Onan Transfer Switch

Cummins Power Generation Onan PowerCommand Transfer Switch
Onan Sales and Technical Training
Table of Contents
Lesson One: The New PowerCommand Transfer Switch ............................................. 1
Objectives .................................................................................................................................... 1 Overview of the New Transfer Switch .......................................................................................... 1 Progress Check............................................................................................................................. 7
Lesson Two: The New PowerCommand Transfer Switch Control................................. 10

Objectives ...................................................................................................................................10 Overview of Components of the New Control..............................................................................10 Overview of PCTS Control..........................................................................................................11 Control Packages.........................................................................................................................11 Control Features ..........................................................................................................................15 Control Options ...........................................................................................................................17 Interfaces.....................................................................................................................................19 Progress Check............................................................................................................................26
Lesson Three: How Onan Compares with the Competition ........................................... 29

Objectives ...................................................................................................................................29 Overview of Competitive Products ..............................................................................................29 Transfer Switch Level 1 Control Package ....................................................................................29 Positioning the PowerCommand Transfer Switch Level 1 Control ...............................................31 PowerCommand Transfer Switch Level 2 Control .......................................................................34 Positioning the PowerCommand Transfer Switch Level 2 Control ...............................................34 Transfer Switch Features Compared to Other Suppliers ...............................................................38 Progress Check............................................................................................................................42
Lesson Four: The PowerCommand Control Network .................................................... 44

Objectives ...................................................................................................................................44 The Opportunity for Network Solutions .......................................................................................44 Benefits of a Network Solution ....................................................................................................45
Onan PowerCommand Transfer Switch
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Opportunities in Healthcare Facilities............................................................................................46 Opportunities in Retail Markets ......................................................................................................49 Opportunities in Telecommunications ............................................................................................50 Connecting to the Network ..........................................................................................................51 Network Communication Module (NCM) Hardware....................................................................51 Network Communication Module Software........................................................................................53 Progress Check............................................................................................................................54
Lesson Five: InPower Service Tool .................................................................................. 56

Objectives ...................................................................................................................................56 Overview of the InPower Service Tool ........................................................................................56 InPower Transfer Switch Information ..........................................................................................58 Progress Check............................................................................................................................59
Lesson Six: Transfer Switch Selection ............................................................................. 61

Objectives ...................................................................................................................................61 Important Factors in the Selection of a Transfer Switch................................................................61 Case Studies ................................................................................................................................61
Appendix A: Digital Alpha Numeric Display................................................................... 67 Appendix B: Transfer Switch Network Input Variables................................................. 69 Appendix C: Transfer Switch Network Output Variables.............................................. 70 Appendix D: Information Monitored by InPower.......................................................... 72 Appendix E: Adjustments Available with InPower ....................................................... 73 Appendix F: Faults/Events History in InPower ............................................................. 75
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List of Figures and Tables Figure 1-1: The OTPC .......................................................................................................... 2 Table 1-1: OTPC Features and Benefits ................................................................................ 3 Table 1-2: Onans Bypass Switch Features and Benefits ....................................................... 4 Table 2-1 Level 1 Transfer Switch Control Features and Benefits ....................................... 12 Table 2-2 Level 2 Control Features and Benefits................................................................. 14 Table 2-3: Features of the Operator Interface for Level 1 and Level 2 Control Options ....... 20 Figure 2-1: The OTPC Operator Panel ................................................................................ 22 Figure 2-2: The OTPC Front Panel...................................................................................... 23 Figure 3-1: Competition for the PowerCommand Transfer Switch Level 1 Control ............. 30 Table 3-1: PowerCommand Transfer Switch Level 1 Control Competitive Comparison...... 32 Table 3-1 (cont.): PowerCommand Transfer Switch Level 1 Control Competitive Comparison................................................................................................................. 33 Figure 3-2: Competition for the PowerCommand Transfer Switch Level 2 Control ............. 34 Table 3-2: PowerCommand Transfer Switch Level 2 Control Competitive Comparison...... 35 Table 3-2 (cont.): PowerCommand Transfer Switch Level 2 Control Competitive Comparison................................................................................................................. 36 Table 3-2 (cont.): PowerCommand Transfer Switch Level 2 Control Competitive Comparison................................................................................................................. 37 Table 3-3: Comparison of Transfer Switch Features Provided by Major Suppliers .............. 39 Table 3-3 (cont.): Comparison of Transfer Switch Features Provided by Major Suppliers ... 40 Table 3-3 (cont.): Comparison of Transfer Switch Features Provided by Major Suppliers ... 41 Table 4-1: Profile of Candidates for PowerCommand Network........................................... 45 Table 4-2: Benefits of PowerCommand Network for the Healthcare Industry...................... 48 Table 4-3: Benefits of PowerCommand Network for the Retail Industry ............................. 49 Table 4-4: Benefits of PowerCommand Network for Telecommunications Industry........... 50 Figure 4-1: NCM Installed on PowerCommand Transfer Switch Level 2 Control................ 52
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Lesson One: The New PowerCommand Transfer Switch

Objectives
After completing this lesson, you should be able to:
Identify the products in the PowerCommand line of transfer switch products. products.
Recognize the difference among the transfer switch
Overview of the New Transfer Switch
The PowerCommand OTPC and BTPC Transfer Switches combine the field-proven OT and BT transfer switch mechanisms with a new high-performance microprocessor-based transfer switch control. The control will be used on a number of transfer switch products, providing consistent levels of performance, user interface, and serviceability. As a result, the OTPC and BTPC PowerCommand Transfer Switches keep many of the benefits of their predecessors while adding comparative advantage in terms of control, networking capability and serviceability. This lesson provides an overview of the PowerCommand Transfer Switch family of products:
OTPC Automatic Transfer Switch BTPC Bypass Isolation Transfer Switch PLTO Automatic Transfer Switch - Open Transition PLTH Closed Transition Transfer Switch PLTS Soft Loading Transfer Switch PowerCommand Network Communication Module Cummins Onan InPower Transfer Switch Service Tool
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OTPC Automatic Transfer Switch
The OTPC Transfer Switch itself has not changed. It still relies on the OTIII switch mechanism used in over 100,000 installations. The control, however, does represent significant improvement over the PowerSentry Control and over the competitions microprocessor controls now on the market. The next lesson deals exclusively with the PowerCommand Transfer Switch Control. See Table 1-1 for the features and benefits of the OTPC. Figure 1-1 is a graphic representation of the OTPC.
SWITCH PANEL BAR GRAPH ASSEMBLY
OPTIONAL BATTERY CHARGER AUTOMATIC TRANSFER SWITCH CONTROLLER BATTERIES TB1
DIGITAL DISPLAY RELAY ASSEMBLY MOTOR DISCONNECT SWITCH POWER MODULE
TB2
Figure 1-1: The OTPC
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Table 1-1: OTPC Features and Benefits

Features Three maintained positionsPreferred Source, Center, and Alternate Source positions Benefits Allows use as load shed equipment in paralleling systems and allows programmed transition functionality for transfer of motors, transformers, UPS, and other SCR equipment without disruption Prevents source-to-source short circuit and meets code requirement Provides uniformly fast operation of contacts on making and breaking regardless of electrical or manual operation. Contacts cannot be teased, drawing dangerous arcs, during manual operation Range of standard continuous ampere ratings covers electrical distribution equipment ratings Covers all commonly used voltage ranges worldwide Does not require special hardware to accommodate 50 Hz applications Allows use on single-phase, three-phase solid neutral, and three-phase switched neutral systems Allows application flexibility for 3-wire systems without a neutral conductor Allows remote annunciation of transfer switch position and control interface with auxiliary equipment Accommodates both types of cable materials. Mechanical pressure lugs are oversized to allow larger cables when required for voltage drop, etc. Provides a provision for switchboard mounting and bus duct connection Permanently attached manual operating handles provide means for safe manual operation and service operation with electrical operator disabled. Available on Onan transfer switches rated at 1000 amps or less. Disables electrical operator for service and manual transfer operation
Mechanical interlock
Stored energy over center mechanism
Ampere ratings: From 40 to 3000 amperes
Voltage ratings: Nine standard voltage ratings from 120 to 600 VAC. Frequency rating: Dual rating for 50 and 60 Hz. 3 or 4 pole switch configurations
Optional neutral bar on 3 pole
Customer auxiliary contacts: Form C contacts on normal and emergency side
Cu/Al mechanical pressure lugs
Bus connects
Manual handles
Motor disconnect switch
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BTPC Bypass Isolation Transfer Switch
The story of the BTPC is similar to the OTPC. The BTPC retains the many benefits of the BT bypass switch mechanism, while adding the new microprocessor transfer switch control. Table 1-2 lists the bypass switch features and associated benefits.
Table 1-2: Onans Bypass Switch Features and Benefits

Features Combination automatic/manual bypass switch Benefits Combines OTIII, a mechanical bypass switch, and a drawout isolation mechanism into a single unit Non-load break design allows switch bypass and isolation to either source without disruption to the load Can bypass to either source as long as acceptable power is available and the transfer switch is connected Prevents inadvertent bypassing to a dead source Able to isolate and bypass load without opening cabinet Controls speed of bypass to prevent out of phase manual transfers Drop into place as ATS is withdrawn to cover primary disconnects Transparent Lexan shields cover all live parts including lugs Allow ATS to be rolled out of cabinet for easy overhead lifting and removal after isolation
Non-load break
Dual source bypass
Electro-mechanical interlock Front panel bypass control Center off position on bypass switch Safety shutters Safety shields Extension rails
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PLTO Automatic Transfer Switch (Available 2000) 2000
The PLTO is a breaker-based high amperage transfer switch available with amperages from 800 to 3000. Service Entrance rating is available as an option. The PLTO uses a pair of insulated case breakers as the switching mechanism. The PowerCommand Transfer Switch control provides all sensing, control and user interface functions. Further information on this new product can be obtained from the Onan Switchgear and Systems Group. The PLTH is a breaker-based paralleling transfer switch that can connect to both sources for a 100-mSec transfer time. A derivative of the Paralleling Load Transfer Equipment (PLTE), the PLTH uses a pair of drawout insulated case breakers as the switching mechanism. The PowerCommand Transfer Switch Control provides all sensing, control functions and operator interfaces. Service Entrance rating is available as an option. Further information on this new product is beyond the scope of this training, contact the Onan Systems Group for additional data. The PLTS is a breaker-based paralleling transfer switch that can connect to both sources for a configured transfer time period to allow load ramping. A derivative of the PLTE Paralleling Load Transfer Equipment, the PLTS uses a pair of drawout insulated case breakers as the switching mechanism. The PowerCommand Transfer Switch control provides all sensing, control (including ramping) and operator interfaces. Service Entrance rating is available as an option. A product specification sheet is included with all sales tools. Again, further information on this new product is beyond the scope of this training; contact the Onan Systems Group.
PLTH Closed Transition Transfer Switch (Available 2000)
PLTS Soft Loading Transfer Switch (Available 2000)
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PowerCommand Network Communication Module (NCM)
Onan transfer switches now have the capability to be connected directly to the PowerCommand Network. The Network Communication Module (NCM) allows the transfer switch to talk to networked generator sets, annunciators or any other LONMark compliant device. Note: LonMark is the organization set up by Echelon to create and define standards to promote interoperability among LonWorks products. This allows one vendors product to work with another vendors product without requiring customization. Onan is a member of the LonMark Interoperability Association and wrote the Transfer Switch Standards. The NCM is a digital board that can be ordered with the transfer switch or added in the field. Lesson Four, The PowerCommand Control Network, describes the Network Communication Module in detail.
InPower Transfer Switch Service Tool
The Cummins Onan InPower Service Tool provides improved service. Available on a standard laptop PC, InPower provides configuration setup downloads, on-line diagnostics, data analysis tools and real time monitoring. Lesson Five describes this tool in detail.
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Lesson One Progress Check

Answer the following questions based on information provided in the lesson. When finished, check your responses against the answers shown following this progress check. 1. List the seven products that comprise the PowerCommand Transfer Switch family of products. ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ 2. The OTPC Transfer Switch relies on the OTIII mechanism but the _______________ Control is replaced by the ________________ Control. 3. The is a breaker-based paralleling transfer switch that can connect to both sources for a _________ transfer time. It uses a pair of ___________ ___________ ________________ as the switching mechanism. 4. The allows PowerCommand Transfer Switches to talk to networked generator sets, annunciators, or any other compliant device. 5. List five features and the associated benefits of the OTPC transfer switch. Features Benefits
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Lesson One Progress Check (Cont.)

6. List five features and the associated benefits of the BTPC transfer switch. Features Benefits
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Answers to Lesson One Progress Check 1. The seven products comprising the PowerCommand Transfer Switch family of products are:
OTPC Automatic Transfer Switch BTPC Bypass Isolation Transfer Switch PLTO Automatic Transfer Switch - Open Transition PLTH Closed Transition Transfer Switch PLTS Soft Loading Transfer Switch PowerCommand Network Communication Module Cummins Onan InPower Transfer Switch Service Tool
2. The OTPC Transfer Switch relies on the OTIII mechanism but the PowerSentry Control is replaced by the PowerCommand Control. 3. The PLTH is a breaker-based paralleling transfer switch that can connect to both sources for a 100-mSec transfer time. It uses a pair of insulated case breakers as the switching mechanism. 4. The Network Communication Module (NCM) allows PowerCommand Transfer Switches to talk to networked generator sets, annunciators, or any other LONMark compliant device. 5. Refer to Table 1-1 for a complete list of features and benefits for Onans OTPC transfer switch. 6. Refer to Table 1-2 for a complete list of features and benefits for Onans BTPC transfer switch.
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Lesson Two: The New PowerCommand Transfer Switch Control

Objectives
State the features, functions and benefits available

with the new PowerCommand Transfer Switch Control.
List the features of the Transfer Switch Level 1 and

Level 2 Control packages.
Identify the various interfaces of the transfer switch

control.
Overview of Components of the New Control
This lesson addresses the features and functions of the new PowerCommand Transfer Switch Control. The new control represents a step-change improvement in transfer switch control technology. This new microprocessorbased control can be tailored for use with both basic transfer switch applications and for more sophisticated requirements such as load monitoring. The lesson first covers the two levels of transfer switch control options in detail. Next, the lesson describes the three types of transfer switch control interfaces:
Operator interface (covered in detail) Network interface via the Network Communications
Module (described in greater detail in Lesson Four)
Cummins Onan InPower Software Service Tool

(discussed in greater detail in Lesson Five)
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2. The New PowerCommand Transfer Switch Control
Overview of PCTS Control
The PowerCommand Transfer Switch Control is a fully featured microprocessor-based control with a choice of two levels of option packages. All features, settings, and adjustments are software enabled with no hardware adjustments necessary. As a result, there are no potentiometers to adjust or banks of dipswitches to set. Adjustments can be downloaded from the InPower service tool or made from the digital display. A real-time clock provides data and time stamping of all events, faults and generator exercise functions.
Control Packages
Two levels of transfer switch control options are available allowing flexibility for customers in determining the most suitable level of control for a given application:
Level 1 provides a basic level of sensing and control

with superior performance to other value switch control packages.
Level 2 provides more sensing options and additional

options for load monitoring and metering. Closed transition functionality is available for PLTH and PLTS. Level 1 Control Package The Level 1 Transfer Switch Control provides a basic level of control for use with standby power applications. See Table 2-1(next page) for a chart of the features and benefits of the Level 1 control package.
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2. The New PowerCommand Transfer Switch
Table 2-1: Level 1 Transfer Switch Control Features and Benefits

Features Microprocessor-based control electronics PowerCommand network option Local RS-232 serial port Benefits Improved reliability and performance Ability to access the PowerCommand network with a simple, and economical hardware upgrade Allows quick configuration downloads, service diagnostics, or data acquisition using a laptop PC and InPower software. Reduced setup time, improved reliability and ease of use Serves most common type of standby applications. Provides an economical sensing package designed for standby power applications Monitors variations in frequency on both sources Provides software adjustable time limits for the four primary transfer time delays Reliably transfers motors, transformers, UPS, and other SCR equipment without disruption or long term wear and tear damage Allows user-flexible scheduling of generator exercise periods. Exercise times can be set up on a multi-day schedule, rather than limited to 1,2, or 4 weeks Allows the operator to quickly enable a transfer, bypassing all time delays Long-life LEDs provide at-a-glance source and transfer switch status for quick summary of system conditions Disables front panel buttons and switches to prevents operation by unauthorized personnel Provides convenient and quick access to review current power and load conditions, make adjustments, review events or check network status (if network option is used)
Software based trims and adjustments Utility-to-generator applications Over/under three-phase voltage sensing on utility, single phase over/undervoltage sensing on emergency, software adjustable Frequency sensing on both sources, singlephase Start, transfer, retransfer, and stop time delays, adjustable Programmed transition for inductive load transfer, software adjustable Programmable generator set exerciser
Front panel test switch and time delay bypass switch Front panel LED indicators for: normal available/normal connected, emergency available/emergency connected, not-in-auto, active test Front panel security key Optional digital display for front panel adjustments and monitoring
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Level 2 Control Package
The Level 2 Transfer Switch Control accommodates a full range of applications. As noted in the following summary of features and benefits, it can be used not only for utilityto-generator applications, but also for utility to utility and generator-to-generator applications. It also provides:
Three-phase voltage sensing of the emergency source

in contrast to the single phase undervoltage sensing provided in the Level 1 control.
Phase rotation and voltage imbalance sensing. The digital display panel is a standard part of this
package, where it is optional in the Level 1 control.
The Level 2 control offers an optional load

monitoring package and a calendar-based programmable generator set exerciser. The BTPC transfer switch is available with the Level 2 control only. See Table 2-2 (next page) for a chart of the features and benefits of the Level 2 control package.
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Table 2-2: Level 2 Control Features and Benefits

Features
Microprocessor-based control electronics PowerCommand network option Local RS-232 serial port Software based trims and adjustments Utility-to-generator, utility-to-utility, or generator-togenerator configurations Over/under three-phase voltage sensing on both sources, software adjustable Frequency sensing on both sources, single-phase Phase rotation and voltage imbalance sensing Start, transfer, retransfer, and stop time delays, software adjustable Programmed transition for inductive load transfer, software adjustable Load monitoring package option
Benefits
Improved reliability and performance Ability to access the PowerCommand network with a simple, and economical hardware upgrade Allows quick configuration downloads, service diagnostics, or data acquisition using a laptop PC and InPower software Improved reliability, ease of use Accommodates a full range of applications Provides complete sensing of the supply voltages for critical applications Monitors variations in frequency on both sources Safeguards against installation mistakes and severe single-phase imbalance loading Provides software adjustable time limits for the four primary transfer time delays Reliably transfers motors, transformers, UPS, and other SCR equipment without disruption or long term wear and tear damage Records the maximum load phase currents and neutral current showing reserve capacity for future addition of load. Warns of excessive neutral current resulting from third harmonic non-linear loading or an unbalanced load Allows complete flexibility of scheduling generator exercise periods. Exercise times can be set up on a calendar basis to take advantage of plant shut-down, non-working days, or other scheduled opportunities Provides convenient and quick access to review current power and load conditions, make adjustments, review events; network status can be checked if network option is used Allows the operator to quickly enable a transfer, bypassing all time delays Long-life LEDs provide at-a-glance source and transfer switch status for quick summary of system conditions Disables front panel buttons and switches to prevent operation by unauthorized personnel Allows at-a-glance confirmation of system status and analog indication, voltage, current, frequency, KW and power factor
Programmable calendar-based generator set exerciser with specific date/time scheduling
Digital display (standard with Level 2 control) provides front panel adjustments and monitoring
Front panel test switch and time delay bypass switch Front panel LED indicators for normal available/normal connected, emergency available/emergency connected, not-in-auto, active test Front panel security key Analog LED bar graph meter option
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Control Features
This section provides a summary of the major features of the PowerCommand Transfer Switch Control. Most features can be enabled or disabled depending on customer preference. Both Level 1 and Level 2 controls include a real time clock that keeps track of the date and time. This clock is Y2K compliant and can be set to correct for daylight savings time and leap years. Start Time Delay (TDES): A short time delay to prevent the generator from starting during brief power interruptions. This delay is adjustable from 0 to 15 seconds on the level 1 controls and from 0-120 sec on the level 2 controls. Transfer Time Delay (TDNE): This time delay allows the generator to stabilize before the load is transferred. It has an adjustable range of 0 120 seconds. Retransfer Time Delay (TDEN): This delay begins after source 1 voltage and frequency have returned to specified values, allowing it to stabilize before load is transferred back. It has an adjustable range of 0-30 minutes. Stop Time Delay (TDEC): During this time delay, the generator cools down at no load before stopping. This delay is adjustable from 0 to 30 minutes. Both control levels include under-voltage sensors for both source 1 and source 2. The Level 1 control includes 3phase sensing on Normal and single phase sensing on Emergency. Level 2 provides 3-phase sensing on both Normal and Emergency.
Real Time Clock
Time Delays
Under-Voltage Sensing
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Over-Voltage Sensing
Both Control levels include over-voltage sensors for source 1 and 2. The Level 1 control includes 3-phase sensing on Normal and single phase sensing on Emergency. Level 2 provides 3-phase sensing on both Normal and Emergency. Both control levels include over- and under- frequency sensing of Normal and Emergency.
Frequency Sensing Two-wire Starting
The generator start circuit uses a two-wire start control. Three-wire starting is not supported in the PowerCommand Control.
Programmed Transition
The PowerCommand Transfer Switch Control is available in open transition mode with programmed transition as standard on both Control Levels 1 and 2, but may be turned on or off based on customer requirements. Programmed transition stops the transfer switch in a neutral position, disconnected from both sources, for an adjustable time interval to allow inductive loads to decay.
Closed Transition Transfer
The PowerCommand Transfer Switch Control is available in closed transition mode on two standard versions of Paralleling Load Transfer Equipmentthe PLTS and PLTH. The PLTH is capable of closing to both sources for uninterrupted transfer of 100-mSec or less. The PLTS is a soft loading transfer switch that can parallel both sources and ramp up load over preset time duration.
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Programmable Generator Exerciser
Both control levels include a programmable generator exerciser. Level 1 includes one programmable exercise event that can set a repetitive exercise schedule of any number of days. Level 2 allows up to 8 schedules including repetitive sequences, exceptions (when the customer does NOT want to exercise), and special dates (could be off-peak hours, holidays, plant shutdowns, etc.). Generator exercise can be set up to operate with or without transferring load. Level 2 controls on 3-phase transfer switches include a voltage imbalance sensor. The sensor indicates a source failure when the deviation from average voltage is greater than the user-specified value. Level 2 Controls on 3-phase transfer switches include a phase rotation sensor to indicate a failure when source 1 and source 2 do not have the same phase. Level 2 Control on 3-phase transfer switches can detect the loss of a single phase on either source.
Voltage Imbalance Sensor
Phase Rotation Sensor Loss of Single Phase Sensor
Control Options
Load Monitoring
This section provides a summary of the major options of the PowerCommand Transfer Switch Control. Load monitoring can be selected as an option with the Level 2 control. The control senses the phase and neutral currents, load voltages and power factor angles. The control calculates KW, KVA and PF. All load information is displayed on the digital display panel, or can be displayed on the LED bargraph meters. The control will also issue a warning when neutral currents exceed user-specified values.
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2. The New PowerCommand Transfer Switch Relay Signal Module The Level 1 and Level 2 Relay Signal Modules includes the following 8 form C relay contacts: Source 1 Connected Source 1 Available Source 2 Connected Source 2 Available Test Active ATS Not in Auto Elevator pre-Transfer Load Shed Active
The Level 2 version also includes the following for a total of 11 Form C relay contacts: Fail to Close Load Shed Fail to Synchronize Fail to Disconnect
The Load Shed function is used to disconnect the load from Source 2 in order to reduce demand on the generator set for a period of time. When load shed is initiated, the transfer switch is moved to the neutral position and signals that the switch is Not in Auto. Both the Level 1 and Level 2 controls can include up to 8 timed network variables to use for turning on loads in sequence after a transfer, retransfer or both. The network variables activate relays on the Network Digital I/O Module (DIM). The Network Communications Module (NCM) is required to use this option. The NCM will be addressed in greater detail in Lesson 4. The transfer switch may be wired with a remote test switch, which causes the switch to sense a simulated utility power failure, initiate the transfer sequence and transfer load to source 2 when it is available.
Load Sequencer Option
Remote Test Transfer Option
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2. The New PowerCommand Transfer Switch Float Battery Charger Option The same 2 A and 10 A float chargers available on the OTIII and BT are also available on the OTPC and BTPC. The 2 A charger is designed for use at either 12 or 24 volts. The 10 A charger provides a choice of 12 or 24 volts. The optional auxiliary relays provide contacts for energizing external alarms, remote indicators and control equipment such as louver motors or water pumps. The OTPC and BTPC offer several types of new or improved interfaces including:
Auxiliary Relay Option
Interfaces
High-visibility LED indicators A vacuum fluorescent digital display An analog LED bargraph meter option
The new network interface is the LONWorks-compliant PowerCommand Network Communication Module (NCM). The NCM allows the transfer switch to interface with a PowerCommand system via the network. The network will be adressed in greater detail in Lesson 4. The Cummins Onan InPower Service Tool Interface provides configuration download, on-line diagnostics, data analysis tools, and real time monitoring using a laptop PC. InPower will be discussed further in Lesson 5. Operator Interface The operator interface includes the following features: Basic interface panel Front panel security key option
Digital alpha numeric display Analog LED bar graph metering These features are illustrated and described in greater detail on the following pages.
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Table 2-3: Features of the Operator Interface for Level 1 and Level 2 Control Options
Features Basic interface panel Front panel security key option Digital alpha numeric display Analog bar graph meters Level 1 Standard Option Option Not available Level 2 Standard Option Standard Option
Basic interface panel
High-intensity LED indicator lamps designed for long life and easy reading in common lighting situations provide a quick summary of system conditions (see Figure 2-1). The interface panel is a standard feature on all OTPC transfer switches. It contains six indicator lamps and three membrane switches. The control switches are tactile push buttons. These lamps and switches include the following: Lamps Source 1 Available and Source 2 Available: These indicators are lit when the corresponding power sources are producing power. These indicators can be lit simultaneously. Source 1 Connected: This indicator is lit when the automatic 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 automatic transfer switch is in the emergency position and Source 2 is supplying power to the load. Not in Auto: For GensettoUtility configurations, the Not in Auto indicator lights when the genset On/Off/Auto switch is not in the Auto position. For GensettoGenset configurations, the Not in Auto indicator lights when On/Off/Auto switch on the non preferred genset is not in the Auto position. For Utility to Utility configurations, the Not in Auto indicator is not used. Test/Exercise Active: The Test/Exercise Active indicator is lit when the transfer switch has a test or exercise in progress.
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Switches Test: The Test (Hold 2 Sec.) switch sends a start signal to the generator set designated Power Source 2 and lights the Test/Exercise Active indicator. After the transfer time delay, Source 2 starts and assumes the load provided that the With Load option is selected. 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. The Programmed Transition, Synch Check, and Engine Cool Down are not affected by this switch. If you press this switch while the Transfer Inhibit input is also active, the switch immediately transfers the load. If you press this switch while the ReTransfer Inhibit input is active, the switch immediately retransfers the load. Reset/Lamp Test:The Reset/Lamp Test switch turns on all control panel indicators.
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Analog LED Bar Graph Metering
Basic Interface Panel
Front Panel Key Option Security
Digital Alpha Display Numeric
Figure 2-1: The OTPC Operator Panel
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Front Panel Security Key Option
The option for a front panel security key can be used to prevent activation of any commands to the front panel, preventing unauthorized transfers or testing. Without the security key only the Reset/Lamp Test Switch and monitor functions of the digital display can be accessed.
Front Panel Security Key Option
Figure 2-2: The OTPC Front Panel
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Digital Alpha Numeric Display
The alphanumeric operator interface panel, a menu-driven interface with a Main Menu, has six push buttons. The Home button returns the operator to the Main Menu screen and Previous Menu returns the panel to the previous major menu. Four buttons are used for menu navigation and input. You can find a detailed description of the display menus in Section 4 of the Operators Manual (962-0126). The operator can use the digital alphanumeric display to view detailed control information and to set up and configure the control system using this display. It allows two lines to appear with 20 characters for each line. Information available on the panel is provided in Appendix A. Main Menu: The main menu system consists of three top-level main menus that list vertical menus (or submenus). The sub-menus display status information. This information cannot be changed in the main menus. The main menus contain eight sub-menus including the Setup Menus. Setup Menu: Before you can navigate the setup menus, you must enter a password. When this information is changed in any setup menu, you are prompted to either save the changes or restore the old values. A graphic of the menu structure is included in the file tsmenu.PDF on your CD-ROM.
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Analog Bar Graph Meters
A multi-function-metering package provides analog AC output metering for service to the loads. Bar Graph Meters are not available on Level 1 controls and are optional on Level 2 controls. The bar graph meters include a 3-phase AC ammeter, a power meter, a power factor meter, a frequency meter, and a three phase AC voltmeter: AC Ammeter: The ammeter measures the line currents of the load. Power Meter: The power meter measures the real power in percent of full load. Power Factor Meter: The power factor meter measures the real power delivered to an inductive load. Frequency Meter: This meter measures the output frequency of the selected power source in hertz. AC Voltmeter: The voltmeter measures linetoline and line to neutral voltages of the selected power source.
The vertical LED bar graph meters are consistent with other PowerCommand products. The metering is color coded as a percent of nominal conditions. Green is normal. Amber indicates warning. Red indicates that unacceptable conditions exist on the power supply fed from the transfer switch. These meters provide indications of system acceptability at a glance without having to interpolate values from an analog dial.
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Lesson Two Progress Check

Answer the following questions based on information provided in the lesson. When finished, check your responses against the answers shown following this progress check. 1. Write in the interfaces that are available for each level of the transfer switch control according to whether they are standard, optional or not available.
Features Level 1 Standard Option Option Not available Level 2 Standard Option Standard Option
2. What are the major differences in source sensing between the Level 1 and Level 2 controls? (Check which are available for each level of transfer switch option.) Sensing Parameters Voltage imbalance Phase rotation Undervoltage Overvoltage Frequency Loss of single phase 3. Neutral current can be read using the __________ ___________ when the Level ___ control and _________ _____________ feature is selected. 4. Select the following that apply only to the Level 2 PowerCommand Transfer Switch Control features: a. Programmed transition for inductive load transfer, software adjustable b. Utility-to-generator, utility-to-utility, or generator-to-generator configurations c. Load monitoring package option d. Programmable calendar-based generator set exerciser e. Front panel test switch and override switch
Onan PowerCommand Transfer Switch Self-Study Page 26
Level 1
Level 2
2. The New PowerCommand Transfer Switch 5. Using the menu from the tsmenu.pdf file on your CD, trace the path for how you would arrive at the number of transfers and order the following steps correctly, the first step as number 1 and so on. _____ Scroll to number of transfers _____ Second main menu _____ Statistics _____ First main menu (more) 6. Only the Level 2 control includes a real-time clock for exerciser programming and event logging. _____ True _____ False
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2. The New PowerCommand Transfer Switch Answers to Lesson Two Progress Check
1.
Features Basic interface panel Front panel security key option Digital alpha numeric display Analog bar graph meters Level 1 Standard Option Option Not available Level 2 Standard Option Standard Option
2. Sensing Parameters Voltage imbalance Phase rotation Undervoltage Level 1 Level 2 4 4 4

(3-phase normal, 3phase emergency)
4
Overvoltage
4
4
Frequency Loss of single phase
4 4
3. Neutral current can be read using the digital display when the Level 2 control and load monitoring feature is selected. 4. b,c,d. The Level 2 PowerCommand Transfer Switch Control is the only package to offer utility-to-generator, utility-to-utility, or generator-to-generator configurations, a load monitoring package option, and a programmable calendar-based generator set exerciser. 5. ___4__ ___2__ ___3__ ___1__ Scroll to number of transfers Second main menu Statistics First main menu (more)
6. False, both levels of control include a real-time clock.
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Lesson Three: How Onan Compares with the Competition

Objectives
Compare Onans transfer switch product line to that of the

competition.
Explain the importance and benefits of selling Onan

transfer switches. This lesson explains how to position both the transfer switch levels 1 (basic level of control) and 2 (premium) control packages with competitive offerings.
Overview of Competitive Products
Even though the transfer switch market has a number of competitors, only a handful constitutes the major sellers of transfer switches in North America. These include the following:
Onan Asco Russelectric
Kohler Generac Zenith
Transfer Switch Level 1 Control Package
Industrial grade transfer switches generally share the same basic features in terms of minimum performance:
Listed to UL 1008 and CSA certified Electrically operated, mechanically held switch mechanism Mechanically interlocked to prevent uncontrolled closure
of both sources
A full range of single phase and 3 phase voltages Fuse or breaker rated withstand and closing ratings
Customers looking for switches with a basic level of control expect a good quality product and adherence to UL1008, CSA and US National Electrical Code is assumed in even the most basic transfer applications.
3. How Onan Compares with the Competition The two primary basic transfer switches that can be compared to the OTPC with Transfer Switch Control Level 1 are the Asco 300 and the Zenith ZTG. Onan is not aware of any basic switch that is available from Russelectric. Less expensive switches than those we refer to as basic switches are available, but they are usually deficient in either quality or performance. Some specific examples are residential switches such as WINCO and Generac.
Asco 300
Zenith ZTG with MX 100 Controls
Figure 3-1: Competition for the PowerCommand Transfer Switch Level 1 Control Of prime consideration for the basic switches is the ability to get a low price per amp and to obtain prompt delivery. Customers are seeking reliable local service and often do not have on-site maintenance expertise. Because these customers depend heavily on factory service, the local reputation of the distributor representative may influence the sale.
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3. How Onan Compares with the Competition
Positioning the PowerCommand Transfer Switch Level 1 Control
The PowerCommand Transfer Switch Control packages are positioned to compete across the range of transfer switch products from basic to premium products.
The chart on the following pages (Table 3-1) compares the features the PowerCommand Transfer Switch Level 1 Control offers with those of competitive products.
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3. How Onan Compares with the Competition Table 3-1: PowerCommand Transfer Switch Level 1 Control Competitive Comparison
PowerCommand Transfer Switch Level 1 Control Control Platform
Microprocessor-based Software-based adjustment of transfer switch settings via InPower Software or optional Digital Display Password protection of settings 3-phase over/undervoltage sensing normal. 1-phase emergency Frequency sensing on both sources Standard Open Transition Programmed Transition
Asco 300
Zenith ZTG
This is important because:
Microprocessor-based Dipswitch adjustment of settings
Microprocessor-based Potentiometer adjustment of settings
Dipswitch adjustments require lookup tables to set. Potentiometers can be difficult to set because they require trial and error. They can also drift over time and temperature. Only Onan provides software based adjustments set from the front panel display. Only Onan offers a full sensing package on the normal source.
Sensing
3-phase undervoltage sensing normal, 1phase emergency Frequency sensing on emergency only
3-phase undervoltage sensing on normal, 1phase emergency Frequency sensing on both sources
Transfer modes
Standard Open Transition In-Phase Monitor
Standard Open Transition In-Phase Monitor Programmed Transition available at added cost
Only Onan offers Programmed Transition as standard on every switch. Asco cannot offer Programmed Transition on the 300 Series. Zenith requires an upgrade to a more expensive switch with a center off position. It cannot be upgraded in the field. Only Onan provides this level of flexibility as standard. This means that a customer can select intervals of any number of days based on site requirements and plant maintenance requirements.
Generator set Exerciser
Programmable exerciser allows exercise times set up on any daily interval schedule from 1-225 days
7 day exerciser
7 day exerciser
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3. How Onan Compares with the Competition Table 3-1 (cont.): PowerCommand Transfer Switch Level 1 Control Competitive Comparison
PowerCommand Transfer Switch Level 1 Control External Interfaces
Basic panel (source available/ connected indicators, test/ exercise/ bypass buttons) Optional vacuum fluorescent digital display Optional Front Panel Security Key
Asco 300
Zenith ZTG
Panel with source available and connected LEDs, exerciser switch, test switch, and time delay bypass switch
Basic panel with source available and connected and time delay timing LEDs
Onan provides the option of adding a vacuum fluorescent digital display. Other transfer switches do not provide displays. Vacuum fluorescent displays have better performance over extreme temperatures than LCD displays. The security key enables operation of the switch at the front panel preventing unauthorized personnel from initiating a transfer. All PowerCommand switches can interface with other LONWorks compliant devices allowing economical addition of transfer switch information into PowerCommand Systems and Building Automation networks. Only Onan provides time sequenced transfer switch and network event information at the digital display. This will greatly improve troubleshooting and serviceability of the entire power system. Only the OTPC can move the entire load to a neutral position, disconnected from both sources
Network
LONWorks compliant network interface
Serial Communications board for use with PowerQuest.
None
Events
Sequenced event recording Optional network event display
None
None
Options
Signal module Loadshed
Load disconnect signal
Elevator pre-signal
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PowerCommand Transfer Switch Level 2 Control
At the upper end of the transfer switch market are those businesses with a requirement for high reliabilitycentral office telecommunications, data centers, health care and critical care facilities. These customers want products that enhance total system reliability, and they are willing to pay for it. Typically they require more sophisticated sensing and control features and often incorporate the transfer switch into a more elaborate back-up power scheme.
Asco 7000 Series
Figure 3-2: Competition for the PowerCommand Transfer Switch Level 2 Control
Positioning the PowerCommand Transfer Switch Level 2 Control
In addition to Onan, three suppliers make premium switchesAsco, Russelectric and Zenith. As mentioned, the Zenith business strategy to follow Asco limits their comparative advantage, particularly in this high range of product. As a result, we will focus on a comparison of the Onan OTPC Transfer Switch Level 2 Control, the Asco 7000 and Russelectric Model 2000 (see Table 3-2).
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Table 3-2: PowerCommand Transfer Switch Level 2 Control Competitive Comparison

PowerCommand Transfer Switch Level 2 Control Control platform
Microprocessor-based Multi-language display Password protection of settings
Asco 7000
Microprocessor-based Voltage selectable Multi-language display Password protected
Russelectric 2000
Microprocessor-based Password protected

Onans microprocessor is designed to be common platform that can directly communicate with other PowerCommand products for applications worldwide Onan provides a competitive sensing package designed to meet industry specifications
Sensing
3-phase over/under voltage sensing on normal and emergency Under/over frequency on normal and emergency Voltage imbalance sensing Phase rotation sensing Loss of single phase detection Standard open transition Standard programmed transition In-phase monitor with programmed transition backup (on the PLTO) Closed transition (on the PLTH) Closed transition with active synchronization (on the PLTS and PLTH) Optional bypass isolation (available on the BTPC)
3-phase over/under voltage sensing on-phase normal and emergency Under/over frequency on normal and emergency (+/- 0.2%) Voltage imbalance sensing Phase sequence sensing Standard open transition Delayed transition (requires additional switch hardware) In-phase monitor Closed transition option Optional bypass isolation
3-phase over/under voltage sensing on normal and emergency Under/over frequency on normal and emergency Phase sequence detection Voltage imbalance sensing Phase differential monitoring Standard open transition Delayed transition (requires additional switch hardware) Sync check (In-phase monitor) Closed transition option available Optional bypass isolation
Transfer modes
The OTPC and BTPC remain the only switches on the market that can provide programmed transition as standard. Onan has also improved the in-phase monitor by providing a programmed transition backup. The PLTS and PLTH can actively synchronize with a PCCII generator set.
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3. How Onan Compares Against the Competition Table 3-2 (cont.): PowerCommand Transfer Switch Level 2 Control Competitive Comparison
PowerCommand Transfer Switch Level 2 Control Generator set exerciser
Calendar-based exerciser
Asco 7000
Russelectric 2000
1, 7 14 or 28 day exerciser clock
Calendar-based exerciser
The Onan calendar-based exerciser uses a real-time clock that allows up to 8 separate exercise programs to be set up to accommodate plant maintenance schedules, plant shutdowns, holidays, etc. The clock also automatically corrects for daylight savings and leap year. Vacuum fluorescents provide higher visibility and better performance at extreme temperatures, especially below 20C. Only Onan offers meters as a pricebook option. The LED bar graph meters provide color-coded indication for at-a-glance visual determination of source and load acceptability. Onans network interface is designed to be LONMark compliant, allowing integration into building automation systems.
External interfaces
Vacuum fluorescent digital display Basic panel (source available/ connected indicators, test/ exercise/ bypass buttons) Optional digital LED bargraph meter panel Front panel Security Key Optional network board Lonworks compatible Transfer switch and generator set status from network
LCD digital display Touchpad programming of features and settings
LCD digital display Source connected LEDs Optional annunciation plate with source available, connected, not in auto, and audible alarm.
Network
Serial comm board (RS 422/485 protocol) for use with proprietary PowerQuest
Serial comm port (RS422/485 ModBus RTU protocol) for use with BMS or Russel Scada system
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3. How Onan Compares Against the Competition Table 3-2 (cont.): PowerCommand Transfer Switch Level 2 Control Competitive Comparison
PowerCommand Transfer Switch Level 2 Control Events/ history
Date/time stamped 50 logged events Network event information available at the digital display
Asco 7000
Russelectric 2000
Date/time stamp 99 logged events Total ATS transfers ATS failures due to source failure Total days of ATS operation Total source available hours Programmable loadshed
Date/time stamped most recent 10 transfer events (numeric codes) Total each source available Total each source connected Number of transfer operations to each source Loadshed
Onan provides more types of event and history information to make diagnostics and record-keeping easier.
Options
Signal module Loadshed Load power and load current monitoring Load sequencing via the network
Only Onan senses source voltage current, load, KW and PF in the transfer switch. This means that the information is available from the transfer switch and can be accessed using InPower or communicated across the network from one device. Both Asco and Russelectric rely on separate add-on load monitoring packages.
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Transfer Switch Features Compared to Other Suppliers
The following pages (Table 3-3) chart a comparison of the features Onans transfer switches offer to those available from other major suppliers. Understanding exactly where Onan fits in this market is essential to successfully positioning your products with customers.
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Table 3-3: Comparison of Transfer Switch Features Provided by Major Suppliers

Feature Mechanically held switch Onan Asco Russel Zenith Generac Kohler Why this is important: Mechanically latched contacts help the switch withstand faults by locking the contacts closed. Some switches can be manually operated but not latched, so an improper service operation can leave the switch closed, but not latched. This can cause failure of the ATS. Silver alloy provides better durability than pure silver. Arc chutes accelerate arc extinguishing and minimize contact wear on switching. Prevents improper operation of the switch during service operations. Makes switch safer to operate manually. Most effective way to deal with transfer of inductive loads. Permanent mounting helps prevent misoperation, loss of manual operators. Safer manual operation. Barriers prevent direct inadvertent contact to dangerous voltage levels. Allows visual inspection of the switch mechanism without moving protective covers. see note 1 Prevents accidental out of phase paralleling of sources, or energizing a generator set that is shut down. Either can cause serious damage to the generator set. Eliminates the danger of misoperation of neutral poles, which can cause operational and safety hazards. Provides for synchronized opening of all contacts and minimizes the possibility of transient switching overvoltages.
Silver alloy contacts Multiple leaf arc chutes Quick-make, quick-break mechanism Programmed transition Permanently attached manual operators Barriers over all live parts, including lugs Transparent barriers Positive mechanical interlock True 4-pole (simultaneous) neutral switching Common Crossbar on 3Pole and 4-Pole Switches
see note 2 see note 3
see note 2
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3. How Onan Compares Against the Competition Table 3-3 (cont.): Comparison of Transfer Switch Features Provided by Major Suppliers
Feature Controls door-mounted Controls isolated from switch for service Standard sensing and timing in one control package One electronic control for all ratings High voltage surge and noise immunity Onan Asco Russel Zenith Generac Kohler Why this is important: Door-mounting the control makes it more accessible, easier and safer to work on. Control disconnect plug allows isolation of the control for service without interrupting power to loads. Entire control system prototype-tested as system. Ease of service, availability of spares is improved. Improved reliability. Control is resistant to voltage surges due to lightning and other transient effects. If the voltage surge exceeds specified parameters, the Onan control will start the generator set and transfer power, so customer knows failure has occurred, and problem can be fixed. Provides diagnostics and fault indicators to make service easier. LEDs designed to operate for the life of the control. Helps to protect the control from voltage surges and transient conditions that might damage the control. Allows field modification of voltage conditions to suit the needs of the application. More reliable Indication of failed source. Voltage sensors identical for both sources. Better parts availability, easier service and calibration. Better protection for loads. Single source for technical information, product startup, service, warranty, parts.
Internal LED status lamps Control I/O isolated Field adjustable, calibrated voltage sensors Sensors on all phases of both sources Service for entire power system from a single supplier
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3. How Onan Compares Against the Competition Table 3-3 (cont.): Comparison of Transfer Switch Features Provided by Major Suppliers
Feature Can be networked with any transfer switch from any supplier Can be networked with any generator set from any supplier Non-Load break bypass available Bypass to any source at any time Bypass includes deadsource interlock Onan Asco Russel Zenith Generac Kohler Why this is important: Network is suitable for use in any building, even when switches from several suppliers are in place. Minimizes costs of system monitoring. Network is suitable for use in any building, even when equipment from several suppliers are in place. Minimizes costs of system monitoring. No power interruption to critical loads when maintenance or service of switch is needed. Bypass switch is isolated from current surges that could damage it in day to day operation. Ease of operation. System is more reliable. Prevents situation where system is connected to a source that is not available.
see note 1
Asco/Kohler Notes 1. Switch can be manually operated to a new position without locking contacts in place. Or, could leave in neutral position and switch cant recover. 2. Model 300, 940 and 962 are not available with this feature. In phase monitor substituted. 3. Closed transition transfer switches (Model 436) do not have mechanical interlock. Mechanical interlock is required on transfer switches by NFPA 99. 4. Kohler can offer switch mechanisms that meet this requirement. Russelectric Notes: 1. Russelectric has quoted non-load break bypass switches, but we have not seen any literature describing them. Standard product is a load break bypass. Zenith Notes 1. Switch can be manually operated to a new position without locking contacts in place. 2. Zenith offers a closed transition transfer switch that does not include mechanical interlock. Mechanical interlock required by NFPA99. 3. Mechanical interlock is required on transfer switches by NFPA 99. Generac Notes 1. Switch can be manually operated to a new position without locking contacts in place. 2. Silver contacts used on larger ATS models. 3. Not available on switches rated 250VAC and lower 4. Available only on switches rated 250VAC and lower
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Lesson Three Progress Check

Answer the following questions based on information provided in the lesson. When finished, check your responses against the answers shown following this progress check. 1. List three competitive advantages of the Onan Level 1 control versus the Asco 300.
2. List three competitive advantages of the Onan Level 2 control versus the Asco 7000.
3. The OTPC load monitoring option is integral to the Onan transfer switch. Explain the competitive advantage over Russelectric and Asco.
4. Explain the importance of LONMark compliance.
5. Describe the importance of a single source supplier.
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3. How Onan Compares Against the Competition Answers to Lesson Three Progress Check 1. Refer to Table 3-1 for a comprehensive listing of the competitive advantages of the Onan Level 1 control. 2. Refer to Table 3-2 for a comprehensive listing of the competitive advantages of the Onan Level 2 control. 3. Only Onan senses source voltage current, load, KW and PF in the transfer switch. This means that the information is available from the transfer switch and can be accessed using InPower or communicated across the network from one device. Both Asco and Russelectric rely on separate add-on load monitoring packages. 4. LONMark compliance is an industry standard that ensures compatibility with other building maintenance systems. 5. A single source supplier offers many advantages. For example, service is more easily arranged since only one vendor needs to be contacted. The system is more integrated; if the design of one or more components change system integrity is preserved. The components are designed originally to complement a systems approach.
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Lesson Four: The PowerCommand Control Network

Objectives
After completing this section, you should be able to:
Characterize the market for PowerCommand

Networks. Explain the features and benefits of adding transfer switches to a PowerCommand Network. Describe the Network Communication Module hardware and how to add the feature to an OTPC or BTPC. Describe the types of information that can be sent and received by the PowerCommand Transfer Switch.
The Opportunity for Network Solutions
Lets begin by looking at the type of facilities that can benefit from a network solution. After examining key market opportunities, the lesson continues on to explain the key features and benefits of the transfer switch Network Communication Module (NCM). The NCM is the interface between the transfer switch and the network. While the PowerCommand Network can be applied to any generator set application, it is most ideal for those companies with multiple buildings and sites and a large number of generator sets to manage. The following provides a profile of the type of plant to target for this application and identifies the industries where you might find customers with these types of needs. Keep in mind that when new construction is being planned, the opportunity for the PowerCommand Network is even greater, because savings on installation and material costs are easy to estimate in this early stage.
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4. The PowerCommand Control Network Table 4-1: Profile of Candidates for PowerCommand Network
Physical Plant Characteristics Life-safety code-driven buildings, such as single buildings over 6 stories and facilities governed by NFPA 99 or 110 Generator sets in multiple buildings or installations on one site Examples of Industries Healthcare Hotels Commercial real estate Colleges and universities Correctional facilities Manufacturing plants Wastewater treatment facilities Some healthcare facilities Retail chains Public utilities Telecommunications Gas pipelines Some healthcare facilities
Multiple installations distributed over a wide area
Benefits of a Network Solution
For these targeted customers, it is important to consider the following benefits when evaluating a sales opportunity. A network solution:
Reduces or controls the cost of monitoring and

servicing standby power at all sites.
Improves system reliability through improved

operations and maintenance.
Is proactive in its automatic alarm notification to local

or distant technical personnel.
Provides complete and convenient documentation of

operation, maintenance, and service.
Is compliant with code requirements for record

keeping.
Allows flexibility in adding or modifying facilities

and does so economically.
Connects easily with building automation systems.
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4. The PowerCommand Control Network
Now, take a closer look at specific markets that can benefit from PowerCommand Network. The three segments that will be examined in more detail further on are as follows: Healthcare Retail Telecommunications
Opportunities in Healthcare Facilities
The healthcare industry has particular stringent requirements for power, because patients they treat often depend on equipment for survival. Reliability is a critical factor in their decision to buy any power system. This is reinforced by building and National Fire Protection Association (NFPA) codes, specifically those that apply to healthcare facility construction: NFPA 110 defines the performance required of emergency or standby power systems. NFPA 99 is the standard for healthcare facilities. It tells how the testing and record-keeping requirements of the emergency and standby power system are to be met. It also specifies loads that must be transferred to the generator. State and local building codes will reference this code. The Joint Commission on the Accreditation of Healthcare Organizations (JAHCO), often referred to as the Joint Commission, also influences requirements. It inspects facilities every six months for accreditation renewal and can be compared to professional licensing for the hospital business.
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Joint Commission Requirements
The Joint Commissions Accreditation Manual for Hospitals references NFPA 99 and includes requirements for documenting the maintenance and testing of the emergency/standby power system during routine operations. The healthcare facility must inspect the emergency standby power system weekly and exercise it monthly. When the Joint Commission makes accreditation visits, it reviews the records of these inspections and tests. The monthly exercise is required to be performed for 30+ minutes at operating temperature at no less than 30% of the generator rating. You will find that the parameters monitored during monthly exercising are displayed on PowerCommand Control and can be monitored locally or remotely via a PC. The following table summarizes features and benefits of the PowerCommand Network that benefit healthcare operations. The table lists several features that address Joint Commission requirements.
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4. The PowerCommand Control Network Table 4-2: Benefits of PowerCommand Network for the Healthcare Industry
PowerCommand Network Features PowerCommand Control design enhances reliable generator set startup Automatic alarm notification Dial-out capability for change-of-state, warning or shutdown conditions PowerCommand software for Windows keeps records of system status and test performance conveniently PowerCommand software for Windows permits local or remote monitoring and control. Local distributorships can perform diagnostics from their distributorship. Benefits to Healthcare Customers Risk management Minimizes repair time and expense Greater flexibility because staff can circulate within or away from the facility Risk management because no need for humans to transfer alarm messages Low cost, convenient, compliance with accreditation and code requirements Date/time stamp of events provide verification of actual system performance Saves time for the facility engineer Saves personnel costs: a few highly qualified individuals monitor and control remotely, while less qualified people do simpler on-site tasks Enhances system reliability through wellqualified technical service Saves money on installation Saves money on future modification Operating personnel need not be present Events recording provides verification of actual system performance
PowerCommand Network uses logical connections rather than hardwiring between modules. Automatically records duration, load level, and operating temperature conditions of generator set during monthly exercise and whenever generator set runs for any reason (actual outage, testing after repairs, etc.) Automatically collects all available generator set operating data at user-defined intervals and stores data in permanent record. Formats generator set operating data in standard printed report. Records date and time intervals of automatic generator start-up and shutdown processes (during exercise and actual outages) Records date and time intervals of automatic transfer switch tests and transfer switch position Records automatic transfer switch operating data (current and voltage) on user-defined intervals and stores data in permanent record. Automatic alarms notification to monitoring PC, via local network wiring and/or telephone modems to remote location, including automatic paging capability for unacknowledged alarms. Provides near immediate notification from unattended equipment whether running or not.
Record may be viewed, downloaded or printed No manual transcription errors Operating personnel need not be present Meets documentation requirements of JAHCO Consistency of data Saves time for facility engineer Meets data requirements of JAHCO Events recording provides verification of actual system performance Meets data requirements of JAHCO Events recording provides verification of actual system performance Meets data requirements of JAHCO Events recording provides verification of actual system performance Meets data requirements of JAHCO Operating personnel need not be present
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Opportunities in Retail Markets
Retail facilities are realizing the growing importance of emergency power for several reasons including:
The need to protect public safety and avoid liability. Prevention of lost sales by enabling customer to keep
shopping during power outages.
Prevention of losses due to theft or spoilage.

National chains benefit from PowerCommand Networks remote monitoring and automatic dial-up alarms, which relieve the need for local expertise and help ensure reliability at all locations. The following figure summarizes benefits of PowerCommand Network for the retail industry. Table 4-3: Benefits of PowerCommand Network for the Retail Industry
PowerCommand Network Features Benefits to Retail Customers
Remote monitoring and control of systems with PowerCommand Network
Reduces the need for on-site expertise. Skilled individuals at headquarters or distributor can manage preventive maintenance. Technically qualified individuals are available through Onan distributors
Cummins/Onan distributors can provide technical assistance. PowerCommand Network can be set up to notify the distributor when service is needed. Reliability of the standby power system under PowerCommand Network Cost of system could be offset by customer benefits
Ensures public safety, loss prevention and (with a 100% standby system) continuity of operations and revenue flow. Cost of standby system with PowerCommand Network may be offset by reduced time driving to sites, exercising generator sets and recording information.
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Opportunities in Telecommunications
Telecommunications has become a highly competitive industry that includes regional operating companies, which deliver telephone service over telephone lines, operations that serve smaller areas, and cellular companies that use radio equipment and sell communications. All of these operations involve dispersed locations that require a reliable power source. With the remote monitoring and exercising of generator sets available with the PowerCommand Network, a qualified engineer at a central location can perform diagnostics and send appropriate technicians to perform the service, which is of tremendous value in convenience and time. And because the loss of telephone service can cost these companies as much as $10,000 per minute of lost revenue, the increased reliability with PowerCommand Network will provide even greater value.
Table 4-4: Benefits of PowerCommand Network for Telecommunications Industry

PowerCommand Network Features PowerCommand Control design enhances reliable generator set startup Benefits to Telecomm Customers Maximizes reliability of standby power system, which in turn minimizes lost revenue and supports life-critical applications such as 9-1-1 service. Saves travel and personnel costs by allowing monitoring and control of multiple sites at a central location, requiring fewer skilled people to operate. Provides operational information to a central monitoring point via modem for evaluation and dispatch by trained personnel. Reduces travel and troubleshooting time by providing key information before the service technician leaves for the call. Convenient method for system-wide testing and evaluation concerns.
Permits remote monitoring and control from a central monitoring facility.
Automatic alarm notification. Dial-out capability for change-of-state, warning or shutdown conditions
Can communicate data necessary for evaluation of system status and test performance Onan PowerCommand Transfer Switch
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4. The PowerCommand Control Network Next the lesson examines how transfer switches interface to the PowerCommand Network with hardware and software components.
Connecting to the Network
Incorporating transfer switches into a PowerCommand network can provide powerful benefits to the customer. As part of an integrated standby power system, the transfer switch can start a generator set and monitor conditions with reduced installation and wiring costs to the facility. Building automation or SCADA systems can use real time source and load data to maximize power reliability, reduce facility energy costs and manage emergency conditions. Now well examine the hardware interface of the transfer switch with the network. The Network Communication Module (NCM) provides a LONWorks network interface to the OTPC and BTPC Controls. The NCM uses the (existing) 78 KBPS twistedpair, transformer-coupled transceiver to interface to the PowerCommand Network. The NCM is an add-on daughter-board module to the OTPC and BTPC Level 1 and Level 2 digital control boards. It is connected to the OTPC and BTPC control through a ribbon cable connector. The NCM requires two three-volt lithium cells for back-up power during extended power outages. Additional battery input is provided for external (DC) power supplies. The NCM is compatible with all existing PowerCommand Network modules (CCM, DIM, and GCM). The NCM provides remote communications, monitoring, and dialout to PowerCommand Network sites via modem (and gateway) hardware. (See Figure 4-1 for the location of the NCM.)
Network
Communication
Module (NCM) Hardware
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Network Communications Module added here
Figure 4-1: NCM Installed on PowerCommand Transfer Switch Level 2 Control
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Network Communication Module Software
The Network Communication Module operates by sending defined packets of information out on the network. These packets, called network variables, are available to all devices residing on the network. Usually, only specific types of devices are programmed to use specific variables. LONMark compliance means that the Onan network variables are formatted to the LONMark standard and that all LONMark compliant devices can recognize and use the information. As the author of the LONMark transfer switch standard, Onan has ensured that we meet the requirements for basic and optional network variable information. We have additional network variables that allow our generator sets, transfer switches and other equipment to have an even tighter level of integration. As the sole-source supplier of an emergency power system, the network is a key advantage in terms of system integration and improved reliability, service and information to the end user. The transfer switch network input and output variables are detailed in Appendixes B and C. The charts define the purpose of each variable and the types of equipment that provide the inputs or can receive and use the inputs.
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Lesson Four Progress Check

Answer the following questions based on information provided in the lesson. When finished, check your responses against the answers shown following this progress check. 1. What advantage does the PowerCommand Control provide to healthcare facilities that must inspect their emergency standby power systems weekly and exercise them monthly? _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ 2. In the telecommunications industry where dispersed operations require a reliable power source, what value does the PowerCommand Network provide? _______________________________________________________________________ _______________________________________________________________________ 3. Which of the following applies to the Network Communication Module (NCM)? a. The NCM does not require back-up power. b. It is compatible with two of the three existing PowerCommand Network modules. c. It provides a LONWorks network interface to the OTPC and BTPC Controls. d. It interfaces with the PowerCommand Network by a twisted-pair transformer-coupled transceiver. 4. The Network Communication Module operates by sending defined packets of information called _______________ __________________ out on the network. 5. _________________ _____________________means that the Onan network variables are formatted to the standard and that all compliant devices can recognize and use the information.
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4. The PowerCommand Control Network Answers to Lesson Four Progress Check
1. The parameters monitored during monthly exercising are displayed on the PowerCommand Control and can be monitored locally or remotely via a PC. 2. A qualified engineer at a central location can perform diagnostics and send appropriate technicians to perform any service required, which is of value in convenience and time. 3. c and d. It provides a LONWorks network interface to the OTPC and BTPC Controls and it interfaces with the PowerCommand Network by a twisted-pair transformer-coupled transceiver. 4. The Network Communication Module operates by sending defined packets of information called network variables out on the network. 5. LONMark compliance means that the Onan network variables are formatted to the LONMark standard and that all LONMark compliant devices can recognize and use the information.
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Lesson Five: InPower Service Tool

Objectives
List the products available with the InPower Service

Tool.
Identify the tasks that can be performed on the

PowerCommand Transfer Switch using InPower.
Describe the requirements for a personal computer

and how it is used with the InPower software.
Explain the information that the InPower Service Tool

can monitor.
Overview of the InPower Service Tool
As described in previous lessons, the PowerCommand Transfer Switch microprocessor technology provides a high level of sophistication in terms of monitoring adjustment capability and record keeping. The most effective way to use this technology is with the InPower Service Tool. InPower will transfer information between your laptop PC and the PowerCommand Transfer Switch in a Windowsbased environment to perform the following tasks:
Features of InPower
Adjustments for trims and settings Monitoring of parameter values Display of faults and online access to the Fault
Information System (FIS). Note: The FIS online help files are not available with InPower Verson 1.09.
Test of inputs and outputs Strip chart for viewing and comparing selected
parameters
Data logging Reporting and printing of parameter values Creation of a capture file of device parameter values
5. InPower Service Tool This lesson concentrates on the information available specifically for transfer switches. Other generic features of InPower such as pull down menus and strip chart functions are covered in separate training available on InPower hardware and software. This lesson provides a quick reference for getting started. How InPower Works The PC running the software is connected to the transfer switch by an RS-232 serial communications cable. This serial cable is connected (COM) port on the service PC with a DB9 connector. Both generator set and transfer switch applications use a DB9 connector. (Generator set applications can also use the 9-pin Deutsch connector and connect via the engine harness.) InPower uses a hardware security lock called a dongle, which prevents unauthorized copying of the software and unregistered access to a controller. The dongle must be attached to the service PC curing InPower installation. It stores the InPower product serial number and the registration password. The registration password is obtained by contacting the Cummins Service and Support group. It can be entered by during the initial InPower installation or by reinstalling InPower. Minimum PC Requirements The service PC that is used for this application must meet the following requirements:
Microsoft Windows 95, Windows 98, or Windows

NT 4.0 operating system
An IBM PC or compatible with a minimum of

Pentium 300
32 to 64 megabytes of RAM and 75 megabytes free

hard drive space recommended
Active matrix display Microsoft bus mouse or compatible pointing device
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5. InPower Service Tool
24X CD-ROM One free serial communications port

(COM1- COM 4)
Parallel port Windows supported A4 printer (optional)
InPower Transfer Switch Information

Monitor
InPower software for the PowerCommand transfer switch has three sections of information:
Monitor Adjustments Faults/Events

InPower can be used to monitor many parameters of the PowerCommand transfer switch. See Appendix D for a chart of information and parameters that InPower monitors. All adjustments can be made using InPower. While most parameters can be reached from the Alphanumeric Display, the Windows-based format will allow adjustments to be made more quickly. See Appendix E for the adjustments or set-ups that are available. The PowerCommand Transfer Switch keeps a rolling log of the last fifty events or faults. It also keeps historical statistics on each type of fault. This information can be pulled up by InPower for diagnostics and reporting. See Appendix F for the faults and event information that can be obtained from the transfer switch using InPower.
Adjustments
Faults/Events
Self-Study Page 58
5. InPower Service Tool
Lesson Five Progress Check

1. True or False. The computer running InPower software must have one serial port and two parallel ports available in order to run the application. 2. Identify the three sections of the InPower Service Tool:
3. InPower will tell the operator total number of voltage imbalance failures seen by the transfer switch. What else will it tell the operator about Source undervoltage failure? ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ 4. Name some of the tasks performed by InPower. ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ 5. True or False. InPower is never required when an alphanumeric display is included in the transfer switch.
Self-Study Page 59
5. InPower Service Tool Answers to Lesson Five Progress Check
1. False. The computer running InPower must have one communications port and one parallel port available. 2. The InPower Service Tool has three sections of information: It can monitor information about the transfer switch. It can be used to make adjustments. It provides fault information.
3. For each type of fault or event, the system will tell the operator the: Event code Current status of event Time last occurred Total occurrences Dialout status (yes/no)
4. The following tasks will be performed by InPower: Adjustments for trims and settings Monitoring of parameter values Display of faults and online access to the Fault Information System. Note: The FIS online help files are not available with InPower Verson 1.0. Test of inputs and outputs Strip chart for viewing and comparing selected parameters Data logging Reporting and printing of parameter values Creation of a capture file of device parameter values
5. False. InPower is required regardless of whether an alpha numeric display is included in the transfer switch.
Self-Study Page 60
Lesson Six: Transfer Switch Selection

Objectives
Identify the primary factors to consider when

selecting a transfer switch.
Review a specification for an automatic and a bypass

transfer switch.
Important Factors in the Selection of a Transfer Switch
The proper selection of a transfer switch is based on a number of factors. These include the following:
Criticality of load Maintenance requirements Ampere rating of feeder circuit breaker/AIC of circuit
breaker
Type of load 3-pole or 4-pole Voltage/frequency/three phase or single phase Indoor or outdoor Controls sophisticationsensing, interface and communications capabilities
Case Studies
The two following situations give you an opportunity to decide how to handle a request that comes in from a prospective customer. Read each case, then refer to specification sheets as needed, and write a description of what you would recommend to the prospect. Following these exercises, you will find feedback on what would be appropriate recommendations.
Self-Study Page 61
6. Transfer Switch Selection
Exercise 1: Hospital Setting
A consulting engineer is doing design work for a hospital and he has requested your help in selecting a switch. He provides the following information:
The load consists of life support and monitoring

equipment for the hospitals new burn unit.
The hospitals chief facility engineer is concerned

about failure modes and minimizing extended interruptions to the load under all circumstances.
This switch will be located in the basement and the

generator set will be on the roof.
The system is 277/480 volts with ground fault

protection on the service and feeder breakers.
The feeder is 800 amps and the available fault current

is 65 KA. What would you recommend? (Record your response here.)
Self-Study Page 62
Exercise 2: Wastewater Treatment Plant
An engineer has asked you to help select a switch for a wastewater treatment plant. You learn the following:
It is a wet, dirty environment. The customer wants to test the system unattended. The systems voltage is 277/480 with ground fault
protection.
There is a 600A feeder with an available fault current

of 65 KA.
The steady-state load is 75% of the capacity of the

generator set KW rating. The load is lighting and pumping equipment. The engineer does not want to increase the size of the generator in order to keep the project cost down.
This is a water authority with multiple sites that they

want to monitor. They want to use Intellution software to monitor all sites at a central location. All other sites currently have Onan OTIII switches and generator sets with PowerCommand controls. What would you recommend? (Record your response here.)
Turn to the following page and compare your recommendations to the ones provided.
Self-Study Page 63
6. Transfer Switch Selection The following recommendations would be appropriate for the settings described in each exercise. Exercise 1: Potential Solution For the hospital setting you can propose the following:
This is a critical care facility. A burn unit will have a

large number of monitoring devices as well as other equipment. Inductive loads are not an issue so programmed transition is not required. If, at a later date, new loads are added that may require programmed transition, it is always included as standard and can be enabled from the front panel digital display.
The facility engineer is concerned about maximizing

system reliability. Points to discuss would be: The bypass isolation feature allows service and unloaded testing of the transfer switch without interruption to the load. In the event of an emergency or unexpected maintenance situation, the BTPC is a non-loadbreak bypass capable of being safely transferred to either live source at any time. In the event that the transfer switch does not operate, the engineer can easily and reliably get power to the load using the manual bypass capability, which can be operated without opening the cabinet. The switch can be serviced quickly and safely while the load is bypassed.
Transparent Lexan shields cover all live parts,

including lugs.
Safety shutters close to prevent inadvertent contact

with the disconnected conductors.
Extension rails allow the ATS to be rolled out of the

cabinet for easy removal.
Load monitoring and bar graph metering are options

6. Transfer Switch Selection that will provide power and current data and at-aglance visual indications that the load is within rated parameters.
A network could be recommended, emphasizing that

the engineer could obtain generator set status and event data at the transfer switch without going to the roof.
This switch will be located in the basement so a UL

Type 1 enclosure will be acceptable.
With a 277/480-volt system with ground fault

protection, a four-pole switch would be recommended. The four-pole switch eliminates a parallel path for returning ground fault current on the neutral. This ensures that the sensing for ground fault protection is accurate.
The feeder is 800 amps and the available fault current

is 65 KA, so the BTPC will meet these requirements. Emphasize that every manufacturers circuit breaker listed with our BTPC is individually reviewed and endorsed by UL. This can make the engineers job easier since the trip curves have already been researched. This cannot be said of 3 cycle ratings, because even if a transfer switch has a 3 cycle rating, it is up to the engineer to confirm that the two devices (transfer switch and breaker) are compatible. Exercise 2: Potential Solution For the water treatment plant, you want to make a recommendation such as the following:
Since the ground fault protection is only at the

service, a 3-pole, 277/480 VAC switch should be proposed.
Because central monitoring is required, networking

should be discussed, including Onans previous experience with a variety of third party software including Intellution.
Self-Study Page 65
Because the customer wants to test the system

unattended, you can emphasize that exercise clocks are always standard. Also emphasize that remote testing can be done via the network from the central monitoring facility.
With a steady-state load at 75% of generator set and a

number of large motor loads, the engineer will want to break up the load and stagger them onto the generator set to minimize the inrush. This can be done in several ways. Several transfer switches can be used with varying transfer or programmed transition time delays to start individual loads sequentially. Another method would be to use the network load sequencing option. In this case, the transfer switch would send signals to network I/O modules with pre-configured delays for contact closures. These would turn the motor loads on in a prescribed order. Other options the engineer may want to consider are time delay relays on the motor starters or the use of a PLC to control the motor loads.
Again, a 600-amp feeder with an available fault current of 65 KA is appropriate for an OTPC 600. And you will want to emphasize once more that every manufacturers circuit breaker listed with our BTPC is individually reviewed and endorsed by UL.
For a wet, dirty environment, this setting will require a NEMA Type 4 enclosure that is suitable for clean in place. If a customer requires a NEMA 4X (corrosionresistant), discuss providing an open construction switch and arrange for a custom enclosure.
Self-Study Page 66
Appendix A: Digital Alpha Numeric Display

Control Display Source-1 and Source-2 Information Setup Statistics Summary Information
Network About Information
AC Load Monitoring (Optional)
Voltage L1-L2, L2-L3, L3-L1 Source frequency Sensors and setpoints Time delays On time Source 1 On time Source 2 Average transition time Total transfers
Source connected On-time Test Generator set exerciser Total Source 1 failure Total Source 2 failure Control battery status Battery charger status
Generator status for up to 16 networked generator sets Load sequencer for sequencing signals for up to eight loads Version Date of manufacture Serial number PRODUCTION CODE AC volts (line to line and line to neutral) Frequency Current (amps) Rest power (kW) Apparent power (kVA) Power factor Neutral current ATS mode LONWorks Interface Module installed Relay Module installed
Self-Study Page 67
Digital Alpha Numeric Display
Control Display Events
Detailed Information
Fault event definitions Controller checksum error Low controller battery ATS fail to close: retransfer ATS fail to close: transfer ATS fail to disconnect Battery charger malfunction Network battery low Network communications error ATS common alarm (network only) Non-fault event definitions Source-1 connected Source-1 available Source-2 connected Source-2 available Emergency start-A Test start-A Emergency start-B Test start-B Time delay start-A (TDES-A) Time delay start-B (TDES-B) Time delay normal-to-emergency (TDNE) Time delay emergency-to-normal (TDEN) Time delay engine cool-down (TDEC) Time delay programmed transition (TDPT) Transfer pending (TDEL) Test in progress Exercise in progress
Source-1 under-voltage failure Source-1 over-voltage failure Source-1 over/under frequency failure Source-1 voltage imbalance failure Source-1 loss of phase failure Source-2 under-voltage failure Source-2 over-voltage failure Source-2 over/under frequency failure Source-2 voltage imbalance failure Source-2 loss of phase failure Phase rotation failure Not in auto: ATS motor disconnected Not in auto: load shed Not in auto: transfer inhibit Not in auto: re-transfer inhibit Not in auto: ATS bypassed to Source-1 Not in auto: ATS bypassed to Source-2 Not in auto: common output (network) Service tool connected Closed transition transfer Synch enable output Speed adjust command (network) System fail to synchronize Load sequencer outputs (1-8) Network wink
Self-Study Page 68
Appendix B: Transfer Switch Network Input Variables

Network Variable NviTestCmd NviStartCmd Description Network Remote Test (w or w/o load) is used to allow another network device to test the transfer switch This input is used only for dual standby operation (both Source1 and Source2 are generator sets) where the ATS is made to 'appear' as a single generator set. When true, the PowerCommand Transfer Switch Control will start one of the backup generator sets. Used By Master Control PowerCommand Transfer Switch Control, ATS w/ Control Communications Module (CCM) Master Control Master,PowerCommand Control 1 (PCC1), PCC2 Master Control Master Control Master Control PowerCommand for Windows (PCW) PCW PCW PCW PowerCommand Control Transfer Switch Control, ATS w/CCM PCC 1, 2, Generator set w/CCM
NviFaultResetCmd NviLoadShedCmd
This input will clear or acknowledge the current ATS fault(s). This input is used to instruct the ATS to shed and restore its load.
NviOverrideCmd NviTransInhCmd NviRetransInhCmd NviRelayControl1* NviRelayControl2* NviRelayControl3* NviRelayControl4* NviATSStatus
This input is used to instruct the transfer switch to override (bypass) any delays or inhibits, but not load shed. This input is used to disable the ATS from transferring to Source2. This input is used to disable the ATS from transferring back to Source1. PowerCommand for Windows uses this input to remotely shed and restore load from the ATS. PowerCommand for Windows uses this input to remotely inhibit transfer of the ATS. PowerCommand for Windows uses this input to remotely test the ATS. PowerCommand for Windows uses this input to override a transfer delay or inhibit. This input is used to allow the transfer switch to view the status of other transfer switches in the system. The input is limited to monitor a maximum of 16 transfer switches. Information that can be viewed include: device name, auto/not-in-auto, source connected, event code and type (fault, warning, inoperable), % rated load current, KW, NFPA annunciation, extended annunciation This input is used to allow the transfer switch to view the status of other generator sets on the network. The input is limited to monitor 16 generator sets. Information that can be viewed includes: Generator set name Generator set type (PCC 1, 2, generator set with GCM) Control position (off, run/manual) Generator set state (stopped, start pending, warm-up-idle, running, cool down rated, cool down idle) Fault code and type (event, warning, derate, shutdown with cool down, shutdown) % rated KW NFPA annunciation Extended annunciation This input is used to allow the transfer switch to view the status of Source1. The input is limited to monitor a single generator set. This input is used to allow the transfer switch to view the status of Source2. The input is limited to monitor a single generator set. This input is used to allow the generator set to view the status of the Master Control. The input is limited to monitor a single Master Control. This input is used to allow the generator set to view the AC load data at the Master Control. The input is limited to a single Master Control.
NviGenStatus
nviSrc1Status nviSrc2Status NviMasterStatus NviMasterACData
PCC 1, 2 Generator set w/CCM PCC 1, 2, Generator set w/CCM Master Control Master Control
* Required for PowerCommand for Windows v1.10.
Self-Study Page 69
Appendix C: Transfer Switch Network Output Variables

Network Variable NvoStartTypeB Description This output is only used with a PowerCommand Control 2 generator set. This output is used to configure the PowerCommand Control 2 generator set for emergency or non-emergency start. It will not start or stop the generator set. This output is used to start a generator set (when it is Source1) Used By PowerCommand Control 2 (PCC2)
NvoStartCmdB
NvoStartTypeA
NvoStartCmdA
This output is only used with a PowerCommand Control 2 generator set. This output is used to configure the generator set for emergency or non-emergency start. It will not start or stop the generator set. This output is used to start a generator set (which is Source2).
PCC 2, Generator Communication Module (GCM), Generator set w/CCM PCC 2
PCC 2, GCM, Generator set w/CCM PCC 2 PCC 2 ATS, Relay
NvoSpeedAdjCmd NvoSyncEnableCmd nvoLoadInhCmd[9]
Increase Source2 freq ('passive' parallel) Enable Source2 synchronizing These outputs are used to allow the PowerCommand Transfer Switch Control to sequence the loading of either source. This allows the transfer switch to apply load gently to a source, avoiding full step loading. This output is used to inform other devices on the network that a power source transfer is pending (to either source). This output is equivalent to the 'Elevator Signal'. This output is used to provide the current operating status of this transfer switch for other devices on the network (PowerCommand Control 2 generator sets, PowerCommand Transfer Switch Controls and Master Control). Load: Hz, PF, kW, kVA, kVAR, V, A Source1 & 2: Hz, V This output is used to annunciate the NFPA 110 states to the new annunciator (Source 1 connected, Source 2 connected, battery charger malfunction). This output is used to annunciate the NFPA 110 states (Source 1 connected, Source 2 connected, battery charger malfunction) to the old annunciator.
NvoTransPending
Elevator
NvoATSStatus
Master, PCC 2, PowerCommand Transfer Switch Control Master Control, Modbus Master Control, Modbus Network Annunciation Module (NAM) NAM (old)
NvoLoadACData NvoSrcACData nvoNFPA110Annun
NvoRemoteAnnun1
Self-Study Page 70
Transfer Switch Network Output Variables
Network Variable NvoExtendedAnnun
Description This output is used to annunciate the extended transfer switch alarms to the annunciator:
Used By NAM

nvo8PointAnnun
Source1 Available Source2 Available Source1 Connected Source2 Connected Test In Progress Load Shed Transfer Inhibit
Retransfer Inhibit ATS Alarm This output is used to annunciate a simplified transfer switch status to the annunciator:
Fail To Close Fail To Disconnect Fail To Sync Slow Transfer Low ATS Battery Not In Auto Controller Error NAM

nvo4PointAnnun
Source1 Available Source2 Available Source1 Connected
Test In Progress Load Shed Not In Auto NAM
ATS Alarm Source2 Connected This output is used to annunciate a 'short' generator set status to the annunciator:

nvoFaultStatus nvoNotInAuto nvoTestActive
Source2 Available Source2 Connected This output is used to report the fault status of the transfer switch. This output is similar to a 'Common Alarm' output of a generator set. This output is used to report the readiness of the transfer switch. When the state field is true, the transfer switch's front panel switch is not in the 'Auto' position. This output is used to report the transfer switch is performing a test or exercise. 'Test' refers to a manual test of the transfer switch while 'exercise' refers to scheduled test. This output is used to report that Source1 is available for loading and it is within rated voltage and frequency. This output is used to report that Source2 is available for loading and is within rated voltage and frequency. This output is used to report that Source-1 is connected to the load. This output is used to report that Source-2 is connected to the load. This output is used to provide the current ac data of the load.
Source1 Available
Source1 Connected
NAM NAM NAM
nvoSrc1Available nvoSrc2Available nvoSrc1Connected nvoSrc2Connected NvoACData*
NAM NAM PCC 2, NAM PCC 2, NAM PowerCommand for Windows (PCW)
freq total_pf total_kva total_kw total_kvar volts_ab
volts_bc volts_ca volts_a volts_b volts_c amps_a
amps_b amps_c percent_amps_a percent_amps_b percent_amps_c
* Required for PowerCommand for Windows. Onan PowerCommand Transfer Switch Self-Study Page 71
Appendix D: Information Monitored by InPower

Information
About the Controller Statistics System
Parameters
Name tag Control package level Software version Relay module connection Network module connection Load module connection ATS serial number ATS model number Build date Nominal current Nominal voltage for Source-1 Nominal voltage for Source-2 Voltage V1N, V2N, V3N Voltage V12, V23, V31 Frequency Amps L1, L2, L3, neutral Total KVA Total KW Power factor Position Voltage L12, L23, L31 Voltage L1N, L2N, L3N Frequency Run time Position Voltage L12, L23, L31 Voltage L1N, L2N, L3N Frequency Run time Run time for Source-1 Run time for Source-2 Average transfer time Number of transfers Total Source-1 failures Total Source-2 failures Control battery status Battery charger status Controller on-time Peak current Peak power Load shed enable Alphanumeric display enable Meter package enable Network module enable Battery status
Model Data
Load Data
Source-1 Data
Source-2 Data
Transfer switch data for each ATS on network: Generator set data for each generator set on network:
Self-Study Page 72
Appendix E: Adjustments Available with InPower

Adjustments Controller Mode Parameters Application Configuration: Utility to generator Utility to utility Generator set to generator set Test Refresh: Voltage sensing constants Frequency sensing constants Save: Permanently saves all changed variables Set up: Exercise programs 1-8 Exception programs 1-8 Set Clock for: Year Month Date Day of the week Hours Minutes Enable/disable daylight savings feature Nominal voltage for Source-1 (lineline voltage for level 1 control, line neutral for level 2 control) Nominal voltage for Source-2 (lineline voltage for level 1 control, line neutral for level 2 control) Nominal current (in amps) for all phases Warning current level for neutral current (in amps) Time delay for neutral current warning (seconds) Source-1 nominal frequency Source-2 nominal frequency Single phase, 2-phase, or Nominal frequency of Source-1 3-phase sensing Pick-up setting Nominal voltage Frequency sensor dropout setting Under voltage pick up setting Frequency sensor dropout time Under voltage dropout setting delay Under voltage dropout time Voltage imbalance sensor enable delay Voltage imbalance sensor Over voltage sensor enable dropout setting Over voltage pickup setting Voltage imbalance sensor dropout time delay setting Over voltage dropout setting Over voltage dropout time delay Loss of phase sensor enable Phase rotation enable for Enable frequency sensing Source-1 and Source-2 Frequency sensor
Exerciser Clock
Real Time Clock
Nominal Voltage
Nominal Current Neutral Current Nominal Frequency Source-1 Sensing
Self-Study Page 73
Adjustments Available with InPower
Adjustments Source-2 Sensing
Time Delays
Voltage Adjustment Current Adjustment Power Factor Adjustment Preferred Source Feature Enable
Parameters Single phase, 2-phase, or 3 Frequency sensor pickup setting phase sensing Frequency sensor dropout setting Nominal voltage Frequency sensor dropout time Under voltage pick up setting delay Under voltage dropout setting Voltage imbalance sensor enable Under voltage dropout time Voltage imbalance sensor delay dropout setting Over voltage sensor enable Voltage imbalance sensor dropout time delay setting Over voltage pickup setting Loss of phase sensor enable Over voltage dropout setting Over voltage dropout time delay Phase rotation enable for Source1 and Source-2 Nominal frequency of Source-1 Enable frequency sensing Time delay engine start - A ( for U-G systems) Time delay transfer from normal to emergency Time delay retransfer from emergency to normal Time delay programmed transition Time delay engine cool-down - A (for U-G systems) Time delay (elevator) pre-transfer signal Time delay engine start B (for G-G systems) Time delay cool down B (for G-G systems) Changeover timer for generator-generator mode only Over crank timer for generator-generator mode Source-1 V12, V23, V31 Source-2 V12, V23, V31 Source-1 V1N, V2N, V3N Source-2 V1N, V2N, V3N Load current L1, L2, L3, N Nominal current Phase 1 angle Phase 2 angle Phase 3 angle Confirm preferred source Alphanumeric display Loadshed Bargraph meter LONMark communications
Self-Study Page 74
Appendix F: Faults/Events History in InPower

Faults/Events
Faults
Information Available
Log of active faults: Controller checksum error Low controller battery ATS fail to close: retransfer ATS fail to close: transfer ATS fail to charge (future) Rolling list of last 50 events: Source-1 connected Source-1 available Source-2 connected Source-2 available Emergency start A Test start A Emergency start B Test start B Time delay start A (TDES-A) Time delay start B (TDES-B) time delay normal To emergency (TDNE) Time delay emergency to normal (TDEN) Time delay engine cool down (TDEC) Time delay programmed transition (TDPT) Transfer pending (TDEL) Test in progress Exercise in progress In-phase transfer active Source-1 under voltage failure Source-1 over voltage failure Source-1 Over/under frequency failure ATS Fail to Disconnect Battery charger malfunction Network battery low Network communications error ATS common alarm Source-1 voltage imbalance failure Source-1 loss of phase failure Source-2 undervoltage failure Source-2 overvoltage failure Source-2 over/under frequency failure Source-2 voltage imbalance failure Source-2 loss of phase failure Phase rotation failure Not in auto: ATS motor disconnected Not in auto: load shed Not in auto: transfer inhibit Not in auto: retransfer inhibit Not in auto: ATS bypassed to Source-1 Not in auto: ATS bypassed to Source-2 Not in auto: common output Service tool connected Closed transition transfer Synch enable output Speed adjust command System fail to synchronize Load sequencer outputs (1-8)
Event History Log
Event Records
For each type of event or fault listed above: Event code Current status of event Time last occurred Total occurrences Dialout status (yes/no)
Self-Study Page 75

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Cummins Power Generation Onan PowerCommand Transfer Switch

Onan Sales and Technical Training

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

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

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

Onan PowerCommand Transfer Switch

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

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

Onan PowerCommand Transfer Switch

Onan PowerCommand Transfer Switch

Self-Study Page iii

Lesson One: The New PowerCommand Transfer Switch

Recognize the difference among the transfer switch

Overview of the New Transfer Switch

Onan PowerCommand Transfer Switch

OTPC Automatic Transfer Switch

SWITCH PANEL BAR GRAPH ASSEMBLY

OPTIONAL BATTERY CHARGER AUTOMATIC TRANSFER SWITCH CONTROLLER BATTERIES TB1

DIGITAL DISPLAY RELAY ASSEMBLY MOTOR DISCONNECT SWITCH POWER MODULE

Figure 1-1: The OTPC

Onan PowerCommand Transfer Switch

Table 1-1: OTPC Features and Benefits

Stored energy over center mechanism

Ampere ratings: From 40 to 3000 amperes

Optional neutral bar on 3 pole

Customer auxiliary contacts: Form C contacts on normal and emergency side

Cu/Al mechanical pressure lugs

Motor disconnect switch

Onan PowerCommand Transfer Switch

BTPC Bypass Isolation Transfer Switch

Table 1-2: Onans Bypass Switch Features and Benefits

Dual source bypass

Onan PowerCommand Transfer Switch

PLTO Automatic Transfer Switch (Available 2000) 2000

PLTH Closed Transition Transfer Switch (Available 2000)

PLTS Soft Loading Transfer Switch (Available 2000)

Onan PowerCommand Transfer Switch

PowerCommand Network Communication Module (NCM)

InPower Transfer Switch Service Tool

Onan PowerCommand Transfer Switch

Lesson One Progress Check

Onan PowerCommand Transfer Switch

Lesson One Progress Check (Cont.)

Onan PowerCommand Transfer Switch

Onan PowerCommand Transfer Switch

Lesson Two: The New PowerCommand Transfer Switch Control

State the features, functions and benefits available

List the features of the Transfer Switch Level 1 and

Identify the various interfaces of the transfer switch

Overview of Components of the New Control

Cummins Onan InPower Software Service Tool

Onan PowerCommand Transfer Switch

2. The New PowerCommand Transfer Switch Control

Overview of PCTS Control

Level 1 provides a basic level of sensing and control

Level 2 provides more sensing options and additional

Onan PowerCommand Transfer Switch

2. The New PowerCommand Transfer Switch

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

Onan PowerCommand Transfer Switch

2. The New PowerCommand Transfer Switch

Level 2 Control Package

Three-phase voltage sensing of the emergency source

The Level 2 control offers an optional load