Owner Owner Manual Manual: Operator/Installation/Service/Parts Transfer Switch 800-3000 Amps

Owner Manual
Operator/Installation/Service/Parts
Transfer Switch
800-3000 Amps
PLT (Spec A)
English
Original Instructions 3-2018 A034T068 (Issue 6)
CONTENTS
Introduction IN--1
Safety and Maintenance 1
Major Components 2
System Specifications 4
Safety Precautions SP--1
Operation OP--1
Sequence of Operations 1
PowerCommand Genset Control 38
System Faults 43
Control Service and Calibration 44
Periodic Maintenance PM--1
Wiring Diagrams WD--1
Operation & Maintenance Manual

i
Copyright © 2018 Cummins Inc.
This Page Intentionally Left Blank.

INTRODUCTION
Cummins Inc. of Fridley, Minnesota, supplied the electrical power equipment for this
project. This instruction manual provides a description of the major components, their
operation, maintenance, and troubleshooting.
This section of the manual describes the major components of the power-generating
system.
Safety and Maintenance
This system must be operated by trained personnel only. Severe injury, including
death and property and equipment damage may result from failure to read and follow
safety precautions, maintenance instructions and other details of operation.
Especially significant information is highlighted using these symbols:
Indicates an imminently hazardous situation, which, if not avoided, will result
in death or serious injury
Indicates a potentially hazardous situation, which, if not avoided, could result
in death or serious injury
Indicates a potentially hazardous situation, which, if not avoided, may result
in minor or moderate personal injury or damage to product or property. May
also be used to alert against unsafe practices.
This relates to, expands on, or highlights a particular fact or procedure.
Cummins Inc. Systems Manual IN--1

INTRODUCTION
Major Components
The PowerCommand Parallel Interface system includes an integrated control system
and diesel engines/generators.
Integrated Control System
The integrated control system, Cummins Inc. Model PLT, includes the following
major components:
System control and protective relays
The Digital Power TransferControl consists of control devices and panels that
monitor normal and emergency bus, monitor and control the system main circuit
breakers, protect the load and both sources from faults and failures, and start
and stop an emergency source (generator set ) to provide power to a load bus.
The system contains the following replaceable fuses:
9 - Bussman 0.8A, 600V, Type LP-CC, Class CC, Rejection Type
4 - Bussman 3A, 600V, Type LP-CC, Class CC, Rejection Type
4 - Bussman 10A, 600V, Type LP-CC, Class CC, Rejection Type
Circuit breakers
The normal circuit breaker connects the normal source (utility) to the load bus.
In the system drawings, this breaker is designated as 52-U.
The emergency circuit breaker connects the emergency source (genset) to the
load bus. In the system drawings, this breaker is designated as 52-G.
Optional Multifunction Relay
Closed and soft load transition switches may be configured with optional feature
M051-7. When selected; a Schweitzer model SEL-351-7(03517032561XXX)
will be installed. The sensing PT and CT part numbers and their corresponding
ratios are shown in the table below.
Cummins Inc. Systems Manual IN-2

INTRODUCTION
PT PN Ratio
208V 0315-0557 1.73:1
480V 0315-0560 4:1
CT PN Ratio Ratio:1
800A 0302-1495-02 1000:5 200
1200A 0302-1495-04 1500:5 300
1600A 0302-1495-06 2000:5 400
2000A 0302-1495-07 2500:5 500
2500A 0302-1495-08 3000:5 600
3000A 0302-1495-08 3000:5 600

INTRODUCTION
System Specifications
This section identifies the performance, environmental and physical characteristics of
the power generating and switching system components.
PLT Transition
This system provides open or closed transition transfer switch control of the power
between the normal and emergency sources to the system load. It also functions to
provide emergency power to the facility.
Refer to the PLT data sheet for more details.


SAFETY PRECAUTIONS
The Cummins Power Command integrated control system generates and utilizes high
voltage, which presents a serious burn and shock hazard that can result in injury or
death. Observe all danger, warning, and caution notations within this manual and obey
all safety placards on the equipment.
Arc flash and shock hazard appropriate personal protective equipment
(PPE) is required. Do not operate controls or open covers without
appropriate PPE. Failure to comply may result in injury or death.
Refer to NFPA 70E for minimum PPE requirements.
x Read this manual before operating or performing any maintenance procedures

on this equipment.
x Keep the area surrounding the equipment clean and free of obstructions. Remove any
unused equipment, tools, or debris and keep the room clean and dry.
x Know the locations of fire extinguishers and be aware of the uses of different types of
extinguishers.
x Insure all guards, fasteners, supports, doors, and panels are in place and secure.
x Do not work around this equipment when mentally or physically fatigued or after using
alcohol or other drugs that may affect mental or physical abilities.

SP-1
SAFETY PRECAUTIONS
Equipment Cabinets
High voltage is present in the equipment cabinets, the generator sets, and the
switchgear bus bars and cabling.
High voltage can cause severe burns or shock resulting in serious injury
or death. Avoid contact with body parts, clothing, jewelry, and damp
surfaces.
x Keep equipment cabinet panel doors closed and locked. Make sure that only trained,
authorized personnel have keys.
x Before performing maintenance or adjustments to any system equipment, observe
that all equipment cabinet key locks are off and the engine control panel switch is in
the Stop/Off position.
x Disconnect the battery charger prior to removing the negative battery cable from the
battery as arcing could occur. Disconnect engine batteries negative contact first.
x Use insulated mats on dry wood platforms over metal or concrete floors when working
on any system equipment.
x Do not wear jewelry, damp clothing or shoes, or allow wet skin surfaces to contact the
system equipment.
x Keep away from the generator set while it is running, except to use the control panel.
Moving Parts
Maintain a safe clearance between all moving parts and body parts. Do not
wear loose clothing or jewelry around generator sets. Contact may result in
severe electric shock or mutilation causing personal injury or death.
Before performing any maintenance on the generator sets:
x Only qualified, trained personnel should perform maintenance.
x The generator set engine control panels must be in the Stop/Off position.
x To prevent arcing, disconnect the battery charger prior to removing the negative
battery cable from the battery.
x Disconnect the negative contact first on engine batteries.
Always disconnect a battery charger from its power source before removing
the battery cables. Disconnecting the cables can result in voltage spikes
high enough to damage the DC control circuit of the set.

SP-2
OPERATION
SEQUENCE OF OPERATIONS
PLT – Open Transition

Under normal operating conditions, utility power is provided to the load through the
normal (utility) circuit breaker. The emergency (Genset) circuit breaker is open and
the Genset is stopped.
Open transition operation will provide a load break transfer between sources.
Loss of Normal Power
On the loss of normal power the PowerCommand ATS controller will signal the
GenSet to start (hard wired and network output) and after the time delay start
has expired, the GenSet will start and accelerate to rated speed and voltage.
When the frequency and voltage reach their normal operating range and after
the transfer time delay has expired, the controller will signal the normal (utility)
breaker to open, wait for the program transition time delay and then permit the
emergency (Genset) breaker to close so that the GenSet will be supplying the
full facility load.
Return of Normal Power
Once the normal power returns the PowerCommand ATS controller will wait for
the retransfer time delay and then issue the emergency breaker open signal. It
will verify that the emergency breaker is open, wait for the program transition
time delay and then initiate a normal (utility) breaker close signal. The ATS
controller will remove its start signal from the GenSet, the GenSet will continue
to run for a cool down period and then shut down.
Test/Exercise Mode
Once the test or exercise mode is selected the PowerCommand ATS controller
will signal the GenSet to start (hard wired and network output) and after the
time delay start has expired, the GenSet will start and accelerate to rated speed
and voltage. When the frequency and voltage reach their normal operating
range and after the transfer time delay has expired, the controller will signal the
normal (utility) breaker to open, wait for the program transition time delay and
then permit the emergency (GenSet) breaker to close so that the GenSet will be
supplying the full facility load.
The GenSet will continue to carry the load until the test/exercise mode is
terminated either by the operator or a time-out at which time the load will be
transferred back to the normal source as described in the “Return of Normal
Power” section above.

OP--1
OPERATION
PLT – Momentary Transfer Parallel Mode
Modes of Operation
x Open Transition
x Closed Transition Momentary (100ms maximum)
Under normal operating conditions, utility power is provided to the load through
the normal (utility) circuit breaker. The emergency (Genset) circuit breaker is
open and the Genset is stopped. Two modes of operation are available and can
be configured from the front panel of the PowerCommand ATS controller. This
is a password protected function.
Open transition will provide a load break transfer between sources.
Closed transition momentary will provide a non-load break transfer but
depending on the GenSet size and the load on the system could cause a
voltage and frequency transient. During a momentary transfer the two sources
are connected together for a maximum of 100 ms which will effectively block
load the GenSet with the full system load, possibly causing voltage and
frequency deviations that exceed desired levels. Special attention should be
used in selecting the proper GenSet for this application.
When the frequency and voltage reach their normal operating range, and after
the transfer time delay has expired the controller will signal the normal (utility)
breaker to open, and permit the emergency (Genset) breaker to close so that
the GenSet will be supplying the full facility load.
Once the normal power returns the PowerCommand ATS controller will
respond according to the mode that has been selected by the operator.
If open transition is selected, the PowerCommand ATS controller will wait for

OP--2
OPERATION
If closed transition momentary is selected, following the retransfer time delay
the controller will signal the GenSet to enable the synchronizer (GenSet
function), and the GenSet will synchronize to the normal source and hold the
two sources in sync.
The ATS controller monitors the two sources and when they are in sync
according to the adjustable in-sync acceptance criteria a normal (utility) breaker
close signal is initiated. The controller verifies that the normal breaker has
closed and starts timing for the maximum parallel time (100ms). As soon as the
time expires, it will issue the emergency breaker open signal. At no time during
the transfer is there an interruption in the power supplying the loads. The ATS
Test/Exercise Mode:
will respond according to the mode that has been selected by the operator.
If open transition is selected, following the transfer time delay the
PowerCommand ATS controller will signal the GenSet to start (hard wired and
network output) and after the time delay start has expired, the GenSet will start
and accelerate to rated speed and voltage. When the frequency and voltage
reach their normal operating range and after the transfer time delay has
expired, the controller will signal the normal (utility) breaker to open, wait for the
program transition time delay and then permit the emergency (GenSet) breaker
to close so that the GenSet will be supplying the full facility load.
If closed transition momentary is selected, following the transfer time delay the
controller will signal the GenSet to start. The GenSet will start, accelerate to
rated speed and voltage and synchronize (GenSet function) to the normal
source and hold the two sources in sync. The ATS controller monitors the two
sources and when they are in sync according to the adjustable in-sync
acceptance criteria the GenSet breaker close inhibit is removed allowing the
breaker to close. The controller verifies that the GenSet breaker has closed and
starts timing for the maximum parallel time (100ms). As soon as the time
expires, it will issue the normal breaker open signal. At no time during the
transfer is there an interruption in the power supplying the loads. The GenSet
will continue to carry the load until the test/exercise mode is terminated either
by the operator or a time-out at which time the load will be transferred back to
the normal source as described in the “Return of Normal Power” section above.

OP--3
OPERATION
PLT – Soft Ramp Transfer Mode
Modes of Operation
x Open Transition
x Closed Transition Momentary (100ms maximum)
x Closed Transition Ramping
Under normal operating conditions, utility power is provided to the load through
the normal (utility) circuit breaker. The emergency (Genset) circuit breaker is
open and the Genset is stopped. Four modes of operation are available and
can be configured from the front panel of the PowerCommand ATS controller.
This is a password protected function.
Open transition will provide a load break transfer between sources.
Closed transition momentary will provide a non-load break transfer but
depending on the GenSet size and the load on the system could cause a
voltage and frequency transient. During a momentary transfer the two sources
are connected together for a maximum of 100 ms which will effectively block
load the GenSet with the full system load, possibly causing voltage and
frequency deviations that exceed desired levels. Special attention should be
used in selecting the proper GenSet for this application.
Closed transition ramping will provide a non-load break transfer and a smooth
transition of the load between sources at a rate that can be adjusted at the
GenSet control.

When the frequency and voltage reach their normal operating range, and after
the transfer time delay has expired the controller will signal the normal (utility)
breaker to open, and permit the emergency (Genset) breaker to close so that
the GenSet will be supplying the full facility load.

OP--4
OPERATION
Once the normal power returns the PowerCommand ATS controller will
respond according to the mode that has been selected by the operator.
If open transition is selected, the PowerCommand ATS controller will wait for
If closed transition momentary is selected, following the retransfer time delay
the controller will signal the GenSet to enable the synchronizer (GenSet
function), and the GenSet will synchronize to the normal source and hold the
two sources in sync. The ATS controller monitors the two sources and when
they are in sync according to the adjustable in-sync acceptance criteria a
normal (utility) breaker close signal is initiated. The controller verifies that the
normal breaker has closed and starts timing for the maximum parallel time
(100ms). As soon as the time expires it will issue the emergency breaker
open signal. At no time during the transfer is there an interruption in the power
supplying the loads. The ATS controller will remove its start signal from the
GenSet, the GenSet will continue to run for a cool down period and then shut
down.
If closed transition ramping is selected, following the
retransfer time delay the controller will signal the GenSet to enable the
synchronizer (GenSet function); the GenSet will synchronize to the normal
acceptance criteria a normal (utility) breaker close signal is initiated. The
controller verifies that the normal breaker has closed and starts timing for the
maximum parallel time. When the GenSet sees both source breakers closed
and the unload signal on its external load set lines, it will ramp the load onto the
utility source. As soon as the time expires or the controller receives and input
signal from the GenSet indicating it is unloaded, it will issue the emergency
breaker open signal. At no time during the transfer is there an interruption in
the power supplying the loads. The ATS controller will remove its start signal
from the GenSet, the GenSet will continue to run for a cool down period and
then shut down.

OP--5
OPERATION
Test/Exercise Mode
will respond according to the mode that has been selected by the operator.
If open transition is selected, following the transfer time delay the
PowerCommand ATS controller will signal the GenSet to start (hard wired and
network output) and after the time delay start has expired, the GenSet will start
and accelerate to rated speed and voltage. When the frequency and voltage
reach their normal operating range and after the transfer time delay has
expired, the controller will signal the normal (utility) breaker to open, wait for the
program transition time delay and then permit the emergency (GenSet) breaker
to close so that the GenSet will be supplying the full facility load.
If closed transition momentary is selected, following the transfer time delay the
starts timing for the maximum parallel time (100ms). As soon as the time
expires or the controller receives and input signal from the utility indicating it is
unloaded, it will issue the normal breaker open signal. At no time during the
transfer is there an interruption in the power supplying the loads. The GenSet
will continue to carry the load until the test/exercise mode is terminated either
by the operator or a time-out at which time the load will be transferred back to
the normal source as described in the “Return of Normal Power” section above.
If closed transition ramping is selected, following the transfer time delay the
starts timing for the maximum parallel time. When the GenSet sees both source
breakers closed and the load signal on its external load set lines, it will ramp the
load onto the GenSet source. As soon as the time expires or the controller
receives and input signal from the utility indicating it is unloaded, it will issue the
normal breaker open signal. At no time during the transfer is there an
interruption in the power supplying the loads. The GenSet will continue to carry
the load until the test/exercise mode is terminated either by the operator or a
time-out at which time the load will be transferred back to the normal source as
described in the “Return of Normal Power” section above.

OP--6
OPERATION
This section of the manual describes the operating controls of the emergency
standby power generating system. This section contains the sequence of operation,
information on system operation, system settings and troubleshooting help for the
control.
System Operation
The utility and emergency circuit breakers, in association with the Keystone
TransferControl, function as a transfer switch with selectable open, manual or closed
transition operation modes.
An emergency system block diagram of the system equipment is shown on the next
page.
Normal Power Failure Operation: Open Transition Mode
(Load Break Retransfer)
Select Open Transition. Select the Test button to initiate open transition.
Keystone TransferControl
The Keystone TransferControl is the system controller for paralleling the genset to
the utility bus. The front display panel shows fault and alarm conditions.
Figure 1. Keystone TransferControl

OP--7
OPERATION
Open Transition
normal (52-UM) circuit breaker. The emergency (52-GM) circuit breaker opens and
the genset is stopped.
On a loss of normal power, after the time delay start expires, the genset starts and
accelerates to rated speed and voltage. When the frequency and voltage reach their
normal operating range, and after the transfer time delay expires, 52-UM opens and
52-GM closes. Loads are now supplied power by the genset.
Once normal power returns and after the retransfer time delay, 52-GM opens and
after the program transition time delay has expired, 52-UM closes. During the short
delay, no power is provided to the loads. The genset continues to run for a
cooldown period, and then shuts down.
Transfer, retransfer, and program transition time delays are fully adjustable and are
located on the system control screen.
Figure 1 . Emergency system block diagram (typical)

OP--8
OPERATION
Normal Power Failure Operation: Closed Transition Mode
(non- load break retransfer)
Select Close Transition. Press the Test button to initiate a closed transition.
normal (52-UM) circuit breaker. The emergency (52-GM) circuit breaker is open and
the genset is stopped.
On a loss of normal power, after the time delay start expires, the genset starts and
accelerates to rated speed and voltage. When the frequency and voltage reach their
normal operating ranges, and after the transfer time delay has expired, 52-UM
opens and 52-GM closes. Loads are now supplied power by the genset.
When normal utility power returns and after the retransfer time delay, the genset
synchronizes to the normal source and allows 52-UM to close. Circuit breaker 52-
GM immediately opens. There is no power outage in the return to normal transfer.
The genset continues to run for a cooldown period, then shuts down.
Test Operation: Open Transition (load break)
Select Open Transition. Press the Test button to initiate an open transition.
On signal from the test button, the genset starts. After the genset frequency and
voltage reach their operating ranges, 52-UM opens and after the program transition
time delay, 52-GM closes. During the short delay, no power is provided to the loads.
On returning to the normal control mode and after the retransfer time delay,
52-GM opens, and after the program transition time delay, 52-UM closes. During the
short delay, no power is provided to the loads. The genset continues to run for a
cooldown period, then shuts down.
Select Retransfer Control mode to bypass the retransfer time delay.

OP--9
OPERATION
Test Operation: Closed Transition (non- load break)
Select Close Transition
Pressing the Test button sends a start signal to the genset. After the genset
frequency and voltage reach their operating ranges and the genset synchronizes
with the normal source, 52-GM closes and 52-UM opens. There is no loss of power
to the loads during the transfer from the utility to the genset.
After returning to normal control mode and after the retransfer time delay, the
genset synchronizes to the normal source and 52-UM closes and 52-GM opens.
There is no loss of power to the loads during the transfer. The genset continues to
run for a cooldown period, and then shuts down.
Select Override Control mode to bypass the retransfer time delay.

OP--10 -1
OPERATION
Application Considerations for Closed Transition Transfer Switches
Closed transition power transfer introduces risk to the power system because two
live sources are momentarily connected together. The following simple
installation practices can minimize these risks.
 Prevent multiple transfer switches from transferring at the same time. Multiple transfer
switches transferring simultaneously can result in the genset voltage being unstable during
transfer. Two methods for preventing simultaneous transfer are:
o Staggering time delays between switches and
o Interconnecting aux contacts with inhibit functions.
 Prevent the two sources from remaining connected indefinitely by connecting the ATS fail to
disconnect output to the shunt trip input of one of the breakers feeding the ATS. This
function is actually required by many utilities.
Staggering Time Delays

Setting time delays on different transfer switches to different values will prevent
the switches from transferring at the same time. For example setting the
Emergency to Normal Time Delays (TDEN) to different values on each switch will
prevent the switches from re-transferring to the normal source at the same time
after the source has returned after a failure or at the end of a test. When using
this method care should be taken to make sure that all of the sensing settings are
the same on each of the switches to make sure that the switches recognize the
source as being available at the same time.
Note that it is only necessary to stagger the time delays when transferring
between live sources. After a utility failure it is not necessary to stagger time
delays for switching loads on to the genset unless the genset needs time to
recover after taking on the individual loads as is often the case when starting
large motors.
Re-transfer and Transfer Inhibit Functions

The transfer and re-transfer inhibit functions can be used to prevent multiple
transfer switches from transferring at the same time. For example to prevent two
switches from re-transferring from the genset to the utility at the same time wire
the normally closed contact that indicates the first ATS is connected to the
normal source into the retransfer inhibit input of the transfer switch that is
intended to transfer second. Ground the common aux contact on the first switch
so that the re-transfer inhibit input on the second switch is grounded when the

10-2
OP-11
OPERATION
first transfer switch is not connected to the normal source. This will inhibit the
second switch from beginning its retransfer sequence (including all time delays)
until after the first transfer switch has transferred back to the normal source. A
similar wiring scheme can be used when transferring to the emergency source so
that only one switch transfers at a time. Switch position outputs are available on
the relay signal module which is included with all Cummins closed transition ATS
models. Figures 1 and 2 illustrate how this can be accomplished with all of
Cummins’ closed transition transfer switch models.
Figure 1 – Using source connected contacts to inhibit transfers such that only
one ATS will transfer at a time for CHPC and BTPC 1600 – 3000 amp transfer
switches

10-3
OP-12
OPERATION
Figure 2 - Using source connected contacts to inhibit transfers such that only one
ATS will transfer at a time for OTPC 1000 – 4000 and BTPC 125-1200 and 4000
amp transfer switches
Fail to disconnect
The Fail to Disconnect relay is active when the transfer switch remains connected
to both sources for more than 100 msec during a closed transition transfer. It
should be wired to the shunt trip of the breaker feeding the ATS on either the
normal or the emergency side. The fail to disconnect relay is located on the relay
signal module. See Figure 3.

10-4
OP-13
OPERATION
Figure 3 – Using the fail to disconnect output to shunt trip a breaker.

10-5
OP-14
OPERATION
Digital Display Menu System
This section describes the Digital Display Menu System and illustrates navigation
through the menus. The menus display status information, events and setup menus.
Setup menus contain parameters with adjustable values. Descriptions in this section
include ranges for the parameters and default values.The system menus can also be
accessed with the PC service tool.
Digital Display
The Digital Display Menu System is a two-line by 20-character graphical display
screen and six buttons, including Home and Previous Menu. The screen or menu
displays status information, parameters, events and messages. The buttons change
screens and parameters. Messages include navigational indicators for the other four
buttons.
Main Menus
The main menu system consists of three top-level menus that list vertical menus (or
submenus). The submenus display status information. This information cannot be
changed in the main menus. The main menus contain eight submenus, including the
Setup menus.
Setup Menus
Enter a password and unlock the key switch on the front panel, or bypass the
password and examine—but do not change—any parameter. When parameters are
changed in any setup menu, a prompt to either save the changes or to restore the
old value appears. Setting and navigating through the password menus is described
on the Events submenu.

OP--11
OPERATION
Version 1.13.244 Software Updates
x An exercise can be set up to repeat on a specific day of each month. This feature was
not available with previous software.
x An exercise can be set up to repeat every 0 to 100 weeks. With previous software, an
exercise could be set up to repeat every 0 to 52 weeks.
x With level 1 controllers, two exercise periods and two exercise exceptions are
available. With previous software, only one exercise period and one exercise
exception were available through the digital display of level 1 controllers.
x With level 2 controllers, eight exercise periods and eight exceptions are available.
With previous software, only two exercise periods and two exercise exceptions were
available through the digital display of level 2 controllers; additional exercises and
exceptions could be set using the PC service tool.
x Viewing information on all exercises and exercise exceptions can be done without
entering a password. As with previous software, setting up or modifying exercises and
exercise exceptions cannot be done until the password is entered.

OP--12
OPERATION
Figures 2 though 26 are describe the operation of this system. These figures are
excerpted from transfer switch manual 0962-0126.
Main Menu navigation

OP--13
OPERATION
Main Menu descriptions

OP--14
OPERATION
First Main Menu—Source 1 and 2 Submenus

OP--15
OPERATION
First Main Menu—Load Submenus

OP--16
OPERATION
Second Main Menu—Statistics Submenus

OP--17
OPERATION
Second Main Menu—Events Submenus

OP--18
OPERATION
Second Main Menu—Setup Submenus

OP--19
OPERATION
Setup Menu navigation and description

OP--20
OPERATION
Changing Setup Parameters

OP--21
OPERATION
Setup Group 1—Sensor 1 and 2 Submenus

OP--22
OPERATION
Setup Group 1—Sensor 1 and 2 Submenus (continued)

OP--23
OPERATION
Setup Group 2—Time Delay Submenus

OP--24
OPERATION
Setup Group 2—Time Delay Submenus (continued)
Setup Group 2—Time Delay Submenus (continued)

OP--25
OPERATION
Setup Group 2—Test Submenus

OP--26
OPERATION
Setup Group 2—Exercise Submenus

OP--27
OPERATION
Setup Group 2—Exercise Submenus (continued)

OP--28
OPERATION
Setup Group 2—Exercise Exception Submenus

OP--29
OPERATION
Setup Group 2—Exercise Exception Submenus (continued)

OP--30
OPERATION
Second Main Menu—Setup Submenus

OP--31
OPERATION
Setup Group 2—Exerciser Submenus

OP--32
OPERATION
Setup Group 2—Exerciser Submenus (continued)

OP--33
OPERATION
Setup Group 2—Exercise Submenus

OP--34
OPERATION

OP--35
OPERATION
Setup Group 2—Exerciser Submenus

OP--36
OPERATION

OP--37
OPERATION
Setup Group 3—Mode Submenus

OP--38
OPERATION
Setup Group 3—Clock Submenus

OP--39
OPERATION
Setup Group 3—Sequencer Submenus

OP--40
OPERATION
Third Main Menu —About Submenus

OP--41
OPERATION
Third Main Menu —About Submenus (continued)

OP--42
OPERATION
Third Main Menu—System Submenu

OP--43
OPERATION
Third Main Menu—Active TD Submenus

OP--44
OPERATION
Second Main Menu diagram

OP--45
OPERATION
Second Main Menu diagram (continued)

OP--46
OPERATION
Second Main Menu diagram (continued)

OP--47
PERIODIC MAINTENANCE
The recommended schedule for maintaining this equipment is based on our experience
with these types of installations. Cummins recommends a maintenance schedule based
on calendar lapsed time as applied to the entire paralleling system.
This power system presents risks of serious injury or death from

asphyxiation, shock, burns, or strangulation. Both utility and genset power
must be disconnected from the equipment while maintenance is performed.
System Maintenance Schedule

Maintenance item Weekly Monthly Annual
Wipe down the
entire system
Clean cabinet exteriors
using a soft, lint-
free cloth.
Disconnect this
equipment from
its power source
before cleaning.
Clean operator interface panel
Use a damp
cloth. Do not use
liquid or spray
detergents for
cleaning.
Manuals,
maintenance
Check power system equipment charts, and logs
must be
documentation accessible to
operations and
maintenance
personnel.
Operate running system test See page PM-3.

Check batteries and chargers See page PM-4.
Clean and inspect switchgear See page PM-4.

PM-1
Operation of a Protective Device

Use of this test procedure will cause a momentary power failure to the
loads in the system that are connected to the transfer switches being
tested. Before proceeding, ensure sure that this power outage will not
cause personal injury or property damage.
Operation of a protective device to interrupt normal power to one or more transfer switches
causes the transfer switch to sense a normal power failure and signal the paralleling
system to start. When the gensets close to the bus, the transfer switches connect their
loads to the emergency bus exactly as they would during a normal power failure.
Transfer switches may be wired to close to the bus in priority sequence. If not all gensets
in the system start, transfer switches feeding low-priority loads may not be automatically
transferred to the paralleling system. System controls include provisions for manually
adding loads to the system.
When the system is up and running, record information on the appropriate maintenance
log. See the Appendix of this manual for maintenance logs.
On reclosure of the protective device feeding the transfer switch, the transfer switch
signals the paralleling system that normal power has returned and begins timing to
retransfer to the normal bus.
When all transfer switches are retransferred to normal power, the paralleling breakers
open and the gensets operate for a cooldown period, and then shut down.

PM-2
Periodic Running Test of Power System Equipment

The power system equipment should be run periodically to maintain the operational
reliability of the system. Failure to do so can increase maintenance and reduce the
reliability of the equipment.
Testing can expose personnel to hazards that can result in serious injury
or death. Make sure that all persons are clear of the equipment and are
aware of this test. Some of these tests will momentarily disrupt power to
the loads. Be sure to alert all areas requiring power prior to running tests
to prevent an emergency.
System Test
The paralleling system equipment should be operated on a weekly basis to enhance the
operational integrity of the system. Failure to do so may increase maintenance costs and
reduce the reliability of the equipment. It is recommended that the system be operated
under load for a running test of the equipment.
The system test can be accomplished by three separate control actions. (The first two
selections may be used when the power system includes transfer switches.)
x Open the potential test switches feeding the normal side of one or more of the transfer
switches in the system.
x Select manual transfer mode then start the genset and initiate transfer to the genset
from the Manual Control screen.
x Select the Test Control Mode on the System Control screen.
The first two options cause a momentary power failure to the loads in the facilities that
are fed by the transfer switches used for testing. Momentary power failure occurs on
initiation of the test sequence and on return of the loads to the normal utility service.
Alert all appropriate areas requiring power before running tests to prevent
causing an emergency.
Weekly Preventative Maintenance

Weekly preventative maintenance must be performed to maintain the operational
reliability of the paralleling switchboards, station batteries, and battery charger.

PM-3
Monthly Preventative Maintenance

Service the batteries to provide proper charge. Maintain clean and tightened battery
terminals and battery cables.
See the Appendix of this manual for maintenance logs.
Annual Preventative Maintenance

Yearly preventative maintenance insures operational reliability of the paralleling
equipment. The permanent equipment log must contain a record of the work performed
and the date, together with comments on the condition of the system and system
components.
Perform the following procedure:
1. De-energize the power system and disable operational capability of the gensets by
doing the following:
a. Make sure the genset Run/Off/Auto switch is set to off.
b. Disconnect the battery charger prior to removing the negative battery cable from
the battery. Disconnect battery cables, negative cable first.
c. Make sure all circuit breakers feeding the system are open.
d. Open service to the PLT from other locations. Lock out the service to prevent
accidental energizing while service is being performed.
2. Clean the equipment
a. Thoroughly dust and vacuum all controls, meters, circuit breakers, and bus
compartments.
b. Wash cabinet surfaces and meter faces using mild detergent and a damp
sponge. Do not allow excess water to enter meters or cabinets; components
could short circuit and become inoperable.
3. Inspect the equipment
a. Visually inspect system buswork and supports for carbon tracking, cracks,
corrosion, or other signs of deterioration.
b. Check system buswork hardware for loose connections.
c. Visually inspect all control wiring and power cables for signs of wear and/or
deterioration, especially wiring between hinged doors.
d. Check all control wiring and power cables for loose connections. Tighten if
necessary.
e. Check system cabinets for loose or missing hardware.

PM-4
4. Perform preventive maintenance

a. Tighten all system buswork and cabinet hardware, as well as all control wiring
and power cables.
b. Service or replace station batteries.
c. Verify proper operation of the station battery charger.
5. Check operations
a. Energize the power system and enable the operational capability of the gensets.
b. Run the system test (if available) and operate all controls while observing meters
and indicator lights.
c. Check the operational capability of all protective circuits and devices while
observing meters and indicator lights.
See the Appendix of this manual for maintenance logs.
If service is required or problems arise relating to this system, contact a Cummins
service representative.

PM-5

Annual Maintenance Log
Annual preventative maintenance insures operational reliability of the paralleling
equipment. The permanent equipment log must contain a record of the work performed
and the date, together with comments on the condition of the system and system
components.
Clean the equipment

1. Thoroughly dust and vacuum all controls, meters, circuit breakers, and bus
compartments.
2. Wash cabinet surfaces and meter faces using mild detergent and a damp sponge.
Date
Observations
Actions taken

Inspect the equipment
1. Visually inspect system buswork and supports for carbon tracking, cracks, corrosion, or
other signs of deterioration.
2. Check system buswork hardware for loose connections.
3. Visually inspect all control wiring and power cables for signs of wear and/or deterioration,
especially wiring between hinged doors.
4. Check all control wiring and power cables for loose connections. Tighten if necessary.
5. Check system cabinets for loose or missing hardware.
Date
Observations
Actions taken

Perform preventive maintenance
1. Tighten all system buswork and cabinet hardware, as well as all control wiring and
power cables.
2. Service or replace station batteries.
3. Verify proper operation of the station battery charger.
Date
Observations
Actions taken

Check operations
1. Energize the power system and enable the operational capability of the gensets.
2. Run a system test (if available) and operate all controls while observing meters and
indicator lights.
3. Check the operational capability of all protective circuits and devices while observing
meters and indicator lights.
Date
Observations
Actions taken

WIRING DIAGRAMS
Cummins Inc.
Hard copies of these items are shipped with PLT.
x Certificate(s) of test
x Settings sheets

WD--1

AMP 800-3000, NEMA1
Outline Drawing No
Top Utility Bottom Utility
Front View Section View Front View Section View
Without AUX Section 0500-3959 0500-3526 0500-3960 0500-3527
With AUX Section

0500-3963 0500-3526 0500-3964 0500-3527
(AUX Left, No Bus)
With AUX Section
0500-3513 0500-3530 A034S248 0500-3531
(AUX Left, Bussed)
With AUX Section
0500-3961 0500-3526 0500-3962 0500-3527
(AUX Right, No Bus)
With AUX Section
0500-3511 0500-3528 0500-3512 0500-3529
(AUX Right, Bussed)
Table 1. Summary of Outline Drawings


Reference Interconnection Drawing Part Numbers
Transition Mode
Closed Momentary Closed Momentary

CPG Genset
Delayed** without Optional M051- with Optional M051-7 Soft - Load
Control
7 Relay ** Relay
3100: PCC1 with
630-2636 N/A 630-2634 630-2577
Network
3100: PCC1
630-2244 N/A 630-2546 630-2209
without Network
3201: PCC11
630-2806 N/A 630-3227 630-2745
with Network
3201: PCC11
630-2807 N/A 630-2756 630-2746
without Network
2100: with
630-3405 630-3405 N/A N/A
Network
2100: without
630-3404 630-3404 N/A N/A
Network
2300: with
A059X513 N/A N/A N/A
Network
** This switch design does not provide interconnect points for the generator set to control the PLT
generator set side breakers.
Table 2. Summary of Interconnection Drawings


R R
PTC Creo Parametric
6 5 4 3 2 1
REL NO LTR NO REVISION DWN CKD APVD DATE
ECO-175733 A 1 PRODUCTION RELEASE JFM GAC T.BEAUCAGE 27FEB18
CUMMINS GENERATOR SET

WITH PCC2300 CONTROL
PowerCommand ä MASTER CONTROL
TB21
TB11
TYPICAL FOR GENSET CONTROL POWER
GEN B+ 1 1 1 1
D
TB1 2 2
(1)
1 1 B+ D
REMOTE E-STOP 16
(25) GEN GND 3 3 (8) 2 2
GND 15 (3)
14 GEN ST 4 4 2 2
FAULT IN # 2 (4)
13 8 8 3 3
GND
FAULT IN # 1 12 9 9 3 3
(46) GND
REMOTE START 11 10 10 (7) 4 4
(4)
GND 10 11 11 4 4
OUT2-NO 9 12 12 5 5
OUT2-COM (23)
8 GEN SHUTDWN 14 14 6 6 REMOTE START
(8) (14)
OUT1-NO 7 (SEE NOTE 3)
(14) 16 16 7 7
OUT1-COM 6
(7) GEN NOT IN AUTO 23 23 8 8 REMOTE EMERGENCY
B+ (FUSED 5A) 5 (23)
READY TO LOAD 4 E-STOP 25 25 9 9 STOP (SEE NOTE 3) PLTx DELAYED TRANSITION
(25)
GND 3 (3) 26 26 10 10 86-U
2 27 27 11 11 CONTACT
RS 485 DATA B
J2-4
RS 485 DATA A 1 32 32 12 12 GEN BREAKER
J2-3 (6)
33 33 13 13 POSITION AUX
GF 46 46 14 14 CONTACTS
(46)
J20 51 51
(51) (5)
15 15 UTILITY BREAKER
LOW FUEL 18 52 52 16 16 POSITION AUX
(52) CONTACTS
GND 6 61 61 17 17
62 62 18 18
63 63 19 19
64 64 20 20
80 80 21 21
C DAY TANK TO B+ 81 81 22 22 C
TERMINAL
ON STARTER (1) 23 23
LOW FUEL
ALARM
CONTACT
2-12 2-13 (5)
SPLICE BY INSTALLER
2-14 (6)
CUSTOMER FUSED B+
SEE NOTE 6
RUN #2
SEE NOTE 4 TBHTR (OPTIONAL)
ANNUNCIATOR 120 VAC CP1 CP1

(+) (1)
300-5929 7 FROM CUST. CP0 CP0
TB1 (-) (2)
1 CUSTOMER FAULT 1
B CUSTOMER FAULT 2
B
2
NOTES:
3 CUSTOMER FAULT 3
2-14
4 GENSET SUPPLYING LOAD 1. INTERCONNECTION WIRING TO BE 14 AWG STRANDED WIRE MINIMUM. AC AND
5 CHARGER AC FAILURE DC CONTROL WIRES TO BE RUN IN SEPARATE CONDUITS.
6 LOW COOLANT LEVEL
2-12 2. BATTERY CHARGER TO BATTERY WIRING TO BE SIZED FOR CHARGER OUTPUT
7 LOW FUEL LEVEL
2-13 AND LENGTH OF RUN.
8 NORMAL UTILITY OR CHECK GENSET FOR DC CONNECTIONS: USE 14 AWG OR LARGER FOR WIRE UP TO 40 FEET.
9 USE 12 AWG OR LARGER FOR WIRE UP TO 50 FEET.
10 USE 10 AWG OR LARGER FOR WIRE UP TO 100 FEET.
11
J2 FOR AC CONNECTIONS: USE 14 AWG OR LARGER FOR WIRE UP TO 100 FEET.
1 GND 1
12
2 3. CUSTOMER USE OF THE REMOTE EMERGENCY STOP AND THE REMOTE START
13 TB1-1 CONTROL FUNCTIONS ARE OPTIONAL.
14 3
TB1-2
GND 15 4 4. REFER TO 0900-0301 FOR INSTALLATION OF 0300-5929
CUSTOMER FUSED B+ 16 BATT 5
TP
5. NETWORK CONNECTIONS: 18 GA TWISTED PAIR OR CAT 5 CABLE. TOTAL
17 GND
5 NETWORK LENGTH CANNOT EXCEED 4000 FEET. UP TO 20 NODES CAN BE
TB2 CONNECTED TO THE NETWORK. (NOTE: ANY COMMUNICATIONS WIRE
1 GND NETWORK MODULE
CONNECTED TO THE GENSET SHOULD BE STRANDED CABLE.)
2 NOT IN AUTO
3 GENSET RUNNING
NET DATA (51)
+ 6. CUSTOMER SUPPLIED FUSED B+ SOURCE. USE AT LEAST 5 AMP FUSE.
4 -
5 (52) 7. 2 CONDUCTOR 18 AWG STRANDED AND SHIELDED.
6
7 FAIL TO START
A 8 LOW COOLANT TEMP A
9 PRE-HIGH ENGINE TEMP
10 HIGH ENGINE TEMP
11 PRE-LOW OIL PRESSURE
12 LOW OIL PRESSURE
13 OVERSPEED
UNLESS OTHERWISE SPECIFIED, ALL SIM TO
. DWN J.McCARTHY
14 DIMENSIONS ARE IN MILLIMETERS C UMMINS P OWER G ENERATION
DO NOT SCALE PRINT
X #1 0.00- 4.99 +0.15/-0.08
CKD G.COLLEEN
HOLE
5.00- 9.99 +0.20/-0.10 APVD
T.BEAUCAGE
DIM
.X # 0.8 10.00-17.49 +0.25/-0.13 DIAGRAM,INTERCONNECT WIRING
.XX # 0.38 17.50-24.99 +0.30/-0.13
DATE
27FEB18 SITE CODE
- CONFIDENTIAL -FOR INTERPRETATION FIRST USED ON DWG
SIZE
SHEET DWG
REV
ANG TOL: # 1.0 SCALE: 1/1 PROPERTY OF CUMMINS
POWER GENERATION GROUP
OF DIMENSIONING AND
TOLERANCING, SEE
ASME Y14.5M-1994 PLT PGF D A059X513 1 OF 1 B
6 5 4 3 2 Copyright ©1 2018 Cummins Inc.

Ground Fault Sensing
52G Lock-0ut Relay
Mutifunction Relay
Service Entrance
Network
Schematic Wiring
Open/Delayed Transition (O)
208 V ● ● A034M235 A034G522
480 V ● ● A034M239 A034G524
Closed Transition (H)
208 V ● ● A034M235 A034G522
● ● ● A034M242 A034G526
480 V ● ● A034M239 A034G524
● ● ● A034M232 A034G520
● ● ● ● 0625-4779 0630-3116
● ● ● 0625-4653 0630-2882
● ● ● ● A034S250 A034M637
● ● 0625-4821 0630-3195
Soft-load Transition (S)
208 V ● ● A034M242 A034G526
480 V ● ● A034M232 A034G520
● ● ● 0625-4779 0630-3116
● ● 0625-4653 0630-2882
● ● ● A034S250 A034M637
● 0625-4821 0630-3195
Table 3. Summary of Schematic and Wiring Diagrams


power.cummins.com
Copyright 2018 Cummins Inc. All rights reserved.
Cummins, the “C” logo, PowerCommand, AmpSentry, and InPower are trademarks of Cummins Inc.
Other company, product, or service names may be trademarks or service marks of others.
Specifications are subject to change without notice.

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Safety Precautions SP--1

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x Read this manual before operating or performing any maintenance procedures

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PLT – Open Transition

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Loss of Normal Power

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Figure 1. Keystone TransferControl

Operation & Maintenance Manual

Figure 1 . Emergency system block diagram (typical)

Operation & Maintenance Manual

Operation & Maintenance Manual

Operation & Maintenance Manual

Staggering Time Delays

Re-transfer and Transfer Inhibit Functions

Operation & Maintenance Manual

Operation & Maintenance Manual

Operation & Maintenance Manual

Figure 3 – Using the fail to disconnect output to shunt trip a breaker.

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Operation & Maintenance Manual

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Main Menu navigation

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Main Menu descriptions

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First Main Menu—Source 1 and 2 Submenus

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First Main Menu—Load Submenus

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Second Main Menu—Statistics Submenus

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Second Main Menu—Events Submenus

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Second Main Menu—Setup Submenus

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Setup Menu navigation and description

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Changing Setup Parameters

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Setup Group 1—Sensor 1 and 2 Submenus

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Setup Group 1—Sensor 1 and 2 Submenus (continued)

Operation & Maintenance Manual