Service Manual for Transfer Switches 150-1000 Amperes

Service Manual
Transfer Switch
BTPCB (Spec A)
BTPCC (Spec A−B)
BTPCD (Spec A)
150−1000 Amperes
English 10−2009 962−0518 (Issue 6)

i
Table of Contents
SECTION TITLE PAGE
SAFETY PRECAUTIONS ix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. INTRODUCTION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About This Manual 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Switch Application 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bypass Switch Function 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drawout Isolation Mechanism 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Utility-to-Genset Operation 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Utility-to-Utility Operation 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and Replacing Electronic Control Components 1-2. . . . . . . . . . . . . . . . . .
Model Identification 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to Obtain Service 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. DESCRIPTION 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cabinet 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Panel 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bar Graph Meter Panel 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Ammeter (A−) 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Meter (kW) 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Factor Meter (PF) 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frequency Meter (Hz) 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Voltmeter (V−) 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch Panel 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Indicator Lamps 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Source 1 Available and Source 2 Available 2-2. . . . . . . . . . . . . . . . . . . . . . . . . .
Source 1 Connected 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Source 2 Connected 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Not in Auto 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test/Exercise Active 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Membrane Pushbuttons 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Override 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reset/Lamp Test 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Digital Display 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Security Key Switch Option 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bypass Switch 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contact Assemblies 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary Contacts 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bypass Switch Controls 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Indicators 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bypass Handle and Select Switch 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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SECTION TITLE PAGE
Drawout-Isolation Mechanism 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drawout Cranking Handle 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Transfer Switch 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contact Assemblies 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Linear Actuator 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary Switches 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Disconnect 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Control System 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Control Circuit Modules 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Digital Module 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Module 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Single Linear Motor (Open Transition): 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dual Linear Motor (Closed Transition): 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Two-Wire Starting 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Control Options 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relay Module Option 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Load Monitoring 2-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Test Transfer 2-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary Relays 2-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Charger Options 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Original Float Battery Chargers 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Current Float Battery Chargers 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-Amp Battery Charger 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15/12-Amp Battery Charger 2-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Load Shed 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PowerCommand Network Interface 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. OPERATION 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional Programs 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transition Modes 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Open Transition with Sync Check 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programmed Transition 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Closed Transition 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Time Delays 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Time Delay Engine Start (TDESa) 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Time Delay Engine Cooldown (TDECa) 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Time Delay Normal to Emergency (TDNE) 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Time Delay Emergency to Normal (TDEN) 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programmed Transition Time Delay (TDPT) 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Elevator Time Delay (TDEL) 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Average Transfer Time(s) 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Sensors 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Undervoltage Sensors 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overvoltage Sensors 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frequency Sensors 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage Imbalance Sensor 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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SECTION TITLE PAGE
Phase Rotation Sensor 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loss of Single Phase Sensor 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sync Check Sensor 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Active Sync Feature 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speed Adjust 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Tests, Exercises, and Exercise Exceptions 3-10. . . . . . . . . . . . . . . . . . . . . .
Testing With or Without Load 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Set Start Test Without Load 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Set Start Test With Load 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Real-Time Clock 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sleep Mode 3-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programmable Generator Set Exercises 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Exercise(s) − For Software Versions Prior to 1.5.190 3-12. . . . . . . . . . .
Setting Exercise(s) − Starting with Software Version 1.5.190 3-14. . . . . . . . . . .
Setting Exercise Exception(s) − Starting with Software Version 1.5.190 3-15.
Setting Exercise(s) − Starting with Software Version 1.13.244 3-16. . . . . . . . . .
Setting Exercise Exception(s) − Starting with Software Version 1.13.244 3-17
Events 3-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Operation 3-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bypassing the Transfer Switch 3-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bypassing Load to Normal (Source 1) 3-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bypassing Load to Emergency (Source 2) 3-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Isolating the Transfer Switch 3-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reconnecting the Transfer Switch 3-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Load is Bypassed to the Normal Source 3-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Testing 3-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Set Start Test 3-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
With Load Standby Test 3-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Non-Load Break Transfer Switch Test 3-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Switch Maintenance 3-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power System Functional Tests 3-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weekly Inspection 3-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Monthly Testing 3-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Annual Maintenance and Testing 3-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean and Inspect the Switch 3-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Annual Testing 3-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermography 3-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. DIGITAL DISPLAY MENU SYSTEM 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Menus 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup Menus 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Navigation 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Menu Navigation 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using the Previous Menu Button 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Menu Descriptions 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Source 1 and Source 2 Submenus 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Load Submenus 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Statistics Submenus 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prior to Software Version 1.12 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting with Software Version 1.12 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Events Submenus 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup Submenus 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup Menu Navigation and Description 4-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Setup Parameters 4-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Software Versions Prior to Version 1.12 4-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor 1 & Sensor 2 Submenus 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sync Check Submenus 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Time Delay Submenus 4-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Submenus 4-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exerciser Submenus 4-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Software Versions Prior to 1.5.190 4-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting with Software Version 1.5.190 4-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercise Exceptions Submenus 4-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting with Software Version 1.5.190 4-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting with Software Version 1.13.244 4-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mode Submenu 4-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prior to Software Version 1.20.250 4-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clock Submenus 4-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sequencer Submenus 4-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About Submenus 4-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prior to Software Version 1.20.250 4-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Submenus 4-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Active TD Submenus 4-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prior to Software Version 1.12 4-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. EVENTS 5-1.
Introduction 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Event History 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Events 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ATS Common Alarm 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Charger Fault 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

v
SECTION TITLE PAGE
Common Alarm A 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Common Alarm B 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Battery Low 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emergency Start A 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercise Active 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fail to Sync 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fail to Disconnect 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fail to Retransfer 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fail to Transfer 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Neutral Amps 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Load Shed 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Disconnect 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Network Battery Low 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Network Error 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Network Wink 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Not in Auto 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel Lock Switch 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Phase Rotation Fail 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Retransfer Inhibit 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S1 Failed to Close 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S1 Failed to Open 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S1 Frequency Fail 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S1 Imbalance Fail 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S1 Loss Phase 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S1 Over Voltage 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S1 Under Voltage 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S2 Failed to Close 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S2 Failed to Open 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S2 Frequency Fail 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S2 Imbalance Fail 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S2 Loss Phase 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S2 Over Voltage 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S2 Stopped 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S2 Under Voltage 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sequencer Output 1
thru
Sequencer Output 8 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Tool 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Source-1 Available 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Source-1 Connected 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Source-2 Available 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Source-2 Connected 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speed Adjust 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sync Check Active 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sync Enable 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TDECa (Time Delay Engine Cool-Down (A)) 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
TDEL (Transfer Pending) 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TDEN (Time Delay Source 2 (E) to Source 1 (N)) 5-6. . . . . . . . . . . . . . . . . . . . . . .

vi
SECTION TITLE PAGE
TDESa (Time Delay Engine
Start A) 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TDNE (Time Delay Source 1 (N) to Source 2 (E)) 5-6. . . . . . . . . . . . . . . . . . . . . . .
TDPT (Time Delay Programmed Transition) 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test In Progress 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Start A 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Inhibit 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. TROUBLESHOOTING 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
InPower Service Tool 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About Network Applications and Customer Inputs 6-1. . . . . . . . . . . . . . . . . . . . . . . . .
Digital Module 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Module 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control LED Indicators and Switch 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LED Indicators 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exerciser Enable/Disable Switch 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sequence of Events 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer from Source 1 to Source 2 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer from Source 2 to Source 1 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Using Fault Codes 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Events 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Flash-Out 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Event Definitions 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controller Checksum Error 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Controller Battery 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ATS Fail to Close: Transfer 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ATS Fail to Close: Re-Transfer 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Charger Malfunction 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Network Battery Low 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Network Communications Error 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting with Symptoms 6-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Warnings 6-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. AUTOMATIC TRANSFER SWITCH SERVICE 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Membrane Switch Test 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Module Test 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Digital Board Replacement 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial Calibration 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup with a Capture File 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup Without a Capture File 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
After the Setup is Completed 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Automatic Transfer Switch 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bypass and Isolate the Transfer Switch 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remove the Transfer Switch 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Automatic Transfer Switch (When Finished) 7-7. . . . . . . . . . . . . . . .
Reconnecting the Transfer Switch 7-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

vii
SECTION TITLE PAGE
Linear Actuator Removal and Replacement (150-225-260 Amperes) 7-8. . . . . . . . .
Removing Actuator 7-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Actuator 7-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Block and Cross-Bar Assembly Removal and Replacement (150-225-260 Amperes)
7-11
Removing the Block and Cross-Bar Assembly (Normal or Emergency) 7-11. . . . .
Replacing Block and Cross-Bar Assembly (Normal or Emergency) 7-14. . . . . . . .
Auxiliary Switch Removal and Replacement (150-225-260 Amperes) 7-15. . . . . . . .
Removing Auxiliary Switch Assembly 7-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Auxiliary Switch Assembly 7-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Linear Actuator Removal and Replacement (300-400 Amperes Spec A and 300−600
Amperes Spec B) 7-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Block and Cross-Bar Assembly Removal and Replacement (300-400 Amperes Spec
A and 300-600 Amperes Spec B) 7-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary Switch Removal and Replacement (300−400 Amperes Spec A and
300−600 Amperes Spec B) 7-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Linear Actuator Removal and Replacement (600-800-1000 Amperes Spec A) 7-24.
Block and Cross-Bar Assembly Removal and Replacement (600-800-1000 Amperes
Spec A) 7-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary Switch Removal and Replacement (600-800-1000 Amperes Spec A) 7-31
Mis-Wired Current Transformers 7-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8. BYPASS SWITCH SERVICE 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bypass, Isolation, and Removal Procedure 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remove the Transfer Switch 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disconnect AC Power 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reconnect AC Power and Install and Reconnect the Automatic Transfer Switch . . . .
8-1
Installing the Automatic Transfer Switch (When Finished) 8-2. . . . . . . . . . . . . . . .
Reconnecting the Transfer Switch 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Block and Cross-Bar Assembly Removal and Replacement (150-225-260 Amperes)
8-2
Auxiliary Switch Removal and Replacement (150-225-260 Amperes) 8-8. . . . . . . .

viii
SECTION TITLE PAGE
Block and Cross-Bar Assembly Removal and Replacement (300-400 Amperes Spec
A and 300-600 Amperes Spec B) 8-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Block and Cross-bar Assembly (Normal or Emergency) 8-10. . . . .
Replacing the Block and Cross-bar Assembly (Normal or Emergency) 8-14. . . . .
Auxiliary Switch Removal and Replacement (300-400 Amperes Spec A and 300-600
Amperes Spec B) 8-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Block and Cross-Bar Assembly Removal and Replacement (600-800-1000 Amperes
Spec A) 8-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Block and Cross-bar Assembly (Normal or Emergency) 8-17. . . . .
Replacing the Block and Cross-bar Assembly (Normal or Emergency) 8-22. . . . .
Auxiliary Switch Removal and Replacement (600-800-1000 Amperes Spec A) 8-23
9. PROTECTIVE RELAY 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.SCHEMATICS 10-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Schematic PAG
E 10-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER MODULE (PIN-OUTS) 10-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER MODULE AC POWER CONNECTIONS (PIN-OUTS) 10-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIGITAL MODULE (PIN-OUTS) 10-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Interconnection Diagram
(Sheet 1 of 10) 10-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Interconnection Diagram (Sheet 2 of 10) 10-10. . . . . . . . . . . . . . . . . . . . . . . .
(Sheet 3 of 10) 10-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Sheet 5 of 10) 10-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Sheet 7 of 10) 10-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Sheet 9 of 10) 10-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Interconnection Diagram (Sheet 10 of 10) 10-18. . . . . . . . . . . . . . . . . . . . . . .
Typical Wiring Diagram (Sheet 1 of 5) 10-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
125−1000 Amp Dual Linear Motor Typical Wiring Diagram (Sheet 1 of 5) 10-24. .

ix
SECTION TITLE PAGE
Power Module 2 Assembly 10-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Interconnect Diagram − Genset to Genset, Plant to Plant 10-30. . . . . . . . .
Typical Interconnect Diagram − Genset to Genset, Dual Stand-By System 10-31.
M045 − Protective RElay 10-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M045 PROTECTIVE RELAY 10-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M046/M047 − Protective RELAY 10-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M046/M047 PROTECTIVE RELAY 10-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M046/M047 − Protective RELAY 10-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M046/M047 PROTECTIVE RELAY 10-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

x
Safety Precautions
This manual includes the following symbols to indi-
cate potentially dangerous conditions. Read the
manual carefully and know when these conditions
exist. Then take the necessary steps to protect per-
sonnel and the equipment.
DANGER This symbol warns of immediate
hazards that will result in severe personal inju-
ry or death.
WARNING This symbol refers to a hazard or
unsafe practice that can result in severe per-
sonal injury or death.
CAUTION This symbol refers to a hazard or
unsafe practice that can result in personal inju-
ry or product or property damage.
ELECTRICAL SHOCK CAN CAUSE
SEVERE PERSONAL INJURY OR DEATH
High voltage in transfer switch components pres-
ents serious shock hazards that can result in se-
vere personal injury or death. Read and follow
these suggestions.
Keep the transfer switch cabinet closed and
locked. Make sure only authorized personnel have
the cabinet and operational keys.
Due to the serious shock hazard from high voltages
within the cabinet, all service and adjustments to
the transfer switch must be performed only by an
electrician or authorized service representative.
Whenever the bypass switch is in the Emergency
position, an auxiliary switch closes a set of normally
open contacts to provide a constant generator set
start/run signal. The transfer switch, the emer-
gency bus, and the load bus are energized by
the output of the generator set and present a
serious shock hazard whenever the bypass
switch is in the Emergency position.
UTILITY-TO-GENSET OR GENSET-TO-
GENSET APPLICATIONS
If the cabinet must be opened for any reason:
1. Move the operation selector switch on the gen-
erator set to Stop.
2. Disconnect the battery charger.
3. Disconnect the starting batteries of the gener-
ator set or sets (remove the ground [−] lead
first).
4. Remove AC power to the automatic transfer
switch. If the instructions require otherwise,
use extreme caution due to the danger of
shock hazard.
UTILITY-TO-UTILITY APPLICATIONS
If the cabinet must be opened for any reason, re-
move AC power to the automatic transfer switch. If
the instructions require otherwise, use extreme
caution due to the danger of shock hazard.
GENERAL PRECAUTIONS
Place rubber insulative mats on dry wood platforms
over metal or concrete floors when working on any
electrical equipment. Do not wear damp clothing
(particularly wet shoes) or allow skin surfaces to be
damp when handling any electrical equipment.
Jewelry is a good conductor of electricity and
should be removed when working on the electrical
equipment.
Wear safety glasses whenever servicing the trans-
fer switch and and do not smoke near the batteries.
Do not work on this equipment when mentally or
physically fatigued, or after consuming alcohol or
any drug that makes the operation of equipment
unsafe.
WARNING
INCORRECT SERVICE OR REPLACEMENT OF PARTS CAN RESULT IN DEATH, SEVERE
PERSONAL INJURY, AND/OR EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST BE
TRAINED AND EXPERIENCED TO PERFORM ELECTRICAL AND/OR MECHANICAL SER-
VICE.
BTPC-2

xi
This Page Intentionally Left Blank

1-1
1. Introduction
ABOUT THIS MANUAL
This manual contains service procedures for By-
pass Transfer Switch PowerCommandR (BTPC)
automatic transfer switches (ATS) rated at
150−1000 amperes and 300−600 amperes. This
manual provides information on the following
transfer switch models.
BTPC transfer switches are open transition trans-
fer switches. With an open transition switch there
is never a time when both sources are supplying
power to the load. BTPC transfer switches are ca-
pable of executing Open Transition with Sync
Check, Programmed Transition, and Closed Tran-
sition transfer modes.
An Open Transition with Sync Check Transfer
Mode executes an open transition when both
sources of power are within specified tolerances of
frequency, voltage, and relative phase difference.
If both sources meet the tolerances, a fast transfer
occurs.
A Programmed Transition Transfer Mode exe-
cutes an open transition by disconnecting the load
from the source of power, pausing in the neutral
position of the transfer switch (between switched
positions) to allow transient currents from the load
to diminish, and then the load is switched to the
other source.
A Closed Transition Transfer Mode executes a
load transfer by momentarily paralleling both
sources (a maximum of 100ms) before switching
sources.
Refer to the schematic and wiring diagram pack-
age that was shipped with the ATS for specific in-
formation about its configuration.
Use normal and necessary safety precautions be-
fore starting any service procedure. Identify all
hazards by referring to the Safety Precautions and
observe all warnings and cautions within the
manual. Whenever you are troubleshooting, re-
member that the generator set, ATS, and utility
power source are all interdependent.
TRANSFER SWITCH APPLICATION
The BTPC transfer switch combines an automatic
transfer switch, a manual bypass switch and a
drawout isolation mechanism in one unit.
Transfer switches are an essential part of a build-
ing’s standby or emergency power system. Power
Source 1 (Normal), commonly the utility line, is
backed up by Power Source 2 (Emergency), often
a generator set. The transfer switch automatically
switches the electrical load from one source to the
other.
The load is connected to the common of the ATS
(Figure 1-1). Under normal conditions, the load is
supplied with power from Source 1 (illustrated as
Normal). If Source 1 is interrupted, the load is
transferred to Source 2 (Emergency). When
Source 1 returns, the load is retransferred to
Source 1. The transfer and retransfer of the load
are the two most basic functions of the ATS.
SOURCE 1
(NORMAL)
SOURCE 2
(EMERGENCY)
LOAD
ISOLATING
CONTACTS
AUTOMATIC
TRANSFER
SWITCH
ES1968
BYPASS
TRANSFER
SWITCH
FIGURE 1-1. BTPC TRANSFER SWITCH (TYPICAL
FUNCTION)
Automatic transfer switches, capable of automatic
operation without operator intervention, perform
the basic function of transferring the load to the
available source. The controller monitors each
source for allowable voltage and frequency range.
PowerCommand is a registered trademark of Onan Corporation.
Onan and Cummins are registered trademarks of Cummins Inc.

1-2
Bypass Switch Function
The bypass switch allows the operator to manually
connect the load to the available power source, by-
passing the automatic transfer switch (Figure 1-1).
When bypassed, the automatic transfer switch can
be isolated for service or removal without causing
a power interruption.
Drawout Isolation Mechanism
The drawout isolation mechanism allows the auto-
matic transfer switch to be withdrawn for testing or
service. The transfer switch is mounted on rails
and is connected to the load, power sources, and
controls through isolation contacts. Turning a
drawout cranking handle moves the automatic
transfer switch along the rails and engages and
disengages the isolation contacts to permit testing
or service. If necessary, the switch can be lifted
from its rails and removed for service.
UTILITY-TO-GENSET OPERATION
In utility-to-genset applications, the transfer switch
performs the following functions:
1. Senses the interruption of the Source 1 pow-
er.
2. Sends a start signal to the generator set
(Source 2).
3. Waits for the voltage to stabilize and then
transfers the load to the Source 2.
4. Senses the return of Source1.
5. Retransfers the load to Source 1.
6. Sends a stop signal to the generator set.
UTILITY-TO-UTILITY OPERATION
In utility-to-utility applications, the transfer switch
performs the following functions:
1. Senses the interruption of the Source 1 pow-
er.
2. Transfers the load to the Source 2.
3. Senses the return of Source 1.
4. Retransfers the load to Source 1.
The controller can control a two-utility configura-
tion for prime power. One utility is designated the
preferred source. The control automatically trans-
fers the load between the two utilities and detects
alarm conditions. The exercise routine is not avail-
able in this configuration.
The operator can select either source as the pre-
ferred source (see Figure 1-2). The Preferred
Source menu is included in the Test submenus
(see Figure 4-17). The PC service tool can also be
used to designate either source as the preferred
source.
Y Preferred Source
Source 1/Source 2 "
FIGURE 1-2. PREFERRED SOURCE SUBMENU
REMOVING AND REPLACING
ELECTRONIC CONTROL COMPONENTS
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. Disconnect connector J10/P10
before working on the electronic control sys-
tem.
Disconnecting J10/P10 removes all power to the
door.
Be sure to remove all power before replacing elec-
tronic control modules and components. This in-
cludes removing one of the lithium batteries from
the Digital Module. Reinstall the lithium battery af-
ter performing service parts replacement.
No special tools are required to remove and re-
place control system components. Be sure to use
all of the hardware when remounting components.
Refer to “Power Module Test” on page 6-2 for spe-
cial instructions when replacing the power mod-
ules. If possible, use the InPowert service tool to
create a capture file of the calibration and adjust-
ment settings in the Digital Module. Use the cap-
ture file to write these settings to a replacement
Digital Module.
InPower is a trademark of Onan Corporation.

1-3
MODEL IDENTIFICATION
Identify your model by referring to the Model and
Specification number as shown on the nameplate.
Electrical characteristics and application informa-
tion are shown on the lower portion of the name-
plate. The nameplate is located on the cabinet
door.
If it’s necessary to contact a dealer or distributor re-
garding the transfer switch, always give the com-
plete Model, Specification, and Serial number as
listed on the nameplate. This information is neces-
sary to properly identify your unit among the many
types manufactured.
Feature/option codes are listed on the follow-
ing page.
The model number is made up of code segments
that designate various features or options:
BTPCB00000 Spec. A
| | | |
1 2 3 4
1. BTPC − Bypass Transition PowerCommand
Control.
2. Ampere Rating:
B = 150−260
C = 300−400 (Spec A)
C = 300−600 (Spec B)
D = 600−1000 (Spec A)
3. Assigned Spec Number − issued for each
specific combination of accessories, volt-
ages, frequency and standards codes.
4. Specification Letter − advances with produc-
tion modification.
HOW TO OBTAIN SERVICE
When the transfer switch requires servicing, con-
tact your nearest Cummins Power Generation dis-
tributor. Factory-trained Parts and Service repre-
sentatives are ready to handle all your service
needs.
To contact your local Cummins Power Generation
(CPG) distributor in the United States or Canada,
call 1-800-888-6626 (this automated service uti-
lizes touch-tone phones only). By selecting Option
1 (press 1), you will be automatically connected to
the distributor nearest you.
If you are unable to locate a dealer or distributor,
consult the Yellow Pages. Typically, distributors
are listed under:
Generators-Electric,
Engines-Gasoline or Engines-Diesel, or
Recreational Vehicles-Equipment,
Parts and Service.
For outside North America, call Cummins Power
Generation, 1-763-574-5000, 7:30 AM to 4:00 PM,
Central Standard Time, Monday through Friday.
Or, send a fax to Cummins Power Generation us-
ing the fax number 1-763-528-7290.
When contacting your distributor, always supply
the complete Model Number and Serial Number as
shown on the nameplate.

1-4
FEATURE DESCRIPTION
FEATURE
OPTION
Poles:
3 Poles
4 Poles
A028
A029
Application:
Utility to Genset
Utility to Utility
A035
A036
Agency Approvals:
UL Listing
UL/NFPA Listing
A046
A064
Frequency:
60 Hertz
50 Hertz
A044
A045
Voltage:
190 VAC
208 VAC
220 VAC
240 VAC
380 VAC
416 VAC
440 VAC
480 VAC
600 VAC
R038
R021
R022
R023
R024
R025
R035
R026
R027
Controls:
Level 2 Switch Control C024
Transfer Mode:
Open Transition
Programmed Transition
Closed Transition
A077
A078
A079
Control Options:
Front Panel Security Key
Digital Display
LONWORKS Network Communications
Module
Load Monitoring
Relay Module
Relay−Protective, 62PL Timer, 86 Lock
Out
Out, 32R Single Phase Sense
Out, 32R 3 Phase Sense
M017
M018
M020
M022
M023
M045−7
M046−7
M047−7
FEATURE DESCRIPTION
FEATURE
OPTION
Phase:
1 Phase, 2-W or 3-W
3 Phase, 3-W or 4-W
A041
A042
Meters:
Digital Bar Graph Meters D009
Battery Charges:
2A, 12/24VDC
10 Amp, 12VDC − No Longer Available
10 Amp, 24VDC − No Longer Available
15 Amp, 12 VDC
12 Amp, 24 VDC
K001
K002
K003
KB59
KB60
Auxiliary Relays:
24 VDC Coil
Emergency Position
Normal Position
Generator Start
12 VDC Coil
Emergency Position
Normal Position
Generator Start
L101
L102
L103
L104
L201
L202
L203
L204
Miscellaneous:
Terminal Block − 30 Position
Load Shed − From Emergency
Terminal Block − Battery Charger
Alarms
Bus Stubs Connection (Open
Construction)
4 Ft. Harness Extension (Open
Construction)
M003
M007
N002
N009
N013
Cabinet:
Type 1 − General use, Indoor
Type 3R − Outdoor use
Type 4 − Indoor or Outdoor use
Open Construction − No Enclosure
Type 12 − Indoor, dust-tight and
drip-tight
Type 4X − Indoor or Outdoor use
B001
B002
B003
B004
B010
B025

2-1
2. Description
This section describes the standard and optional
control features as well as the control cabinet and
bypass transfer switch.
CABINET
The standard cabinet meets the requirements of
the National Electrical Manufacturers Association
(NEMA) for a UL Type 1 cabinet. Cabinets are
available in NEMA types 1, 3R, 4, 4X, and 12. The
various types are designated as general-purpose,
indoor or outdoor cabinets. Two examples of cabi-
nets, showing interior components are shown in
Figures 2-6 and 2-7.
CONTROL PANEL
The panel features are divided into three groups:
Bar Graph Meters, Switch Panel and Digital Dis-
play (see Figure 2-1). Bar Graph Meters are op-
tional equipment.
KEY SWITCH
(OPTIONAL)
POWERCOMMAND
BAR GRAPH
METER PANEL
(OPTIONAL)
SWITCH PANEL
DIGITAL DISPLAY
FIGURE 2-1. PORTION OF CABINET WITH OPTIONS

2-2
BAR GRAPH METER PANEL
The Bar Graph Meter Panel (optional) includes a
three phase AC ammeter, a power meter, a power
factor meter, a frequency meter, and a three phase
AC voltmeter.
AC Ammeter (A−)
The ammeter displays the percentage of full load
current in amperes (1−125%).
Power Meter (kW)
The power meter displays the real power in per-
centage of full load in kilowatts (0−125%).
Power Factor Meter (PF)
The power factor meter displays real power deliv-
ered to the load (1.0−0.6 lagging) and (1.0−0.9
leading).
Frequency Meter (Hz)
This meter displays the output frequency (percent-
age of nominal frequency), of the power source
connected to the load (70−110%).
AC Voltmeter (V−)
The voltmeter displays the percentage of line to
neutral voltages of either power source connected
to the load (70−110%).
FIGURE 2-2. BARGRAPH METER PANEL
SWITCH PANEL
The switch panel (Figure 2-3) contains six indica-
tor lamps and three membrane pushbuttons.
FIGURE 2-3. SWITCH PANEL
Indicator Lamps
Source 1 Available and Source 2 Available
These indicators are lit when the corresponding
sources have acceptable output voltage and/or
frequency. These indicators can be lit simulta-
neously.
Source 1 Connected
This indicator is lit when the transfer switch is in the
normal position and Source 1 is supplying power to
the load.
Source 2 Connected
This indicator is lit when the transfer switch is in the
emergency position and Source 2 is supplying
power to the load.
Not in Auto
This indicator lights when the transfer switch is not
in the Automatic mode of operation and when any
of the following signals are active:
S Drawout lever is in the Release Position
S Control Mode/Configuration is set to “Off-
line”
S Bypass switch is connected to Normal or
Emergency
Test/Exercise Active
The Test/Exercise Active indicator is lit when the
transfer switch test or exercise operation is active.

2-3
Membrane Pushbuttons
Pressing any pushbutton will “wake up” the display
panel if it is in a sleep mode.
Test
For utility-to-genset applications, the Test switch
sends a start signal to the generator set desig-
nated Source 2 and flashes the Test/Exercise Ac-
tive indicator. After the start and transfer time de-
lays, Source 2 starts and assumes the load pro-
vided the With Load option is enabled. Press the
Test switch again to end the test; the Test/Exercise
Active indicator goes out and Source 1 resumes as
the source of power.
Override
The Override switch terminates most system time
delays. Program Transition, Elevator signal and
Engine Cool Down are not affected by this switch.
Pressing this switch while the Transfer or Retran-
sfer Inhibit inputs are active, immediately transfers
or retransfers the load.
Reset/Lamp Test
The Reset/Lamp Test switch turns on all control
panel indicators. This switch also acknowledges
events.
DIGITAL DISPLAY
The Digital Display contains a 2-line by 20-charac-
ter Digital Display Module and 6 momentary con-
tact membrane buttons. The module displays the
menu system. The buttons are used to navigate
through the menu system.
Each menu indicates the function of the four but-
tons at the sides of the Display Module. Not all but-
tons are active for each menu. Refer to Section 4:
Digital Display Menu System for complete digital
display menu details.
FIGURE 2-4. DIGITAL DISPLAY
SECURITY KEY SWITCH OPTION
The optional security key switch is located on the
front panel. When it is in the Panel Lock position, it
disables the Test and Override buttons on the front
panel. It also prevents changes through the Digital
Display to the Setup menus; however, the current
values can be viewed. Changes can be made
when the key switch is in the Program position
(Figure 2-5).
The key switch can be disabled in PowerCom-
mand using the InPowert service tool.
FIGURE 2-5. KEY SWITCH
InPower is a trademark of Onan Corporation.

2-4
OPTIONAL
BATTERY
CHARGER
BARGRAPH
DIGITAL
BOARD
DIGITAL
DISPLAY
POWER
MODULE
CONTROL
RELAYS
POWER
TRANSFORMER
DRAWOUT
CRANK
HANDLE
SOURCE
SELECT
SWITCH
BYPASS
SWITCH
HANDLE
FIGURE 2-6. INTERIOR/COMPONENTS − 150−400 AMP SPEC A, 300−600 AMP SPEC B SWITCH
(TYPE 1 CABINET)

2-5
OPTIONAL
BATTERY
CHARGER
DIGITAL
DISPLAY
BARGRAPH
DIGITAL BOARD
POWER
MODULE
CONTROL
RELAYS
POWER
TRANSFORMER
SOURCE
SELECT
SWITCH
DRAWOUT
CRANK
HANDLE
BYPASS
SWITCH
HANDLE
FIGURE 2-7. INTERIOR/COMPONENTS − 600−1000 AMP SPEC A SWITCH (TYPE 3R CABINET)

2-6
BYPASS SWITCH
The bypass switch, located behind the automatic
transfer switch, is used to open and close the con-
tacts connecting the load to the Normal or Emer-
gency power source. The manually operated by-
pass switch is mechanically interlocked to prevent
simultaneous closing to a dead source or to both
power sources at the same time. Operation of the
bypass switch is accomplished with the Bypass
Switch Handle and the Source Select switch.
Contact Assemblies
Like the automatic transfer switch, the bypass
switch has either three or four poles. Three pole
transfer switches are provided with a neutral bar.
The contact assemblies are manually actuated to
connect the load to one of the two power sources,
bypassing the automatic transfer switch. When
closed to either the Normal or the Emergency pow-
er source, the contacts are mechanically held.
Auxiliary Contacts
Auxiliary contacts are provided on the Normal and
Emergency sides of the bypass switch. The Nor-
mal side auxiliary contact switch is actuated when
the bypass switch is in the Normal position. The
Emergency side auxiliary contact switch is actu-
ated when the bypass switch is in the Emergency
position. The auxiliary contacts have current rat-
ings of 10 amperes at 250 VAC and are wired to
terminal block TB1.
BYPASS SWITCH CONTROLS
Indicators
The Drawout Position indicator shows which posi-
tion the automatic transfer switch is in. The draw-
out mechanism can be latched in one of three posi-
tions: Connected, Test, and Isolated (see Figure
2-8).
The Bypass to Normal and Bypass to Emergency
position indicators show the position of the bypass
switch contacts.
DRAWOUT CRANK
HANDLE
SOURCE SELECT
SWITCH
BYPASS SWITCH
HANDLE
BYPASS SWITCH
POSITION INDICATOR
BYPASS SWITCH
POSITION INDICATOR
DRAWOUT LEVER
(Open Position)
DRAWOUT POSITION
INDICATOR
DRAWOUT
RELEASE
CONNECTED
FIGURE 2-8. BYPASS PANEL
When the Bypass switch handle is in the Bypass to
Normal position, the bypass switch contacts con-
nect the load to the Normal source and the word
“Closed” is shown in the Bypass to Normal indica-
tor slot. When the Bypass switch handle is in the
Bypass to Emergency position, the bypass switch
contacts connect the load to the Emergency
source and the word “Closed” is shown in the By-
pass to Emergency indicator slot. In both cases,
the word “Open” is shown in the opposite indicator
slot.
When the Bypass switch handle is in the center
position, the bypass switch contacts are discon-
nected from both sources and the word “Open” is
shown in both indicator slots.

2-7
Bypass Handle and Select Switch
The Source Select Switch is a spring loaded return-
to-center, three-position switch used to select the
source to bypass. Prior to operating the Manual
Bypass handle, this switch must be turned to the
source to which the bypass contacts will connect.
The Bypass Switch Handle is used in conjunction
with the Source Select Switch. The Source Select
switch controls an interlock device, which prevents
the bypass switch from connecting the load to a
dead source or to both sources at the same time.
Before operating the Bypass Switch Handle, the
Source Select Switch must be turned to the source
the load will be connected to. Mechanical and
electrical interlocks control the bypass operation.
Bypassing to the Same Source: If the automatic
transfer switch is already connected to the source
to be bypassed, the operator can turn and hold the
Source Select switch then move the Bypass
Switch Handle, closing the bypass contacts to that
same source, without interrupting the load.
Bypassing to the Opposite Source: If the auto-
matic transfer switch is NOT already connected to
the source to be bypassed, interlocks force the fol-
lowing conditions to be met:
1. The bypass operation is permitted only when
the selected source is available. When by-
passing to the Emergency source, for exam-
ple, it is necessary to first check that the
Source 2 Available lamp is lit. (Refer to Sec-
tion 3: Operation.)
2. As the bypass switch handle is moved to the
opposite source, electrical and mechanical in-
terlocks force the automatic transfer switch to
the neutral position in a break-before-make
action. This operation causes a brief power in-
terruption. (Refer to Section 3: Operation.)
DRAWOUT-ISOLATION MECHANISM
The drawout-isolation mechanism allows the auto-
matic transfer switch to be isolated for testing or
service. Three sets of primary isolation contacts
(Normal source, Emergency source, and Load)
connect the switching contacts to the terminal
lugs. A set of secondary isolation contacts con-
nects the automatic transfer switch controls to the
available power source.
Drawout Cranking Handle
The drawout cranking handle is used to isolate and
reconnect the automatic transfer switch. The
cranking handle turns a gear drive that moves the
transfer switch along a mechanically guided path.
The cranking handle will operate only when the
bypass switch is connected to one of the
sources. The operator must lift the drawout lever
to deactivate the cranking interlocks.
CAUTION Improper usage of the drawout
cranking handle can result in equipment dam-
age. Do not use excessive force when operat-
ing the handle and do not operate if the bypass
switch is not connected to one of the sources.
The Drawout Position Indicator shows the position
of the automatic transfer switch. The drawout
mechanism can be stopped in one of three posi-
tions: Automatic, Test, and Isolate.
In the Automatic position, both the primary and the
secondary isolation contacts are closed. The auto-
matic transfer switch is in its normal operating posi-
tion.
In the Test position, the primary isolation contacts
are open and the secondary isolation contacts are
closed. The load-supplying contacts of the auto-
matic transfer switch are out of service, but the
controller and linear actuator are powered and ful-
ly operational. In this position, the controller, linear
actuator, and contact mechanisms can be tested.
In the Isolate position, both the primary and the
secondary isolation contacts are open. The trans-
fer switch mechanism is completely isolated from
both the power and control circuits and can be re-
moved for service.
WARNING Improper removal of the automatic
transfer switch can cause severe personal in-
jury or death. Removal of the automatic trans-
fer switch must only be performed by trained
and experienced personnel, following the pro-
cedures provided in the Sections 6 and 7.

2-8
AUTOMATIC TRANSFER SWITCH
The automatic transfer switch (Figure 2-9) opens
and closes the contacts that transfer the load be-
tween the two power sources (1 and 2). The switch
is mechanically interlocked to prevent simulta-
neous closing to both power sources, unless it is a
closed transition transfer switch. The main parts of
the transfer switch discussed here are the Contact
Assemblies, Linear Actuator, Motor Disconnect,
and the Auxiliary Contacts.
GND
Drawout
Release
Bypass to
Drawout
Bypass Source
Select
EmergencyNormal
Position
Lock
OPEN
Bypass to
Emergency
OPEN
Normal
AUTOMATIC
TRANSFER
SWITCHas
1
FIGURE 2-9. TRANSFER SWITCHES
Contact Assemblies
The automatic transfer switch has either three or
four poles. Three pole transfer switches are pro-
vided with a neutral bar. The contact assemblies
make and break the current flow. When closed to
either the Normal or the Emergency power source
(1 or 2), the contacts are mechanically held.
The power contacts are rated at 600 VAC. They
are made of a long-life silver alloy which resists
burning and pitting, and feature separate arcing
surfaces.
Linear Actuator
The linear actuators are the operator or motor that
moves the contact assemblies between the Nor-
mal (Source 1) power and the Emergency (Source
2) power. Linear actuator operation is initiated au-
tomatically with automatic transfer switches.
Auxiliary Switches
Eight auxiliary switches are configured to respond
to the position of the transfer switch. When the
transfer switch is in the Source 1 (Normal) position,
switches S2, S3, S4, and S5 are actuated. When
the transfer switch is in the Source 2 (Emergency)
position, switches S6, S7, S8, and S9 are actu-
ated. Refer to Section 5 and to the schematic and
wiring diagram package for more information on
the functions of the individual switches.
Motor Disconnect
Moving the Drawout Lever to the Release position
disables the linear actuators. The Not In Auto indi-
cator on the front panel will light and the display in-
dicates a Motor Disconnect event.

2-9
ELECTRONIC CONTROL SYSTEM
This section describes the standard and optional
components of the electronic control system.
WARNING Improper calibration or adjustment
of electronic control modules can cause death,
severe personal injury, and equipment or prop-
erty damage. Calibration and adjustment of
these components must be performed by tech-
nically qualified personnel only.
NOTE: When making adjustments, do not operate the linear
motor more then once every two minutes.
All calibration and adjustment procedures are de-
scribed in the Installation manual (shipped with the
transfer switch). The InPower service tool can be
used to create a capture file of all the calibration
and adjustment settings in the Digital Module. Re-
fer to the InPower User’s Guide.
WARNING Accidental actuation of the linear
motor could cause severe personal injury. Be-
fore making any adjustments, disable the lin-
ear actuator.
WARNING AC power within the cabinet and
the rear side of the cabinet door presents a
shock hazard that can cause severe personal
injury or death. Use extreme caution to avoid
touching electrical contacts whenever the cab-
inet door is open. Do not wear long hair, damp
clothing, or jewelry. Use insulated tools, stand
on a dry rubber mat or wood platform and wear
safety glasses.
Electronic Control Circuit Modules
The Bypass Transfer Switch PowerCommandR
(BTPC) transfer switch control incorporates a Digi-
tal Module and a Power Module. Power Modules
are available in three different voltage ranges. The
Digital Module has two 3-volt batteries to power
the real-time clock when no source voltage is avail-
able. Replace these batteries every two years.
Digital Module
The Digital Module (Figures 2-10 and 2-11) con-
tains the logic and timing circuits that control trans-
fer switch operation. These modules also contain
many customer interface circuits (including the
genset start signal and network port), the RS-232
communications port for the InPower service tool,
and drivers for the control panel indicators,
switches, and bar graph meter panel.
For information on battery maintenance, see
Table 3-2.
BAR GRAPH
ASSEMBLY
DIGITAL
MODULE
DIGITAL
DISPLAY
POWER
MODULE
DIGITAL MODULE
BATTERIES
OPTIONAL
NETWORK
COMMUNICATIONS
MODULE
NETWORK
MODULE
BATTERIES
FIGURE 2-10. INTERIOR CONTROL
COMPONENTS
BATTERIES
J20 J29
J26
J27
J24 J28 J25
J26
S1 SWITCH
FIGURE 2-11. LEVEL 2 DIGITAL MODULE

2-10
Power Module
The Power Module supplies power to the Digital
Module and contains voltage sensing transform-
ers and relays. These modules also hold interface
circuits for the transfer switch including position
sensing switches and relay drivers. 10 VDC rectifi-
cation and regulation circuits on this module are
powered by both sources through transformers T1
and T2.
The Power Module contains eight transformers.
• Each source (1 and 2) uses three transform-
ers. Source 1 and 2 voltages are sensed by
transformers T1 and T2.
Both sources are connected A:N, B:N and
C:N except for 120 volt switches. For 120 volt
switches, connect A:N for 2-wire, and AN:CN
for 3 wire single phase systems.
• The remaining two transformers are used to
power the 10 VDC supply on the module. One
transformer is connected to Source 1 and the
other to Source 2 (Figure 2-12).
DANGER
TO J24 ON
DIGITAL BOARD
K12
K14
K15
K13
K16
K17
T1
T2
T3
T4
T5
T6
T7
T8
TB13
TB14
TB11
TB12
J11
FIGURE 2-12. POWER MODULE
Power Modules contain six pilot relays defined as:
K12 Neutral to Source 1
K13 Source 2 to Neutral
K14 Neutral to Source 2
K15 Source1 to Neutral
K16 Not Used
K17 Not Used
CAUTION Improper voltage can result in
equipment damage. Replacement Power Mod-
ules on all BTPC transfer switches of 1000
amps or less must have jumpers J18 and J19
cut prior to installation.
Control Plate
The Control Plate contains two transformers; one
for Emergency supply and one for Normal supply
(Figure 2-13).
K6K5K2K1 K3
OPTIONAL
BATTERY
CHARGER
POWER
TRANSFORMERS
CONTROL
RELAYS
TO P10SINGLE LINEAR MOTOR
K4
DUAL LINEAR MOTOR
TO P10
CONTROL
RELAYS
OPTIONAL
BATTERY
CHARGER
POWER
TRANSFORMERS
OPTIONAL
LOAD SHED
(K7)
FIGURE 2-13. CONTROL PLATE
On 150−1000 Amp switches, relays K1 through K7
control the opening and closing of various
switches.

2-11
Single Linear Motor (Open Transition):
K1 Transfer to Normal
K2 Transfer to Emergency
K3 Programmed Transition
K4 Optional Load Shed
K5 Bypass to Normal
K6 Bypass to Emergency
K7 Not Installed
Dual Linear Motor (Closed Transition):
K1 Open Emergency
K2 Open Normal
K3 Close Emergency
K4 Close Normal
K5 Bypass to Normal
K6 Bypass to Emergency
K7 Optional Load Shed
Connectors P1 and P10 are the interface and pow-
er sources for the cabinet door, the bypass switch
and the transfer switch.
Two-Wire Starting
The starting circuit is a basic supervisory function
of the electronic control. Water-cooled generator
sets use a two-wire start control.
Although the logic is more involved, the two-wire
starting circuit can be thought of as a single pole,
single throw switch. A closed switch starts the gen-
erator set. An open switch stops the generator.
Three-wire starting is not available on BTPC
transfer switches.
ELECTRONIC CONTROL OPTIONS
Relay Module Option
The Relay Module (see Figure 2-15) provides nine
sets of Form-C contacts and two sets of normally
open contacts that are rated for 2 Amps at 30 VDC
or 0.60 Amps at 120 VAC. Connections to these
relays are made at J14 and J15 on the Relay Mod-
ule. The Relay Module is located on the left inside
wall of the transfer switch enclosure. See Table 2-1
for relay module connections.
The Source 1 or Source 2 Connected relays are
energized when their respective power sources
are available, ready to produce power, and con-
nected to the load. These relays are latching re-
lays and will retain their last state in case of a com-
plete loss of power.
The Source 1 or Source 2 Available relays are en-
ergized when their respective power sources are
producing power.
The Test/Exercise relay is energized when the sys-
tem is in test or exercise mode.
The Elevator Pre-Transfer relay is energized dur-
ing the elevator signal time delay. The relay con-
tacts are used to provide a warning that a transfer
or retransfer is about to occur.
This time delay (TDEL) is adjustable over a range
of 0 to 60 seconds. The default value is 0 seconds.
The value is set with the InPower Service tool or
the digital display (see page 4-18 or page 4-19, de-
pending on software version) when it is available.
Y TDEL
"B 0.0 Seconds
FIGURE 2-14. TDEL SUB-MENU
The Fail to Transfer/Retransfer relay is energized
whenever the transfer switch does not open or
close within a set time interval after the command
to transfer or retransfer.
The Fail to Synchronize relay is energized when
the two power sources did not come into synchron-
icity (frequency, voltage, phase) within a two-min-
ute limit, during a transfer between two live
sources.
The Fail to Disconnect fault is used only in
closed transition modes. The relay is ener-
gized whenever the two sources remain paral-
lel longer than a set time limit (100 millisec-
onds).
The ATS Not-In-Auto relay is energized when any
one of the following occurs:
• The drawout release lever is lifted
• Fail-to-Disconnect event is active
• Wiring harness is disconnected from J12 on
the Power Module
• Controller is set to Offline
The Load Shed relay is active when the transfer
switch has been commanded to disconnect the
load from power Source 2.
Use number 22 to number 12 AWG wire. For con-
nection to the screw terminal, strip the insulation
back 3/8 inch (10 mm).

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