of AC power.
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8-2018 5. Transfer Switch Service WARNING Ignition of explosive battery gases can cause severe personal injury. Do not smoke or cause any spark, arc, or flame while servicing batteries. WARNING Accidental starting of the generator set can cause severe personal injury or death due to electrocution or contact with moving parts. Disconnect the starting battery cables, before performing service. Batteries emit hydrogen, a highly explosive gas.
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5. Transfer Switch Service 8-2018 FIGURE 31. RA 100A/200A CIRCUIT BREAKER 2. RA 400A service entrance transfer switch models only: a. Remove all sources of power from the transfer switch in the following order. i. Move the operation selector switch on the generator set to Stop (Off). CAUTION Always disconnect a battery charger from its AC source before disconnecting the battery cables. Otherwise, disconnecting the cables can result in voltage spikes high enough to damage the DC control circuits. ii.
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8-2018 5. Transfer Switch Service iv. Remove AC power to the automatic transfer switch. b. Remove the transfer switch cabinet door panel. c. Remove the following: i. The plastic barrier covering access to the mechanical lugs ii. The two M10X1.25 bolts and washers securing the mechanical lugs to the circuit breaker iii. The two 3/8-16 bolts and washers securing the busbars to the breaker iv. The four #10-32 bolts, washers, and nuts securing the breaker to the breaker mounting bracket v.
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5. Transfer Switch Service 8-2018 FIGURE 32. 5.7 RA 400A CIRCUIT BREAKER Utility Sense Relay (K2) Replacement Procedure WARNING The transfer switch presents a shock hazard that can cause severe personal injury or death. Before beginning installation, remove all sources of AC power.
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8-2018 5. Transfer Switch Service WARNING Accidental starting of the generator set can cause severe personal injury or death due to electrocution or contact with moving parts. Disconnect the starting battery cables, before performing service. Batteries emit hydrogen, a highly explosive gas. Thoroughly ventilate the battery compartment before removing battery cables. Remove the negative (-) cable (s) first to reduce the risk of arcing. c. Disconnect the generator starting battery (negative [-] lead first).
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Appendix A. Parts Information Table of Contents Figure 33. RA Series 100A/200A Non-Service Entrance Transfer Switch Model ................................... 64 Figure 34. RA Series 400A Non-Service Entrance Transfer Switch Model ............................................ 65 Figure 35. RA Series 100A/200A Service Entrance Transfer Switch Model ........................................... 66 Figure 36. RA Series 400A Service Entrance Transfer Switch Model ....................................................
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Appendix A. Parts Information 8-2018 This section includes information on replaceable parts used with RA transfer switches for both service entrance and non-service entrance models. FIGURE 33. RA SERIES 100A/200A NON-SERVICE ENTRANCE TRANSFER SWITCH MODEL Copyright © 2018 Cummins Inc.
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Appendix A. Parts Information FIGURE 37. 8-2018 RA SERIES 100A/200A NON-SERVICE ENTRANCE MODELS TABLE 12. RA SERIES 100A/200A NON-SERVICE ENTRANCE MODELS Ref No. Part No. Qty. - - 306-5191 1 100A 306-5192 1 200A 2 308-1235 2 Limit Switch 3 319-6882 1 Terminal Cover, Switch Mechanism 1 Copyright © 2018 Cummins Inc.
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8-2018 Appendix A. Ref No. Part No. Qty.
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8-2018 Appendix A. Parts Information TABLE 14. RA SERIES 400A NON-SERVICE ENTRANCE MODELS No. Part No. Qty.
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8-2018 Appendix A. Parts Information TABLE 16. RA SERIES 100A/200A SERVICE ENTRANCE MODELS Ref No. Part No. Qty.
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Appendix A. Parts Information 8-2018 TABLE 18. RA SERIES 400A SERVICE ENTRANCE MODELS Ref No. Part No. Qty.
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Appendix B. Wiring Diagrams Table of Contents Figure 41. RA112N3, RA212N3, RA112S3, and RA212S3 Transfer Switch Wiring Diagram (Sheet 1 of 2) .................................................................................................................................................................... 79 Figure 42. RA112N3, RA212N3, RA112S3, and RA212S3 Transfer Switch Wiring Diagram (Sheet 2 of 2) ..........................................................................................................
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Appendix B. Wiring Diagrams 8-2018 The drawings included in this section are representative. For current complete information, refer to the drawing package that was shipped with the unit. Copyright © 2018 Cummins Inc.
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8-2018 Appendix B. B.1 RA Series Transfer Switch Wiring Diagrams FIGURE 41. A056K730 (Issue 4) Wiring Diagrams RA112N3, RA212N3, RA112S3, AND RA212S3 TRANSFER SWITCH WIRING DIAGRAM (SHEET 1 OF 2) 79 Copyright © 2018 Cummins Inc.
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8-2018 Appendix B. B.2 RA Series Transfer Switch Interconnections FIGURE 45. A056K730 (Issue 4) Wiring Diagrams RA112N3, RA212N3, RA112S3, AND RA212S3 TRANSFER SWITCH INTERCONNECTIONS (SHEET 1 OF 3) 83 Copyright © 2018 Cummins Inc.
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Appendix C. Outline Drawings Table of Contents Figure 50. RA112S3 and RA212S3 Spec B Control Box Outline Drawing .............................................. 91 Figure 51. RA112N3 Control Box Outline Drawing ................................................................................... 92 Figure 52. RA212N3 Control Box Outline Drawing ................................................................................... 93 Figure 53. RA412N3 Control Box Outline Drawing ..................................
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Appendix C. Outline Drawings 8-2018 The drawings included in this section are representative. For current complete information, refer to the drawing package that was shipped with the unit. Copyright © 2018 Cummins Inc.
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8-2018 Appendix C. C.1 RA112S3 and RA212S3 Spec B Control Box Outline Drawing FIGURE 50. A056K730 (Issue 4) Outline Drawings RA112S3 AND RA212S3 SPEC B CONTROL BOX OUTLINE DRAWING 91 Copyright © 2018 Cummins Inc.
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power.cummins.com Copyright © 2018 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.