Cummins Power Generation Onan PowerCommand™ Transfer Switch Onan Sales and Technical Training
Cummins Power GenerationOnan PowerCommand™Transfer Switch
Onan Sales and Technical Training
Onan PowerCommand Transfer Switch Self-StudyPage i
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 Self-StudyPage ii
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
Onan PowerCommand Transfer Switch Self-StudyPage iii
List of Figures and Tables
Figure 1-1: The OTPC .......................................................................................................... 2
Table 1-1: OTPC Features and Benefits ................................................................................ 3
Table 1-2: Onan’s 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
Onan PowerCommand Transfer Switch Self-StudyPage 1
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.
• Recognize the difference among the transfer switch
products.
Overview ofthe NewTransfer
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
Onan PowerCommand Transfer Switch Self-StudyPage 2
OTPCOTPC
AutomaticAutomatic
TransferTransfer
SwitchSwitch
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 competition’s 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.
Figure 1-1: The OTPC
AUTOMATIC TRANSFERSWITCH
OPTIONAL BATTERY CHARGER
BAR GRAPHASSEMBLY
SWITCH PANEL
DIGITAL DISPLAY
RELAY ASSEMBLYPOWER MODULE
MOTOR DISCONNECT SWITCH
CONTROLLERBATTERIES
TB1
TB2
Onan PowerCommand Transfer Switch Self-StudyPage 3
Table 1-1: OTPC Features and Benefits
Features BenefitsThree maintained positionsPreferredSource, Center, and Alternate Sourcepositions
Allows use as load shed equipment in parallelingsystems and allows programmed transitionfunctionality for transfer of motors, transformers,UPS, and other SCR equipment without disruption
Mechanical interlock Prevents source-to-source short circuit and meetscode requirement
Stored energy over center mechanism Provides uniformly fast operation of contacts onmaking and breaking regardless of electrical ormanual operation. Contacts cannot be ‘teased’,drawing dangerous arcs, during manual operation
Ampere ratings: From 40 to 3000 amperes Range of standard continuous ampere ratingscovers electrical distribution equipment ratings
Voltage ratings: Nine standard voltage ratingsfrom 120 to 600 VAC.
Covers all commonly used voltage rangesworldwide
Frequency rating: Dual rating for 50 and 60Hz.
Does not require special hardware to accommodate50 Hz applications
3 or 4 pole switch configurations Allows use on single-phase, three-phase solidneutral, and three-phase switched neutral systems
Optional neutral bar on 3 pole Allows application flexibility for 3-wire systemswithout a neutral conductor
Customer auxiliary contacts: Form C contactson normal and emergency side
Allows remote annunciation of transfer switchposition and control interface with auxiliaryequipment
Cu/Al mechanical pressure lugs Accommodates both types of cable materials.Mechanical pressure lugs are oversized to allowlarger cables when required for voltage drop, etc.
Bus connects Provides a provision for switchboard mounting andbus duct connection
Manual handles Permanently attached manual operating handlesprovide means for safe manual operation andservice operation with electrical operator disabled.Available on Onan transfer switches rated at 1000amps or less.
Motor disconnect switch Disables electrical operator for service and manualtransfer operation
Onan PowerCommand Transfer Switch Self-StudyPage 4
BTPC BypassBTPC Bypass
IsolationIsolation
TransferTransfer
SwitchSwitch
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: Onan’s Bypass Switch Features and Benefits
Features Benefits
Combination automatic/manual bypass switch Combines OTIII, a mechanical bypass switch,and a drawout isolation mechanism into a singleunit
Non-load break Non-load break design allows switch bypass andisolation to either source without disruption to theload
Dual source bypass Can bypass to either source as long asacceptable power is available and the transferswitch is connected
Electro-mechanical interlock Prevents inadvertent bypassing to a dead source
Front panel bypass control Able to isolate and bypass load without openingcabinet
Center off position on bypass switch Controls speed of bypass to prevent out of phasemanual transfers
Safety shutters Drop into place as ATS is withdrawn to coverprimary disconnects
Safety shields Transparent Lexan shields cover all live partsincluding lugs
Extension rails Allow ATS to be rolled out of cabinet for easyoverhead lifting and removal after isolation
Onan PowerCommand Transfer Switch Self-StudyPage 5
PLTO AutomaticPLTO Automatic
Transfer SwitchTransfer Switch
(Available 2000(Available 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.
PLTH ClosedPLTH Closed
TransitionTransition
Transfer SwitchTransfer Switch
(Available 2000)(Available 2000)
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.
PLTS SoftPLTS Soft
Loading TransferLoading Transfer
SwitchSwitch
(Available 2000)(Available 2000)
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.
Onan PowerCommand Transfer Switch Self-StudyPage 6
PowerCommandPowerCommand
NetworkNetwork
CommunicationCommunication
Module (NCM)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 vendor’s
product to work with another vendor’s 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.
InPowerInPower
Transfer SwitchTransfer Switch
Service ToolService 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.
Onan PowerCommand Transfer Switch Self-StudyPage 7
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
Onan PowerCommand Transfer Switch Self-StudyPage 8
Lesson One Progress Check (Cont.)
6. List five features and the associated benefits of the BTPC transfer switch.
Features Benefits
Onan PowerCommand Transfer Switch Self-StudyPage 9
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 Onan’s OTPC transfer
switch.
6. Refer to Table 1-2 for a complete list of features and benefits for Onan’s BTPC transfer
switch.
Onan PowerCommand Transfer Switch Self-StudyPage 10
Lesson Two: The New PowerCommand
Transfer Switch Control
Objectives After completing this lesson, you should be able to:
• 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 ofComponents
of the NewControl
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 microprocessor-
based 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)
2. The New PowerCommand Transfer Switch Control
Onan PowerCommand Transfer Switch Self-StudyPage 11
Overview ofPCTS 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.
ControlPackages
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 ControlLevel 1 Control
PackagePackage
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.
2. The New PowerCommand Transfer Switch
Onan PowerCommand Transfer Switch Self-StudyPage 12
Table 2-1: Level 1 Transfer Switch Control Features and Benefits
Features Benefits
Microprocessor-based control electronics Improved reliability and performance
PowerCommand network option Ability to access the PowerCommand network with asimple, and economical hardware upgrade
Local RS-232 serial port Allows quick configuration downloads, servicediagnostics, or data acquisition using a laptop PCand InPower software.
Software based trims and adjustments Reduced setup time, improved reliability and ease ofuse
Utility-to-generator applications Serves most common type of standby applications.
Over/under three-phase voltage sensing onutility, single phase over/undervoltagesensing on emergency, software adjustable
Provides an economical sensing package designedfor standby power applications
Frequency sensing on both sources, single-phase
Monitors variations in frequency on both sources
Start, transfer, retransfer, and stop timedelays, adjustable
Provides software adjustable time limits for the fourprimary transfer time delays
Programmed transition for inductive loadtransfer, software adjustable
Reliably transfers motors, transformers, UPS, andother SCR equipment without disruption or long termwear and tear damage
Programmable generator set exerciser Allows user-flexible scheduling of generator exerciseperiods. Exercise times can be set up on a multi-dayschedule, rather than limited to 1,2, or 4 weeks
Front panel test switch and time delay bypassswitch
Allows the operator to quickly enable a transfer,bypassing all time delays
Front panel LED indicators for: normalavailable/normal connected, emergencyavailable/emergency connected, not-in-auto,active test
Long-life LEDs provide at-a-glance source andtransfer switch status for quick summary of systemconditions
Front panel security key Disables front panel buttons and switches toprevents operation by unauthorized personnel
Optional digital display for front paneladjustments and monitoring
Provides convenient and quick access to reviewcurrent power and load conditions, makeadjustments, review events or check network status(if network option is used)
2. The New PowerCommand Transfer Switch
Onan PowerCommand Transfer Switch Self-StudyPage 13
Level 2 ControlLevel 2 Control
PackagePackage
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 utility-
to-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.
2. The New PowerCommand Transfer Switch
Onan PowerCommand Transfer Switch Self-StudyPage 14
Table 2-2: Level 2 Control Features and Benefits
Features BenefitsMicroprocessor-based control electronics Improved reliability and performance
PowerCommand network option Ability to access the PowerCommand network with asimple, and economical hardware upgrade
Local RS-232 serial port Allows quick configuration downloads, service diagnostics,or data acquisition using a laptop PC and InPower software
Software based trims and adjustments Improved reliability, ease of use
Utility-to-generator, utility-to-utility, or generator-to-generator configurations
Accommodates a full range of applications
Over/under three-phase voltage sensing on bothsources, software adjustable
Provides complete sensing of the supply voltages forcritical applications
Frequency sensing on both sources, single-phase Monitors variations in frequency on both sources
Phase rotation and voltage imbalance sensing Safeguards against installation mistakes and severesingle-phase imbalance loading
Start, transfer, retransfer, and stop time delays,software adjustable
Provides software adjustable time limits for the four primarytransfer time delays
Programmed transition for inductive load transfer,software adjustable
Reliably transfers motors, transformers, UPS, and otherSCR equipment without disruption or long term wear andtear damage
Load monitoring package option Records the maximum load phase currents and neutralcurrent showing reserve capacity for future addition of load.Warns of excessive neutral current resulting from thirdharmonic non-linear loading or an unbalanced load
Programmable calendar-based generator setexerciser with specific date/time scheduling
Allows complete flexibility of scheduling generator exerciseperiods. Exercise times can be set up on a calendar basisto take advantage of plant shut-down, non-working days, orother scheduled opportunities
Digital display (standard with Level 2 control)provides front panel adjustments and monitoring
Provides convenient and quick access to review currentpower and load conditions, make adjustments, reviewevents; network status can be checked if network option isused
Front panel test switch and time delay bypassswitch
Allows the operator to quickly enable a transfer, bypassingall time delays
Front panel LED indicators for normal available/normalconnected, emergency available/emergencyconnected, not-in-auto, active test
Long-life LEDs provide at-a-glance source and transferswitch status for quick summary of system conditions
Front panel security key Disables front panel buttons and switches to preventoperation by unauthorized personnel
Analog LED bar graph meter option Allows at-a-glance confirmation of system status andanalog indication, voltage, current, frequency, KW andpower factor
2. The New PowerCommand Transfer Switch
Onan PowerCommand Transfer Switch Self-StudyPage 15
ControlFeatures
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.
Real TimeReal Time
ClockClock
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.
Time DelaysTime Delays 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.
Under-VoltageUnder-Voltage
SensingSensing
Both control levels include under-voltage sensors for both
source 1 and source 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.
2. The New PowerCommand Transfer Switch
Onan PowerCommand Transfer Switch Self-StudyPage 16
Over-VoltageOver-Voltage
SensingSensing
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.
FrequencyFrequency
SensingSensing
Both control levels include over- and under- frequency
sensing of Normal and Emergency.
Two-wireTwo-wire
StartingStarting
The generator start circuit uses a two-wire start control.
Three-wire starting is not supported in the
PowerCommand Control.
ProgrammedProgrammed
TransitionTransition
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.
ClosedClosedTransitionTransition
TransferTransfer
The PowerCommand Transfer Switch Control is available
in closed transition mode on two standard versions of
Paralleling Load Transfer Equipment—the 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.
2. The New PowerCommand Transfer Switch
Onan PowerCommand Transfer Switch Self-StudyPage 17
ProgrammableProgrammable
GeneratorGenerator
ExerciserExerciser
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.
VoltageVoltage
ImbalanceImbalance
SensorSensor
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.
PhasePhase
RotationRotation
SensorSensor
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.
Loss of SingleLoss of Single
Phase SensorPhase Sensor
Level 2 Control on 3-phase transfer switches can detect
the loss of a single phase on either source.
ControlOptions
This section provides a summary of the major options of
the PowerCommand Transfer Switch Control.
LoadLoad
MonitoringMonitoring
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.
2. The New PowerCommand Transfer Switch
Onan PowerCommand Transfer Switch Self-StudyPage 18
Relay SignalRelay Signal
ModuleModule
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
• Fail to Synchronize
• Fail to Disconnect
Load ShedLoad Shed 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.’
LoadLoad
SequencerSequencer
OptionOption
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.
Remote TestRemote Test
TransferTransfer
OptionOption
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.
2. The New PowerCommand Transfer Switch
Onan PowerCommand Transfer Switch Self-StudyPage 19
Float BatteryFloat Battery
ChargerCharger
OptionOption
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.
AuxiliaryAuxiliary
Relay OptionRelay Option
The optional auxiliary relays provide contacts for
energizing external alarms, remote indicators and control
equipment such as louver motors or water pumps.
Interfaces The OTPC and BTPC offer several types of new or
improved interfaces including:
• 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 Interfaceprovides configuration download, on-line diagnostics,
data analysis tools, and real time monitoring using a
laptop PC. InPower will be discussed further in Lesson 5.
OperatorOperator
InterfaceInterface
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.
2. The New PowerCommand Transfer Switch
Onan PowerCommand Transfer Switch Self-StudyPage 20
Table 2-3: Features of the Operator Interface for Level 1 and Level 2 Control Options
Features Level 1 Level 2
Basic interface panel Standard Standard
Front panel security key option Option Option
Digital alpha numeric display Option Standard
Analog bar graph meters Not available Option
Basic interface panel High-intensity LED indicator lamps designed for long lifeand easy reading in common lighting situations provide aquick summary of system conditions (see Figure 2-1).The interface panel is a standard feature on all OTPCtransfer switches. It contains six indicator lamps and threemembrane switches.
The control switches are tactile push buttons. These
lamps and switches include the following:
Lamps
Source 1 Available and Source 2 Available: Theseindicators are lit when the corresponding power sourcesare producing power. These indicators can be litsimultaneously.
Source 1 Connected: This indicator is lit when theautomatic transfer switch is in the normal position andSource 1 is supplying power to the load.
Source 2 Connected: This indicator is lit when theautomatic transfer switch is in the emergency position andSource 2 is supplying power to the load.
Not in Auto: For Genset–to–Utility configurations, theNot in Auto indicator lights when the genset On/Off/Autoswitch is not in the Auto position.
For Genset–to–Genset configurations, the Not in Autoindicator 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 Autoindicator is not used.
Test/Exercise Active: The Test/Exercise Active indicatoris lit when the transfer switch has a test or exercise inprogress.
2. The New PowerCommand Transfer Switch
Onan PowerCommand Transfer Switch Self-StudyPage 21
Switches
Test: The Test (Hold 2 Sec.) switch sends a start signal tothe generator set designated Power Source 2 and lightsthe Test/Exercise Active indicator. After the transfer timedelay, Source 2 starts and assumes the load provided thatthe With Load option is selected. Press the Test switchagain to end the test; the Test/Exercise Active indicatorgoes out and Source 1 resumes as the source of power.
Override: The Override switch terminates most systemtime delays. The Programmed Transition, Synch Check,and Engine Cool Down are not affected by this switch. Ifyou press this switch while the Transfer Inhibit input isalso active, the switch immediately transfers the load. Ifyou press this switch while the Re–Transfer Inhibit inputis active, the switch immediately retransfers the load.
Reset/Lamp Test:The Reset/Lamp Test switch turns onall control panel indicators.
2. The New PowerCommand Transfer Switch
Onan PowerCommand Transfer Switch Self-StudyPage 22
Figure 2-1: The OTPC Operator Panel
Analog LEDBar GraphMetering
Basic InterfacePanel
Front PanelSecurityKey Option
Digital AlphaNumericDisplay
2. The New PowerCommand Transfer Switch
Onan PowerCommand Transfer Switch Self-StudyPage 23
Front Panel SecurityKey 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.
Figure 2-2: The OTPC Front Panel
Front Panel SecurityKey Option
2. The New PowerCommand Transfer Switch
Onan PowerCommand Transfer Switch Self-StudyPage 24
Digital Alpha NumericDisplay
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 Operator’s
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 sub-
menus). 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.
2. The New PowerCommand Transfer Switch
Onan PowerCommand Transfer Switch Self-StudyPage 25
Analog Bar GraphMeters
A multi-function-metering package provides analog ACoutput metering for service to the loads. Bar GraphMeters are not available on Level 1 controls and areoptional on Level 2 controls. The bar graph metersinclude a 3-phase AC ammeter, a power meter, a powerfactor meter, a frequency meter, and a three phase ACvoltmeter:
AC Ammeter: The ammeter measures the line currentsof the load.
Power Meter: The power meter measures the real powerin percent of full load.
Power Factor Meter: The power factor meter measuresthe real power delivered to an inductive load.
Frequency Meter: This meter measures the outputfrequency of the selected power source in hertz.
AC Voltmeter: The voltmeter measures line–to–line andline 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.
2. The New PowerCommand Transfer Switch
Onan PowerCommand Transfer Switch Self-StudyPage 26
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 Level 2
Standard Standard
Option Option
Option Standard
Not available 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 Level 1 Level 2
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
2. The New PowerCommand Transfer Switch
Onan PowerCommand Transfer Switch Self-StudyPage 27
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
2. The New PowerCommand Transfer Switch
Onan PowerCommand Transfer Switch Self-StudyPage 28
Answers to Lesson Two Progress Check
1.
Features Level 1 Level 2
Basic interface panel Standard Standard
Front panel security key option Option Option
Digital alpha numeric display Option Standard
Analog bar graph meters Not available Option
2.
Sensing Parameters Level 1 Level 2
Voltage imbalance 4
Phase rotation 4
Undervoltage 4(3-phase normal, 1-
phase emergency)
4(3-phase normal, 3-
phase emergency)
Overvoltage 4(3-phase normal, 1-
phase emergency)
4(3-phase normal, 3-
phase emergency)
Frequency 4 4
Loss of single phase 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__ Scroll to number of transfers
___2__ Second main menu
___3__ Statistics
___1__ First main menu (more)
6. False, both levels of control include a real-time clock.
Onan PowerCommand Transfer Switch Self-StudyPage 29
Lesson Three: How Onan Compares with
the Competition
Objectives After completing this lesson, you should be able to:
• Compare Onan’s 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.
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:
Overview ofCompetitive
Products• Onan
• Asco
• Russelectric
• Kohler
• Generac
• Zenith
TransferSwitch Level 1
ControlPackage
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
Onan PowerCommand Transfer Switch Self-StudyPage 30
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.
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.
Asco 300Zenith ZTG with MX 100 Controls
3. How Onan Compares with the Competition
Onan PowerCommand Transfer Switch Self-StudyPage 31
Positioning thePowerCommandTransfer SwitchLevel 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.
3. How Onan Compares with the Competition
Onan PowerCommand Transfer Switch Self-StudyPage 32
Table 3-1: PowerCommand Transfer Switch Level 1 Control Competitive Comparison
PowerCommandTransfer SwitchLevel 1 Control
Asco 300 Zenith ZTG This is important because:
ControlPlatform
• Microprocessor-based
• Software-basedadjustment of transferswitch settings viaInPower Software oroptional Digital Display
• Password protection ofsettings
• Microprocessor-based
• Dipswitch adjustmentof settings
• Microprocessor-based
• Potentiometeradjustment of settings
• Dipswitch adjustments require lookup tablesto set.
• Potentiometers can be difficult to setbecause they require trial and error. Theycan also drift over time and temperature.
• Only Onan provides software basedadjustments set from the front panel display.
Sensing • 3-phaseover/undervoltagesensing normal. 1-phaseemergency
• Frequency sensing onboth sources
• 3-phase undervoltagesensing normal, 1-phase emergency
• Frequency sensing onemergency only
• 3-phase undervoltagesensing on normal, 1-phase emergency
• Frequency sensing onboth sources
• Only Onan offers a full sensing packageon the normal source.
Transfermodes
• Standard OpenTransition
• Programmed Transition
• Standard OpenTransition
• In-Phase Monitor
• Standard OpenTransition
• In-Phase Monitor
• Programmed Transitionavailable at added cost
• Only Onan offers Programmed Transitionas standard on every switch.
• Asco cannot offer Programmed Transitionon the 300 Series.
• Zenith requires an upgrade to a moreexpensive switch with a center off position.It cannot be upgraded in the field.
GeneratorsetExerciser
• Programmable exerciserallows exercise times setup on any daily intervalschedule from 1-225 days
• 7 day exerciser • 7 day exerciser • Only Onan provides this level offlexibility as standard. This means thata customer can select intervals of anynumber of days based on siterequirements and plant maintenancerequirements.
3. How Onan Compares with the Competition
Onan PowerCommand Transfer Switch Self-StudyPage 33
Table 3-1 (cont.): PowerCommand Transfer Switch Level 1 Control Competitive Comparison
PowerCommandTransfer SwitchLevel 1 Control
Asco 300 Zenith ZTG This is important because:
ExternalInterfaces
• Basic panel (sourceavailable/ connectedindicators, test/ exercise/bypass buttons)
• Optional vacuumfluorescent digital display
• Optional Front PanelSecurity Key
• Panel with sourceavailable andconnected LEDs,exerciser switch, testswitch, and timedelay bypass switch
• Basic panel with sourceavailable and connectedand time delay timing LEDs
• Onan provides the option of adding avacuum fluorescent digital display.Other transfer switches do not providedisplays. Vacuum fluorescent displayshave better performance over extremetemperatures than LCD displays.
• The security key enables operation ofthe switch at the front panel preventingunauthorized personnel from initiating atransfer.
Network • LONWorks compliantnetwork interface
• SerialCommunicationsboard for use withPowerQuest.
None • All PowerCommand switches caninterface with other LONWorkscompliant devices allowing economicaladdition of transfer switch informationinto PowerCommand Systems andBuilding Automation networks.
Events • Sequenced eventrecording
• Optional network eventdisplay
None None • Only Onan provides time sequencedtransfer switch and network eventinformation at the digital display. Thiswill greatly improve troubleshooting andserviceability of the entire powersystem.
Options • Signal module
• Loadshed
• Load disconnectsignal
• Elevator pre-signal • Only the OTPC can move the entireload to a neutral position, disconnectedfrom both sources
3. How Onan Compares with the Competition
Onan PowerCommand Transfer Switch Self-StudyPage 34
PowerCommandTransfer SwitchLevel 2 Control
At the upper end of the transfer switch market are those
businesses with a requirement for high reliability—central
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.
Figure 3-2: Competition for the PowerCommand Transfer Switch Level 2 Control
Positioning thePowerCommandTransfer SwitchLevel 2 Control
In addition to Onan, three suppliers make premium
switches—Asco, 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).
Asco 7000
Series
3. How Onan Compares with the Competition
Onan PowerCommand Transfer Switch Self-Study Page 35
Table 3-2: PowerCommand Transfer Switch Level 2 Control Competitive Comparison
PowerCommand TransferSwitch Level 2 Control
Asco 7000 Russelectric 2000 This is important because:
Controlplatform
• Microprocessor-based
• Multi-language display
• Password protection ofsettings
• Microprocessor-based
• Voltage selectable
• Multi-language display
• Password protected
• Microprocessor-based
• Password protected
• Onan’s microprocessor isdesigned to be commonplatform that can directlycommunicate with otherPowerCommand productsfor applications worldwide
Sensing • 3-phase over/under voltagesensing on normal andemergency
• Under/over frequency onnormal and emergency
• Voltage imbalance sensing
• Phase rotation sensing
• Loss of single phasedetection
• 3-phase over/undervoltage sensing on-phasenormal and emergency
• Under/over frequency onnormal and emergency(+/- 0.2%)
• Voltage imbalancesensing
• Phase sequence sensing
• 3-phase over/under voltagesensing on normal andemergency
• Under/over frequency onnormal and emergency
• Phase sequence detection
• Voltage imbalance sensing
• Phase differentialmonitoring
• Onan provides a competitivesensing package designedto meet industryspecifications
Transfermodes
• Standard open transition
• Standard programmedtransition
• In-phase monitor withprogrammed transitionbackup (on the PLTO)
• Closed transition (on thePLTH)
• Closed transition withactive synchronization (onthe PLTS and PLTH)
• Optional bypass isolation(available on the BTPC)
• Standard opentransition
• Delayed transition(requires additionalswitch hardware)
• In-phase monitor
• Closed transition option
• Optional bypassisolation
• Standard open transition
• Delayed transition(requires additionalswitch hardware)
• Sync check (In-phasemonitor)
• Closed transition optionavailable
• Optional bypass isolation
• The OTPC and BTPC remainthe only switches on the marketthat can provide programmedtransition as standard. Onanhas also improved the in-phasemonitor by providing aprogrammed transition backup.The PLTS and PLTH canactively synchronize with aPCCII generator set.
3. How Onan Compares Against the Competition
Onan PowerCommand Transfer Switch Self-Study Page 36
Table 3-2 (cont.): PowerCommand Transfer Switch Level 2 Control Competitive Comparison
PowerCommandTransfer SwitchLevel 2 Control
Asco 7000 Russelectric 2000 This is important because:
Generatorsetexerciser
• Calendar-basedexerciser
• 1, 7 14 or 28 dayexerciser clock
• Calendar-based exerciser • The Onan calendar-based exerciseruses a real-time clock that allows upto 8 separate exercise programs tobe set up to accommodate plantmaintenance schedules, plantshutdowns, holidays, etc. The clockalso automatically corrects fordaylight savings and leap year.
Externalinterfaces
• Vacuum fluorescentdigital display
• Basic panel (sourceavailable/ connectedindicators, test/ exercise/bypass buttons)
• Optional digital LED bar-graph meter panel
• Front panel Security Key
• LCD digital display
• Touchpad programmingof features and settings
• LCD digital display
• Source connected LEDs
• Optional annunciationplate with sourceavailable, connected, notin auto, and audible alarm.
• Vacuum fluorescents provide highervisibility and better performance atextreme temperatures, especiallybelow –20C.
• Only Onan offers meters as apricebook option. The LED bargraph meters provide color-codedindication for at-a-glance visualdetermination of source and loadacceptability.
Network • Optional network board
• Lonworks compatible
• Transfer switch andgenerator set status fromnetwork
• Serial comm board (RS422/485 protocol) for usewith proprietaryPowerQuest
• Serial comm port(RS422/485 ModBus RTUprotocol) for use with BMSor Russel Scada system
• Onan’s network interface isdesigned to be LONMark compliant,allowing integration into buildingautomation systems.
3. How Onan Compares Against the Competition
Onan PowerCommand Transfer Switch Self-Study Page 37
Table 3-2 (cont.): PowerCommand Transfer Switch Level 2 Control Competitive Comparison
PowerCommandTransfer SwitchLevel 2 Control
Asco 7000 Russelectric 2000 This is important because:
Events/history
• Date/time stamped 50logged events
• Network eventinformation available atthe digital display
• Date/time stamp 99logged events
• Total ATS transfers
• ATS failures due tosource failure
• Total days of ATSoperation
• Total source availablehours
• Date/time stamped mostrecent 10 transfer events(numeric codes)
• Total each sourceavailable
• Total each sourceconnected
• Number of transferoperations to each source
• Onan provides more types of eventand history information to makediagnostics and record-keepingeasier.
Options • Signal module
• Loadshed
• Load power and loadcurrent monitoring
• Load sequencing via thenetwork
• Programmable loadshed • Loadshed • Only Onan senses source voltagecurrent, load, KW and PF in thetransfer switch. This means that theinformation is available from thetransfer switch and can be accessedusing InPower or communicatedacross the network from one device.Both Asco and Russelectric rely onseparate add-on load monitoringpackages.
3. How Onan Compares with the Competition
Onan PowerCommand Transfer Switch Self-StudyPage 38
TransferSwitch
FeaturesCompared to
OtherSuppliers
The following pages (Table 3-3) chart a comparison of
the features Onan’s 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.
3. How Onan Compares with the Competition
Onan PowerCommand Transfer Switch Self-Study Page 39
Table 3-3: Comparison of Transfer Switch Features Provided by Major SuppliersFeature Onan Asco Russel Zenith Generac Kohler Why this is important:
Mechanically held switch • • • • • • Mechanically latched contacts help the switch withstand faults bylocking the contacts closed. Some switches can be manuallyoperated but not latched, so an improper service operation canleave the switch closed, but not latched. This can cause failure ofthe ATS.
Silver alloy contacts • • • • see note2
• Silver alloy provides better durability than pure silver.
Multiple leaf arc chutes • • • • see note3
• Arc chutes accelerate arc extinguishing and minimize contactwear on switching.
Quick-make, quick-breakmechanism
• • Prevents improper operation of the switch during serviceoperations. Makes switch safer to operate manually.
Programmed transition • seenote 2
• • see note1
seenote 2
Most effective way to deal with transfer of inductive loads.
Permanently attachedmanual operators
• • see note1
seenote 1
Permanent mounting helps prevent misoperation, loss of manualoperators. Safer manual operation.
Barriers over all liveparts, including lugs
• Barriers prevent direct inadvertent contact to dangerous voltagelevels.
Transparent barriers • • • Allows visual inspection of the switch mechanism without movingprotective covers.
Positive mechanicalinterlock
• seenote 3
• seenote 1
• seenote 1
Prevents accidental out of phase paralleling of sources, orenergizing a generator set that is shut down. Either can causeserious damage to the generator set.
True 4-pole(simultaneous) neutralswitching
• • Eliminates the danger of misoperation of neutral poles, which cancause operational and safety hazards.
Common Crossbar on 3-Pole and 4-PoleSwitches
• • • • Provides for synchronized opening of all contacts and minimizesthe possibility of transient switching overvoltages.
3. How Onan Compares Against the Competition
Onan PowerCommand Transfer Switch Self-Study Page 40
Table 3-3 (cont.): Comparison of Transfer Switch Features Provided by Major SuppliersFeature Onan Asco Russel Zenith Generac Kohler Why this is important:
Controls door-mounted • • • • • Door-mounting the control makes it more accessible, easier andsafer to work on.
Controls isolated fromswitch for service
• • • • Control disconnect plug allows isolation of the control for servicewithout interrupting power to loads.
Standard sensing andtiming in one controlpackage
• • Entire control system prototype-tested as system. Ease ofservice, availability of spares is improved.
One electronic control forall ratings
• • Improved reliability.
High voltage surge andnoise immunity
• • Control is resistant to voltage surges due to lightning and othertransient effects. If the voltage surge exceeds specifiedparameters, the Onan control will start the generator set andtransfer power, so customer knows failure has occurred, andproblem can be fixed.
Internal LED statuslamps
• Provides diagnostics and fault indicators to make service easier.LED’s designed to operate for the life of the control.
Control I/O isolated • Helps to protect the control from voltage surges and transientconditions that might damage the control.
Field adjustable,calibrated voltagesensors
• • • • Allows field modification of voltage conditions to suit the needs ofthe application. More reliable Indication of failed source.
Sensors on all phases ofboth sources
• Voltage sensors identical for both sources. Better partsavailability, easier service and calibration. Better protection forloads.
Service for entire powersystem from a singlesupplier
• Single source for technical information, product startup, service,warranty, parts.
3. How Onan Compares Against the Competition
Onan PowerCommand Transfer Switch Self-Study Page 41
Table 3-3 (cont.): Comparison of Transfer Switch Features Provided by Major SuppliersFeature Onan Asco Russel Zenith Generac Kohler Why this is important:
Can be networked withany transfer switchfrom any supplier
• Network is suitable for use in any building, even when switchesfrom several suppliers are in place. Minimizes costs of systemmonitoring.
Can be networked withany generator set fromany supplier
• Network is suitable for use in any building, even when equipmentfrom several suppliers are in place. Minimizes costs of systemmonitoring.
Non-Load breakbypass available
• • seenote 1
• No power interruption to critical loads when maintenance or serviceof switch is needed. Bypass switch is isolated from current surgesthat could damage it in day to day operation.
Bypass to any sourceat any time
• • Ease of operation. System is more reliable.
Bypass includes dead-source interlock
• • • • Prevents situation where system is connected to a source that isnot available.
Asco/Kohler Notes1. Switch can be manually operated to a new position without locking contacts in place. Or, could leave in neutral position and switch can’t 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 Notes1. 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 Notes1. 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 lower4. Available only on switches rated 250VAC and lower
3. How Onan Compares with the Competition
Onan PowerCommand Transfer Switch Self-Study Page 42
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.
3. How Onan Compares Against the Competition
Onan PowerCommand Transfer Switch Self-StudyPage 43
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.
Onan PowerCommand Transfer Switch Self-Study Page 44
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.
TheOpportunityfor Network
Solutions
Let’s 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.
4. The PowerCommand Control Network
Onan PowerCommand Transfer Switch Self-StudyPage 45
Table 4-1: Profile of Candidates for PowerCommand Network
Physical Plant Characteristics Examples of Industries
Life-safety code-driven buildings, such as single buildingsover 6 stories and facilities governed by NFPA 99 or 110
• Healthcare
• Hotels
• Commercial real estate
Generator sets in multiple buildings or installations on onesite
• Colleges and universities
• Correctional facilities
• Manufacturing plants
• Wastewater treatment facilities
• Some healthcare facilities
Multiple installations distributed over a wide area • Retail chains
• Public utilities
• Telecommunications
• Gas pipelines
• Some healthcare facilities
Benefits of aNetworkSolution
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.
4. The PowerCommand Control Network
Onan PowerCommand Transfer Switch Self-StudyPage 46
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
Opportunitiesin 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.
4. The PowerCommand Control Network
Onan PowerCommand Transfer Switch Self-StudyPage 47
JointJoint
CommissionCommission
RequirementsRequirements
The Joint Commission’s 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.
4. The PowerCommand Control Network
Onan PowerCommand Transfer Switch Self-StudyPage 48
Table 4-2: Benefits of PowerCommand Network for the Healthcare IndustryPowerCommand Network Features Benefits to Healthcare Customers
PowerCommand Control design enhances reliablegenerator set startup
• Risk management
• Minimizes repair time and expense
Automatic alarm notificationDial-out capability for change-of-state, warning orshutdown conditions
• Greater flexibility because staff can circulatewithin or away from the facility
• Risk management because no need for humansto transfer alarm messages
PowerCommand software for Windows keepsrecords of system status and test performanceconveniently
• Low cost, convenient, compliance withaccreditation and code requirements
• Date/time stamp of events provide verification ofactual system performance
PowerCommand software for Windows permits localor remote monitoring and control. Localdistributorships can perform diagnostics from theirdistributorship.
• Saves time for the facility engineer
• Saves personnel costs: a few highly qualifiedindividuals monitor and control remotely, whileless qualified people do simpler on-site tasks
• Enhances system reliability through well-qualified technical service
PowerCommand Network uses logical connectionsrather than hardwiring between modules.
• Saves money on installation
• Saves money on future modification
Automatically records duration, load level, andoperating temperature conditions of generator setduring monthly exercise and whenever generator setruns for any reason (actual outage, testing afterrepairs, etc.)
• Operating personnel need not be present
• Events recording provides verification of actualsystem performance
Automatically collects all available generator setoperating data at user-defined intervals and storesdata in permanent record.
• Record may be viewed, downloaded or printed
• No manual transcription errors
• Operating personnel need not be present
Formats generator set operating data in standardprinted report.
• Meets documentation requirements of JAHCO
• Consistency of data
• Saves time for facility engineer
Records date and time intervals of automaticgenerator start-up and shutdown processes (duringexercise and actual outages)
• Meets data requirements of JAHCO
• Events recording provides verification of actualsystem performance
Records date and time intervals of automatictransfer switch tests and transfer switch position
• Meets data requirements of JAHCO
• Events recording provides verification of actualsystem performance
Records automatic transfer switch operating data(current and voltage) on user-defined intervals andstores data in permanent record.
• Meets data requirements of JAHCO
• Events recording provides verification of actualsystem performance
Automatic alarms notification to monitoring PC, vialocal network wiring and/or telephone modems toremote location, including automatic pagingcapability for unacknowledged alarms. Providesnear immediate notification from unattendedequipment whether running or not.
• Meets data requirements of JAHCO
• Operating personnel need not be present
4. The PowerCommand Control Network
Onan PowerCommand Transfer Switch Self-StudyPage 49
Opportunitiesin RetailMarkets
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 Network’s
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 systemswith PowerCommand Network
• Reduces the need for on-site expertise.
• Skilled individuals at headquarters ordistributor can manage preventivemaintenance.
• Cummins/Onan distributors can providetechnical assistance.
• PowerCommand Network can be set up tonotify the distributor when service is needed.
• Technically qualified individuals are availablethrough Onan distributors
• Reliability of the standby power system underPowerCommand Network
• Ensures public safety, loss prevention and(with a 100% standby system) continuity ofoperations and revenue flow.
• Cost of system could be offset by customerbenefits
• Cost of standby system withPowerCommand Network may be offset byreduced time driving to sites, exercisinggenerator sets and recording information.
4. The PowerCommand Control Network
Onan PowerCommand Transfer Switch Self-StudyPage 50
Opportunities inTelecommunica-
tions
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 IndustryPowerCommand Network Features Benefits to Telecomm Customers
PowerCommand Control design enhancesreliable generator set startup
• Maximizes reliability of standby powersystem, which in turn minimizes lostrevenue and supports life-criticalapplications such as 9-1-1 service.
Permits remote monitoring and control from acentral monitoring facility.
• Saves travel and personnel costs byallowing monitoring and control of multiplesites at a central location, requiring fewerskilled people to operate.
Automatic alarm notification. Dial-out capabilityfor change-of-state, warning or shutdownconditions
• Provides operational information to acentral monitoring point via modem forevaluation and dispatch by trainedpersonnel.
• Reduces travel and troubleshooting time byproviding key information before theservice technician leaves for the call.
Can communicate data necessary forevaluation of system status and testperformance
• Convenient method for system-wide testingand evaluation concerns.
4. The PowerCommand Control Network
Onan PowerCommand Transfer Switch Self-StudyPage 51
Next the lesson examines how transfer switches interface
to the PowerCommand Network with hardware and
software components.
Connecting tothe 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.
NetworkCommunication
Module(NCM)
Hardware
Now we’ll 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 twisted-
pair, 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 dial-
out to PowerCommand Network sites via modem (and
gateway) hardware. (See Figure 4-1 for the location of the
NCM.)
4. The PowerCommand Control Network
Onan PowerCommand Transfer Switch Self-StudyPage 52
Figure 4-1: NCM Installed on PowerCommand Transfer Switch Level 2 Control
NetworkCommunicationsModule addedhere
4. The PowerCommand Control Network
Onan PowerCommand Transfer Switch Self-StudyPage 53
NetworkCommunication
ModuleSoftware
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.
4. The PowerCommand Control Network
Onan PowerCommand Transfer Switch Self-StudyPage 54
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.
4. The PowerCommand Control Network
Onan PowerCommand Transfer Switch Self-StudyPage 55
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.
Onan PowerCommand Transfer Switch Self-Study Page 56
Lesson Five: InPower Service Tool
Objectives After completing this lesson, you should be able to:
• 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 ofthe 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.
Features ofFeatures of
InPowerInPower
InPower will transfer information between your laptop PC
and the PowerCommand Transfer Switch in a Windows-
based environment to perform the following tasks:
• 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
Onan PowerCommand Transfer Switch Self-StudyPage 57
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 InPowerHow InPower
WorksWorks
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 PCMinimum PC
RequirementsRequirements
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
5. InPower Service Tool
Onan PowerCommand Transfer Switch Self-StudyPage 58
• 24X CD-ROM
• One free serial communications port
(COM1- COM 4)
• Parallel port
• Windows supported A4 printer (optional)
InPowerTransfer
SwitchInformation
InPower software for the PowerCommand transfer switch
has three sections of information:
• Monitor
• Adjustments
• Faults/Events
MonitorMonitor 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.
AdjustmentsAdjustments 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.
Faults/EventsFaults/Events 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.
5. InPower Service Tool
Onan PowerCommand Transfer Switch Self-StudyPage 59
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.
5. InPower Service Tool
Onan PowerCommand Transfer Switch Self-StudyPage 60
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.
Onan PowerCommand Transfer Switch Self-Study Page 61
Lesson Six: Transfer Switch Selection
Objectives After completing this lesson, you should be able to:
• Identify the primary factors to consider when
selecting a transfer switch.
• Review a specification for an automatic and a bypass
transfer switch.
ImportantFactors in
the Selectionof 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 sophistication—sensing, 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.
6. Transfer Switch Selection
Onan PowerCommand Transfer Switch Self-StudyPage 62
Exercise 1:Exercise 1:
HospitalHospital
SettingSetting
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 hospital’s new burn unit.
• The hospital’s 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.)
6. Transfer Switch Selection
Onan PowerCommand Transfer Switch Self-StudyPage 63
Exercise 2:Exercise 2:
WastewaterWastewater
TreatmentTreatment
PlantPlant
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 system’s 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.
6. Transfer Switch Selection
Onan PowerCommand Transfer Switch Self-StudyPage 64
The following recommendations would be appropriate for
the settings described in each exercise.
Exercise 1:Exercise 1:
PotentialPotential
SolutionSolution
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-load-
break 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
Onan PowerCommand Transfer Switch Self-StudyPage 65
that will provide power and current data and at-a-
glance 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 manufacturer’s circuit breaker
listed with our BTPC is individually reviewed and
endorsed by UL. This can make the engineer’s 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:Exercise 2:
PotentialPotential
SolutionSolution
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 Onan’s previous
experience with a variety of third party software
including Intellution.
6. Transfer Switch Selection
Onan PowerCommand Transfer Switch Self-StudyPage 66
• 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
manufacturer’s 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 (corrosion-
resistant), discuss providing an open construction switch
and arrange for a custom enclosure.
Onan PowerCommand Transfer Switch Self-Study Page 67
Appendix A: Digital Alpha Numeric Display
ControlDisplay
Summary Information
Source-1 andSource-2Information
• Voltage L1-L2, L2-L3, L3-L1
• Source frequency
• Source connected
• On-time
Setup • Sensors and setpoints
• Time delays
• Test
• Generator set exerciserStatistics • On time Source 1
• On time Source 2
• Average transition time
• Total transfers
• Total Source 1 failure
• Total Source 2 failure
• Control battery status
• Battery charger statusNetwork • Generator status for up to 16 networked generator sets
• Load sequencer for sequencing signals for up to eight loads“About”Information
• Version
• Date of manufacture
• Serial number
• PRODUCTION CODE
• ATS mode
• LONWorks Interface Module installed
• Relay Module installed
AC LoadMonitoring(Optional)
• AC volts (line to line and line to neutral)
• Frequency
• Current (amps)
• Rest power (kW)
• Apparent power (kVA)
• Power factor
• Neutral current
Digital Alpha Numeric Display
Onan PowerCommand Transfer Switch Self-StudyPage 68
ControlDisplay
Detailed Information
Events • 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
Onan PowerCommand Transfer Switch Self-Study Page 69
Appendix B: Transfer Switch Network
Input VariablesNetwork Variable Description Used By
NviTestCmd Network Remote Test (w or w/o load) is used to allow another network device
to test the transfer switch
Master Control
NviStartCmd 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 generatorset. When true, the PowerCommand Transfer Switch Control will start one of
the backup generator sets.
PowerCommand
Transfer SwitchControl, ATS w/
Control
Communications
Module (CCM)
NviFaultResetCmd This input will clear or acknowledge the current ATS fault(s). Master Control
NviLoadShedCmd This input is used to instruct the ATS to shed and restore its load. Master,Power-
Command Control 1
(PCC1), PCC2
NviOverrideCmd This input is used to instruct the transfer switch to override (bypass) any delays
or inhibits, but not load shed.
Master Control
NviTransInhCmd This input is used to disable the ATS from transferring to Source2. Master Control
NviRetransInhCmd This input is used to disable the ATS from transferring back to Source1. Master Control
NviRelayControl1* PowerCommand for Windows uses this input to remotely shed and restore load
from the ATS.
PowerCommand for
Windows (PCW)
NviRelayControl2* PowerCommand for Windows uses this input to remotely inhibit transfer of the ATS. PCW
NviRelayControl3* PowerCommand for Windows uses this input to remotely test the ATS. PCW
NviRelayControl4* PowerCommand for Windows uses this input to override a transfer delay or inhibit. PCW
NviATSStatus 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
PowerCommand
Control Transfer
Switch Control, ATS
w/CCM
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:
NviGenStatus
• 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
PCC 1, 2, Generator
set w/CCM
nviSrc1Status 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.
PCC 1, 2 Generator
set w/CCM
nviSrc2Status 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.
PCC 1, 2, Generator
set w/CCM
NviMasterStatus 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.
Master Control
NviMasterACData 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.
Master Control
* Required for PowerCommand for Windows v1.10.
Onan PowerCommand Transfer Switch Self-Study Page 70
Appendix C: Transfer Switch Network
Output VariablesNetwork Variable Description Used By
NvoStartTypeB This output is only used with a PowerCommand Control 2 generatorset. This output is used to configure the PowerCommand Control 2generator set for emergency or non-emergency start. It will not start orstop the generator set.
PowerCommandControl 2 (PCC2)
NvoStartCmdB This output is used to start a generator set (when it is Source1) PCC 2,GeneratorCommunicationModule (GCM),Generator setw/CCM
NvoStartTypeA This output is only used with a PowerCommand Control 2 generatorset. This output is used to configure the generator set for emergencyor non-emergency start. It will not start or stop the generator set.
PCC 2
NvoStartCmdA This output is used to start a generator set (which is Source2). PCC 2, GCM,Generator setw/CCM
NvoSpeedAdjCmd Increase Source2 freq ('passive' parallel) PCC 2
NvoSyncEnableCmd Enable Source2 synchronizing PCC 2
nvoLoadInhCmd[9] These outputs are used to allow the PowerCommand Transfer Switch Controlto sequence the loading of either source. This allows the transfer switch toapply load ‘gently’ to a source, avoiding full step loading.
ATS, Relay
NvoTransPending This output is used to inform other devices on the network that apower source transfer is pending (to either source). This output isequivalent to the 'Elevator Signal'.
Elevator
NvoATSStatus This output is used to provide the current operating status of thistransfer switch for other devices on the network (PowerCommandControl 2 generator sets, PowerCommand Transfer Switch Controlsand Master Control).
Master, PCC 2,PowerCommandTransfer SwitchControl
NvoLoadACData Load: Hz, PF, kW, kVA, kVAR, V, A Master Control,Modbus
NvoSrcACData Source1 & 2: Hz, V Master Control,Modbus
nvoNFPA110Annun This output is used to annunciate the NFPA 110 states to the newannunciator (Source 1 connected, Source 2 connected, batterycharger malfunction).
NetworkAnnunciationModule (NAM)
NvoRemoteAnnun1 This output is used to annunciate the NFPA 110 states (Source 1connected, Source 2 connected, battery charger malfunction) to theold annunciator.
NAM (old)
Transfer Switch Network Output Variables
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Network Variable Description Used By
This output is used to annunciate the extended transfer switch alarms tothe annunciator:
NvoExtendedAnnun
• Source1 Available
• Source2 Available
• Source1 Connected
• Source2 Connected
• Test In Progress
• Load Shed
• Transfer Inhibit
• Retransfer Inhibit
• Fail To Close
• Fail To Disconnect
• Fail To Sync
• Slow Transfer
• Low ATS Battery
• Not In Auto
• Controller Error
• ATS Alarm
NAM
This output is used to annunciate a simplified transfer switch status tothe annunciator:
nvo8PointAnnun
• Source1 Available
• Source2 Available
• Source1 Connected
• Source2 Connected
• Test In Progress
• Load Shed
• Not In Auto
• ATS Alarm
NAM
This output is used to annunciate a 'short' generator set status to theannunciator:
nvo4PointAnnun
• Source1 Available
• Source2 Available
• Source1 Connected
• Source2 Connected
NAM
nvoFaultStatus This output is used to report the fault status of the transfer switch. Thisoutput is similar to a 'Common Alarm' output of a generator set.
NAM
nvoNotInAuto This output is used to report the readiness of the transfer switch. When the statefield is true, the transfer switch's front panel switch is not in the 'Auto' position.
NAM
nvoTestActive This output is used to report the transfer switch is performing a test orexercise. 'Test' refers to a manual test of the transfer switch while'exercise' refers to scheduled test.
NAM
nvoSrc1Available This output is used to report that Source1 is available for loading and it iswithin rated voltage and frequency.
NAM
nvoSrc2Available This output is used to report that Source2 is available for loading and iswithin rated voltage and frequency.
NAM
nvoSrc1Connected This output is used to report that Source-1 is connected to the load. PCC 2, NAM
nvoSrc2Connected This output is used to report that Source-2 is connected to the load. PCC 2, NAM
This output is used to provide the current ac data of the load.NvoACData*
• freq
• total_pf
• total_kva
• total_kw
• total_kvarvolts_ab
• volts_bc
• volts_ca
• volts_avolts_b
• volts_c
• amps_a
• amps_b
• amps_c
• percent_amps_a
• percent_amps_b
• percent_amps_c
Power-Command forWindows(PCW)
* Required for PowerCommand for Windows.
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Appendix D: Information Monitored by
InPower
Information ParametersAbout the Controller • Name tag
• Control package level
• Software version
• Relay module connection
• Network module connection
• Load module connection
• Load shed enable
• Alphanumeric display enable
• Meter package enable
• Network module enable
• Battery status
Model Data • ATS serial number
• ATS model number
• Build date
• Nominal current
• Nominal voltage for Source-1
• Nominal voltage for Source-2
Load Data • Voltage V1N, V2N, V3N
• Voltage V12, V23, V31
• Frequency
• Amps L1, L2, L3, neutral
• Total KVA
• Total KW
• Power factor
Source-1 Data • Position
• Voltage L12, L23, L31
• Voltage L1N, L2N, L3N
• Frequency
• Run time
Source-2 Data • Position
• Voltage L12, L23, L31
• Voltage L1N, L2N, L3N
• Frequency
• Run time
Statistics • 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
System • Transfer switch data for each ATS on network:
• Generator set data for each generator set on network:
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Appendix E: Adjustments Available with
InPowerAdjustments Parameters
Controller Mode Application Configuration:• Utility to generator• Utility to utility• Generator set to generator set• TestRefresh:• Voltage sensing constants• Frequency sensing constantsSave: Permanently saves all changed variables
Exerciser Clock Set up:• Exercise programs 1-8• Exception programs 1-8
Real Time Clock Set Clock for:• Year• Month• Date• Day of the week• Hours• MinutesEnable/disable daylight savings feature
Nominal Voltage • Nominal voltage for Source-1 (line–line voltage for level 1 control, line–neutral for level 2 control)
• Nominal voltage for Source-2 (line–line voltage for level 1 control, line–neutral for level 2 control)
Nominal Current Nominal current (in amps) for all phasesNeutral Current • Warning current level for neutral current (in amps)
• Time delay for neutral current warning (seconds)NominalFrequency
• Source-1 nominal frequency• Source-2 nominal frequency
Source-1 Sensing • Single phase, 2-phase, or3-phase sensing
• Nominal voltage• Under voltage pick up setting• Under voltage dropout setting• Under voltage dropout time
delay• Over voltage sensor enable• Over voltage pickup setting• Over voltage dropout setting• Over voltage dropout time delay• Enable frequency sensing• Frequency sensor
• Nominal frequency of Source-1• Pick-up setting• Frequency sensor dropout setting• Frequency sensor dropout time
delay• Voltage imbalance sensor enable• Voltage imbalance sensor
dropout setting• Voltage imbalance sensor
dropout time delay setting• Loss of phase sensor enable• Phase rotation enable for
Source-1 and Source-2
Adjustments Available with InPower
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Adjustments ParametersSource-2 Sensing • Single phase, 2-phase, or 3-
phase sensing• Nominal voltage• Under voltage pick up setting• Under voltage dropout setting• Under voltage dropout time
delay• Over voltage sensor enable• Over voltage pickup setting• Over voltage dropout setting• Over voltage dropout time delay• Nominal frequency of Source-1• Enable frequency sensing
• Frequency sensor pickup setting• Frequency sensor dropout setting• Frequency sensor dropout time
delay• Voltage imbalance sensor enable• Voltage imbalance sensor
dropout setting• Voltage imbalance sensor
dropout time delay setting• Loss of phase sensor enable• Phase rotation enable for Source-
1 and Source-2
Time Delays • 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
VoltageAdjustment
• Source-1 V12, V23, V31• Source-1 V1N, V2N, V3N
• Source-2 V12, V23, V31• Source-2 V1N, V2N, V3N
CurrentAdjustment
• Load current L1, L2, L3, N• Nominal current
Power FactorAdjustment
• Phase 1 angle• Phase 2 angle• Phase 3 angle
Preferred Source Confirm preferred sourceFeature Enable • Alphanumeric display
• Bargraph meter• Loadshed• LONMark communications
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Appendix F: Faults/Events History in
InPower
Faults/Events Information AvailableFaults 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)
• ATS Fail to Disconnect
• Battery charger malfunction• Network battery low• Network communications error• ATS common alarm
Event History Log 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
• 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 toSource-1
• Not in auto: ATS bypassed toSource-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 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)