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Operation Manual, Model KCT/KCP ATS (TP

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1. Merlin Gerin Open transition models only Programmed transition models only A 62 Appendix TP 6126 8 02 Ratings with Specific Manufacturers Circuit Breakers continued Molded Case Circuit Breakers Voltage Max Manufacturer Type SGL4 SGP4 TB4 THLC4 TLB4 Max Size Amps SGLA SGL6 SGP6 TB6 SKHA SKL8 SKP8 TKL CJD6 HHJD6 HHJXD6 HJD6 SCJD6 SHJD6 CLD6 HHJD6 HHLXD6 HLD6 SCLD6 SHLD6 CMD6 HMD6 HND6 MD6 MXD6 SCMD6 SHMD6 SMDE SND6 Square D LG LI MH Cutler Hammer HKD KDC LCL Tri Pac LA HLD Tri Pac NB ABB 5 S6 Merlin Gerin CJ600 GE TB8 Microversatrip TKL CLD6 HHLD6 HHLDX6 HLD6 SCLD6 SHLD6 CMD6 HMD6 SCMD6 SHMD6 CND6 HND6 SCND6 SHND6 CPD6 Square D MH Series 2 SE LS Trip SEH LS Trip Cutler Hammer Tri Pac NB Tri Pac PB RDC ABB S6 S7 Merlin Gerin CJ600 CK1200 Open transition models only Programmed transition models only Environmental Specifications Environmental Specifications Operating Temperature 20 C to 70 C 4 F to 158 F Storage Temperature 40 C to 70 C 40 F to 158 F Humidity 5 to 95 noncondensing Altitude TP 6126 8 02 0 to 3050 m 10000 ft without derating Appendix A 63 Codes and Standards
2. Source N load shed time delays Source mzio m z mzmz m z mzm zmz m zmz Source E load shed time delays Source In phase monitor synch Source m Preferred to standby time delay Function Standby to preferred time delay Function Failure to acquire standby source Function Pretransfer to preferred signal Function Pretransfer to standby signal Function Post transfer to preferred signal Function Post transfer to standby signal Function Off to standby time delay programmed transition only Function Off to preferred time delay programmed transition only Function Figure 6 3 Preferred Source Selection Effect on System Parameters and Time Delays TP 6126 8 02 Section 6 Accessories 43 6 3 2 Supervised Transfer Control Switch The supervised transfer control switch AUTO MANUAL TRANSFER switch is a three position key operated switch that allows manual control of load transfers The switch has maintained AUTO and MANUAL positions and a momentary TRANSFER position The key can be removed in either the AUTO or MANUAL position The key cannot be removed when the switch is in the TRANSFER position Figure 6 4 shows the switch The manual mode allows the system to run on the standby source indefinitely even if the preferred source is available In manual mode the controller is inhibited from initiating a transfer sequence until the keyswitch is turned to the TRANSFER position
3. It is not necessary to hold the switch in the TRANSFER position during the transfer sequence Turn the switch to TRANSFER and release it to initiate transfer The transfer sequence will proceed after the switch returns to the MANUAL position executing all programmed time delays and transferring the load to the other source if it is available Automatic and Non Automatic Transfer Switches The switch operation differs for automatic and non automatic switches An automatic transfer switch transfers automatically to an available source if the connected source is lost A non automatic transfer switch does not transfer automatically even if the connected source is lost Figure 6 5 summarizes the switch operation Note Transfer switches are built and UL labeled as automatic or non automatic by the factory and Switch Position AUTO Operation Automatic Switches cannot be converted in the field The supervised transfer control switch cannot be removed from non automatic switches in the field Test and Peak Shave Operation When the supervised transfer control switch on an automatic system is in the MANUAL position pressing the Test button or sending a peak shave command causes transfer to the standby source However ending the test or removing the peak shave signal will not cause a transfer back to the preferred source Move the supervised transfer control switch to the TRANSFER position to initiate transfer back to the prefer
4. TP 6126 8 02 FUSE HOLDER 2 234 4 AGC 10 10A 9 5 FASTBLOW FUSE 215 9 y RED LIGHT _7 GREEN LIGHT I 34 9 95 3 REF 10 32 TERMINALS TYP 4 _ LEAD LENGTH REF CHARGER BODY TO INSERTION END OF CONNECTOR Figure 6 19 Battery Charger 6 8 1 Battery Charger Connection The battery charger is powered by the load side of the transfer switch contactor through a factory installed wiring harness with a 9 pin inline connector Verify that the power to the ATS is disconnected before connecting or disconnecting the 9 pin connector to the battery charger Ring terminals for battery charger connections are included with the battery charger The installing technician must supply the cable with terminals between the battery charger and the battery Figure 6 21 provides details regarding cable length and gauge Using red cable for battery positive and black cable for battery negative is strongly recommended Use the following procedure to connect the battery charger TP 6126 8 02 GM22502 A TERMINAL INSERTION END CONNECTOR PIN OUT WIRE FUNCTION 1 NEUTRAL INPUT 208 VAC INPUT 240 VAC INPUT 480 VAC INPUT EARTH GROUND 600 VAC INPUT O BINIO aA Alwolm a I O Aa te i N Figure 6 20 Battery Charger Pow
5. 0 0c eee eee 20 3 3 3 Communications Connections 0 cee eee ee 21 3 4 Programmed Transition Interface Board PTIB 00c cece e eee 22 3 5 System Settings and Time Delays 00 cece eee teens 22 3 5 1 System Parameters tii ie ew de eae bide eae 22 3 5 2 Lime Delays oia A end A 23 3 6 Generator Set Preparation 0 0 cece teens 23 3 7 Eunctional lest soe tebe dat 23 3 7 1 Manual Operation Test 00 cc cece eect ee eee eee 23 3 7 2 Noltag Gheck ii AnS 23 3 7 3 Automatic Operation Test 000 c cece cece eens 25 3 8 Exerciser Setup sssri eri pia li ad oes Lag a bn 26 3 9 Warranty Registration 0 aseenaan 26 Section 4 Operation sities tee kee eae des WS aw eee end Pele wee eee Seed Bs 27 4 1 i INt FOGUCHON oi a hed he be he Bawa ng A ee eS A 27 4 2 Sequence of Operation 0 eect teens 27 4 2 1 Automatic Operation Open and Programmed Transition Switches 27 E AE O O A AO 29 4 2 3 Exercise li sd 31 TP 6126 8 02 Table of Contents Table of Contents continued 4 2 4 Peak Shave Area Protection Operation Sequence 34 4 25 Pre and Post Transfer Load Control Sequence 0 35 4 3 FaultS veins os Bod be deadening eked ahaa sala end A Vee aa eng neha 36 4 3 1 Service Required LED c cocino Vega ace ack deat 36 43 2 Auxiliary Switch Faults 00 00 ec cece eens 36
6. Y e source Post transfer load control as programmed Y Y at A Post transfer load control as programmed Tine delay engine caoldami TEC 1 as programmed default 0 Ca Generator set engine start contacts open See the Setup Program Operation Manual Figure 4 5 Test with Load Sequence N N OFF E E Load Test System Test Available Position Position Available Position Control flashing Engine Start Time Delay Preferred to Standby Time Delay Pre transfer to Standby Load Control Off to Standby Time Delay programmed transition only Post transfer to Standby Load Control Pre transfer to Preferred Load Control Off to Preferred Time Delay programmed transition only Post transfer to Preferred Load Control Engine Cooldown Time Delay Default 0 Figure 4 6 User Interface LED Indicators During a Loaded Test 30 Section 4 Operation TP 6126 8 02 4 2 3 Exerciser Activate the exerciser after ATS installation by pressing and holding the exercise button until the exercise LED flashes quickly See Figure 3 1 for the location of the Exercise button and LED on the user interface panel Press the Exercise button while the exercise is running to end the exercise early if desired Figure 4 7 shows the exerciser factory default settings The exercise mode is set through the Setup Software All other settings in Figure 4 7 are set through DIP
7. Hazardous voltage can cause severe injury or death An ungrounded battery charger may cause electrical shock Connect the battery charger enclosure to the ground of a permanent wiring system As an alternative install an equipment grounding conductor with circuit conductors and connect it to the equipment grounding terminal or the lead on the battery charger Install the battery charger as prescribed in the equipment manual Install the battery charger in compliance with local codes and ordinances Connecting the battery and the battery charger Hazardous voltage can cause severe injury or death Reconnect the battery correctly positive to positive and negative to negative to avoid electrical shock and damage to the battery charger and battery ies Have a qualified electrician install the battery ies Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Installing accessories to the transformer assembly Hazardous voltage can cause severe injury or death To prevent electrical shock disconnect the harness plug before installing accessories that will be connected to the transformer assembly primary terminals on microprocessor logic models Terminals are at line voltage Making line or auxi
8. Transfer switch controller Figure 6 12 I O Circuit Board Module Harness Connection to Transfer Switch Controller VO Module Hem Rang Input 16 mA 12 VDC Output 2 A 250 VAC Figure 6 13 O Module Ratings Section 6 Accessories 47 taa og OLLSONDVIO vody vo eloo a0 Oe OH Oea OH zodu i i E sod8 ody INdLNO AVIS allo o elo o olo oe O 1 Controller harness connection 2 Address DIP switches 3 Input connections 4 Output connections Figure 6 14 1 O Module Input and Output Connections 1 O Module Connection Procedure 1 Disconnect power to the transfer switch before connecting to the I O modules 2 Remove the I O module cover and connect devices to the I O module input terminals on terminal block TB1 or output terminals on terminal block TB2 See Figure 6 14 for the terminla block locations The output connections on the I O module are labelled RDO relay driver output 1 through 6 Use wire sizes within the specifications in Figure 6 15 for the input and output connections 3 Tighten the connections to 0 5 Nm 4 4 in lb 4 Record the connections on the label on the cover and replace the cover 5 Use the Setup Program to set up the I O board communications and to define the I O board inputs and outputs Refer to the Setup Program Operation Manual for instructions Number Wire Size Tightening Component of Wires Range Torque Controller termi
9. When the output is activated the contact opens for the programmed length of time before transfer default setting 3 seconds to allow controlled disconnection of selected loads The contact closes at the time of transfer default post transfer time delay setting 0 The contact is not activated if the controller detects no available source See Section 4 2 5 for more information about the pre transfer and post transfer load control signal operation sequence The pre and post transfer time delays can be adjusted using the optional setup program Load Bank Control Output Assigned to terminals TB1 3 TB1 5 programmable The load bank control output can be used to apply a load to the generator set during the exercise The load bank control output closes or opens a contact that can be used to signal the load bank controller to operate If the Normal source is lost during an exercise period the load bank control output is deactivated to remove the load bank and allow the transfer of the building load to the emergency source Peak Shave Area Protection Input Assigned to terminals TB1 6 and TB1 7 programmable input 1 Starts the generator set and transfers to the standby source ignoring the Time Delay Engine Start and Standby to Preferred time delays The system attempts to transfer to the preferred source when the input is removed The peak shave command is overridden if the standby source fails TB1 Input Output Factory Setting
10. and other information about the transfer switch See Figure 1 2 Copy the model designation serial number and accessory information from the nameplate to the spaces provided in the Product Identification Information section inside the front cover of this manual for use when requesting service or parts Copy the model designation into the spaces in Section 1 3 and use the accompanying chart to interpret the model designation The serial number is also shown on a label inside the transfer switch enclosure TP 6126 8 02 Section 1 Product Description Normal Utility Emergency Generator Power Power E E O Start Generator Power O Switching a Device___ __ ITALO Ll Electrical Controls Luci Automatic Transfer Switch PI To Load Figure 1 1 KOHLER KOHLER CO KOHLER WI USA 1 800 544 2444 MATERIAL MODEL SERIAL NO AMPS VOLTS WIRES PHASE POLES HERTZ BAR CODE Typical ATS Block Diagram TRANSFER SWITCH FOR EMERGENCY SYSTEMS NEMA ENCLOSURE MFG DATE ACCESSORIES 1 Model designation 2 Serial number Q N LISTED TRANSFER SWITCH c aL FOR EMERGENCY SYSTEMS GM21291 3 Factory installed accessory numbers Figure 1 2 Typical Transfer Switch Nameplate Section 1 Product Description 1 1 3 Model Code Record the transfer switch model designation in the boxes below The transfer switch model designation defines characteristics and ratings as
11. reconnecting the battery Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together Hazardous Voltage Electrical Shock A DANGER Hazardous voltage Will cause severe injury or death Disconnect all power sources before opening the enclosure A DANGER Hazardous voltage Will cause severe injury or death Disconnect all power sources before servicing Install the barrier after adjustments maintenance or servicing A DANGER Hazardous voltage Will cause severe injury or death Only authorized personnel should open the enclosure A WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Open the main circuit breakers of all power sources before servicing the equipment Configure the installation to electrically ground the generator set transfer switch and related equipment and electrical circuits to comply with applicable codes and standards Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution TP 6126 8 02 Installing the battery charger
12. switches on the contoller s main logic board See Section 3 3 1 Figure 4 8 describes the exercise LED operation Exerciser Parameter Factory Setting 1 week 2 week exercise 1 week Enable No load 30 minutes Disable enable exercise Load no load exercise Run duration Exercise mode Switch Input Figure 4 7 Exerciser Factory Settings Exerciser LED Indicates Steady Illumination Unloaded exercise active Slow Flash 1 Hz Rapid Flash 4 Hz Loaded exercise active When exercise button is pressed and held rapid flashing indicates the exercise has been started and set Rapid flashing at any other time indicates that the exercise is inhibited by the DIP switch setting Figure 4 8 Exerciser LED Indicator Loaded Unloaded Exercise A DIP switch on the controller circuit board allows the selection of loaded or unloaded exercise runs See Section 3 3 for DIP switch locations Selecting unloaded exercise allows the ATS to start and run the generator set without transfering the building load The exercise LED flashes to indicate a loaded exercise The exercise sequence starts the generator set engine immediately and activates the pre transfer load control sequence The in phase monitor or programmed transition time delays operate if programmed The post transfer load control sequence operates as programmed after the load is transferred See Figure 4 9 and Figure 4 10 for the exerciser sequences
13. the PTIB connector location GM21079 1 Controller assembly located inside the enclosure door 2 PTIB connection 3 PTIB Figure 3 10 Programmed Transition Interface Board PTIB 22 Section 3 Setup and Test 3 5 System Settings and Time Delays The system can be operated using the factory settings listed in the following sections Use the Setup Program to change the controller time delays pickup and dropout settings inputs outputs and options if necessary 3 5 1 System Parameters The system parameter factory settings are shown in Figure 3 11 The controller voltage and frequency sensing are factory set to the default values shown in Figure 3 12 The voltage and frequency debounce time delays prevent nuisance transfers caused by brief spikes and dips in the power supply System Parameter Factory Setting Open or programmed transition Set to order Set to order Single three phase Operating voltage Set to order Operating frequency 50 or 60 Hz Set to order Phase rotation ABC Commit to transfer yes or no No Rated current Set to order Operating mode Generator toGenerator Utility to Generator or Utility to Utility In phase monitor Utility to Generator Disabled In phase monitor transfer angle 0 Transfer mode automatic or non automatic Set to order The tran
14. 13 14 15 Not used Not used ol o plas VPS alt ET Wher di 1 Engine start contacts 14 and 15 GM21311 1 Typical terminal block location 2 Decal 3 Engine start contacts 1 and 2 4 Auxiliary contacts 4 27 see the schematic diagram for s F contacts closed on Normal or closed on Emergency Figure 2 22 Engine Start Contacts 225 400 Amp Open Transition Models Figure 2 23 Engine Start and Auxiliary Contact Terminal Block Programmed Transition Models and 600 4000 Amp Open Transition Models 14 Section 2 Installation TP 6126 8 02 2 5 3 Auxiliary Contacts Connect the auxiliary contacts to customer supplied alarms remote indicators or other devices Auxiliary contacts provide contacts that close when the transfer switch is in the Normal position and contacts that close when the transfer switch is in the Emergency position Each contact is rated 10 amps at 32 VDC or 250 VAC The table in Figure 2 24 lists the number of auxiliary contacts provided with each transfer switch Figure 2 23 Figure 2 25 and Figure 2 26 show the locations of the auxiliary contacts for different models Refer to the schematic diagram provided with the transfer switch to i
15. 2 Installation ce hee teen ce en eee Ra he Se oe ee ee 3 21 Introducir bate ede be eee UA eis sd 3 2 2 Receipt OF Unit ii A a dette Maa tia see ai ate 3 2 2 1 INSPECUOM see dete A A sa ade ake es 3 22 2 ro A fetes ot oR Ge Roe aa es ee rae Rs PE 3 Z237 Ll EN A A oa ei eal Bag nd hl eas 4 224 Unpacking ez osint dace A Ga eG Bag kee 4 2 3 Mechanical Installation 0 0 ete tees 4 2 4 Manual Operation Check 000 cee tet e eee e eens 5 2 4 1 Manual Operation 30 200 Amp Open Transition Switches 5 2 4 2 Manual Operation 225 4000 Amp Open Transition Switches 6 2 4 3 Manual Operation Programmed Transition Switches 8 2 5 Electrical WIFI ascitis sois pls a A AAA aac 9 2 5 1 AC Power Connections ooooccccccoccoo ees 10 2 5 2 Engine Start Connection 000 c cece cette eee 13 2 5 3 Auxiliary Contacts anaana eenaa 15 2 5 4 Controller Ground 0 teens 16 Section 3 Setup and Test cun eve ce ee ede eee eee ee ea ee ee eee ie ee eens 17 3T o ON siaa nta NN 17 3 2 User Interface Panel ccc eens 17 3 2 1 Pushbuttons and LED Indicators 00 eee eee eee 17 3 2 2 Controller Reset 0 cece eee ees 18 3 3 Controller Main Logic Board 0c cece cece ccc ete eae 19 3 3 1 Main Logic Board DIP Switch Settings 0ooooo ooooo 20 3 3 2 Main Logic Board Inputs and Outputs
16. 25 Note The generator set may have an engine cooldown time delay that causes the generator set engine to run after the transfer switch engine start signal is removed This completes the functional test 3 8 Exerciser Setup The installer must activate the exerciser Press and hold the Exercise button for approximately 3 seconds until it flashes to activate the exerciser start an exercise run and set the time and date of the next exercise run The exercise time is set to the time that the button is pushed The default setting for the exerciser run duration is 30 minutes The time delay LEDs show the time remaining in the exercise run Press and hold the exercise button again to end the exercise period early if desired Note Pressing the end time delay button does not end an exercise run Set the exerciser period every week or every 2 weeks and load condition by using DIP switches on the controller circuit board The factory settings for the exerciser are shown in Figure 3 14 Exerciser Parameter Factory Setting 1 week 2 week exercise DIP switch 1 week Enable No load 30 minutes Disable enable exercise DIP switch Load no load exercise DIP switch Run duration Figure 3 14 Exerciser Factory Settings Use the Setup Program to change the exerciser run duration if desired See Section 4 2 3 for more information about the exerciser 26 Section 3 Setup and Test The exerciser can be set witho
17. 8 02 6 5 Programmable Inputs and Outputs Programmable inputs and outputs are available through the controller main logic board terminal strip and through optional input output I O modules Programmable monitoring control and fault detection outputs are available through the terminal strip on the controller or through the programmable input output I O modules The main logic board inputs and outputs are factory assigned to the functions listed in Section 3 3 2 The I O modules are shipped with the input and output assignments undefined The Setup Program is required to change the main logic board terminal strip input and output assignments and also to set up and assign inputs and outputs to the optional I O modules The table in Figure 6 7 lists the available inputs Figure 6 8 lists the available programmable outputs Programmable Inputs Low External Battery Fault Peak Shave Area Protection Inhibit Transfer Remote Bypass Time Delay Remote Test Forced Transfer to OFF programmed transition models only requires load shed accessory Remote Common Fault Figure 6 7 Programmable Inputs Section 6 Accessories 45 6 5 1 Programmable Input Output 10 Preferred Source Available Monitor Modules Standby Source Available Monitor Programmable Input Output I O modules provide two Contactor in Preferred Position Monitor inputs and six outputs numbered 1 6 for controller Contactor in Standby
18. Programmed transition models only TP 6126 8 02 Appendix A 61 Ratings with Specific Manufacturers Circuit Breakers continued Molded Case Circuit Breakers Voltage Max Manufacturer Type TEL THED THLC1 Max Size Amps TFL THLC2 SFL SFLA SFP SGL4 SGP4 TB4 THLC4 TLB4 SGLA SGL6 SGP6 TB6 ITE CFD6 HFD6 CJD6 HHJD6 HHJXD6 HJD6 SCJD6 SHJD6 CLD6 HHLD6 HHLXD6 HLD6 SHLD6 Square D KC Kl LG LI Cutler Hammer HJD JDC LCL Tri Pac LA HKD KDC HLD Tri Pac NB ABB 3 Merlin Gerin CF250 CJ400 GE TFL THFK THLC2 SFL SFP TFJ TFK SGL4 SGP4 TLB4 CFD6 FD6 FXD6 HFD6 CJD6 HHJD6 HHJXD6 HJD6 JD6 JXD6 SCUD6 SHJD6 SJD6 Square D KA KC KH KI LG LI LA LH Cutler Hammer HJD JD JDB JDC LCL Tri Pac LA HKD KD KDB KDC Merlin Gerin CF250 CJ400 TFL THLC2 SFL SFLA SFP SGL4 SGP4 TB4 THLC4 TLB4 SGLA SGL6 SGP6 TB6 SKHA SKLB SKP8 TKL CFD6 FD6 FXD6 HFD6 CJD6 HHJD6 HHJXD6 HJD6 JD6 JXD6 SCUD6 SHJD6 SJD6 CLD6 HHLD6 HHLXD6 HLD6 SCLD6 SHLD6 CMD6 HMD6 HND6 MD6 MXD6 SCMD6 SHMD6 SMDE SND6 Square D KC KI LG LI MH Cutler Hammer HJD JDC HKD KDC LCL Tri Pac LA HLD Tri Pac NB ABB S5 S6
19. The ATS meets or exceeds the requirements of the e EN61000 4 5 Surge Immunity Class 4 following specifications voltage sensing and programmable inputs only e Underwriters Laboratories UL 508 Standard for e EN61000 4 4 Fast Transient Immunity Industrial Control Equipment Severity Level 4 e Underwriters Laboratories UL 1008 Standard for e IEC Specifications for EMI EMC Immunity Automatic Transfer Switches e CISPR 11 Radiated Emissions e Underwriters Laboratories Inc listed to Canadian Safety Standards cUL e IEC 1000 4 2 Electrostatic Discharge e NEPA 70 National Electrical Code e IEC 1000 4 3 Radiated Electromagnetic Fields e NFPA 99 Essential Electrical Systems for Health e IEC 1000 4 4 Electrical Fast Transients Bursts Care Facilities e IEC 1000 4 5 Surge Voltage e NFPA 110 Emergency and Standby Power Systems e IEC 1000 4 6 Conducted RF Disturbances e IEEE Standard 446 IEEE Recommended Practice for Emergency and Standby Power Systems for Commercial and Industrial Applications e IEC 1000 4 8 Magnetic Fields e IEC 1000 4 11 Voltage Variations and e NEMA Standard IC10 1993 formerly ICS2 447 Interruptions AC Automatic Transfer Switches Diagrams and Drawings Dimension Drawing Schematic Wiring Diagram Enclosure Drawing Number 30 200A Open Transition NEMA 1 ADV 6698 GM20611 GM20601 NEMA 12 4 4X ADV 6699 225 400A Open Transition NEMA 1 ADV 6700 GM20611 GM20615 NEMA 12 4 4X ADV 6701 600 8
20. add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid with water and dry the area Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do not smoke or permit flames or sparks to occur near a battery at any time particularly when it is charging Do not dispose of a battery in a fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases Il Safety Precautions and Instructions Battery short circuits Explosion can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove all jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when
21. delay Does not end the exercise active or programmed transition time delays 1 Hold the Lamp Test button until the LEDs flash Do not release the button 2 Continue to hold the Lamp Test button in and press the End Time Delay button The LEDs will flash when the controller resets Fault See Section 4 3 Auxiliary Switch Fault Auxiliary Switch Open Failure to Acquire Standby Source Failure to Transfer 1 0 Module Communications Lost 1 O Module Not Installed 1 O Module Not Found Phase Rotation Fault Remote Common Fault External Low Battery Figure 3 4 Service Required LED 18 Section 3 Setup and Test TP 6126 8 02 3 3 Controller Main Logic Board A DANGER a Hazardous voltage Will cause severe injury or death Disconnect all power sources before opening the enclosure NOTICE Electrostatic discharge damage Electrostatic discharge ESD damages electronic circuit boards Prevent electrostatic discharge damage by wearing an approved grounding wrist strap when handling electronic circuit boards or integrated circuits An approved grounding wrist strap provides a high resistance about 1 megohm not a direct short to ground The controller s main logic board is mounted in a plastic housing on the inside of the transfer switch enclosure door Itis not necessary to open the cover to access the DIP switches or the PC connector on the circuit board Figu
22. disconnecting the controller harness TP 6126 8 02 3 1 Introduction This section explains the setup and test of the transfer switch Follow the instructions in this section after completing the physical installation described in the previous section Note Be sure to perform the functional tests explained in Section 3 7 before putting the transfer switch into operation The instructions in this section explain how to set up the system to operate using factory default settings This section includes e User interface panel pushbuttons and LED indicators e DIP switch functions and settings e Main logic board input and output connections and default settings e Communications connections e Factory default settings for voltage frequency and time delay functions e Functional tests e Exerciser setup e Warranty registration The transfer switch is designed to be set up and operated using the factory settings for time delays Section 3 Setup and Test voltage and frequency pickup and dropout and other system parameters To view and change the system settings a personal computer running the MPAC 1000 Setup Program is required See TP 6135 Software Operation Manual for instructions to use the Setup Program 3 2 User Interface Panel 3 2 1 Pushbuttons and LED Indicators The user interface panel is located on the transfer switch door Figure 3 1 shows the user interface pushbuttons and LED indicators The LEDs light
23. logic board terminal strip programmable input 2 terminals 8 and 9 Connect the forced transfer to off signal from the generator set controller or other customer device to terminals 8 and 9 following the instructions in Section 3 3 2 Use 12 24 AWG wire and tighten the terminals to 0 5 Nm 4 4 in Ib 6 7 Security Cover The gasketed hinged security cover prevents unauthorized access to the transfer switch controls and protects the user interface from harsh environmental conditions Use acustomer supplied padlock to lock the cover The cover is available with or without a window for NEMA 1 enclosures NEMA 3R enclosures include a windowless cover as standard equipment Section 6 Accessories 49 6 8 Battery Charger The GM22502 is a 3 stage electronic battery charger designed for 12 or 24 VDC systems Itis designed to be used for lead acid batteries flooded cell or AGM types and gel cell batteries The sealed and potted design is rainproof lightweight silent and completely automatic The charger contains internal self resetting short circuit protection for the outputs and fuses for reversed polarity protection The battery charger produces 12 VDC at 6Amps or 24 VDC at 3 Amps Red and green LEDs indicate that the unit is recharging or maintaining the battery Figure 6 19 shows the battery charger Refer to the transfer switch dimension drawing for the location of the battery charger A WARNING Sulfuric acid in ba
24. maintenance purposes only Return the transfer switch to the normal position Remove the manual operator handle if used and store it in the place provided on the transfer switch when service is completed Manual Operation Test Procedure 150 4000 Amp Programmed Transition Transfer Switches Check the operation of both operators by following the instructions in Section 2 4 2 for both the Normal and Emergency operators in the following sequence 1 Starting with the contactor in the Normal position use the maintenance handle to move the Normal operator from the closed to the open position See Figure 2 13 and Figure 2 14 2 Move the Emergency operator from the open position to the closed position 3 Return the Emergency operator to the open position and the Normal operator to the closed position 4 Remove the maintenance handle and store it in the place provided on the switch 8 Section 2 Installation A a PO E ZA TA D m Emergency Operator shown open Cs CD KS I TE A g JS A Li f Y A Normal Operator shown closed Figure 2 13 Programmed Transition Switch Normal and Emergency Operators 600 1200 Amp Model shown in Normal position 1 Emergency contact indicator O is Open C is closed 2 Normal contact indicator Figure 2 14 Contact Position Indicators located on the right side of the contactor assembly shown in Normal position TP 6126 8 02 2 5 Electrical Wiri
25. min Cc cal CARB CB cc CCA CCW CEC cfh cfm CG CID CL cm CMOS cogen COM conn ampere after bottom dead center alternating current analog to digital analog to digital converter adjust adjustment advertising dimensional drawing anticipatory high water temperature American Iron and Steel Institute anticipatory low oil pressure alternator aluminum American National Standards Institute formerly American Standards Association ASA anticipatory only American Petroleum Institute approximate approximately as required as requested as supplied as stated as suggested American Society of Engineers American Society of Mechanical Engineers assembly American Society for Testing Materials after top dead center automatic transfer switch automatic auxiliary audiovisual average automatic voltage regulator American Wire Gauge appliance wiring material battery before bottom dead center battery charger battery charging battery charging alternator Battery Council International before dead center brake horsepower black paint color block engine block heater brake mean effective pressure bits per second brass before top dead center British thermal unit British thermal units per minute Celsius centigrade calorie California Air Resources Board circuit breaker cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code cubic feet per hour cubic feet per mi
26. of operation Figure 4 11 shows the operation of the user interface LEDs during the exercise run Refer to Section 4 2 5 for additional information about pre transfer time delays TP 6126 8 02 Exercise Mode The exerciser is factory set to operate in switch input mode which uses the Exercise button on the user interface to start stop and set the exerciser and the 1 week 2 week DIP switch to determine the exercise schedule Calendar modes with and without override are also available The Setup Program software is required to select and set up the exerciser calendar modes See the Setup Program Operation manual The calendar mode overrides the exercise button on the user interface Pressing the exercise button when the exerciser is set for calendar mode will not start an exercise or set the exercise time Calendar mode with override allows the starting and setting of the exerciser by pressing the exercise button Pressing the exercise button while in calendar mode with override resets the exerciser to the switch input mode Exercise Schedule The exercise repeats at the same time each week or every two weeks depending on the 1 Week 2 Week DIP switch position See Section 3 3 for the DIP switch location Note The exerciser clock is accurate to within 1 minute per month Pressing the exercise button starts the exercise and sets the time for the next exercise according to the position of the 1 week 2 week DIP switch Chan
27. set and disconnect the power by opening the circuit breakers or switches for both sources before manually operating the transfer switch Follow the instructions in Section 2 4 to check the transfer switch manual operation A contactor in normal and serviceable condition transfers smoothly without binding when operated manually Do not place the transfer switch into service if the contactor does not operate smoothly without binding contact an authorized distributor dealer to service the contactor Note Do not reconnect the power sources at this time Proceed to the voltage check procedure described in the following section 3 7 2 Voltage Check The voltage frequency and phasing of the transfer switch and the power sources must be the same to avoid damage to loads and the transfer switch Compare the voltage and frequency ratings of the utility source transfer switch and generator set and verify that the ratings are all the same Use the voltage check procedure explained in this section to verify that the voltages and phasing of all power sources are compatible with the transfer switch before connecting the power switching device and controller wire harnesses together Read and understand all instructions on installation drawings and labels on the switch Note any optional accessories that have been furnished with the switch and review their operation Section 3 Setup and Test 23 Note Source N is the source connected to
28. 00A Open Transition NEMA 1 ADV 6702 GM20612 GM20602 NEMA 12 4 4X ADV 6702 1000 1200A Open Transition GM20612 GM20602 NEMA 1 ADV 6663 1600 2000A Open Transition NEMA 1 ADV 6664 GM20613 GM20604 NEMA 1 Front Connected 2500 3000A Open Transition GM20611 GM20605 NEMA 1 ADV 6665 4000A Open Transition GM20611 GM20605 NEMA 1 ADV 6666 150 400A Programmed Transition GM20616 GM20606 NEMA 1 ADV 6704 600 800A Programmed Transition NEMA 1 ADV 6702 GM20617 GM20607 NEMA 12 4 4X ADV 6703 1000 1200A Programmed Transition GM20619 GM20609 NEMA 1 ADV 6663 1600 2000A Programmed Transition NEMA 1 ADV 6664 GM20619 GM20609 NEMA 1 Front Connected 2500 3000A Programmed Transition GM20616 GM20610 NEMA 1 ADV 6665 4000A Programmed Transition GM20616 GM20610 NEMA 1 ADV 6666 ADV 6684 ADV 6684 A 64 Appendix TP 6126 8 02 TP 6126 8 02b 2002 by Kohler Co All rights reserved KOHLER POWER SYSTEMS KOHLER CO Kohler Wisconsin 53044 Phone 920 565 3381 Fax 920 459 1646 For the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KohlerPowerSystems com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 264 6422 Fax 65 264 6455
29. 1 second and then begins monitoring the source phases in preparation for transfer When the sources are in phase the system attempts to transfer After three unsuccessful attempts to transfer the system stops attempting to transfer and generates a fault The Service Required LED illuminates The fault clears when the contactor transfers successfully Depress the Lamp Test button until the LEDs flash to clear the Service Required LED 4 3 5 Phase Rotation Faults A fault occurs if the phase rotation of an input channel does not match the system s phase rotation direction setting ABC or CBA The unit will not transfer to a source if the source s phase rotation does not match the system setting If the system detects a phase rotation fault in the connected source it attempts to transfer to an alternate source that has the correct phase rotation The controller logs phase rotation faults in the event history If the system detects phase rotation faults on both sources the Service Required LED lights The system does not transfer from the connected source 4 4 Controller Power Supply The controller is powered by the sources connected to the transfer switch The dark time is that period of time when neither source is available During the dark time capacitors maintain the controller power for about 15 seconds The capacitors require approximately one hour to completely recharge after a power loss The controller s time d
30. 2 5 Environmental Specifications 2 2 4 Unpacking Allow the equipment to warm to room temperature for at least 24hours before unpacking to prevent condensation on the electrical apparatus Use care when unpacking to avoid damaging transfer switch components Remove dirt and packing material that may have accumulated in the transfer switch or any of its components Do not use compressed air to clean the switch Cleaning with compressed air can cause debris to lodge in the components and damage the switch 4 Section 2 Installation For 600 800 amp transfer switches remove the lag screws that secure the transfer switch to the shipping skid For 1000 4000 amp transfer switches open the enclosure door to remove the lag screws that secure the transfer switch to the skid 2 3 Mechanical Installation NOTICE Foreign material contamination Cover the transfer switch during installation to keep dirt grit metal drill chips and other debris out ofthe components Coverthe solenoid mechanism during installation Afterinstallation usethe manual operating handle to cycle the contactor to verify that it operates freely Do not use a screwdriver to force the contactor mechanism NOTICE Hardware damage The transfer switch may use both American Standard and metric hardware Use the correct size tools to prevent rounding of the bolt heads and nuts Check the system voltage and frequency Compare the voltage and frequency shown on the tr
31. 4 3 3 Failure to Acquire Standby Source 0 eee 36 4 3 4 Failure to Transfer 0 eee eens 36 4 3 5 Phase Rotation Faults cece eect eee eee 36 4 4 Controller Power Supply 000 cece cece recente eens 36 Section 5 Scheduled Maintenance oooooccccccccccccc eee eee eens 37 ST INtOMUCHION ces cit a e eae eile Raed dia wh Pend ae 37 5 20 A ANT 38 5 2 1 Weekly Generator Set Exercise 000 0 cece eee eee 38 5 2 2 Monthly Automatic Control System Test 0c eee eee 38 5 3 Inspection and Service sie qese serene cece eet teen E a 38 5 3 1 General INSPECHON vastama iiei mae ees ete oP al 38 5 3 2 Other Inspections and Service 000 c cece eee eee 39 5 4 Service Schedule 0 ccc ete e ene ees 40 Section 6 Accessories 22 scc0 sic ccec rensas animanu aa eet eee eee AA enews 41 6 1 INTOUCH N cia Ads 41 6 2 Setups PROGrany ita di toda 41 6 3 Control Switches re esris erechi a t 41 6 3 1 Preferred Source Switch 0 41 6 3 2 Supervised Transfer Control Switch 000 cece eee 44 6 4 n Phase Monitor osorno Cd dada bol toed Soe A 45 6 5 Programmable Inputs and Outputs 000 c cee cece eee eee eee 45 6 5 1 Programmable Input Output I O Modules 022006 46 6 5 2 I O Module Connection 0 0 cee ees 47 6 5 3 I O Module Address 0 cece eect e eee 48 6 5 4 I O Module
32. Faults and Diagnostics 0 0 0 0 cece eee 48 6 6 Load Shed Forced Transfer to OFF 0 cece cece 49 6 6 1 Description aiana e ea aa a A 49 6 6 2 Connect iii a a A e AA 49 6 7 Security COVER sos tit il tl ia dea 49 6 8 Battery Charge ici A ad Shanti eS 50 6 8 1 Battery Charger Connection 000 c cece cent eees 51 6 8 2 Battery Charger Operation 0 cece cece teens 54 6 8 3 Battery Charger Troubleshooting 0 cece eee eee eeees 55 6 8 4 Battery Charger Specifications 00 cece eee eee 56 Appendix A Abbreviations 0 ttn nett tenet ene A 57 Appendix B Specifications a k pa cet d E Eai iaa ta EEE A 60 Table of Contents TP 6126 8 02 IMPORTANT SAFETY INSTRUCTIONS Electromechanical equipment including generator sets transfer switches switchgear and accessories can cause bodily harm and pose life threatening danger when improperly installed operated or maintained To prevent accidents be aware of potential dangers and act safely Read and follow all safety precautions and instructions SAVE THESE INSTRUCTIONS This manual has several types of safety precautions and instructions Danger Warning Caution and Notice A DANGER Danger indicates the presence of a hazard that will cause severe personal injury death or substantial property damage A WARNING Warning indicates the presence of a hazard that can cau
33. LID CONTROLLER E _ NEUTRAL 40 O A ENGINE START CONNECTIONS SEE NOTE 2 3 POLE TRANSFER SWITCH L1 L1 SINGLE PHASE L2 GENERATOR L3 L2 SINGLE PHASE Lo COMMERCIAL OR NORMAL SOURCE L3 o SWITCHED CONTROLLER _ NEUTRAL 40 o A ENGINE START CONNECTIONS SEE NOTE 2 4 POLE TRANSFER SWITCH GENERATOR Li __ OVERLAPPING NEUTRAL 10 o i NOTES ral 1 WHEN OVERLAPPING NEUTRAL IS USED WIRE NEUTRAL PER DOTTED LINES 2 ENGINE START CONNECTIONS ON CONTACTOR LOCATED AS FOLLOWS 30 200A OPEN TRANSITION LOWER LEFT SIDE 225 400A OPEN TRANSITION UPPER LEFT SIDE 600 4000A OPEN TRANSITION amp 150 4000A PROGRAMMED TRANSITION FIELD CONNECTION TERMINAL BLOCK TERMS 1 amp 2 3 CENTER POLE OF 3 POLE CONTACTOR MAY BE USED FOR SWITCHED NEUTRAL IN SINGLE PHASE 3 WIRE APPLICATIONS 4 POWER CABLES AND CONTROL WIRING MUST BE RUN IN RIGID METAL CONDUIT 5 MAXIMUM DISTANCE BETWEEN BATTERY CHARGER OPTIONAL AND THE BATTERY 12 AWG WIRE 4 5M 15 FT 10 AWG WIRE 7 5M 25 FT Figure 2 20 Interconnection Diagram 12 Section 2 Installation TP 6126 8 02 2 5 2 Engine Start Connection A WARNING Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the batter
34. M21287 _ Figure 6 2 Preferred Source Selector Switch Operating Modes The transfer switch is factory set for the generator set to utility mode of operation This mode uses one generator set which is connected to the Emergency side of the contactor Source E and one engine start relay The engine start relay connections are located on the contactor on 30 400 amp units and on the customer connection terminal block on larger units see Section 2 5 2 The engine start contact is assigned to the connected generator set and does not change assignment when the preferred source switch position is changed In this mode ifthe preferred source switch is set to Source E then the system operates the generator set indefinitely transferring to utility power only if the generator set fails Use the setup program to change the mode to generator set generator set or utility utility if necessary The generator set generator set mode uses two generator sets and requires the assignment of a second engine 42 Section 6 Accessories start output Use the setup program to assign one of the main logic board terminal strip or I O module outputs to Start Source N Generator and connect the engine start leads for the Source N generator set to the corresponding terminals on the terminal strip or I O module terminals See Sections 3 3 2 and 6 5 2 The programmed engine start output remains tied to the Source N generator set regardless of the position of t
35. Modbus is a registered trademark of Schneider Electric TP 6126 8 02 remote terminal unit protocol for communication through this port Connect the Modbus input and output to the terminals shown in Figure 3 9 Use 12 24 AWG twisted pair wire Belden cable 9841 or equivalent is recommended Connect the shield to ground as shown in Figure 3 9 Tighten the connections to 0 5 Nm 4 4 in Ibs Note Contact Kohler Co for information about Modbus communication protocol WIRE 12 24 AWG TORQUE 5Nm 4 4Ib in hb TRANSFER PRE SIGNAL 10A 30VDC 250VAC PROGRAMMABLE OUTPUT 2A 30VDC 250VAC PROGRAMMABLE INPUT 1 PROGRAMMABLE INPUT 2 7 oloo O JO AIAI OIN HER MODBUS RS485 XK NZ TN aa No k _ N wo yx MODBUS RS485 K TNA TT a ii Ns Eh pra al pry O GM22366 Customer connections Figure 3 9 Terminal Strip TB1 Connections Section 3 Setup and Test 21 3 4 Programmed Transition Interface Board PTIB Programmed transition model transfer switches use a programmed transition contactor and a programmed transition interface board PTIB The PTIB is mounted on the inside of the enclosure door The PTIB is factory wired and requires no additional wiring in the field Verify that the PTIB wiring harness is connected to the main logic board See Figure 3 10 for
36. NTROL OF MOTORS ELEC DISCHARGE AND TUNGSTEN LAMPS ELEC HEAT ING EQPT WHERE THE SUM OF MOTOR FULL LOAD AMPS AND AMPS OF OTHER LOADS DOES NOT EXCEED THE SWITCH AMP RATING AND THE TUNGSTEN LOAD DOES NOT EXCEED100 OF SWITCH RATING 240V MAX WHEN PROTECTED BY A CIRCUIT BREAKER WITHOUT AN ADJUSTABLE SHORT TIME RESPONSE ONLY OR BY FUSES THIS TRANSFER SWITCH IS RATED FOR USE ON A CIRCUIT CAPABLE OF DELIVERING NOT MORE THEN THE RMS SYMM AMPS AT THE VOLTAGE SHOWN RMS SYMM AMPS MAX AMPS X1000 VOLTS BREAKER MFR TYPE MAX 35 480 ANY ANY ANY PERNEC 22 600 ANY ANY ANY PERNEC 42 480 GE SGL4 SGP4 TB4 400 THLC4 TLB4 400 SGLA SGL6 SGP6 TB6 600 SKHA SKL8 SKP8 TKL 800 42 480 T E CJD6 HHJD6 400 HHJXD6 HJD6 SCJD6 SHJD6 400 CLD6 HHLD6 HHLXD6 HLD6 600 SCLD6 SHLD6 600 CMD6 HMD6 HND6 MD6 MXD6 800 SCMD6 SHMD6 SMD6 SND6 800 42 480 SQUARE D LC LI 600 MH 800 42 480 WESTH HKD KDC LCL 400 TRI PAC LA 400 HLD 600 TRI PAC NB 800 42 480 ABB S5 400 se 800 42 480 MERLIN GERIN 600 CJ600 200 480 FUSE ANY CLASS J 600 USE 75 C MIN CU AL WIRE FOR POWER CONNECTIONS USE 60 C MIN CU WIRE FOR CONTROLS USE COPPER OR ALUMINUM WIRE FOR POWER TERMINALS RECOMMENDED TIGHTENING 483500 007 TORQUE 600 IN LBS REV B C 1 Torque specification Figure 2 19 Typical Rating Torque Label Section 2 Installation COMMERCIAL OR NORMAL SOURCE L1 L2 L3 SINGLE PHASE L1 L2 LOAD Li SINGLE PHASE L1 30 O SO
37. Non programmable output Pre transfer load control Programmable output Load bank control output Programmable input 1 Peak shave Area protection input Programmable input 2 End time delay input Figure 3 7 Terminal Strip Input and Output Factory Settings ON 12345 SW1 OFF DEFAULT POSITIONS SHOWN POSITION ON OFF 1 TEST EXERCISE LOADED UNLOADED 2 LOADED UNLOADED 3 EXERCISE DISABLE ENABLE 4 EXERCISE 2WEEK 1 WEEK 5 MAINTENANCE LOGIC INHIBIT ON OFF GM22365 Figure 3 8 Logic Assembly Decal Showing DIP Switch Settings 20 Section 3 Setup and Test TP 6126 8 02 End Time Delay Input Assigned to terminals TB1 8 and TB1 9 programmable input 2 Allows a remote signal to end an active time delay The signal ends only the time delay that is active at the time the signal is applied Repeated signals are required to end additional time delays Does not end the programmed transition time delays or an exerciser run Other Inputs and Outputs Other input and output functions can be assigned to the programmable TB1 terminals Refer to Section 6 for lists of available programmable inputs and outputs Use the Setup Program to change the input and output assignments if necessary Connections Connect input and output leads to the controller terminal strip on the main logic board MLB To gain access to the terminal strip open the plastic housing by pushing up on the latch on the bottom of the cove
38. Operation and Installation Automatic Transfer Switches dlls Models KCT KCP Power Switching Device Standard Open Transition 30 to 4000 Amps Programmed Transition 150 to 4000 Amps Electrical Controls MPAC 1000 99001 KONER SYSTEMS KOHLER A POWER SYSTEMS maus soa Product Identification Information Product identification numbers determine service parts Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference Record field installed kit numbers after installing the kits Transfer Switch Identification Numbers Record the product identification numbers from the transfer switch nameplate Model Designation Serial Number Accessory Number Accessory Description x in 007 001 Table of Contents Product Identification Information 0 c eee eee eee eee Inside front cover Safety Precautions and Instructions 0c cece cece eee eee eee eee eens l INTO CHORD iaa ue a EE AE EE E EEE EE AE ge i List of Related Materials 0 cece eee eee i S rvice ASSISTANCE snie hte alee ane steers a a cpa ae a ete weed eae ie lei et ee es ii Section 1 Product Description 0c cece eee eee eee eee eee eeeeeeee 1 Wed PURPOSE Cx cos eek ais hte base aks Bele Sects hehe 1 1 2 Nameplate sii ia 1 1 3 Model Code sisir out eden ay Aba eee ohare Maa ad 2 Section
39. Phone 86 21 6288 0500 Fax 86 21 6288 0550 India Bangladesh Sri Lanka India Regional Office Bangalore India Phone 91 80 3366208 91 80 3366231 Fax 91 80 3315972 Japan Korea North Asia Regional Office Tokyo Japan Phone 813 3440 4515 Fax 813 3440 2727 Latin America Latin America Regional Office Lakeland Florida USA Phone 863 619 7568 Fax 863 701 7131 X in 008 001a TP 6126 8 02 1 1 Purpose An automatic transfer switch ATS transfers electrical loads from a normal preferred source of electrical power to an emergency standby source when the normal source falls outside the acceptable electrical parameters When the normal preferred source fails the ATS signals the emergency standby source generator set to start When the emergency standby source reaches acceptable levels and stabilizes the ATS transfers the load from the normal preferred source to the emergency standby source The ATS continuously monitors the normal preferred source and transfers the load back when the normal preferred source returns and stabilizes After transferring the load back to the normal preferred source the ATS removes the generator start signal allowing the generator set to shut down Figure 1 1 shows a typical installation block diagram 1 2 Nameplate A nameplate attached to the controller cover on the inside of the enclosure door includes a model designation a serial number ratings
40. Position Monitor communications Up to four modules can be connected Contactor in OFF position Monitor to the controller Contactor in Source N Position Monitor The I O modules are mounted on a DIN rail and covered by a protective cover See Figure 6 9 Figure 6 10 and Not in Auto Monitor Figure 6 11 show typical I O module locations Load Control Active Monitor Contactor in Source E Position Monitor Exerciser Active Monitor Low Battery on Standby Source Monitor Test Active Monitor Peak Shave Active Monitor Non Emergency Transfer Monitor Load Bank Control Control Start Source N Generator Control Start Source E Generator Control Load Shed Disconnect 0 8 Control Synchronization Output Command Control Common Alarm Fault Undervoltage Source N Fault Overvoltage Source N Fault Loss of Phase Source N Fault Phase Rotation Error Source N Fault Overfrequency Source N Fault Underfrequency Source N Fault Undervoltage Source E Fault Overvoltage Source E Fault Loss of Phase Source E Fault Phase Rotation Error Source E Fault Overfrequency Source E Fault GM21360 Underfrequency Source E Fault ciclo Tel cat Figure 6 9 Input Output Modules and Harness cover is shown transparent to show Auxiliary Switch Open Fault detail Auxiliary Switch Fault F
41. Weights Open Transition Models in NEMA 1 Enclosures Weight kg Ib 3 Pole 179 395 183 403 187 413 600 800 179 395 184 405 188 415 1000 1200 463 1020 485 1070 1600 2000 533 1175 556 1225 150 400 2600 3000 735 1620 765 1685 4000 1115 2457 1160 2557 Figure 2 2 Weights Programmed Transition Models in NEMA 1 Enclosures Section 2 Installation 3 Weight kg Ib 3 Pole 30 200 225 400 600 1200 1600 2000 190 420 2600 3000 213 470 4000 545 1200 590 1300 Figure 2 3 Weights Open Units Open Transition Models Weight kg Ib 3 Pole 150 400 24 53 600 1200 94 205 1600 2000 252 555 2600 3000 300 660 4000 611 1347 657 1447 Figure 2 4 Weights Open Units Programmed Transition Models 2 2 3 Storage Store the transfer switch in its protective packing until final installation Protect the transfer switch at all times from moisture construction grit and metal chips Avoid storage in low temperature and high humidity areas where moisture could condense on the unit See Figure 2 5 for acceptable storage temperatures Item Specification Storage 40 C to 70 C 40 F to 158 F Temperature Operating Temperature 20 C to 70 C 4 F to 158 F Humidity Altitude 5 to 95 noncondensing 0 to 3050 m 10000 ft without derating Figure
42. able the preferred source switch and the supervised transfer control switch The switches are mounted on the enclosure door See Figure 6 1 for typical switch locations Note Factory installed switches are factory wired and require no additional wiring in the field TP 6126 8 02 Section 6 Accessories ADV 6698A 1 Preferred source switch and supervised transfer control switch location Figure 6 1 Control Switch Locations 6 3 1 Preferred Source Switch The two position key operated preferred source selector switch allows selection of either power source as the preferred source The key can be removed with the switch in either position locking the switch into the selected position The preferred source selection cannot be changed remotely through software or the Modbus connection Figure 6 2 shows the preferred source selector switch The transfer switch seeks and transfers to the preferred source whenever it is available Source N is always the source connected to the Normal side of the transfer switch and Source E is always connected to the Emergency side Generator engine start relays are assigned to the the source Source N or Source E The engine start relays do not change when the preferred source switch position changes This prevents the need to change the wiring of the engine start relay s when the preferred source changes Section6 Accessories 41 SOURCE SOURCE PREFERRED SOURCE G
43. amage by wearing an approved grounding wrist strap when handling electronic circuit boards or integrated circuits An approved grounding wrist strap provides a high resistance about 1 megohm not a direct short to ground TP 6126 8 02 This manual provides operation and installation instructions for Kohler Model KCT KCP automatic transfer switches with MPAC 1000 electrical controls t in 002 001a Information in this publication represents data available at the time of print Kohler Co reserves the right to change this literature and the products represented without notice and without any obligation or liability whatsoever Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury Read and follow the Safety Precautions and Instructions section at the beginning of this manual Keep this manual with the equipment for future reference The equipment service requirements are very important to safe and efficient operation Inspect parts often and perform required service at the prescribed intervals Obtain service from an authorized service distributor dealer to keep equipment in top condition x in 002 002 TP 6126 8 02 Introduction List of Related Materials This manual includes operation and installation information for standard open transition and programmed transition transfer switches Decode the transfer switch model number from th
44. ance handle and store it on the frame in the clips provided 6 Section 2 Installation TP 6126 8 02 Turn counterclockwise to Emergency Turn clockwise to Normal 1 Maintenance handle 2 Hub 1 Maintenance handle 2 Shaft Figure 2 11 Manual Operation 1600 3000 Amp Figure 2 9 Manual Operation 225 400 Amp Switches Open Transiton Switches and 150 400 Amp Programmed Transition Switches one operator shown 1 Weight 1 Maintenance handle 2 Maintenance handle 2 Hub Figure 2 12 Manual Operation 4000 amp switches Figure 2 10 Manual Operation 600 1200 Amp Switches TP 6126 8 02 Section 2 Installation 7 2 4 3 Manual Operation Programmed Transition Switches Programmed transition switches have two operators Normal and Emergency on the left side of the contactor assembly Mechanical interlocks prevent closing both operators at the same time Refer to Figure 2 13 for typical locations of the Normal and Emergency operators Position indicators on the right side of the contactor assembly show the positions of the operators See Figure 2 14 Programmed transition models use a detachable manual operating handle Refer to Figure 2 8 through Figure 2 12 A DANGER a Hazardous voltage Will cause severe injury or death Disconnect all power sources before opening the enclosure NOTICE Improper operator handle usage Use the manual operator handle on the transfer switch for
45. andard on 30 4000 A models Available to order on 30 800 A models For larger units consult the factory Current Rating Numbers indicate the current rating of the switch in amperes 0030 0200 0600 1200 2600 0070 0225 0800 1600 3000 0104 0260 1000 2000 4000 0150 0400 Power Connections S Standard F Front bus available on 1600 and 2000 A models only Integral solid neutral is a solid neutral mounted on the contactor Not available on all amperages 2 Section 1 Product Description TP 6126 8 02 2 1 Introduction Kohler transfer switches are shipped factory wired factory tested and ready for installation Have the equipment installed only by trained and qualified personnel and verify that the installation complies with applicable codes and standards Switch installation includes the following steps e Unpacking and inspecting the transfer switch upon receipt e Verifying that the transfer switch voltage and frequency ratings match the voltages and frequencies of the sources e Mounting the transfer switch e Checking the manual operation e Wiring the normal power source utility emergency power source generator set and load circuits e Wiring the generator set engine start connection e Connecting accessories if provided e Connecting and initializing the electrical controls as required e Checking voltages and operation Protect the switch against damage before and dur
46. ansfer switch nameplate to the source voltage and frequency Do not install the transfer switch if the system voltage and frequency are different from the nominal normal utility source voltage and frequency or the nominal emergency source voltage and frequency shown on the generator set nameplate Plan the installation Use the dimensions given on the enclosure dimension ADV drawings Select a mounting site that complies with local electrical code restrictions for the enclosure type Mount the transfer switch as close to the load and power sources as possible Allow adequate space to fully open the enclosure and to service the switch Provide cable bending space and clearance to live metal parts Prepare the foundation Ensure that the supporting foundation for the enclosure is level and straight For bottom cable entry if used install conduit stubs in the foundation Refer to the enclosure dimension drawing for the conduit stub locations When pouring a concrete floor use interlocking conduit spacer caps or a wood or metal template to maintain proper conduit alignment Install the ATS For easy access during installation and wiring remove the front door of the enclosure For 30 200 amp switches support the door and remove the two screws at the bottom Slide the door down until the top clears the enclosure Open the door wide enough to reach the controller wiring on the inside of the door Disconnect the cable plug that connects the
47. are mounted within the enclosure but are not wired through the controls and deenergized by inline connector separation Test circuits with a voltmeter to verify that they are deenergized before servicing Testing live electrical circuits Hazardous voltage or current can cause severe injury or death Have trained and qualified personnel take diagnostic measurements of live circuits Use adequately rated test equipment with electrically insulated probes and follow the instructions ofthe test equipment manufacturer when performing voltage tests Observe the following precautions when performing voltage tests 1 Remove all jewelry 2 Stand on adry approved electrically insulated mat 3 Do not touch the enclosure or components inside the enclosure 4 Be prepared for the system to operate automatically 600 volts and under Heavy Equipment A WARNING Unbalanced weight Improper lifting can cause severe injury or death and equipment damage Use adequate lifting capacity Never leave the transfer switch standing upright unless it is securely bolted in place or stabilized Safety Precautions and Instructions III Moving Parts A WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place A WARNING A Airborne particles Can cause severe injury or blindness Wear protective goggles and clothin
48. ate and all controller settings including time delays system parameters pickups and dropout settings and input output assignments are maintained by a controller battery during power outages TP 6126 8 02 Section 5 Scheduled Maintenance 5 1 Introduction Regular preventive maintenance ensures safe and reliable operation and extends the life of the transfer switch Preventive maintenance includes periodic testing cleaning inspection and replacement of worn or missing components Section 5 4 contains a service schedule for recommended maintenance tasks A local authorized distributor dealer can provide complete preventive maintenance and service to keep the transfer switch in top condition Unless otherwise specified have maintenance or service performed by an authorized distributor dealer in accordance with all applicable codes and standards See the Service Assistance section in this manual for how to locate a local distributor dealer Keep records of all maintenance or service Replace all barriers and close and lock the enclosure door after maintenance or service and before reapplying power A WARNING Tr aS x Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental s
49. ation setting on the controller 8 If the source is a generator set stop the generator set by moving the master switch to the OFF position 9 Disconnect Source N by opening upstream circuit breakers or switches 10 Manually operate the transfer switch to position N 11 Repeat steps 4 through 8 for Source E Then proceed to step 17 12 Disconnect both sources to the transfer switch by opening the circuit breakers or switches 13 Connect the power switching device and controller wiring harnesses together at the inline disconnect plug Note Do not connect or disconnect the controller wiring harness when the power is connected 14 Check the DIP switch settings Verify that the TEST DIP switch is in the loaded position before proceeding with the next test 15 Close and lock the transfer switch enclosure door TP 6126 8 02 16 Reconnect both power sources by closing the circuit breakers or switches 17 Move the generator set master switch to the AUTO position Note If the engine cooldown time delay setting is not set to zero default setting the generator set may start and run until the Time Delay Engine Cooldown TDEC ends 18 Proceed to the automatic operation test 3 7 3 Automatic Operation Test Check the transfer switch s automatic control system immediately after the voltage check The test sequence simulates a loss of the normal source starts the generator set and transfers the load to th
50. ation about the exercise and test functions 5 2 2 Monthly Automatic Control System Test Test the transfer switch s automatic control system monthly See Section 3 7 3 for the test procedure e Verify that the expected sequence of operations occurs as the switch transfers the load to the emergency source when a preferred source failure occurs or is simulated e Observe the indicator LEDs included on the transfer switch to check their operation e Watch and listen for signs of excessive noise or vibration during operation e After the switch transfers the load to the standby source end the test and verify that the expected sequence of operations occurs as the transfer switch retransfers to the preferred source and signals the generator set to shut down after a cooldown period e On programmed transition units verify that the time delay in the OFF position functions during transfer to the standby source and transfer back to the preferred source 5 3 Inspection and Service Contact an authorized distributor dealer to inspect and service the transfer switch annually and also when any wear damage deterioration or malfunction of the transfer switch or its components is evident or suspected 5 3 1 External Inspection Keep the transfer switch clean and in good condition by performing a weekly general external inspection of the transfer switch for any condition of vibration leakage excessive temperature contamination or
51. ault Failure to Acquire Standby Source Fault I O Module Lost Fault 1 O Module Not Found Fault 1 O Module Not Installed Fault Modbus Controlled Relay Driver Control Output 1 Modbus Controlled Relay Driver Control Output 2 Modbus Controlled Relay Driver Control Output 3 Modbus Controlled Relay Driver Control Output 4 Figure 6 8 Available Programmable Outputs 46 Section 6 Accessories TP 6126 8 02 i E e a LJ 6 1 1 O modules Figure 6 10 Typical I O Module Locations welded enclosures Side View Front View gm21360b 1 1 O module locations typ Figure 6 11 Typical I O Module Locations framework enclosures TP 6126 8 02 6 5 2 I O Module Connection Optional input output I O modules are connected to the controller by a factory installed harness Figure 6 12 shows the controller connection The input and output ratings are shown in Figure 6 13 Figure 6 14 shows an I O module with its input and output terminal blocks and address DIP switches Each l O Module requires a unique address Factory installed I O module addresses are set at the factory GM21079 A 1 1 0 module harness GM21341 2
52. ays Operates pre and post transfer load control time delays if both sources are available TP 6126 8 02 6 4 In Phase Monitor Transfer switches are shipped with the in phase monitor disabled The factory settings are shown in Figure 6 6 Use the Setup Program to enable the in phase monitor and adjust the settings if necessary Refer to the Setup Program Operation Manual Note The in phase monitor is not available on programmed transition switches The in phase monitor operates when both sources are available such as when transfering from the standby back to the preferred source The in phase monitor assures that transfer occurs when the two sources are in phase The phase angle measuring accuracy is 5 The in phase monitor does not operate when one source is lost The OFF position LED on the user interface panel flashes at 2 Hz when the in phase monitor is operating Synchronization Output The synchronization output provides a contact closure that can be used to signal some generator set controllers to synchronize the two sources by adjusting the engine speed of a generator set equipped with a variable speed governor See the generator set operation manual The system activates the output after the synch output time delay See Figure 6 6 Parameter Factory setting Enable disable Disable Phase angle degrees 0 Synch output time delay seconds 30 Figure 6 6 In Phase Monitor Factory Settings TP 6126
53. button on the controller to start the test The TEST LED flashes to indicate that the ATS controller is set up to transfer the load during the test Verify that the generator set starts after the engine start delay times out Check that the Source E Available LED lights Verify that the switch transfers the load to Source E a Open Transition Models After the preferred to standby time delay verify that the Position N LED goes out and the Position E LED lights indicating that the switch has transferred the load to Source E b Programmed Transition Models After the preferred to off time delay verify that the Position N LED goes out and the Position OFF LED lights After the off to standby time delay check that the Position E LED lights indicating that the switch has transferred the load to Source E Push the Test button to end the test Verify that the switch transfers the load back to Source N a Open Transition Models After the standby to preferred time delay verify that the Position E LED goes out and the Position N LED lights indicating that the switch has transferred the load to Source N b Programmed Transition Models After the standby to off time delay verify that the Position E LED goes out and the Position OFF LED lights After the off to preferred time delay check that the Position N LED lights indicating that the switch has transferred the load to Source N Section 3 Setup and Test
54. dby position A test sequence can also be started or ended through the setup software See the Setup Program Operation manual The Test LED flashes to indicate a loaded test or lights steadily to indicate a test without load Use the test DIP switch to select loaded or unloaded tests See Section 3 3 1 for DIP switch locations and settings Figure 4 4 and Figure 4 5 illustrate the following test sequences Figure 4 6 shows the operation of the user interface LEDs during the test sequence Test without Load The test without load sequence starts the generator set but does not transfer the load The generator set continues to run until the test button is pushed again Test with Load The test with load sequence simulates a preferred source failure and activates the pre and post transfer load control sequences as programmed Refer to Section 4 2 5 for additional information about pre transfer time delays The test remains active until the test button is pushed again or until a remote test signal is received If the standby source fails during a test cycle the system immediately transfers back to preferred The test sequence executes all time delays that are set up to operate during a normal sequence of operation Press the End Time Delay button to shorten the time delays while they are running if desired The End Time Delay button does not end programmed transition time delays At the start of the test the ATS simulates a prefe
55. dentify which auxiliary contacts are closed on Normal and which are closed on Emergency for 600 4000 amp models Follow the wire size and tightening torque specifications shown on the decal on the transfer switch Auxiliary Position Indicating Contacts rated 10 amps 32 VDC 250 VAC Number of Contacts Closed on Normal Emergency Switch Rating Open Programmed Amps Transition Transition 30 104 2 2 150 400 2 2 150 400 600 800 2 2 1000 3000 8 8 4000 4 4 Programmed transition with switched neutral Figure 2 24 Number of Auxiliary Contacts Available on Each Switch TP 6126 8 02 GM20601 1 Auxiliary contacts 10 13 and 29 32 contacts shown with contactor in Normal position Figure 2 25 Auxiliary Contacts 30 200 Amp Open Transition Models Section 2 Installation 15 H 3 6126 1 Auxiliary contacts 10 13 and 29 32 contacts shown with contactor in Normal position Figure 2 26 Auxiliary Contacts 225 400 Amp Open Transition Models 16 Section 2 Installation 2 5 4 Controller Ground Verify that the grounding wire is connected from the controller s lower left mounting stud to the enclosure This connection provides proper grounding that does not rely upon the door hinges Note Do not connect the controller harness to the contactor until instructed to do so in the voltage check procedure Section 3 7 2 Disconnect the power before connecting or
56. deterioration Remove accumulations of dirt dust and other contaminants from the transfer switch s external components or enclosure with a vacuum cleaner or by wiping with a dry cloth or brush General Inspection TP 6126 8 02 Note Do not use compressed air to clean the transfer switch because it can cause debris to lodge in the components and damage the switch Tighten loose external hardware Replace any worn missing or broken external components with manufacturer recommended replacement parts Contact a local authorized distributor dealer for specific part information and ordering Internal Inspection Disconnect all power sources open the transfer switch enclosure door and inspect internal components monthly or when any condition noticed during an external inspection may have affected internal components Contact an authorized distributor dealer to inspect and service the transfer switch if any of the following conditions are found inside the transfer switch e Accumulations of dirt dust moisture or other contaminants e Signs of corrosion e Worn missing or broken components e Loose hardware TP 6126 8 02 e Wire or cable insulation deterioration cuts or abrasion e Signs of overheating or loose connections discoloration of metal melted plastic or a burning odor e Other evidence of wear damage deterioration or malfunction of the transfer switch or its components If the applicaton does not al
57. e connected source it attempts to transfer to an TP 6126 8 02 Section 4 Operation alternate source The system considers a phase lost if its phase is 45 degrees from the rotation setting The controller logs loss of phase events in the event history Programmed Transition Switches Programmed transition switches provide an OFF position during transfer between two sources The adjustable time off period allows residual voltages in the load circuits to decay before connecting to the second source During the off period the ATS main contacts are open and neither source powers the load The off to standby and off to preferred time delays control the length of the off period for programmed transition switches The time delays are factory set to the defaults shown in Figure 3 13 The time delays can be changed using the optional Setup Program The End Time Delay Button and Remote Bypass command do not override the off to standby and off to preferred time delays Normal preferred power source fails Y Time delay engine start Y Time delay preferred to standby Transfer to OFF position programmed transition only Time delay off to standby programmed transition only Transfer to emergency standby source Y Post transfer load control as programmed See the Setup Program Operation Manual Figure 4 1 ATS Sequence of Operation Transfer to Emergency standby source Section 4 Operation 27 Normal pref
58. e emergency source executing all time delays that are set up to operate during a loss of the normal source When the test is ended in step 7 of the procedure the transfer switch transfers the load back to the normal source and removes the engine start signal executing all appropriate programmed time delays Refer to Section 4 2 2 for a description of the test sequence of operation Note If the standby source fails during a test the ATS will immediately attempt to transfer to the preferred source Optional Switches If the ATS is equipped with a preferred source switch check the switch position before proceeding with the automatic operation test The test procedure assumes that Source N is the preferred source If the transfer switch is equipped with a supervised transfer switch verify that it is set to the Auto position See Section 6 for more information about optional switches Note Close and lock the enclosure door before starting the test procedure A DANGER pas Hazardous voltage Will cause severe injury or death Only authorized personnel should open the enclosure TP 6126 8 02 Automatic Operation Test Procedure 1 Check the controller LED indicators to verify that the Position N and Source N Available indicators are lit Press the lamp test button and check that all controller LEDs illuminate Verify that the generator set master switch is in the AUTO position Press the TEST
59. e red cable and a black boot onto the black cable Attach ring terminals and use a crimping tool to crimp the ring terminals tightly 52 Section 6 Accessories 10 11 Determine whether the generator set electrical system uses 12 or 24 volts This information is shown on the generator set nameplate Connect the jumpers as shown in Figure 6 22 for a12 volt system or Figure 6 23 for a 24 volt system reconnecting the jumper lead for 24 volt systems as shown Place the jumper lead terminal between the two flat washers on the battery charger terminal Note Battery chargers are configured for 12 volt systems atthe factory For 24 volt systems reconnect the jumper lead as shown in Figure 6 23 and discard the second jumper lead Connect the battery cables as shown in Figure 6 22 for 12 VDC systems or Figure 6 23 for 24 VDC systems Note The positive POS P battery post usually has a larger diameter than the negative NEG N post a Connect the red POSITIVE terminal of the battery charger to the positive post of the battery b Connect the black NEGATIVE terminal of the battery charger to the negative post of the battery Slide the boots over the battery charger posts Connect the in line connectors on the battery charger power cord TP 6126 8 02 Battery Charger Disconnection Procedure A DANGER 12VDC O 6Amp Configuration AGC 10 10 Amp 250V fast blow Output Fuses Hazardous
60. e transfer switch nameplate and verify that the it matches the model shown on the front cover of this manual before proceeding with installation Separate manuals cover service and parts information The following table lists the related literature part numbers Literature Item Part Number Specification Sheet G11 80 TP 6127 TP 6158 TP 6135 Service Manual Parts Catalog MPAC Setup Program Operation Manual Introduction i Service Assistance For professional advice on generator power requirements and conscientious service please contact your nearest Kohler distributor or dealer e Consult the Yellow Pages under the heading Generators Electric e Visit the Kohler Power Systems website at KohlerPowerSystems com e Look atthe labels and stickers on your Kohler product or review the appropriate literature or documents included with the product e Call toll free in the US and Canada 1 800 544 2444 e Outside the US and Canada call the nearest regional office Africa Europe Middle East London Regional Office Langley Slough England Phone 44 1753 580 771 Fax 44 1753 580 036 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 264 6422 Fax 65 264 6455 ii Service Assistance China North China Regional Office Beijing Phone 86 10 6518 7950 86 10 6518 7951 86 10 6518 7952 Fax 86 10 6518 7955 East China Regional Office Shanghai
61. ector switch the preferred source is the source connected to the Normal side of the power switching device The source connected to the Emergency side of the contactor is the standby source 4 2 Sequence of Operation 4 2 1 Automatic Operation Open and Programmed Transition Switches Typical ATS operation in utility to generator set mode is divided into two sequences e Failure of the Normal preferred power source and the resulting load transfer to the Emergency standby source e Restoration of the preferred power source and the resulting load transfer back to the preferred source Events such as the failure of the generator set to start can change the sequence of operation If the emergency source fails and the normal source is not available the transfer switch controller powers down until one of the sources returns Figure 4 1 Illustrates the transfer sequence when the normal source fails and Figure 4 2 illustrates the sequence when it returns Figure 4 3 shows the operation of the user interface LEDs during loss and restoration of the normal source Time Delays Time delays before load transfer prevent nuisance transfers during brief power interruptions The voltage and frequency debounce time delays prevent nuisance transfers caused by brief spikes and dips inthe power supply See Section 3 5 for the default settings for the time delays and debounce times Loss of Phase Ifthe system detects a loss of phase in th
62. ed 3 Manually operate the transfer switch to position E See Section 2 4 4 If Source N is a generator set move the generator set master switch to the RUN position The generator set should start 5 Close the Source N circuit breaker or switch 24 Section 3 Setup and Test 6 Use a voltmeter to check the Source N normal phase to phase and phase to neutral if applicable terminal voltages and frequency a If Source N is the utility and the measured input does not match the voltage and frequency shown on the transfer switch nameplate STOP Do not proceed further in installation because the transfer switch is not designed for the application call your distributor dealer to order the correct transfer switch b IfSource Nis a generator set and the generator set output voltage and frequency do not match the nominal system voltage and frequency shown on the transfer switch nameplate follow the manufacturer s instructions to adjust the generator set The automatic transfer switch will only function with the rated system voltage and frequency specified on the nameplate 7 Use a phase rotation meter to check the phase rotation at the Source N normal terminals Rewire the transfer switch Source N terminals to obtain the correct phase sequence if necessary Note The default setting for the phase rotation on the controlleris ABC Ifthe application uses a phase rotation of CBA use the Setup Program to change the phase rot
63. een Operating Condition The battery is discharged and the charger is recharging at the BULK rate stage 1 This charging rate is 6 Amps at 12V or 3 Amps at 24V The measured voltage with the charger on is 11 8 to 14 Volts in 12VDC mode or 23 6 to 28VDC 24VDC mode If the red LED stays on for more than 24 hours refer to Problem 1 in the troubleshooting section in this manual The charger is charging at an ABSORPTION rate of between 1 5 and 5 Amps stage 2 This mode of charging gradually tops off your battery and reduces harmful sulfating While both LED s are on the voltage measured with the charger on should be approx 14 0 to 14 5VDC in 12VDC mode or 28 0 to 29 0 in 24VDC mode If both LED s stay on longer than 24 hours refer to Problem 2 in the troubleshooting section in this manual The charer is charging at a FLOAT or MAINTENANCE rate of less than 1 5 Amps stage 3 The battery is now 90 charged and ready for use This float charging current will gradually decrease to as low as 0 1 Amps as the battery reaches 100 charge The float rate maintains the battery at full charge without overcharging If the green LED stays on when your battery is known to be low refer to Problem 3 in the troubleshooting section in this manual Figure 6 24 Charger Operation Absorption Red LED On Red Green LEDs On 90A M peg oL aBexjon indino gi267712 Figure 6 25 Charging Method 12 VDC 6 A Configurat
64. efore connecting them to the terminals Apply joint compound to the connections of any aluminum conductors Refer to Figure 2 20 Interconnection Diagram and the wiring diagram provided with the switch A list of the drawing numbers for the wiring diagrams and schematics is given in Appendix B The connection points on the contactor are labeled Normal Emergency and Load Be sure to follow the phase markings A B C and N For single phase systems connect to A and C Note Connect the source and load phases as indicated by the markings and drawings to prevent short circuits and to prevent phase sensitive load devices from malfunctioning or operating in reverse On models equipped with the optional preferred source switch connect source N to the normal side and source E to the emergency side of the contactor Verify that all connections are consistent with drawings before tightening the lugs Tighten all cable lug connections to the torque values shown on the label on the switch See Figure 2 19 for a typical rating torque label Carefully wipe off any excess joint compound after tightening the terminal lugs For load connections to bus bars use a compression washer flat washer and a minimum grade 5 bolt and torque the connections to the values in Figure 2 18 Bolt Torque ft Ibs Nm Bolt Size inches Figure 2 18 Tightening torque for bus bars TP 6126 8 02 1 Yee SUITABLE FOR CO
65. en and Programmed Transition Models The following charts list power switching device withstand and closing ratings WCR in RMS symmetrical amperes for specific manufacturers circuit breakers Circuit breakers are supplied by the customer Molded Case Circuit Breakers Manufacturer Square D Type FH Max Size Amps FC Fl KA KC KH KI LA LH TB1 TEL THED THLC1 THLC2 TFL CED6 ED6 HED4 HED6 CFD6 FD6 FXD6 HFD6 Cutler Hammer FCL Tri Pac FB FD FDC HFD HJD JD JDB JDC HKD KD KDB KDC LCL Tri Pac LA ABB S1 3 Merlin Gerin CE104 CE106 Square D FC Fl KA KC KH KI LA LH GE TB1 TEL THED THLC1 THLC2 TFL CED6 ED6 HED4 HED6 CFD6 FD6 FXD6 HFD6 Cutler Hammer FCL Tri Pac FB FD FDC HFD HJD JD JDB JDC HKD KD KDB KDC LCL Tri Pac LA ABB S1 3 Merlin Gerin CE104 CE106 CF250 TEL THED THLC1 TFL THFK THLC2 SFL SFP TFJ TFK SGL4 SGP4 TLB4 CFD6 FD6 FXD6 HFD6 CJD6 HHJD6 HHJXD6 HJD6 JD6 JXD6 SCUD6 SHJD6 SJD6 Square D KA KC KH KI LG LI LA LH Cutler Hammer FD FDC HFD HJD JD JDB JDC LCL Tri Pac LA HKD KD KDB KDC ABB 3 Merlin Gerin CF250 CJ400 Open transition models only
66. enclosure with a vacuum cleaner or by wiping with a dry cloth or brush Do not use compressed air to clean the switch because it can cause debris to lodge in the components and cause damage Test May require tools equipment or training available only through an authorized distributor dealer Symbols used in the chart X The transfer switch operator can perform these tasks Q Quarterly D An authorized distributor dealer must perform these tasks S Semiannually every six months W Weekly Y Yearly annually M Monthly 40 Section 5 Scheduled Maintenance TP 6126 8 02 6 1 Introduction This section describes the installation and or operation of the following accessories e MPAC Setup Program e Control Switches e Preferred source switch e Supervised transfer switch e In phase monitor e Programmable inputs and outputs e Main logic board terminal strip e Input output modules e Load shed Forced transfer to OFF e Security cover Battery charger 6 2 Setup Program The optional MPAC Setup Program allows you to use a personal computer to view and adjust system parameters voltage and frequency pickup and dropout settings time delays input and output functions and other system parameters The software also includes a time stamped event log that is useful for system diagnostics and troubleshooting Refer to the Setup Program Operation Manual for more information 6 3 Control Switches Two control switches are avail
67. ent emergency power source radiator radius random access memory relay driver output reference remote radio frequency interference round head round head machine screw relay root mean square round read only memory rotate rotating revolutions per minute right side room temperature vulcanization Society of Automotive Engineers standard cubic feet per minute silicon controlled rectifier second Systeme international d unites International System of Units side in end out silencer serial number TP 6126 8 02 SPDT single pole double throw SPST single pole single throw spec specs specification s sq square sq cm square centimeter sq in square inch SS stainless steel std standard stl steel tach tachometer TD time delay TDC top dead center TDEC time delay engine cooldown TDEN time delay emergency to normal TDES time delay engine start TDNE time delay normal to emergency TDOE time delay off to emergency TDON time delay off to normal temp temperature term terminal TIF telephone influence factor TIR total indicator reading tol tolerance turbo turbocharger typ typical same in multiple locations UF underfrequency UHF ultrahigh frequency UL Underwriter s Laboratories Inc UNC unified coarse thread was NC UNF unified fine thread was NF univ universal US undersize underspeed UV ultraviolet undervoltage V volt VAC volts alternating current VAR voltampere reactive VDC volts di
68. er Connection Section 6 Accessories 51 Battery Charger Connection Procedure A DANGER Hazardous voltage Will cause severe injury or death Disconnect all power sources before opening the enclosure Connecting the battery and the battery charger Hazardous voltage can cause severe injury or death Reconnect the battery correctly positive to positive and negative to negative to avoid electrical shock and damage to the battery charger and battery ies Have a qualified electrician install the battery ies 1 Verify that power to the ATS is disconnected switches or circuit breakers to the ATS are open 2 Verify that the inline connector to the charger is disconnected 3 Clean the battery terminals and check the battery according to the battery manufacturer s instructions 4 Determine the length of cable needed to connect the battery to the battery charger and refer to Figure 6 21 for the required wire size The distances shown are the one way distances from the charger to the battery Note Use the recommended wire size to prevent overcharging the battery Route AC and DC wiring in separate conduits 5 Remove the boots and ring terminals from the battery charger posts Maximum Battery Charger Eyelet Terminal Distance Terminal Size Part No 4 5m 15 ft 12 AWG No 10 X 283 11 7 5 m 25 ft 10 AWG Figure 6 21 Battery Cable and Terminal Specifications 6 Slide a red boot onto th
69. erred power source returns Y Pre transfer load control as programmed Time delay standby to preferred In phase monitor open transition only as programmed Transfer to OFF position programmed transition only Y Time delay off to preferred programmed transition only Transfer to normal preferred source Y Post transfer load control as programmed Time delay engine cooldown TDEC as programmed Engine start signal removed See the Setup Program Operation Manual Figure 4 2 ATS Sequence of Operation Return to Normal preferred source LED Indicators N N OFF E E Load Loss of Normal Source Available Position Position Available Position Control Engine Start Time Delay Preferred to Standby Time Delay Post transfer to Standby Load Control Standby to Preferred Time Delay Pre transfer to Preferred Load Control Off to Preferred Time Delay programmed transition only Post transfer to Preferred Load Control Engine Cooldown Time Delay Default 0 Figure 4 3 User Interface LED Indicators During Loss of Normal Source 28 Section 4 Operation TP 6126 8 02 4 2 2 System Test A system test simulates a preferred source failure and performs the transfer sequence Press and release the test button to start the test Press and release the test button again to end the test The test sequence does not start if the ATS is in the stan
70. et engine start immediate Load bank control output activated as programmed Exercise time period ends or exercise button pressed Load bank control output deactivated as programmed Time delay engine cooldown as programmed Generator set engine start signal removed See the Setup Program Operation Manual Figure 4 9 Exercise without Load Sequence 32 Section 4 Operation Exercise button pressed or scheduled exercise signaled to begin Generator set engine start Time delay preferred to standby Y Pre transfer load control as programmed Y In phase monitor or transfer to off as programmed Y Transfer to standby source Y Post transfer load control as programmed Exercise time period ends or exercise button pressed Time Delay standby to preferred Pre transfer load control as programmed In phase monitor or transfer to off as programmed Transfer to preferred source Post transfer load control as programmed Y Time delay engine cooldown as programmed Generator set engine start signal removed See the Setup Program Operation Manual Figure 4 10 Exercise with Load Sequence TP 6126 8 02 Loaded Exercise Preferred to Standby Time Delay LED Indicators N Available N Position OFF Position E Available E Position Load Exercise Control flashing Pre Transfer to Standby Load Control Off to Standby Time Delay programmed tra
71. explained in the accompanying chart Model Mechanism Transition Controls Voltage Poles Enclosure Current Rating Connections A A A A A A A A A ee ee al a ali I Kohler Model Designation Key This chart explains the Kohler transfer switch model designation system The sample SAMPLE MODEL DESIGNATION model designation shown is for a Model K automatic transfer switch that uses an open transition contactor with MPAC 1000 electrical controls rated at 480 volts 60 Hz KCT AMTA 0225S 3 poles 4 wires and solid neutral in a NEMA 1 enclosure with a current rating of 225 amperes Not all possible combinations are available Model K Model K automatic transfer switch Mechanism C Automatic B Bypass Isolation See G11 81 N Non automatic Transition T Open Transition P Programmed Transition Electrical Controls A MPAC 1000 Microprocessor ATS Controls Voltage Frequency C 208 Volts 60 Hz G 380 Volts 50 Hz K 440 Volts 60 Hz D 220 Volts 50 Hz H 400 Volts 50 Hz M 480 Volts 60 Hz F 240 Volts 60 Hz J 416 Volts 50 Hz N 600 Volts 60 Hz Number of Poles Wires N 2 pole 3 wire solid neutral W 4 pole 4 wire overlapping neutral T 3 pole 4 wire solid neutral Z 3 pole 4 wire integral solid neutral V 4 pole 4 wire switched neutral Enclosure A NEMA 1 C NEMA 3R F NEMA 4X4 B NEMA 122 D NEMA 42 G Open unit Y St
72. front door components to the internal components and disconnect the grounding wire between the door and the enclosure Set the door out of the way to protect the controls TP 6126 8 02 For units with hinged doors open the door and disconnect the cable plug that connects the front door components to the internal components Disconnect the grounding wire between the door and the enclosure Squeeze the release pins on each hinge together and remove the door See Figure 2 6 Set the door out of the way to protect the controls Vertically mount 30 through 400 amp transfer switches to a wall or other rigid vertical supporting structure Use the template on the shipping carton to locate the mounting holes in the wall Level the template before marking and drilling the holes Clearance holes through the back of each enclosure are provided for mounting Use shims to plumb the enclosure Verify that the door hinges are vertical to avoid distortion of the enclosure or door Bolt 600 through 4000 amp automatic transfer switches directly to floor mounting pads Shim the enclosure so that the enclosure is plumb 2 4 Manual Operation Check A DANGER Hazardous voltage Will cause severe injury or death Disconnect all power sources before opening the enclosure Note A manual operation handle is provided on the transfer switch for maintenance purposes only Do not use the manual operation handle to transfer the load with the powe
73. g when using power tools hand tools or compressed air IV Safety Precautions and Instructions Notice NOTICE Hardware damage The transfer switch may use both American Standard and metric hardware Use the correct size tools to prevent rounding of the bolt heads and nuts NOTICE When replacing hardware do not substitute with inferior grade hardware Screws and nuts are available in different hardness ratings To indicate hardness American Standard hardware uses a series of markings and metric hardware uses a numeric system Check the markings on the bolt heads and nuts for identification NOTICE Improper operator handle usage Use the manual operator handle on the transfer switch for maintenance purposes only Return the transfer switch to the normal position Remove the manual operator handle if used and store it in the place provided on the transfer switch when service is completed NOTICE Foreign material contamination Cover the transfer switch during installation to keep dirt grit metal drill chips and other debris out of the components Cover the solenoid mechanism during installation After installation use the manual operating handle to cycle the contactor to verify that it operates freely Do not use a screwdriver to force the contactor mechanism NOTICE Electrostatic discharge damage Electrostatic discharge ESD damages electronic circuit boards Prevent electrostatic discharge d
74. ging the 1 week 2 week DIP switch position does not change the time of the next exercise because it has already been scheduled The new DIP switch setting becomes effective after the next scheduled exercise The system skips the exercise period if it is scheduled to start when the ATS is running under the following conditions e The ATS is running a test cycle initiated by the Test button on the user interface e The ATS is running on the standby source because the preferred source is not available e TheATS is running on the standby source because of a peak shave area protection command Exercise Duration The default factory setting for the run duration is 30 minutes If the generator set fails during an exercise period the switch immediately transfers back to the preferred source Use the Setup Program to change the run duration if desired Section 4 Operation 31 Load Bank Control The load bank control output can be used to apply a load to the generator set during the exercise The load bank control output provides a contact closure that can be used to signal the load bank controller to operate If the Normal source is lost during an exercise period the load bank control output contact opens to remove the load bank and allow the transfer of the building load to the emergency source See Section 3 3 2 for the load bank control output connection Exercise button pressed or scheduled exercise signaled to begin Generator s
75. he Setup Program to view the event history The event history lists fault conditions and transfers See the software operation manual for more information and instructions After correcting the fault condition press the Lamp Test button for approximately 5 seconds until the LEDs flash twice to clear the Service Required LED 4 3 2 Auxiliary Switch Faults An Auxiliary Switch Fault occurs if the controller cannot determine the contactor switch position The Service Required LED flashes The fault clears when the controller can detect the switch position Depress the Lamp Test button until the LEDs flash to clear the Service Required LED 4 3 3 Failure to Acquire Standby Source A fault occurs if the unit attempts to start the generator set but the standby source does not appear after the Acquire Standby Source to Failure time delay The Service Required LED illuminates Some conditions that may cause this fault are failure of the generator set to start no voltage output from the generator or an error in sensing the voltage output from the generator set 36 Section 4 Operation The fault clears when the system acquires a standby source Depress the Lamp Test button until the LEDs flash to clear the Service Required LED 4 3 4 Failure to Transfer If the unit fails to transfer on command the controller waits 1 second and then initiates another 200 msec attempt to transfer If the in phase monitor is operating the system waits
76. he preferred source switch The utility utility mode is designed to use utility power for both Source N and Source E This mode does not use the engine start outputs Time Delays and Source Parameters Engine start relays and time delays source voltage and frequency trip points and load shed time delays are assigned to the source N or E They do not change assignment when the preferred source switch position is changed Note Source N is always connected to the Normal side of the transfer switch and Source E is always connected to the Emergency side Other time delays are assigned to the source function preferred or standby System parameters that are assigned to the function automatically change source when the preferred source selection changes Figure 6 3 shows which parameters are assigned to the source and which are assigned to the function The last two columns of the table show the effect of the preferred source selector switch position on each parameter or time delay TP 6126 8 02 Preferred Source Switch Position Assignment N E Source N generator engine start relay Source Source E generator engine start relay Source Source N engine start time delay Source Source E engine start time delay Source Source N engine cooldown time delay Source Source E engine cooldown time delay Source Source N voltage and frequency trip points Source Source E voltage and frequency trip points Source
77. ilobyte 210 bytes kg kilogram kg cm kilograms per square centimeter kgm kilogram meter kg m8 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm KQ kilo ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt hour kWm kilowatt mechanical L liter LAN local area network LxWxH length by width by height lb pound pounds lbm ft8 pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display ld shd load shed LED light emitting diode A 58 Appendix Lph liters per hour Lpm liters per minute LOP low oil pressure LP liquefied petroleum LPG liquefied petroleum gas LS left side Lia sound power level A weighted LWL low water level LWT low water temperature m meter milli 1 1000 M mega 10 when used with SI units male ms cubic meter m min cubic meters per minute mA milliampere man manual max maximum MB megabyte 22 bytes MCM one thousand circular mils MCCB molded case circuit breaker meggar megohmmeter MHz megahertz mi mile mil one one thousandth of an inch min minimum minute misc miscellaneous MJ megajoule mJ millijoule mm millimeter mOhm mQ millionm MOhm MQ megohm MOV metal oxide varistor MPa megapascal mpg miles per gallon mph miles per hour MS military standard m sec meters per second MTBF mean time between failure MTBO mean time between overhauls mtg moun
78. ing installation The functional tests in Section 3 7 are a necessary part of the installation Be sure to perform the functional tests which include voltage checks and operation tests before putting the transfer switch into service 2 2 Receipt of Unit 2 2 1 Inspection At the time of delivery inspect the packaging and the transfer switch for signs of shipping damage Unpack the transfer switch as soon as possible and inspect the exterior and interior for shipping damage If damage and or rough handling is evident immediately file a damage claim with the transportation company TP 6126 8 02 Section 2 Installation 2 2 2 Lifting A WARNING Unbalanced weight Improper lifting can cause severe injury or death and equipment damage Use adequate lifting capacity Never leave the transfer switch standing upright unless it is securely bolted in place or stabilized See Figure 2 1 through Figure 2 4 or the dimensional drawing for the weight of the transfer switch Use a spreader bar to lift the transfer switch Attach the bar only to the enclosure s mounting holes or lifting brackets do not lift the unit any other way Close and latch the enclosure door before moving the unit Weight kg Ib 2 Pole 3 Pole 4 Pole 30 200 28 62 65 225 400 52 115 123 600 800 220 485 510 1000 1200 785 1600 2000 1040 2600 3000 649 1430 4000 1043 2300 Figure 2 1
79. ion 54 Section 6 Accessories TP 6126 8 02 O S 3 S 5 S Q o Jl ie a fo lt I lt g O Absorption Red LED On Red Green LEDs On Figure 6 26 Charging Method 24 VDC 3 A Configuration 6 8 3 Battery Charger Troubleshooting Problem Red LED stays on for more than 24 hours One or more defective or damaged cells Solution Load test the battery and replace if necessary Charger has reduced its output voltage below the normal level due to a DC overload or a DC short Remove the source of the overload or short Disconnect the charger s black NEGATIVE ring terminal from the battery Reapply AC power and the green LED only should now light On board DC systems are drawing more current than the charger can replace Turn off excessive DC equipment while charging The red and green LEDs stay on for more than 24 hours On board DC systems are drawing between 1 5 5A Turn off excessive DC equipment while charging One or more defective or damaged cells Load test the battery and replace if necessary Extremely low AC voltage at the battery charger Apply a higher AC voltage source or reduce the length of the power cord Green LED stays on when the battery is known to be low Open DC output fuse Replace the DC output fuse with a Bussmann AGC 10 Faulty or contaminated terminal connections Clean and tighten or repair all terminal connec
80. l to the longer time delay which is 3 seconds When transferring back to the preferred source the standby to preferred time delay is 15 minutes The pre transfer signal operates during the final 3 seconds before transfer to the preferred source The total time delay before transfer back to preferred using the default settings is 15 minutes Preferred to Standby Time Delay 1 second Transfer to Standby aa ae 3 2 1 0 Time before Transfer in Seconds Standby to Preferred Time Delay 15 minutes Pre Transfer Load Control Signal 3 Seconds pas to Preferred lt lt 15 minutes Time before Transfer 30 Figure 4 13 Pre Transfer Time Delay Operation default settings TP 6126 8 02 Section 4 Operation 35 4 3 Faults 4 3 1 Service Required LED The following faults cause the Service Required LED to flash indicating that immediate service is required Auxiliary switch fault Auxiliary switch open Failure to acquire standby source Failure to transfer Phase rotation fault Input output module faults see Section 6 5 1 Find and correct the cause of the fault before trying to reset the controller The cause of the fault may be shown by the other LEDs on the user interface check the Source Available Position Load Control Time Delay Exercise and TestLEDsto diagnose the cause of the faults Ifthe LEDs do notreveal the cause ofthe fault condition connect a PC to the controller and use t
81. liary connections Hazardous voltage can cause severe injury or death To preventelectrical shock deenergize the normal power source before making any line or auxiliary connections TP 6126 8 02 Servicing the transfer switch Hazardous voltage can cause severe injury or death Deenergize all power sources before servicing Open the main circuit breakers of all transfer switch power sources and disable all generator sets as follows 1 Move all generator set master controller switches to the OFF position 2 Disconnect power to all battery chargers 3 Disconnect all battery cables negative leads first Reconnect negative leads lastwhen reconnecting the battery cables after servicing Follow these precautions to prevent the starting of generator sets by an automatic transfer switch remote start stop switch or engine start command from a remote computer Before servicing any components inside the enclosure 1 Remove all jewelry 2 Stand on a dry approved electrically insulated mat 3 Test circuits with a voltmeter to verify that they are deenergized Servicing the transfer switch controls and accessories within the enclosure Hazardous voltage can cause severe injury or death Disconnect the transfer switch controls at the inline connector to deenergize the circuit boards and logic circuitry but allow the transfer switch to continue to supply power to the load Disconnect all power sources to accessories that
82. liquid with water and dry the area Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do not smoke or permit flames or sparks to occur near a battery at any time particularly when itis charging Do not dispose of a battery ina fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases Battery short circuits Explosion can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove all jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together
83. low a power interruption for the time required for the internal inspection have an authorized distributor dealer perform the internal inspection 5 3 2 Other Inspections and Service Have an authorized distributor dealer perform scheduled maintenance service and other maintenance that ensures the safe and reliable operation of the transfer switch See Section 5 4 Service Schedule for the recommended maintenance items and service intervals Have an authorized distributor dealer repair or replace damaged or worn internal components with manufacturer recommended replacement parts Section 5 Scheduled Maintenance 39 5 4 Service Schedule Follow the service schedule below for the recommended service intervals Have all service performed by an authorized distributor dealer except for activities designated by an X which may be performed by the switch operator Adjust See Visually Repair System Component or Procedure Section Inspect Check Replace Clean Test Frequency ELECTRICAL SYSTEM Check for signs of overheating or loose connections discoloration of metal melted plastic or a burning odor Check the contactor s external operating mechanism D clean Y for cleanliness clean and relubricate if dirty an and lube Inspect wiring insulation for deterioration cuts or abrasion Repair or replace deteriorated or damaged wiring Tighten control and power wiring connections to specifications Check
84. ly ground the transfer switch and related equipment and electrical circuits to comply with applicable codes and standards Never contact electrical leads or appliances when standing in water or on wet ground as the chance of electrocution increases under such conditions Servicing the transfer switch Hazardous voltage can cause severe injury or death Deenergize all power sources before servicing Open the main circuit breakers of all transfer switch power sources and disable all generator sets as follows 1 Move all generator set master controller switches to the OFF position 2 Disconnect power to all battery chargers 3 Disconnect all battery cables negative leads first Reconnect negative leads last when reconnecting the battery cables after servicing Follow these precautions to prevent the starting of generator sets by an automatic transfer switch remote start stop switch or engine start command from a remote computer Before servicing any components inside the enclosure 1 Remove all jewelry 2 Stand ona dry approved electrically insulated mat 3 Test circuits witha voltmeter to verify that they are deenergized Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment NOTICE When re
85. n transition models use a detachable manual operating handle NOTICE Improper operator handle usage Use the manual operator handle on the transfer switch for maintenance purposes only Return the transfer switch to the normal position Remove the manual operator handle if used and store it in the place provided on the transfer switch when service is completed Manual Operation Test Procedure 225 4000 Amp Open Transition Transfer Switches 1 Remove the maintenance handle from the clips on the left side of the transfer switch frame See Figure 2 8 1 Maintenance handle 2 Storage clips 2 225 400 amp switches See Figure 2 9 Insert the maintenance handle into the hole in the shaft on the left side of the operator Figure 2 8 Manual Handle Storage 600 1200 Amp Switch Shown 600 1200 amp switches See Figure 2 10 Insert the maintenance handle into the hole in the molded hub on the left side of the operator 1600 2000 amp switches See Figure 2 11 Slide the hub onto the shaft and insert the maintenance handle into the hole in the hub 3000 and 4000 amp switches See Figure 2 12 Insert the maintenance handle into the hole in the weight 3 Move the maintenance handle up or down as shown to manually operate the transfer switch It should operate smoothly without any binding If it does not check for shipping damage or construction debris 4 Return the transfer switch to the Normal position 5 Remove the mainten
86. nal 12 24 AWG 0 5 Nm 4 4 in lb strip 1 O terminals I O board terminals 14 26 AWG Figure 6 15 Input and Output Connection Specifications 48 Section 6 Accessories 6 5 3 I O Module Address Each l O Module requires a unique address Factory installed I O module addresses are set at the factory To check the I O module addresses compare the DIP switch settings with Figure 6 16 starting with the module connected to the controller harness Figure 6 14 shows the address DIP switch location on the I O module Push down the end of the DIP switch near the OPEN label to open the switch or push down the other end to close it See Figure 6 17 1 O Module Address DIP Switches Number 2 Closed Closed Closed Closed Closed Open Closed Open Closed Closed Open Open ofj Jo Jo OPEN 1 Push this side down to open Figure 6 17 I O Module Address DIP Switches 6 5 4 1 O Module Faults and Diagnostics When power is applied to the system the controller attempts to initiate communication with each connected I O board The following faults may occur on powerup if the I O modules are not correctly installed addressed or configured in the setup software Check the LED on each I O module for diagnostic information in the case of a fault Diagnostic LED Each I O module has a diagnostic LED that lights or flashes to indicate the I O board status as described in
87. nerator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer TP 6126 8 02 A DANGER Hazardous voltage Will cause severe injury or death Disconnect all power sources before opening the enclosure A DANGER Hazardous voltage Will cause severe injury or death Disconnect all power sources before servicing Install the barrier after adjustments maintenance or servicing Making line or auxiliary connections Hazardous voltage can cause severe injury or death To prevent electrical shock deenergize the normal power source before making any line or auxiliary connections Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Open the main circuit breakers of all power sources before servicing the equipment Configure the installation to electrically ground the generator setand related equipment and electrical circuits to comply with applicable codes and standards Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution NOTICE Electrostatic discharge damage Electrostatic discharge ESD damages electronic circuit boards Prevent electrostatic discharge damage by wearing an approved grounding wrist strap when handling electronic circuit boards or integrated circuits An approved grounding wris
88. ng All internal electrical connections are factory wired and tested Field installation includes connecting the sources loads generator start circuit s and auxiliary circuits if used Note Do not connect the wiring harness to the controller until instructed to do so in the voltage check procedure Section 3 7 2 Refer to the wiring diagrams provided with the transfer switch Observe all applicable national state and local electrical codes during installation Install DC control and communication system wiring in metal conduit separate from AC power wiring It is not necessary to remove pole covers from the transfer switch for cabling If you do remove them reinstall them carefully A WARNING AS y x Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator setas follows 1 Move the generator set master switch to the OFF position 2 Disconnectthe power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the ge
89. nsition only X In Phase Synch as programmed N A for programmed transition models Xx flashing Post Transfer to Standby Load Control Pre Transfer to Preferred Load Control Off to Preferred Time Delay programmed transition only Post Transfer to Preferred Load Control Engine Cooldown Time Delay Default 0 Figure 4 11 User Interface LED Indicators During a Loaded Exercise TP 6126 8 02 Section 4 Operation 33 4 2 4 Peak Shave Area Protection Operation Sequence The peak shave input signals the transfer switch to start the generator set and transfer to the standby source The engine start TDES time delay is ignored When the peak shave input is removed the system transfers back to preferred if available and removes the generator engine start signal The default setting ignores the standby to preferred time delay when transferring back to preferred Note The setup software can be set to bypass or execute the standby to preferred time delay during the peak shave sequence See the Setup Program Operation Manual See Figure 4 12 for the sequence of operation 34 Section 4 Operation Peak Shave Area Protection signal received by controller Immediate generator set engine start Y Pre transfer load control as programmed Y In phase monitor or transfer to off as programmed Y Preferred to standby time delay Transfer to standby source Post transfe
90. nute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate semiconductor cogeneration communications port connection TP 6126 8 02 cont CPVC crit CRT CSA CT Cu cu in cw CWC cyl D A DAC dB dBA DC DCR deg dept dia DI EO DIN DIP DPDT DPST DS DVR E emer EDI EFR e g EG EGSA EIA El EO EMI emiss eng EPA EPS ER ES ESD est E Stop etc exh ext F fglass FHM fl oz flex freq FS ft ft Ibs ft min 9 ga gal gen genset GFI continued chlorinated polyvinyl chloride critical cathode ray tube Canadian Standards Association current transformer copper cubic inch clockwise city water cooled cylinder digital to analog digital to analog converter decibel decibel A weighted direct current direct current resistance degree department diameter dual inlet end outlet Deutsches Institut fur Normung e V also Deutsche Industrie Normenausschuss dual inline package double pole double throw double pole single throw disconnect switch digital voltage regulator emergency power source electronic data interchange emergency frequency relay for example exempli gratia electronic governor Electrical Generating Systems Association Electronic Industries Association end inlet end outlet electromagnetic interference emission engine Environmental Protection Agency emergency power sy
91. o preferred signal 3 sec Post transfer to standby signal O sec Post transfer to preferred signal O sec Engine cooldown 0 min In phase monitor synch 30 sec Figure 3 13 Factory Settings Time Delays 3 6 Generator Set Preparation A WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Disconnect all power sources to the transfer switch by opening upstream circuit breakers or switches to the transfer switch Prepare the generator set for operation Check the oil level coolant level fuel supply batteries and items specified by the generator set installation or operation checklist or manual Move the generator set master switch to the OFF position reconnect the generator engine start battery cables negative leads last and reconnect power to the generator engine start battery chargers if installed TP 6126 8 02 3 7 Functional Test The functional test includes three checks e Manual Operation Test e Voltage Checks e Automatic Operation Test Note Perform these checks in the order presented to avoid damaging the ATS Read all instructions on the labels affixed to the automatic transfer switch 3 7 1 Manual Operation Test If you have not already done so test the contactor manual operation before proceeding to the voltage check and electrical operation test Note Disable the generator
92. placing hardware do not substitute with inferior grade hardware Screws and nuts are available in different hardness ratings To indicate hardness American Standard hardware uses a series of markings and metric hardware uses a numeric system Check the markings onthe bolt heads and nuts for identification NOTICE Hardware damage The transfer switch may use both American Standard and metric hardware Use the correct size tools to prevent rounding of the bolt heads and nuts NOTICE Electrostatic discharge damage Electrostatic discharge ESD damages electronic circuit boards Prevent electrostatic discharge damage by wearing an approved grounding wrist strap when handling electronic circuit boards or integrated circuits An approved grounding wrist strap provides a high resistance about 1 megohm not a direct short to ground 5 2 Testing 5 2 1 Weekly Generator Set Exercise Use the exerciser or a manual test to start and run the generator set under load once a week to maximize the 38 Section 5 Scheduled Maintenance reliability of the emergency power system Press the Test button on the controller front panel to start and end the test The Test LED flashes during a test with load or lights steadily during a test without load Use the DIP switch to set the system for a loaded test or use a load bank and the load bank control output to run loaded without transferring the building load See Sections 4 2 2 and 4 2 3 for more inform
93. r and swinging the cover up and out The cover is hinged at the top Lift the cover off the hinges to remove it completely if necessary Refer to the label on the plastic housing or Figure 3 9 for the connections Use 12 24 AWG wire and tighten the connections to 0 5 Nm 4 4 in lbs The controller board terminal strip has two programmable inputs Each input has a signal and a return connection Connect inputs to terminals 6 and 7 or 8 and 9 on terminal strip TB1 Record the connections on the label provided Use the setup program to assign the input functions if they are different from the default assignments shown in Figure 3 7 The main logic board has one programmable output which is factory assigned to the load bank control output function Connect to terminals 3 and 4 or 3 and 5 on terminal strip TB1 Use the setup program to assign the output function if it is different from the default assignment Note Always replace the cover before energizing the transfer switch controls 3 3 3 Communications Connections The controller has two communications connections Serial Port For connection to a personal computer to run the Setup Program software This is a non isolated RS 232 port with a connection speed of 57 6 kbps Modbus Network Interface MNI For connection to building management systems programmable logic controls etc This is a non isolated RS 485 port with connection speeds of 9 6 kbps and 19 2 kbps Use RTU
94. r connected Use the manual operation handle to check the manual operation before energizing the transfer switch On programmed transition models check the operation of both the Normal and Emergency operators Use the following manual operation procedures to verify that the contactor operates smoothly without binding Note A contactor in normal and serviceable condition operates smoothly without binding Do not place the transfer switch into service if the contactor does not operate smoothly contact an authorized distributor dealer to service the contactor TP 6126 8 02 1 Hinge release pins Figure 2 6 Hinge 2 4 1 Manual Operation 30 200 Amp Open Transition Switches The 30 200 amp open transition models have an attached manual operating handle See Figure 2 7 Manual Operation Test Procedure 30 200 Amp Transfer Switches 1 Turn the attached handle to manually operate the transfer switch It should operate smoothly without any binding If it does not check for shipping damage or construction debris 2 Return the transfer switch to the Normal position 1 Handle Figure 2 7 Manual Operation Handle 30 200 Amp Open Transition Switches Section 2 Installation 5 2 4 2 Manual Operation 225 4000 Amp Open Transition Switches A DANGER Hazardous voltage Will cause severe injury or death Disconnect all power sources before opening the enclosure The 225 4000 amp ope
95. r load control as programmed Y Peak shave area protection signal removed Pre transfer load control as programmed In phase monitor or transfer to off as programmed Y Standby to preferred time delay as programmed Y Transfer to preferred source Post transfer load control as programmed Y Time delay engine cooldown as programmed default 0 Generator set engine start signal removed See the Setup Program Operation Manual Default settings bypass this time delay Figure 4 12 Peak Shave Area Protection Sequence TP 6126 8 02 4 2 5 Pre and Post Transfer Load Control Sequence The pre transfer and post transfer load control time delays operate during transfer between two live sources such as during a loaded test sequence or a loaded exercise The load control LED lights when the pre and post transfer signals are active The pre transfer load control time delays overlap the preferred to standby and standby to preferred time delays The longer delay determines the time delay before transfer Pre Transfer Load Control Signal 3 Seconds The timelines in Figure 4 13 illustrate the pre transfer time delay sequence using the default settings The default settings for the post transfer signals are equal to zero The default setting for the preferred to standby time delay is 1 second and the default setting for the pre transfer time delay is three seconds The time delay before transfer is equa
96. re 3 6 shows the locations the DIP switches and connectors on the main logic board TRANSTER SWITCH KOHLER ror cuersencv systevs Pob ERMUA NEMA ENCLOSURE MFG DATE waren ACCESSORIES MODEL SERIAL NO james VOLTS wires PHASE POLES RTZ BAR CODE TRANSFER SWITCH FOR EMERGENCY SYSTEMS GM21079 1 Hinges 2 Access openings to DIP switches and PC connection 3 Latch Figure 3 5 Controller Housing TP 6126 8 02 I O board connection P3 User interface connections DIP switches Serial port for PC connection P6 Preferred source switch connection P7 Supervised transfer switch connection P8 Programmed transition interface board PTIB connection factory connection P9 Ground wire Contactor harness connection Serial number decal Terminal strip inputs output Modbus connections TB1 Figure 3 6 Controller Board Component Locations Section 3 Setup and Test 19 3 3 1 Main Logic Board DIP Switch Settings DIP switches on the main logic board control the test and exercise functions A maintenance DIP switch inhibits transfer during ATS service The factory settings for the DIP switches a
97. re shown in Figure 3 8 Before opening the transfer switch enclosure to check or change the DIP switch settings open the circuit breakers to disconnect the power to the transfer switch The DIP switches are located on the controller s main logic board on the inside of the enclosure door Figure 3 6 shows the locations of the switches on the controller circuit board A decal on the logic assembly housing shows the DIP switch positions and settings see Figure 3 8 Itis not necessary to remove the logic assembly cover to see or adjust the DIP switches Check the DIP switch settings and adjust if necessary for the application Note Changing the position of the 1 week 2 week exercise DIP switch after the exerciser has been set does not change the time of the next scheduled exercise The new DIP switch setting becomes effective after the next scheduled exercise See Section 4 2 3 for more information about the exerciser Close and lock the enclosure door before energizing the transfer switch 3 3 2 Main Logic Board Inputs and Outputs The controller main logic board s inputs and outputs are factory assigned to the functions shown in Figure 3 7 Pre Transfer Load Control Output Assigned to terminals TB1 1 and TB1 2 The load control output operates only during the transfer sequence between P8 P7 P6 SUPERVISED PREFERRED RS232 TRANSFER SOURCE INPUT INPUT SOFTWARE SETUP COMPUTER CONNECTION POSITION two live sources
98. rect current VFD vacuum fluorescent display VGA video graphics adapter VHF very high frequency W watt WCR withstand and closing rating w with w o without wt weight xfmr transformer Appendix A 59 Appendix B Specifications Withstand and Closing Ratings Open and Programmed Transition Models Maximum current in RMS symmetrical amperes when coordinated with customer supplied fuses or circuit breakers Withstand and Closing Current Ratings in RMS Symmetrical Amperes Any Circuit Breaker Current Limiting Fuses Specific Circuit Breaker kAmps kAmps Max kAmps Volts Fuse Size 480 VAC 600 VAC 480 VAC Max Amps 10 10 22 35 42 10 22 240 VAC max 240 VAC max 35 42 50 36 3000 4000 480 6000 4000 All values are available symmetrical RMS amperes and tested in accordance with the withstand and close on requirements of UL 1008 200 amp switches are limited to 240 VAC max copper wire only Application requirements may permit higher withstand ratings for certain size switches Contact Kohler Co for assistance Open transition models only Programmed transition models only Optional front connected service limited to 85 000 amps for specific and any breaker ratings Withstand rating only This testing is not defined in UL 1008 A 60 Appendix TP 6126 8 02 Ratings with Specific Manufacturers Circuit Breakers Op
99. red source Test and peak shave signals are ignored by non automatic systems when the supervised transfer control switch is in the MANUAL position SUPERVISED TRANSFER GM21286 Figure 6 4 Supervised Transfer Control Switch Operation Non Automatic Switches e Automatically transfers to the standby source when available if the preferred source is lost Transfers back to the preferred source when it becomes available MANUAL connected source is lost when both sources are available Does not automatically transfer back to preferred e Automatically transfers to an available source ifthe e Enables the Not in Auto indicator e Transfers only when the switch is manually moved to the TRANSFER position e Does not automatically transfer to an available source when the connected source is lost e Does not automatically transfer back to preferred when both sources are available TRANSFER Can use to transfer when the switch is in the MANUAL position and both sources are available Initiates transfer sequence to the other source if available including all programmed time delays Operates pre and post transfer load control time delays if both sources are available Figure 6 5 Supervised Transfer Control Switch Operation 44 Section 6 Accessories Must use for all transfers when the switch is in the MANUAL position Initiates transfer sequence to the other source if available including all programmed time del
100. rred source failure and signals the generator set to start TP 6126 8 02 When the standby source is available and the time delay preferred to standby expires the ATS transfers the load if the test DIP switch is set for a loaded test When the test button is pressed again the ATS transfers the load back to the preferred source if available after the standby to preferred time delay The ATS removes the generator engine start signal after the related time delays expire The generator set may continue to run if the generator set controller provides an additional engine cooldown time delay Test started Time delay engine start TDES Generator set engine start contacts close Load bank control output activated as programmed Test ended Load bank control output deactivated as programmed Time delay engine cooldown TDEC as programmed default 0 Generator set engine start signal removed See the Setup Program Operation Manual Figure 4 4 Test Without Load Sequence Section 4 Operation 29 Test started Time delay engine start TDES Test cided Generator set engine start contacts close Standby to preferred time delay Pre transfer load control as programmed Pre transfer load control as programmed Y In phase monitor or transfer to off as programmed Preferred to standby time delay In phase monitor or transfer to off as programmed as prog Transfer to preferred source
101. se severe personal injury death or substantial property damage A CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage NOTICE Notice communicates installation operation or maintenance information that is safety related but not hazard related TP 6126 8 02 Safety Precautions and Instructions Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely The decals are shown throughout this publication to improve operator recognition Replace missing or damaged decals Accidental Starting A WARNING FAS Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer swi
102. ser is inhibited by the DIP switch setting Load Control Active Pre post transfer load control or peak shave functions are operating Not in Auto ATS is not set for automatic operation or a load shed forced transfer to OFF sequence is active Position N Contactor is in Normal positon Position E Contactor is in Emergency position Position Off In Phase Sync Contactor is in Off position programmed transition models only In phase monitor is operating open transition models only Service Required Fault Non emergency is maintenance required Fault Immediate maintenance is required Source N Available Source N is available Source E Available Source E is available Test Unloaded test is running Loaded test is running Time Delay LED Bar LEDs step down to indicate time remaining in an active time delay or exercise period Figure 3 2 User Interface LED Indicators Pushbutton Exercise Start and stop an exercise and set the exercise time 3 2 2 Controller Reset Description The controller can be reset without disconnecting Lamp Test Test LEDs or reset the Service Required LED power Use the following procedure Test Start and stop a test Controller Reset Procedure Time Delay Figure 3 3 User Interface Pushbuttons Service Required LED Illumination Flashing End an active time
103. sfer mode automatic or non automatic cannot be changed in the field Figure 3 11 System Parameters Voltage and Frequency Sensing Default 90 of nominal 90 of pickup 110 of nominal 95 of dropout 0 5 sec Parameter Undervoltage pickup Undervoltage dropout Overvoltage dropout Overvoltage pickup Voltage debounce time Underfrequency pickup 90 of nominal Underfrequency dropout 99 of pickup Overfrequency dropout 101 of pickup Overfrequency pickup 110 of nominal Frequency debounce time 3 sec Figure 3 12 Factory Settings Voltage and Frequency TP 6126 8 02 3 5 2 Time Delays The factory settings for the time delays are shown in Figure 3 13 The pre transfer time delays operate only when both sources are available These delays allow time to disconnect selected loads before transfer The load control LED on the user interface lights when the pre transfer signal is active The pre transfer and post transfer time delays overlap the preferred to standby and standby to preferred transfer time delays Adjustable Time Delays Time Delay Default Engine start 3 sec Preferred to standby 1 sec Standby to preferred 15 min Off to standby programmed transition only 1 sec Off to preferred programmed transition only 1 sec Failure to acquire standby source 1 min Pretransfer to standby signal 3 sec Pretransfer t
104. steadily or flash to indicate different ATS conditions The tables in Figure 3 2 and Figure 3 3 describe the functions of the pushbuttons and LED indicators Refer to the appropriate section for more details about functions listed in Figure 3 3 and Figure 3 2 see the Table of Contents Figure 3 4 lists the fault conditions that cause the Service Required LED to light or flash Steady illumination indicates that maintenance is needed flashing indicates that service is required immediately 6 POSITION pam E aan SOURCE IN PHASE SYNC SOURCE OFF E L Y AVAILABLE a SERVICE LOAD CONTROL NOT IN y REQUIRED ACTIVE AUTO HOLD FOR 100 ey 5 SEC TO RESET SERVICE REQ D C 50 LOAD FAULT INDICATION 25 seco SET DISABLE a SA Nie LAMP TEST TIME DELAY EXERCISE TEST NO LOAD LOAD 1 4 y 4 Dd 7 5 a PUSH TO TEST RESET J a gt PUSHTO PUSHTO PUSH TO END SET END TEST END _ 3 y i E 1 User interface panel location Figure 3 1 User Interface Panel TP 6126 8 02 GM211077A Section 3 Setup and Test 17 LED Indicator Exercise LED Illumination Unloaded exercise is running Slow Flash Loaded exercise is running Rapid Flash When exercise button is pressed and held rapid flashing indicates the exercise has been started and set Rapid flashing at any other time indicates that the exerci
105. stem emergency relay engineering special engineered special electrostatic discharge estimated emergency stop et cetera and so forth exhaust external Fahrenheit female fiberglass flat head machine screw fluid ounce flexible frequency full scale foot feet foot pounds torque feet per minute gram gauge meters wire size gallon generator generator set ground fault interrupter Appendix A 57 GND ground gov governor gph gallons per hour gpm gallons per minute gr grade gross GRD equipment ground gr wt gross weight H x W x D height by width by depth HC hex cap HCHT high cylinder head temperature HD heavy duty HET high exhaust temperature hex hexagon Hg mercury element HH hex head HHC hex head cap HP horsepower hr hour HS heat shrink hsg housing HVAC heating ventilation and air conditioning HWT high water temperature Hz hertz cycles per second IC integrated circuit ID inside diameter identification IEC International Electrotechnical Commission IEEE Institute of Electrical and Electronics Engineers IMS improved motor starting in inch in H2O inches of water in Hg inches of mercury in Ibs inch pounds Inc incorporated ind industrial int internal int ext internal external 1 0 input output IP iron pipe ISO International Organization for Standardization J joule JIS Japanese Industry Standard k kilo 1000 K kelvin kA kiloampere KB k
106. t strap provides a high resistance about 1 megohm not a direct short to ground Section 2 Installation 9 2 5 1 AC Power Connections Determine the cable size Refer to the table in Figure 2 15 to determine the cable size and number of cables required for the transfer switch Make sure the lugs provided are suitable for use with the cables being installed Watertight conduit hubs may be required for outdoor use Note Use only copper wire for 200 amp models UL Listed Solderless Screw Type Terminals for External Power Connections Normal Emergency and Load Terminals Switch Rating Maximum Number of Range of Wire Sizes Amps Cables per Pole Copper or Aluminum 30 70 104 1 14 AWG to 2 0 AWG 150 1 8 AWG to 3 0 AWG 200 4 8 AWG to 3 0 AWG use copper wire only 1 4 AWG to 600 MCM 225 400 2 1 0 AWG to 250 MCM 600 3 2 AWG to 600 MCM 800 1200 4 1 0 AWG to 750 MCM 1600 2000 6 1 0 AWG to 750 MCM 2600 3000 12 1 0 AWG to 750 MCM 4000 Bus Bar Figure 2 15 Cable Sizes NOTICE Foreign material contamination Cover the transfer switch during installation to keep dirt grit metal drill chips and other debris out ofthe components Coverthe solenoid mechanism during installation Afterinstallation usethe manual operating handle to cycle the contactor to verify that it operates freely Do not use a screwdriver to force the contactor mechanism Drill the entry holes Cover the
107. tarting can cause severe injury or death Before working on the generator set or connected equipment disable the generator setas follows 1 Move the generator set master switch to the OFF position 2 Disconnectthe power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer TP 6126 8 02 A DANGER Hazardous voltage Will cause severe injury or death Disconnect all power sources before opening the enclosure A DANGER Hazardous voltage Will cause severe injury or death Disconnect all power sources before servicing Install the barrier after adjustments maintenance or servicing A DANGER Hazardous voltage Will cause severe injury or death Only authorized personnel should open the enclosure A WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Section 5 Scheduled Maintenance 37 Grounding the transfer switch Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Open main circuit breakers of all power sources before servicing equipment Configure the installation to electrical
108. tch remote start stop switch or engine start command froma remote computer Battery A WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin A WARNING Explosion Can cause severe injury or death Relays in the battery charger cause arcs or sparks Locate the battery in a well ventilated area Isolate the battery charger from explosive fumes Safety Precautions and Instructions l Battery electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or death Battery acid can cause blindness and burn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seek immediate medical aid in the case of eye contact Never add acid to a battery after placing the battery in service as this may result in hazardous spattering of battery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 lb of bicarbonate of soda baking soda toa container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spilled battery acid and continue to
109. the normal side of the contactor Source E is the source connected to the emergency side of the contactor The voltage check procedure requires the following equipment e A digital voltmeter DVM with electrically insulated probes capable of measuring the rated voltage and frequency e Aphase rotation meter A DANGER pS Hazardous voltage Will cause severe injury or death Only authorized personnel should open the enclosure Testing live electrical circuits Hazardous voltage or current can cause severe injury or death Have trained and qualified personnel take diagnostic measurements of live circuits Use adequately rated test equipment with electrically insulated probes and follow the instructions of the test equipment manufacturer when performing voltage tests Observe the following precautions when performing voltage tests 1 Remove all jewelry 2 Stand on a dry approved electrically insulated mat 3 Do not touch the enclosure or components inside the enclosure 4 Be prepared for the system to operate automatically 600 volts and under Voltage Check Procedure Note Perform voltage checks in the order given to avoid damaging the transfer switch 1 Verify that the generator set master switch is in the OFF position and both power sources are disconnected from the transfer switch 2 Disconnect the power switching device and controller wiring harnesses at the inline disconnect plug if they are connect
110. the table in Figure 6 18 I O Module Not Found If the system does not detect an I O module at an expected address the Service Required LED flashes and the software logs the message I O Module Not Found Check that the number of I O modules installed matches the number expected by the setup program Check that the I O TP 6126 8 02 modules are connected and the address DIP switches are set correctly Check the diagnostic LED to verify that the module is receiving power and communicating with the controller 1 O Module Not Installed Ifthe software detects an I O module that is connected but not expected by the setup program the Service Required LED flashes and the software logs the message I O Module Not Installed The system ignores the board if it does not find the setup definition Check that the number of I O modules expected in the Setup Program matches the number of modules installed on the transfer switch Check that the I O module address DIP switches are set correctly Check the diagnostic LED I O Module Communications Lost If communication to an I O module that was previously installed and working is lost the Service Required LED flashes and the software logs the message I O Module Communications Lost Check the I O module connections and diagnostic LED Diagnostic I O board Status LED Unpowered Off On Steady Power but no communication with Quick Flash control board 2 Hz Slow Flash 0 5 H
111. the transfer switch s main power switching contacts condition clean or replace the main contacts or replace the contactor assembly as necessary CONTROL SYSTEM Exercise the generator set under load Test the transfer switch s automatic control system Test all indicators LEDs and all remote control systems for operation GENERAL EQUIPMENT CONDITION Inspect the outside of the transfer switch for any signs of excessive vibration leakage high temperature contamination or deterioration Check that all external hardware is in place tightened and not badly worn Inspect the inside of transfer switch for any signs of excessive vibration leakage high temperature contamination or deterioration Check that all internal hardware is in place tightened and not badly worn Service more frequently if the transfer switch is operated in dusty or dirty areas See Section Read these sections carefully for additional information before attempting maintenance or service Visually Inspect Examine these items visually Check Requires physical contact with or movement of system components or the use of nonvisual indications Adjust Repair Replace Includes tightening hardware and lubricating the mechanism May require replacement of components depending upon the severity of the problem Clean Remove accumulations of dirt and contaminants from external transfer switch s components or
112. ting MW megawatt mW milliwatt uF microfarad N norm normal power source NA not available not applicable nat gas natural gas NBS National Bureau of Standards NC normally closed NEC National Electrical Code NEMA National Electrical Manufacturers Association NFPA National Fire Protection Association Nm newton meter NO normally open no nos number numbers NPS National Pipe Straight NPSC National Pipe Straight coupling NPT National Standard taper pipe thread per general use NPTF National Pipe Taper Fine NR not required normal relay ns nanosecond OC overcrank OD outside diameter OEM original equipment manufacturer OF overfrequency opt option optional OS oversize overspeed OSHA Occupational Safety and Health Administration OV overvoltage oz ounce TP 6126 8 02 P PP PC PCB pF PF ph PHC PHH PHM PLC PMG pot ppm PROM psi PTC PTO PVC qty rad RAM RDO ref rem RFI RH RHM rly rms rnd ROM rot rpm RS RTV SAE scfm SCR S sec SI SI EO sil SN page pages personal computer printed circuit board picofarad power factor phase Phillips head crimptite screw Phillips hex head screw pan head machine screw programmable logic control permanent magnet generator potentiometer potential parts per million programmable read only memory pounds per square inch pint positive temperature coefficient power takeoff polyvinyl chloride quart quantity replacem
113. tions One or more defective or damaged cells Load test the battery and replace if necessary Neither of the LEDs turn on when the AC power is applied No AC power available at the charger Connect AC power or reset the AC breaker on the main panel Component failure Figure 6 27 Battery Charger Troubleshooting TP 6126 8 02 Return charger to the Service Department Section 6 Accessories 55 6 8 4 Battery Charger Specifications Figure 6 28 lists the battery charger specifications Charging 12 Volts DC min at 6 Amps 24 Volts DC min at 3 Amps Maintaining 13 30 Volts DC at 0 1 Amps Rated AC Voltage 208 VAC AC connector pin 2 240 VAC AC connector pin 4 480 VAC AC connector pin 6 600VAC AC connector pin 9 Current Draw 50 60 Hz 0 7 Amps Maximum Maximum Recommended Battery Size Recharging 150 Amp Hours Maintenance only 300 Amp Hours Physical Dimensions 3 5 in 8 9 cm 6 4 in 16 3 cm 2 1 in 5 3 cm 3 5 lb 1 6 kg Figure 6 28 Battery Charger Specifications 56 Section 6 Accessories TP 6126 8 02 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication A amp ABDC AC A D ADC adj ADV AHWT AISI ALOP alt Al ANSI AO API approx AR AS ASE ASME assy ASTM ATDC ATS auto aux A V avg AVR AWG AWM bat BBDC BC BCA BCI BDC BHP blk blk htr BMEP bps br BTDC Btu Btu
114. transfer switch to protect it from metal chips and construction grit Then drill entry holes for the conductors at the locations shown on the enclosure drawings Remove debris from the enclosure with a vacuum cleaner Do not use compressed air to clean the switch because it can cause debris to lodge in the components and cause damage Install and test the power cables Leave sufficient slack in the power leads to reach all of the power connecting lugs on the power switching device Test the power conductors before connecting them to the transfer switch Installing power cables in conduit cable troughs and ceiling suspended hangers often requires considerable force Pulling cables can damage insulation and stretch or break the conductor s strands 10 Section 2 Installation Test the cables after pulling them into position and before they are connected to verify that they are not defective and that they were not damaged during installation Install the cable spacers provided with 30 200 amp switches as shown in Figure 2 16 On 225 400 amp switches verify that the factory installed insulator backing piece shown in Figure 2 17 is in place behind the contactor 1 Insulator backing piece 2 Contactor Figure 2 17 Insulator for 225 400 Amp Switches TP 6126 8 02 Connect the cables Be careful when stripping insulation from the cables avoid nicking or ringing the conductor Clean cables with a wire brush to remove surface oxides b
115. tteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin A WARNING Explosion Can cause severe injury or death Relays in the battery charger cause arcs or sparks Locate the battery in a well ventilated area Isolate the battery charger from explosive fumes 50 Section 6 Accessories Battery electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or death Battery acid can cause blindness and burn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seek immediate medical aid in the case of eye contact Never add acid to a battery after placing the battery in service as this may result in hazardous spattering of battery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda to a container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting
116. ut starting the generator set if necessary Use the following procedure Exerciser Setting Procedure 1 Move the disable enable exercise DIP switch to the DISABLE position and close the enclosure door The Exercise LED flashes rapidly to indicate that the exerciser is disabled 2 Press and hold the exercise button until the Exercise LED goes out for approximately 3 seconds and then starts to flash again 3 Move the disable enable exercise DIP switch back to the ENABLE position 4 Close and lock the enclosure door 5 Verify that the EXERCISE LED is not flashing The exerciser time is set to the time that the button is pushed The exerciser will run in one or two weeks according to the 1 week 2 week DIP switch position 3 9 Warranty Registration The transfer switch seller must complete a Startup Notification Form and submit it to the manufacturer within 60 days of the initial startup date A Startup Notification Form is included with generator sets and covers all equipment in the standby system Standby systems not registered within 60 days of startup are automatically registered using the manufacturer s ship date as the startup date TP 6126 8 02 4 1 Introduction This section contains descriptions and flowcharts for typical transfer switch operating sequences This section also describes faults and provides other information related to the controller operation On systems not equipped with the preferred source sel
117. voltage Will cause severe injury or death Disconnect all power sources before opening the enclosure 1 Before opening the transfer switch enclosure da TODE MegA disconnect power to the transfer switch by opening 6126 switches or circuit breakers to the transfer switch Figure 6 22 12 Volt Battery Charger Connections 2 Disconnect the AC power cord at the in line connector 3 Remove the black NEGATIVE wire from the the 24VDC 3Amp battery terminal first Configuration 4 Remove the red POSITIVE wire from the battery AGC 10 10 Amp 250V fast blow terminal Output Fuses To DC Pos To DC Neg 6126 Figure 6 23 24 Volt Battery Charger Connections 12 Connect the charger to the battery according to the generator set or battery manufacturer s instructions watching the polarity of the connections 13 Close the enclosure door and reconnect power to the transfer switch after the charger connections are complete 14 Use a voltmeter to check the voltage at the battery and compare the readings to Figure 6 25 or Figure 6 26 to verify charger operation TP 6126 8 02 Section 6 Accessories 53 6 8 2 Battery Charger Operation indicator operation Figure 6 25 and Figure 6 26 show the 3 stage charging charging method for 12 VDC and Red and green LEDs on the charger indicate the charge 24 VDC configurations rate Refer to Figure 6 24 for a description of the LED LED ane p
118. y Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer Prevent the generator set from starting by moving the generator set master switch to the OFF position disconnecting power to the generator engine start battery charger if installed and disconnecting all generator engine start battery cables negative leads first Connect the generator set remote starting circuit to the engine start connections located on the transfer switch contactor assembly The engine start terminals are labeled with a red decal See Figure 2 21 Figure 2 22 and Figure 2 23 for the locations of the engine start contacts Refer to the generator set installation manual for wire size specifications TP 6126 8 02 The generator engine start contacts are rated 2 amps 30 VDC 250 VAC SST NA 16 Do not use 1 Engine start contacts 14 and 15 Figure 2 21 Engine Start Contacts 30 200 Amp Switches Section 2 Installation
119. z Operating correctly No defined program at I O module address Figure 6 18 I O Module Diagnostic LED 6 6 Load Shed Forced Transfer to OFF 6 6 1 Description The load shed forced transfer to off accessory allows the removal of non critical loads from the Source E generator set The accessory requires an external signal contact closure to initiate transfer to the Off TP 6126 8 02 position The load shed forced transfer to off accessory is available only for programmed transition transfer switches When the forced transfer to off input is activated contact closed the contactor moves from Source E to the OFF position immediately ignoring all time delays If the normal source is available when the input is activated the ATS transfers to the Off position and then to Source N executing all programmed time delays If Source N is not available the ATS remains in the Off position until the input is deactivated When the input is deactivated the ATS transfers back to Source N if available executing all programmed time delays If Source N is not available the ATS transfers to Source E The load shed forced transfer to off function only sheds loads connected to Source E The preferred source selector switch position if equipped does not affect this function 6 6 2 Connection On transfer switches with the factory installed load shed accessory the forced transfer to off input is assigned to main

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