Attachment 10 Generac ATS Manual Dome.pdf

Owner’s Manual TX Automatic Transfer Switch

Emergency Rated, Service Entrance and Non-Service Entrance 100

- 400 Amp, Single-Phase 208 (Wye and Delta) - 480 VAC (Wye and

Delta)

Register your Generac product at:

WWW.REGISTER.GENERAC.COM

1–888–9ACTIVATE

(1–888–922–8482)

SAVE THIS MANUAL FOR FUTURE REFERENCE

WARNING

CANCER AND REPRODUCTIVE HARM

www.p65warnings.ca.gov (W000393)

2 TX Automatic Transfer Switch Owner’s Manual https://www.p65warnings.ca.gov/

Table of Contents

Section 1: Safety Introduction Safety Rules Read This Manual Thoroughly

Electrical Hazards

Section 2: General Information Equipment Description Automatic Transfer Switch

Communications Generac Digital Control Platform Generators Generator Connection

Transfer Switch Labels Transfer Switch Enclosure Safe Use of Transfer Switch

Section 3: Installation Introduction to Installation Unpacking Mounting Connecting Power Source and Load Lines Transfer Mechanism

Transfer Mechanisms Transfer Mechanism Operation Main Contacts at Source 1 (Utility) Main Contacts at Neutral (Optional

TDN)

Main Contacts at Standby (Emergency) Configuring Controller for Nominal Voltage Connecting Generator 2-Wire Start Signals Connecting Controller Communication Wires Setting RS-485 Terminator Resistor Programming Synchronization Limits Voltage Limits

Auxiliary Contacts

Section 4: Operation Functional Tests and Adjustments Manual Operation Performing Manual Operation Source 1 to Source 2 Transition Source 2 to Source 1 Transition Source 1 or Source 2 to Neutral Position

Voltage Checks Electrical Operation Controller Operation Controller Power Supply Switch Position LEDs Source 1 Available LED (Utility) Source 2 Available LED (Generator/ Emergency) Source Loss Timer Test Mode: Normal Test Mode: Fast Test Turning Test Mode OFF Maintenance Mode Exercise Timer Timer Skip

Sequence of Operation Sequence 1 - Source 1 (Utility) Voltage Dropout Sequence 2 - Line Interrupt Delay Sequence 3 - Engine Minimum Run and Engine Warmup Timers Sequence 4 - Signal Before Transfer Sequence 5 - ATS Transfer to Source 2 (Genera-tor) Position Sequence 6 - Source 1 (Utility) Voltage Pickup Sequence 6a - Return to Source 1 Sequence 7 - Return to Source 1 (Utility) Timer Sequence 8 - Signal Before Transfer Sequence 9 - ATS Transfer to Source 1 (Utility) Position Sequence 10 - Engine Cooldown Timer Permissive & Loadshed Demand Response Timers 2 Wire Start (2WS) Fault Indication Phase Rotation Manual Return to Primary Closed Transitions Programming the Control

Summary of Parameters

TX Automatic Transfer Switch Owner’s Manual 3

ATS Status Icons Menu Map Transfer Switch Options Signal Before Transfer

Customer Programmable Input/Output (I/O) Parameters Outputs Inputs Customer Optional I/O Parameters

Security Security Menu Heater Logging

Section 5: Maintenance Operate Transfer Switch Clean and Inspect Transfer Switch Lubrication Main Current Carrying Contacts Battery Fault Types List of Faults

Section 6: Communications Generac Digital Control Platform Generators HTS Emulation Power Zone Gateway

Section 7: Modbus Map Description Communication Settings Modbus Settings Data Map Status (Viewable Locked) ATS Program (Viewable Maintenance) ATS Settings (Viewable Dealer) Security Exercise Settings (Viewable: Everyone Writable:

Maintenance)

Section 8: Installation Drawings 100-200 Amp ID TX Switch Non Service Entrance 2-pole

100-200 Amp ID TX Switch Non Service En-trance 3-pole 100-200 Amp ID TX Switch Non Service En-trance 4-pole 100-200 Amp ID TX Switch Service Entrance 2-pole 100-200 Amp ID TX Switch Service Entrance 3-pole 100-200 Amp ID TX Switch Service Entrance 4-pole 400 Amp ID TX Switch Non Service En-trance 2-pole 400 Amp ID TX Switch Non Service En-trance 3-pole 400 Amp ID TX Switch Non Service En-trance 4-pole 400 Amp ID TX Switch Service Entrance 2-pole 400 Amp ID TX Switch Service Entrance 3-pole 400 Amp ID TX Switch Service Entrance 4-pole Wiring Diagram - TX Control Transfer

SW

Wiring Diagram - TX Control Transfer

SW

Wiring Diagram - TX Control Transfer

SW

Wiring Diagram - TX Control Transfer

SW

Wiring Diagram - TX Control Transfer

SW

Schematic Diagram - TX Control Transfer

SW

Schematic Diagram - TX Control Transfer

SW

Schematic Diagram - TX Control Transfer

SW

Schematic Diagram - TX Control Transfer

SW

4 TX Automatic Transfer Switch Owner’s Manual

Safety

Section 1: Safety

Introduction Thank you for purchasing a Generac Power Systems Inc.

product. This unit has been designed to provide high per-formance, efficient operation, and years of use when maintained properly. This transfer switch is listed with ETL under the UL1008 standard.

Safety Rules The manufacturer cannot anticipate every possible cir-cumstance that might involve a hazard. The alerts in this manual, and on tags and decals affixed to the unit, are not all inclusive. If using a procedure, work method, or op-erating technique that the manufacturer does not specifi-cally recommend, verify that it is safe for others and does not render the equipment unsafe.

Throughout this publication, and on tags and decals af-fixed to the unit, DANGER, WARNING, CAUTION, and NOTE blocks are used to alert personnel to special in-structions about a particular operation that may be haz-ardous if performed incorrectly or carelessly. Observe them carefully. Alert definitions are as follows:

DANGER

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

(D000001)

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

(W000002)

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

(C000003)

NOTE: Notes contain additional information important to a procedure and will be found within the regular text of this manual.

These safety alerts cannot eliminate the hazards that they indicate. Common sense and strict compliance with the special instructions while performing the action or service are essential to preventing accidents.

Read This Manual Thoroughly

WARNING

Consult Manual. Read and understand man-ual completely before using product.Failure to completely understand manual and prod-uct could result in death or serious injury.

(W000100)

If any section of this manual is not understood, contact the nearest Independent Authorized Service Dealer (IASD) or Generac Customer Service at 1-888-436-3722 (1-888-GENERAC), or visit www.generac.com for start-ing, operating, and servicing procedures. The owner is re-sponsible for proper maintenance and safe use of the unit.

SAVE THESE INSTRUCTIONS for future reference. This manual contains important instructions that must be fol-lowed during placement, operation, and maintenance of the unit and its components. Always supply this manual to any individual that will use this unit, and instruct them on how to correctly start, operate, and stop the unit in case of emergency.

Electrical Hazards

DANGER

Electrocution.High voltage is present at transfer switch and terminals.Contact with live terminals will result in death or serious injury.

(D000129)

DANGER

Electrocution.Water contact with a power source, if not avoided, will result in death or serious injury.

(D000104)

DANGER

Electrocution.In the event of electrical acci-dent, immediately shut power OFF. Use non-conductive implements to free victim from live conductor. Apply first aid and get medical help.Failure to do so will result in death or serious injury.

(D000145)

TX Automatic Transfer Switch Owner’s Manual 5 https://www.generac.com/

Safety

DANGER

Electrical backfeed.Use only approved switchgear to isolate generator from the nor-mal power source.Failure to do so will result in death, serious injury, and equipment damage.

(D000237)

DANGER

Electrocution, equipment and property dam-age.Handle transfer switches carefully when installing. Never install a damaged transfer switch.Doing so could result in death or seri-ous injury, equipment and property damage.

(D000195)

DANGER

Electrocution.Turn utility supply OFF before working on utility connections of the transfer switch.Failure to do so will result in death or serious injury.

(D000123)

DANGER

Electrocution.Do not disable or modify the connection box door safety switch.Doing so will result in death or serious injury.

(D000157)

DANGER

Automatic start-up. Disconnect utility power and render unit inoperable before working on unit. Failure to do so will result in death or serious injury.

(D000191)

DANGER

Equipment Malfunction. Installing a dirty or damaged transfer switch will cause equipment malfunction and will result in death or serious injury.

(D000119)

DANGER

Electrocution.Do not wear jewelry while working on this equipment.Doing so will re-sult in death or serious injury.

(D000188)

DANGER

Electrocution.Only authorized personnel should access transfer switch interior. Trans-fer switch doors should be kept closed and locked.Failure to do so will result in death or serious injury.

(D000213)

WARNING

Electric Shock. Only a trained and licensed electrician should perform wiring and connections to unit. Failure to follow proper installation requirements could result in death, serious injury, and equipment or property damage.

(W000155)

WARNING

Hearing loss.Hearing protection is recom-mended when transferring load.Failure to wear hearing protection could result in per-manent hearing loss.

(W000766)

CAUTION

Equipment damage. Verify all conductors are tightened to the factory specified torque value. Failure to do so could result in damage to the switch base.

(C000120)

CAUTION

Equipment damage. Perform functional tests in the exact order they are presented in the manual. Failure to do so could result in equipment damage.

(C000121)

CAUTION

Equipment damage. Verify that voltage and current are within specification before energizing this equipment.

Exceeding rated voltage and current will damage the auxiliary contacts.

(C000134)

• Competent, qualified personnel should install, oper-ate, and service this equipment. Adhere strictly to local, state and national electrical and building co-des. When using this equipment, comply with regu-lations established by the National Electrical Code (NEC), CSA Standard; the Occupational Safety and Health Administration (OSHA), or the local agency for workplace health and safety.

• If working on this equipment while standing on met-al or concrete, place insulative mats over a dry wood platform. Work on this equipment only while standing on such insulative mats.

• Never work on this equipment while physically or mentally fatigued.

• Any voltage measurements should be performed with a meter that meets UL3111 safety standards, and meets or exceeds overvoltage class CAT III.

6 TX Automatic Transfer Switch Owner’s Manual

General Information

Section 2: General Information

Equipment Description

Automatic Transfer Switch The commercial transfer switch range (TX) is designed to operate independently with any standard generator utiliz-ing 2-wire start. The transfer switch is programmed locally using the integrated display and touchpad.

The TX switch controller dictates all operation of transfer switch operation, generator function, and setpoint/timing considerations. The control monitors voltages and fre-quencies against setpoints, initiates generator function, controls inphase or time delay transfers, manages gener-ator shutdown, performs exercise operations, and logs events. An integrated display is used to change setpoint values, perform desired operational changes, and moni-tor status.

A simple dry contact (Form C) is provided as a 2-Wire Start (2WS) for generator control. This allows for control of nearly any generator with a simple 2-wire system. An additional communications link is provided for RS-485 communication, allowing external query of transfer switch status and remote voltage and optional power and current monitoring.

The automatic transfer switch is used for transferring crit-ical electrical load from a normal (utility) power source to a standby (emergency) power source. Such a transfer of electrical loads occurs automatically when the normal power source has failed or is substantially reduced and the standby source voltage and frequency have reached an acceptable level. The transfer switch prevents electri-cal feedback between two different power sources (such as the normal and standby sources) and, for that reason, codes require it in all standby electric system installations.

Communications Operation of the TX transfer switch is fully functional with-out communications with a Generator or other external device. An RS-485 communications port is available for remote monitoring of the transfer switch via a Modbus client.

Generac Digital Control Platform Generators NOTE: This control is not compatible for direct communi-cation with Generac gensets.

Communications parameters within the TX switch control are by default set to:

• Modbus Server Port

• 9,600 Baud

• No parity, 1 stop bit The Network uses Modbus RTU protocol. Communica-tions should be sent at a rate of one message per second.

Modbus write capability is accessible by writing the pass-word to the security register on the map. If the control is unlocked via Modbus, values in the register are readable and writable. If not, the registers are not visible to Mod-bus. Only installer and dealer passwords are checked.

Password duration for Modbus is five minutes.

Generator Connection This switch is provided with a “2-wire start” output. The 2-wire start output is for the remote start and stop of gener-ator. The 2-wire start connection is J3, pins 8, 9, and 10, wire numbers 178 and 183.

The 2-wire start output allows the Automatic Transfer Switch (ATS) to start and stop the generator automatically.

NOTE: Some emergency applications may use 3-wire start (Normally Open and Normally Closed contacts) for continuous monitoring purposes. This feature is standard.

Transfer Switch Labels A Withstand Ratings label is permanently affixed to the transfer switch enclosure and duplicated on the front cov-

er. Use this transfer switch only with the specific limits shown on the label and on other decals and labels that may be affixed to the switch. This will prevent damage to equipment and property.

When requesting information or ordering parts for this equipment, make sure to include all information from the data label located on the subplate inside the transfer switch.

Transfer Switch Enclosure The standard switch enclosure is a National Electrical Manufacturer’s Association (NEMA) 1 type. NEMA 1 type enclosures primarily provide protection against contact with the enclosed equipment and provide a degree of pro-tection against dust, falling dirt, and dripping noncorrosive liquids. NEMA 1 type enclosures are for indoor use only.

An optional NEMA 3R type steel enclosure version is available and easily recognizable by the addition of seals around the cover and lockable enclosures over the con-troller and circuit breaker (if applicable). The NEMA 3R type enclosure provides additional protection against rain and snow. NEMA 3R type enclosures are for indoor or outdoor use.

TX Automatic Transfer Switch Owner’s Manual 7

General Information

Safe Use of Transfer Switch

WARNING

Consult Manual. Read and understand man-ual completely before using product.Failure to completely understand manual and prod-uct could result in death or serious injury.

(W000100)

Before installing, operating, or servicing this equipment, read the Safety Rulescarefully. Comply strictly with all Safety Rules to prevent accidents and/or damage to the equipment. The manufacturer recommends that a copy of the Safety Rules be posted near the transfer switch. Al-so, be sure to read all instructions and information found on tags, labels and decals affixed to the equipment.

Publications that outline the safe use of transfer switches are the following:

• NFPA 70; National Electrical Code

• NFPA 70E; Standard for Electrical Safety in the

Workplace

• UL 1008; Standard for Safety-Automatic Transfer

Switches NOTE: It is essential to use the latest version of any stan-dard to ensure correct and current information.

8 TX Automatic Transfer Switch Owner’s Manual

Installation

Section 3: Installation

Introduction to Installation Though this equipment has been wired and tested at the factory, the installer should verify all wiring connections are proper. Installing the switch includes the following procedures:

• Mounting the enclosure.

• Connecting power source and load leads.

• Connecting the generator connection.

• Programming setpoints, function options, and schedules within the TX switch controller.

• Installing and connecting any options and accessories.

• Testing functions.

Unpacking Carefully unpack transfer switch. Inspect closely for any damage. Purchaser must file damage claim with carrier for noted shipping damage.

Verify all packing material is removed from switch before installation.

Attach any lifting device to the transfer switch mounting holes or brackets. Do not lift the switch at any other point.

Mounting

DANGER

Electrocution, equipment and property dam-age.Handle transfer switches carefully when installing. Never install a damaged transfer switch.Doing so could result in death or seri-ous injury, equipment and property damage.

(D000195)

DANGER

Electrocution.Turn utility supply OFF before working on utility connections of the transfer switch.Failure to do so will result in death or serious injury.

(D000123)

DANGER

Equipment Malfunction. Installing a dirty or damaged transfer switch will cause equipment malfunction and will result in death or serious injury.

(D000119)

WARNING

Equipment damage. Only qualified service personnel may install, operate, and maintain this equipment. Fail-ure to follow proper installation requirements could result in death, serious injury, and equipment or property damage.

(W000182)

Mounting dimensions for the transfer switch enclosure are in this manual. Enclosures are typically mounted to the wall. Components are generally mounted in a stand-ard NEMA 1-type enclosure. A NEMA 3R, is also avail-able. See Transfer Switch Options.

Install the transfer switch as close as possible to the elec-trical loads that are to be connected to it.

The transfer switch is a modular design. The front enclo-sure cover is removable. The top mounting bracket can be removed for easy mounting to a wall. The controller is hinged for routing power wiring behind it. It also has quick connect electrical connections and a quick release hinge for easy removal during installation.

1. See Figure 3-1. Remove the controller (A) from the transfer switch enclosure by gently lifting the latch release on the inside of the hinge while pulling the controller away from the enclosure.

2. Remove the entire subplate assembly (B) to ease enclosure mounting.

Figure 3-1.

010631

A

B

Figure 3-1. Remove Controller and Subplate Assembly

3. See Figure 3-2. Secure the upper enclosure mounting bracket (C) to the wall and raise the en-closure over the studs (D) to secure the enclosure.

TX Automatic Transfer Switch Owner’s Manual 9

Figure 3-2.

010632

D

C

F

E

Figure 3-2. Secure Mounting Brackets

4. Stand the enclosure on a flat surface. If the surface is not flat, add shims to make the enclosure level.

Mount to a wall or support structure for vertical stability.

5. Secure the lower enclosure bracket (E) to the wall and lower the enclosure over the studs (F) to se-cure the enclosure.

6. To prevent switch distortion, level all mounting points. If necessary, use washers behind mounting holes to level the unit.

7. If any conduits are entering the enclosure, holes should be placed at this time to prevent contami-nates from entering into the electrical components.

8. Reinstall the subplate assembly.

9. The high power connections can be made at the transfer switch contactor and breaker (if equipped).

10. Reinstall the control hinge and connect the control wiring harness to the appropriate connectors. See Configuring Controller for Nominal Voltage to verify it is set for your system voltage.

Connecting Power Source and Load Lines

DANGER

Electrocution.Turn utility and emergency power supplies to OFF before connecting power source and load lines.Failure to do so will result in death or serious injury.

(D000116)

DANGER

Electrocution.Turn utility supply OFF before working on utility connections of the transfer switch.Failure to do so will result in death or serious injury.

(D000123)

Wiring diagrams and electrical schematics are provided in this manual. Power source and load connections are made at a transfer mechanism inside the switch enclosure.

Follow torque requirements listed on the transfer switch for contactor lugs. Follow torque requirements on the main circuit breaker lugs (if equipped). All Switched Neu-tral applications require the Neutral connection furthest from A phase (far right when facing switch).

Transfer Mechanism The transfer mechanism houses the main, current carry-ing contacts, along with other mechanical and electrical components, required for operating the switch. The main contacts are electrically operated and mechanically latched in place. See Figure 3-3.

Power for the operating actuators is taken from the source of supply that the Customer Load is being trans-ferred to. Therefore, transfer to any power source cannot occur unless that power source is available to the switch.

Main contacts are actuated by an over center spring link-age driven by a high speed motor. The rotating shaft as-sembly contains contacts that transfer the load between Source 1 and Source 2. These contacts ensure all phases are actuated together and maintain safe electrical clearances. When equipped with a neutral position, a me-chanical latch is used to maintain a middle position ensur-ing the load is isolated from both Source 1 and Source 2.

The use of a single set of movable contacts allows for faster operation while maintaining proper electrical clearances.

Transfer Mechanisms See Figure 3-3. The 3-pole switch shown is used with a single-phase system, when the single-phase neutral line is to be switched during transfer; or with a three-phase system, when neutral is not to be switched.

10 TX Automatic Transfer Switch Owner’s Manual

All power cables should enter the switch next to the trans-fer mechanism terminals. Standard terminal lugs on the transfer mechanism are solderless, screw type.

Connect power source and load conductors to clearly marked terminal lugs on transfer mechanism as follows:

• Load leads (C): Connect to terminals LA, LB, and

LC.

• Normal (utility) Source Leads (A): To terminals

S1A, S1B, and S1C.

• Standby (emergency) Source Leads (B): Connect to transfer mechanism terminal lugs S2A, S2B, and S2C.

NOTE: For Non Service Rated equipment, S1 and S2 may be reversed for convenience during installation.

Control settings allow for S2 to be set for Utility and S1 to be set for Emergency based on control Primary (Pre-ferred) Source setting.

Figure 3-3.

3”

010622

B

A

C

Figure 3-3. Typical 3-Pole Transfer Mechanism (200 Amp Shown)

The transfer mechanism may be either a 2-pole, 3-pole, or 4-pole type. The switch enclosure includes a neutral block for connection of the neutral line. All Switched Neu-tral applications require the Neutral connection furthest from A phase (far right when facing switch).

A cable support bracket is included and must be installed on the utility side terminals of all three cycle rated switches. Slide the utility wires through the bracket during installation and secure to cabling approximately three (3) inches away from terminal lugs using plastic ties, wire lac-ing, or other appropriate means. If more than one util-ity feed is used, please contact Generac for an additional ca-ble support.

Before connecting wiring cables to terminals, remove any surface oxides from the cable ends with wire brush. If alu-minum conductors are used, apply appropriate No Oxide joint compound. Tighten terminal lugs to the torque val-ues specified on the Transfer Switch Data Label.

Standard terminal lugs on the transfer mechanism are solderless, screw-type and are compatible with copper or aluminum cable.

IMPORTANT NOTE: 400A contactors have factory in-stalled covers on the terminals. Do not remove.

WARNING

Electric shock.Maintain correct electrical clearance between live metal parts and grounded metal according to local code re-quirements.Failure to do so could result in serious injury or equipment damage.

(W000743)

Amps Cable Support Part Number

200A A0000715179

400A A0000715180

Transfer Mechanism Operation The primary driver of the mechanism is a high speed DC motor using a proportional control system allowing con-sistent operation regardless of system voltage. This mo-tor is used to charge a spring and then force the contacts off from their resting position. The charged spring moves the contacts into the middle (OFF) position for a neutral latched mechanism (optional TDN), or to the alternate po-sition for an inphase mechanism (standard). A solenoid is used to release the mechanism from the latched (OFF) position, completing the transfer operation (optional

TDN).

All operations of the switch while energized require the TX switch controller to modulate the source power for proper operation.

TX Automatic Transfer Switch Owner’s Manual 11

Main Contacts at Source 1 (Utility) The illustration shows the load terminals connected to the Source 1 (utility) terminals. The indicator will display “S1.”

See Figure 3-4.

Figure 3-4.

010623

B

A

C

Figure 3-4. Main Contact at Source 1 (Utility)

A Source 1 Position

“ON”

B Source 2 Position

“OFF”

C Load

Main Contacts at Neutral (Optional

TDN)

Load terminals are disconnected from both power supply terminals. “0” will be displayed in the indicating window.

See Figure 3-5.

Figure 3-5.

010624

B

A

C

Figure 3-5. Main Contacts at Neutral

A Source 1 Position

“OFF”

B Source 2 Position

“OFF”

C Load

Main Contacts at Standby (Emergency) Load terminals are connected to the Source 2 (emer-gency) power supply. The indicating window will display “S2.” See Figure 3-6.

Figure 3-6.

010625

B

A

C

Figure 3-6. Main Contacts at Source 2 (Emergency)

A Source 1 Position

“OFF”

B Source 2 Position

“ON”

C Load

12 TX Automatic Transfer Switch Owner’s Manual

Configuring Controller for Nominal Voltage The transfer switch control is compatible with various volt-age sources without additional hardware, but must be properly configured to provide nominal 208-277 VAC to the power control circuit and the correct parallel/series load setting to the anti-condensation heater (if equipped).

Connectors J5/J6 on the main harness (A000041477) and J23/J24 on the heater harness (A0000405404) are used to make the appropriate connections to allow the transfer switch to be connected to the system voltages as listed in the table below. J5/J6 and J23/J24 are connected by the factory for the voltage selected during product se-lection. The harness connections must be con-figured if the product is to be installed at an alternate volt-age. To change selections:

1. See Figure 3-7. Remove the screw and interlock plate (A).

2. Move connectors J5/J6 (B) and J23/J24 (C) to their specified location.

3. Install the interlock plate and screw.

DANGER

Electrocution.High voltage is present at transfer switch and terminals.Contact with live terminals will result in death or serious injury.

(D000129)

IMPORTANT NOTE: The interlock plate MUST be in-stalled after selection to protect against potentially hazardous voltages and to ensure both heater and control power are correctly configured.

CAUTION

Equipment damage. Verify that voltage and current are within specification before energizing this equipment.

Exceeding rated voltage and current will damage the auxiliary contacts.

(C000134) Figure 3-7.

010626

C

B A

Figure 3-7. Remove and Install Interlock Plate

WARNING

Electric Shock. Only a trained and licensed electrician should perform wiring and connections to unit. Failure to follow proper installation requirements could result in death, serious injury, and equipment or property damage.

(W000155)

IMPORTANT NOTE: In applications where the Neu-tral Block is not connected to a wired Neutral, the control power supply connectors MUST be con-nected to J6/J24 (voltage is 208/240VAC) or a 480 V Delta Kit MUST be utilized. The control power supply source, when configured for 480 VAC GRD-Y (J5/J23), is from Phase A to the Neutral Block. An uncon-nected Neutral Block and J5 connection will result in hazardous voltages existing on the otherwise uncon-nected Neutral Block and may pose a shock hazard.

IMPORTANT NOTE: Only the voltages and wiring specified in the table below are acceptable for use with this transfer switch. Voltages such as 120 VAC, 480 V Corner Grounded Delta, 480 V V-Delta, 480 V Ungrounded, 600 V systems, and anything other than listed in the table below are not acceptable without additional hardware. If factory configured for 480 V Delta, additional transformers are included and wired as shown in the schematic diagram. See Schematic Diagram - TX Control Transfer SW.

Connectors System Voltages

J5/J23 480 VAC GRD-Y*

J6/J24 208/240 VAC

*See Important Notes above for all 3-wire applications

Connecting Generator 2-Wire Start Signals The customer connections are accessible through the front sliding door of the control. A connection label is lo-cated on the backside of the sliding door. Connect suit-able, approved wiring to transfer switch terminals J:18:8 (COM) and J:18:9 (2WS NO). Route these wires through suitable, approved conduit (separate from power leads) and connect to identically numbered terminals in the AC connection (lower) panel of the engine-generator set.

See Figure 3-8.

TX Automatic Transfer Switch Owner’s Manual 13

Figure 3-8.

011146

Figure 3-8. Connection Diagram - Three Phase with Neutral Shown (Typical)

NOTE: In the standard 2-wire start system, closure of Wire J3:8 and J3:9 circuit by switch circuit action must re-sult in generator engine cranking and startup.

If the control is not powered by any sources, the 2-wire start system is active (closed). This allows the genset to start in the event of all power loss to the control.

An additional normally Closed contact (J3:10) is provided for 3-wire start systems to intended to meet applications which require continuous monitoring of the 2-wire start system.

Recommended wire gauge sizes for this wiring depends on the length of the wire, as recommended in the follow-ing chart.

MaximumWire Length Recommended Wire Size

460 ft (140 m) No. 18 AWG.

461 to 730 ft (223 m) No. 16 AWG.

731 to 1,160 ft (354 m) No. 14 AWG.

1,161 to 1,850 ft (565 m) No. 12 AWG.

Connecting Controller Communication Wires Use shielded 2-wire communications cable (such as Bel-den #9460) to make the communications line connection to the TX transfer switch. This cable must be routed in a separate conduit between the TS transfer switch and the power cables. The cable must be connected as follows:

• TX transfer switch J13:1 B+, J13:2 A-, and J13:3

Ground located in the customer connection com-partment within the TX switch controller.

Setting RS-485 Terminator Resistor See Figure 3-9. The RS-485 wiring standards require a terminating resistor to be installed on the last component in a string of parallel connected devices. This resistor is located within the TX switch controller in the rear of the customer connection access area. To activate the resis-tor, remove the jumper from between J14:1 and J14:2 and install the jumper between J14:2 and J14:3.

Figure 3-9.

012071

Figure 3-9. Terminator Resistor

Programming

Synchronization Limits Synchronization requirements are:

• Generator frequency within 1Hz

• Voltage within +/- 5% of Nominal

• Phase difference within +/- 10 degrees

Voltage Limits The following criteria are used for a local determination of proper Utility.

Dropout — any phase outside 85% to 110% of nominal (not the average voltage).

Pickup — all phases 90% to 105% of nominal (programmable).

Auxiliary Contacts Two auxiliary switches are offered as standard on the TX switch. Both switches are Form C, with one switch actu-ated when in Source 1 position and the other switch actu-ated when in Source 2 position. See Figure 3-10. Both switches are wired to terminal blocks (A) located on the switch mechanism for convenient wiring.

14 TX Automatic Transfer Switch Owner’s Manual

Figure 3-10.

010629

Figure 3-10. Terminal Block Location Additionally, there are two switches used for the TX switch controller to determine position. SW1 and SW2 in- Figure 3-11 are for the TX controller. SW3 and SW4 are customer auxiliary 3 and 4 respectively.

NOTE: The SW1 and SW2 microswitches are rated spe-cifically for signal wiring with low current gold plated contacts.

Contact operation is shown in the following chart:

Switch Position

Source 1 Neutral Source 2

Customer Auxiliary 3 - Common to Normally Open

Closed Open Open

Customer Auxiliary 3 - Common to Normally Closed

Open Closed Closed

Customer Auxiliary 4 - Common to Normally Open

Open Open Closed

Customer Auxiliary 4 - Common to Normally Closed

Closed Closed Open

NOTE: SW3 and SW4 Customer Auxiliary Contacts are rated 10 amps at 125 or 250 volts AC. Do not exceed the rated voltage or current of the contacts.

Figure 3-11.

010630

SW2

SW1

SW4

SW3

Figure 3-11. 100-400 amp Switches

TX Automatic Transfer Switch Owner’s Manual 15

This page intentionally left blank.

16 TX Automatic Transfer Switch Owner’s Manual

Operation

Section 4: Operation

Functional Tests and Adjustments Following transfer switch installation and interconnection, inspect the entire installation carefully. A competent, qualified electrician should inspect it. The installation should comply strictly with all applicable codes, stand-ards, and regulations. When absolutely certain the instal-lation is proper and correct, complete a functional test of the system. Perform functional tests in the exact order presented in this manual, or damage to the switch could result.

IMPORTANT NOTE: Before proceeding with function-al tests, verify the instructions and information in this section is understood. Also read the information and instructions of labels and decals affixed to the switch. Note any options or accessories that might be installed and review their operation. Confirm that there is no debris present in and/or around the switch mechanism from the installation.

Manual Operation

DANGER

Electrocution.Do not manually transfer under load. Disconnect transfer switch from all power sources prior to manual transfer. Fail-ure to do so will result in death or serious in-jury, and equipment damage.

(D000132)

WARNING

Sudden start-up. Always set the switch control to MAIN- TENANCE MODE before working on equipment. Failure to do so could result in death or serious injury.

(W000683)

WARNING

Hearing loss.Hearing protection is recom-mended when transferring load.Failure to wear hearing protection could result in per-manent hearing loss.

(W000766)

A manual switch handle is shipped with the transfer switch. Manual operation must be checked before the transfer switch is operated electrically. To check manual operation, proceed as follows:

1. In the transfer switch enclosure, set the Mainte-nance Mode setting on the TX Switch Control to MAINTENANCE MODE. This prevents the genera-tor from starting automatically as soon as the utility power source is turned OFF. If actuating prior to ini-tial energization of control, isolate connector J3 of the customer interconnections to ensure generator start command is inhibited.

2. If so equipped, turn the generator’s AUTO/OFF/ MANUAL switch to OFF.

3. Turn OFF both normal and standby power supplies to the transfer switch, with whatever means pro-vided, such as the main line circuit breaker(s).

4. See Figure 4-1. Note position of transfer mecha-nism main contacts by observing the display win-dow (A) as follows:

• “S1” Displayed - load terminals (L1A, L1B, L1C) are connected to Upper Source 1 termi-nals (S1A, S1B, S1C).

• “S2” Displayed - load terminals (L1A, L1B, L1C) are connected to Lower Source 2 termi-nals (S2A, S2B, S2C).

• “O” (White) Displayed - load terminals (L1A, L1B, L1C) are isolated from both sources.

Figure 4-1.

010629

A

Figure 4-1. Main Contacts

5. See Figure 4-2. Insert manual operator into the lower receptacle to prepare to operate the switch manually.

Figure 4-2.

011204

Figure 4-2. Insert Manual Operator into Lower Receptacle

TX Automatic Transfer Switch Owner’s Manual 17

NOTE: Rotate handle counter-clockwise to transfer OUT of Source 1.

Figure 4-3.

011205

Figure 4-3. Rotate Manual Operator Clockwise NOTE: Rotate handle clockwise to transfer OUT of Source 2.

Figure 4-4.

010634

Figure 4-4. Insert Manual Operator into Upper Receptacle

Performing Manual Operation

Source 1 to Source 2 Transition Before proceeding, verify the position of the switch by ob-serving window in Figure 4-1. If window reads “S1,” pro-ceed with Step 1, and if it reads “White” or “S2,” proceed with Step 2.

1. 1. See Figure 4-2. With the manual operator in-serted into the lower receptacle, rotate handle counter-clockwise to transfer out of Source 1. Ap-proximately ten rotations will be necessary. Switch will exit from Source 1 and either “White” or “S2” will be displayed in the observing window. If “S2” is dis-played, transition is complete and manual han-dle may be removed. If switch is equipped with time delay option, “White” will be displayed.

2. If the observing window displays “White,” the switch is in the Neutral Off position and the neutral catch must be released to complete the desired opera-tion. To release the Neutral Off position, insert the manual operator into the upper receptacle on the mechanism as shown in . When fully engaged, use light pressure up to release the latch. The contactor will now be in either Source 1 or Source 2 position.

Repeat Step 1 if necessary.

Source 2 to Source 1 Transition Before proceeding, verify the position of the switch by ob-serving window in Figure 4-1. If window reads “S2,” pro-ceed with Step 1, and if it reads “White” or “S1,” proceed with Step 2.

1. See Figure 4-2. With the manual operator inserted into the lower receptacle, rotate handle clockwise to transfer out of Source 2. Approximately ten rota-tions will be necessary. Switch will exit from Source 2 and either “White” or “S1” will be displayed in the observing window. If “S1” is displayed, transition is complete and manual handle may be removed. If switch is equipped with time delay option, “White” will be displayed.

2. If the observing window display is “White,” the switch is in the Neutral Off position and the neutral catch must be released to complete the desired op-eration. To release the Neutral Off position, insert the manual operator into the upper receptacle on the mechanism as shown in . When fully engaged, use light pressure up to release the latch. The con-tactor will now be in either Source 1 or Source 2 po-sition. Repeat step 1 if necessary.

Source 1 or Source 2 to Neutral Position If switch is equipped with a time delay/neutral option, the switch may be mechanically placed into the neutral posi-tion. This operation is performed by completing Step 1 in the Source 1 to Source 2 Transition or Source 2 to Source 1 Transition. This position is exited by complet-ing Step 2 in the applicable section.

NOTE: The transition between sources must be com-pleted once started and it is not recommended to attempt returning to the previous source once in the neutral position.

NOTE: Remove manual operating handle after use and return it to its storage location.

Voltage Checks

DANGER

Electrocution.High voltage is present at transfer switch and terminals.Contact with live terminals will result in death or serious injury.

(D000129)

IMPORTANT NOTE: Any voltage measurements should be performed with a meter that meets UL3111 safety standards, and meets or exceeds overvoltage class CAT III.

Before performing voltage checks, verify the following:

18 TX Automatic Transfer Switch Owner’s Manual

1. Disconnect all loads from transfer switch until all voltage checks and phase rotation checks have been completed.

2. Set the Maintenance Mode setting on the TX Switch Control to MAINTENANCE MODE. If ac-tuating prior to initial energization of control, isolate connector J3 of the customer interconnections to ensure generator start command is inhibited.

3. Check the transfer switch data label for rated volt-age. Verify voltage is compatible with normal and standby power source voltages. Verify the Transfer Switch Control is properly configured for the system voltage by performing the procedure in Configur-ing Controller for Nominal Voltage and ensuring voltage selection connectors are in the specified locations.

Perform voltage checks as follows:

1. Inside the transfer switch enclosure, verify the con-trol is in MAINTENANCE MODE or connector J3 of the customer interconnections is removed.

2. If generator is so equipped, set the AUTO/OFF/ MANUAL switch to OFF.

3. Verify “1” is visible in the observation window. See Manual Operation for location of position indica-tion window.

IMPORTANT NOTE: Before proceeding, man-ually connect the load to Source 1 power sup-ply. Observation window must indicate “1.”

4. See Figure 4-5. Remove battery isolation tab (A) to energize the transfer switch controller.

Figure 4-5.

010635

A

Figure 4-5. Remove Battery Isolation Tab

NOTE: If the battery isolation tab has been re-moved and both utility and generator sources are unavailable for more than one hour, the internal battery will be depleted and power from Source 1 or Source 2 will be required to activate the control-ler and charge the battery.

5. Turn ON the normal (utility) power supply to the transfer switch, with whatever means provided (such as the main line circuit breaker).

DANGER

Electrocution.High voltage is present at transfer switch and terminals.Con-tact with live terminals will result in death or serious injury.

(D000129)

6. With utility voltage available to the transfer switch, verify the switch position LED for Source 1 on the transfer switch controller is ON. If the switch posi-tion LED is OFF, turn off the utility power supply to the transfer switch by whatever means provided (such as the main line circuit breaker), then return to Step 1 of Voltage Checks.

7. On the transfer switch controller, verify the Source 1 Available LED is ON.

8. With an accurate AC voltmeter, check the phase-to- phase (line-to-line) and phase-to-neutral (line-to- neutral) voltages present at transfer mechanism terminals S1A, S1B, S1C, and neutral. supplied voltages must be fully compatible with transfer switch rated voltage.

IMPORTANT NOTE: Verify the phase rotation of power lines and transfer switch load power lines are compatible. The control has configura-ble phase rotation settings, see Phase Rotation details.

9. Refer to the standby generator owner’s manual.

Make sure the generator engine has been properly serviced and prepared for use, as outlined in that manual. Then start the generator engine manually.

Let the engine stabilize and warm up for a few minutes.

10. Turn ON the standby (emergency) power supply to the transfer switch by whatever means provided (such as the main line circuit breaker).

11. With the generator running, check that the Source 2 Available LED on the switch enclosure door is

ON.

12. With an accurate AC voltmeter, check phase-to phase (line-to-line) and phase-to neutral (line-to neutral) voltages present at transfer mechanism terminals S2A, S2B and S2C. Also check AC fre-quency at those terminals. Generator AC output voltage and frequency must be compatible with transfer switch rated voltage and frequency.

IMPORTANT NOTE: Verify the phase rotation of Source 2 power lines and transfer switch Source 1 and load power lines are compatible.

13. If supplied voltage or frequency is incorrect, refer to standby generator Owner’s Manual. If AC fre-quency is incorrect, adjust engine governed speed.

If voltage is incorrect, adjust generator’s voltage regulator or correct the problem.

TX Automatic Transfer Switch Owner’s Manual 19

14. When supplied voltage and frequency is correct, shut down the engine manually.

IMPORTANT NOTE: Supplied voltages from both Source 1 and Source 2 power sources must be compatible with transfer switch rated voltage before proceeding.

15. Connect the transfer switch load to the transfer switch after completion of Voltage Checks. Con-nect the load to the transfer switch by whatever means provided, such as circuit breaker (s), then proceed to Electrical Operation.

Electrical Operation Test transfer system electrical operation as follows:

1. On the enclosure door, check that the Source 1 available led is ON.

2. On the enclosure door, check that the switch posi-tion Source 1 (utility) LED is ON.

IMPORTANT NOTE: The Source 1 (utility) avail-able LED and the switch position-Source 1 (util-ity) LED (on enclosure door) must both be ON before proceeding to Step 3.

3. Refer to the appropriate owner’s manual. Verify the standby generator is prepared for automatic operation.

4. Set TEST MODE on the TX switch controller to NORMAL. Generator startup and transfer to the standby power source should occur. See Se-quence of Operation.

5. Set TEST MODE on the TX switch controller to OFF to initiate the re-transfer sequence. The cus-tomer load will be transferred back to the Source 1 (utility) power source, using the preset times. The generator will shut down once the engine cool down timer has expired.

Controller Operation This section will familiarize the reader with the Human Machine Interface (HMI) and indicators on the TX Switch Control mounted in the switch, visible through the door.

See Figure 4-6.

Figure 4-6.

010636

Figure 4-6. TX Switch Controller

Controller Power Supply The normal power for operating the controller and the transfer switch contactor is provided by factory wired leads to Source 1, Source 2, and the Neutral Block or Switched Neutral Pole. Completion of the steps in Con-figuring Controller for Nominal Voltage provides the con-troller with the requisite 208-277 VAC nominal power in-puts from S1 and S2 at J1 of the controller. If the volt-age at these terminals is below 150 VAC, the controller will transition to an auxiliary power source if available. If the voltage exceeds 350 VAC, the message “Plug J5/J6 con-nector into J5” should appear, indicating an over voltage condition to the controller. Correct this condition immedi-ately by reconfiguring the controller for nominal voltage.

Extended overvoltage operation will cause dam-age to the controller, even if switching is not attempted.

Normal power source functionality is indicated by the LCD display backlight. The controller can provide power to the contactor, when the backlight is ON, to transition and provide power to the optional I/O module.

All processor functions and the inputs/outputs within the customer wiring area of controller are functional on bat-tery or auxiliary power.

Switch Position LEDs The transfer switch position is monitored by two auxiliary contacts mounted on the transfer switch mechanism.

These LEDs display the position of the main contacts.

If there is a transfer switch error (failure to close or open) the Alarm LED will illuminate. See Fault Indication.

Source 1 Available LED (Utility) This LED indicates Source 1 voltage is present and the source is within tolerances set in the TX Switch Control.

20 TX Automatic Transfer Switch Owner’s Manual

Source 2 Available LED (Generator/Emergency) This LED indicates Source 2 voltage is present and the source is within tolerances set in the TX Switch Control.

Source Loss Timer Both Test Modes are failsafe. If secondary source goes out of tolerances while Primary Source is acceptable, the Source Loss Timer will activate. Once timed-out, the con-trol will initiate transfer back to primary, observing Timer Delay Neutral (if equipped).

Test Mode: Normal Test Mode is used to simulate a power loss condition on the primary source. Setting the Test Mode setting in the TX Switch Control to Normal will command a transfer to Source 2 (standby) using all the pre-programmed timers and settings associated with a power loss with the excep-tion of Signal Before Transfer, which is active during test modes. The unit will transfer back to Source 1 (utility) after the Test Mode setting of OFF is selected and the Re-turn to Source 1 timer expires. If the secondary source fails while in Test Mode, the unit will transfer back to the primary source if available.

Test Mode: Fast Test Fast Test Mode is used to simulate a power loss condition on the primary source, but reduce the duration of the test time while maintaining critical transfer and generator timers. Setting the Test Mode setting in the TX Switch Control to Fast Test will cause a transfer to Source 2 (standby) using the same settings as Normal Test Mode, but with the following timers are reduced to five seconds:

• • Line Interrupt Delay Timer

• Return to Utility Timer

Turning Test Mode OFF Turning OFF the test mode will return the controller to the preferred source using normal sequence of operations with programmed time delays.

Maintenance Mode Setting the Maintenance mode to ON from the ATS menu screen disables all automatic operation of the transfer switch controller. The 2WS and all other outputs associ-ated with transfer logic are removed until Maintenance mode is set to OFF. At this point, the controller will reset the contactor position based upon the position feedback and resume automatic functions. Maintenance mode is to be enabled whenever a manual operation is performed and/or to prevent unintended 2WS, contactor operation, or any other automatic transfer function.

Exercise Timer The ATS control contains an integrated Exercise timer to periodically verify proper functioning of the emergency backup system. The settings for Exercise may be ac-cessed under the Exercise screen. Exercise will attempt to start (and transfer to if selected) the secondary source.

The Exercise Duration Timer starts when the secondary source is called for and completes when the Exercise Du-ration Timer expires. If successful, at the expiration of the Exercise Timer, the Exercise is logged as completed. If the secondary source fails or if the transfer is unsuccess-ful, a Fault Indication is triggered and the fault is logged.

At the conclusion of the Exercise, if applicable, the load is transferred back to the preferred source…