Kohler ZCS series Operation And Installation
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Kohler ZCS series Operation And Installation

Kohler ZCS series Operation And Installation

Automatic transfer switches contactors: 40 to 3000 amperes
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Operation and
Installation
Automatic Transfer Switches
Models:
ZCS
Contactors:
40 to 3000 Amperes
TP-5660 11/98

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Summary of Contents for Kohler ZCS series

  • Page 1 Operation and Installation Automatic Transfer Switches Models: Contactors: 40 to 3000 Amperes TP-5660 11/98...

  • Page 2: Table Of Contents

    Table of Contents Safety Precautions and Instructions ..Section 4. Scheduled Maintenance ..Inspection and Service ..... . . Introduction .

  • Page 3: Safety Precautions And Instructions

    Safety Precautions and Instructions Accidental Starting Battery A transfer switch, like any other electromechanical device, can pose potential dangers to life and limb if WARNING WARNING improperly maintained or operated. The best way to prevent accidents is to be aware of potential dangers and act safely.
  • Page 4 Hazardous Voltage/ WARNING WARNING Electrical Shock WARNING Hazardous voltage. Moving rotor. Explosion. Can cause severe injury or death. Can cause severe injury or death. Relays in battery charger cause Operate generator set only with all arcs or sparks. Hazardous voltage. guards and electrical enclosures in Can cause severe injury or death.
  • Page 5 Heavy Equipment Installing accessories Servicing transfer switch controls transformer assembly. Hazardous accessories within WARNING voltage can cause severe injury or enclosure. Hazardous voltage can death. To prevent the possibility of cause severe injury death. electrical shock, disconnect harness Disconnect transfer switch controls at plug before installing any accessories the inline connector to deenergize the involving connection to transformer...

  • Page 6: Moving Parts

    Moving Parts Notice NOTICE WARNING Hardware damage! Transfer switch may use both American Standard and metric hardware. Use the correct size tools to prevent rounding of bolt heads and nuts. Hazardous voltage. Moving rotor. Can cause severe injury or death. NOTICE When replacing hardware, do not Operate generator set only with all...

  • Page 7: Introduction

    Operation/ All information in this publication represents data Installation available at time of print. Kohler Co. reserves the right to Manual Electrical Controls change this literature and the products represented E33+ (Solid State) TP-5662 without incurring obligation.

  • Page 8: Service Assistance

    Service Assistance Service Information Product Identification For sales, service, or other information about a Kohler To ensure the supply of correct parts and information, Generator Division product, contact a local authorized write the product identification numbers in the spaces distributor or dealer first.

  • Page 9: Section 1. Specifications

    Section 1. Specifications 1.1 Purpose An automatic transfer switch (ATS) transfers critical electrical loads from a normal (preferred) source of electrical power to an emergency (standby) source when the normal source fails to maintain minimum voltage and/or frequency levels. Upon normal source failure, the ATS signals the generator set to start.

  • Page 10: Nameplate

    1.3 Nameplate A nameplate providing characteristic and rating information that affects operation, installation, and AUTOMATIC TRANSFER SWITCH servicing is attached to the inside of the transfer switch PART NO. enclosure door. See Figure 1-3. SERIAL NO. Copy the part number into the blank spaces provided in VOLTS AMPS PHASE...

  • Page 11: Part Number Model Code

    Kohler Part Number Key SAMPLE PART NUMBER This chart explains the Kohler transfer switch part numbering code system. The sample part number shown is for a standard contactor power switch with M340+ logic rated at 600 volts, 60 hertz, 3-phase, 3-pole, and 4 wires in a ZCS-560341-1000 NEMA Type 1 enclosure with a contactor rating of 1000 amperes.

  • Page 12: Standard Features

    1.5 Standard Features D Two-pole, three-pole and four-pole D Four-pole— fully rated The standard features listed here are for the ZCS D Can be operated manually when unpowered contactor power switching device. Refer to the logic controller operation and installation manual for D Two normally open (N.O.) and two normally closed controller specifications.
  • Page 13 Molded-case Circuit Breakers Fuses WCR, RMS Maximum WCR, RMS Maximum Switch Symmetrical Size Symmetrical Size Rating Type or Amperes (amps) Amperes (amps) (amps) Manufacturer Type or Class Class 40, 80, 40, 80, J, RK5, J, RK5, 22,000 22,000 Any, 150 Amperes Maximum Any, 150 Amperes Maximum 200,000 200,000...
  • Page 14 Molded-case Circuit Breakers Fuses WCR, RMS Maximum WCR, RMS Maximum Switch Symmetrical Size Symmetrical Size Type or Rating Amperes (amps) Amperes (amps) Manufacturer Type or Class Class (amps) 40, 80, 40, 80, J, RK5, J, RK5, 18,000 18,000 Any, 150 Amperes Maximum Any, 150 Amperes Maximum 150,000 150,000...

  • Page 15: Application Data

    1.7 Application Data See Figure 1-8 for application data including the range of wire sizes for the transfer switch’ s power terminals. AL/CU UL-listed Solderless Screw-type Terminals for External Power Connections Switch Switch Normal, Emergency, and Load Terminals Normal, Emergency, and Load Terminals Size Size Size...
  • Page 16 Notes 8 Specifications TP-5660 11/98...

  • Page 17: Section 2. Operation

    Section 2. Operation Follow the following steps to power up the transfer WARNING switch and prepare it for automatic operation. Powerup Procedure 1. Move the generator set master switch to the OFF position to prevent the generator set from starting. Hazardous voltage.

  • Page 18: Failure Of Normal Power

    2.2.2 Restoration of Normal Power transfer switch logic controller circuitry, programming, or accessories determine when a power After normal power source restoration, the controller source is acceptable, has failed, or has been restored starts a time delay called Time Delay Emergency to and operates accordingly.

  • Page 19: Manual Operation

    2.3 Manual Operation WARNING To test or troubleshoot the transfer switch, or when the controller fails in an emergency situation, manually operate the power switching device as described below. Hazardous voltage. WARNING Can cause severe injury or death. Disconnect power sources before servicing.

  • Page 20: Programmed Transition Switch

    2.3.1 Programmed Transition Switch, 5. Attach the manual operating handle to the switch lever. 40--260 Amps 6. If the handle is not in the middle (off) position, move Manual Operation Procedure the handle up or down to bring it into the middle (off) 1.

  • Page 21: Programmed Transition Switch

    2.3.2 Programmed Transition Switch, 5. Attach the manual operator handle to the normal switch lever and move it up to the normal position to 400--3000 Amps manually connect the load to the normal source Manual Operation Procedure and move it down to disconnect. The switch should operate smoothly in both directions without 1.

  • Page 22: Standard Switch, 800--3000 Amps

    2.3.3 Standard Switch, 800--3000 Amps 5. Attach the manual operating handle to the switch lever. Manual Operation Procedure 6. Move the handle up to the normal position to 1. Prevent the generator set, which provides the connect the load to the normal source or down to emergency power source to the transfer switch, the emergency position to connect the load to the from starting by moving the generator set master...

  • Page 23: Section 3. Accessories

    Section 3. Accessories 3.1 Programmed Transition Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or connected equipment, disable the generator NOTE set as follows: 1) Move the generator set master switch to the OFF position.

  • Page 24: Other Accessories

    DANGER NOTE When initially applying power to the transfer switch, the engine start contacts remain closed signalling the generator to run until the ATS’ s Time Delay Engine Cooldown (TDEC), if equipped, ends. Hazardous voltage. Will cause severe injury or death. Disconnect power sources before 8.

  • Page 25: Section 4. Scheduled Maintenance

    Section 4. Scheduled Maintenance Scheduled preventive maintenance ensures safe and WARNING reliable operation and extends the life of the transfer switch. Preventive maintenance includes periodic testing, cleaning, inspection, and replacement of worn or missing components. A local authorized distributor or dealer (authorized Accidental starting.

  • Page 26: Inspection And Service

    Servicing the transfer switch. Hazardous voltage can WARNING cause severe injury or death. Deenergize all power sources before servicing. Open main circuit breakers of all power sources to the transfer switch and disable all generator sets as follows: 1) Move all generator set master controller switches to the OFF position.

  • Page 27: General Inspection

    4.1.1 General Inspection 4.1.2 Other Inspections and Service External Inspection Keep the transfer switch clean Have an authorized service center perform scheduled and in good condition by performing a weekly general maintenance, service, and other maintenance that external inspection of the transfer switch for any ensures the safe and reliable operation of the transfer condition of vibration, leakage, noise, temperature, switch including annual inspection and testing.

  • Page 28: Service Schedule

    4.3 Service Schedule Follow the service schedule below for the recommended service intervals. Have all service performed by an authorized service center except for activities limited to the items designated by an X. Visually System Component or Procedure Frequency Section Inspect Check Change...

  • Page 29: Section 5. Diagrams And Drawings

    Section 5. Diagrams and Drawings Diagram or Drawing Drawing Number Page Enclosure Dimensions Drawings 40--260 Amp, NEMA Type 1 and Type 3R ....... . . ADV-6180- 400 Amp, NEMA Type 1 and Type 3R .
  • Page 30 Notes 22 Diagrams and Drawings TP-5660 11/98...
  • Page 31 ADV-6180- Enclosure Dimensions Drawing, 40--260 Amp, NEMA Type 1 and Type 3R TP-5660 11/98 Diagrams and Drawings 23...
  • Page 32 ADV-5934-C Enclosure Dimensions Drawing, 400 Amp, NEMA Type 1 and Type 3R 24 Diagrams and Drawings TP-5660 11/98...
  • Page 33 ADV-5936A-F Enclosure Dimensions Drawing, 600--1200 Amp, NEMA Type 1 and Type 3R TP-5660 11/98 Diagrams and Drawings 25...
  • Page 34 ADV-5936B-B Enclosure Dimensions Drawing, 600--1200 Amp, NEMA Type 12 26 Diagrams and Drawings TP-5660 11/98...
  • Page 35 ADV-5941-E Enclosure Dimensions Drawing, 1600--2000 Amp, NEMA Type 1 TP-5660 11/98 Diagrams and Drawings 27...
  • Page 36 ADV-5990-A Enclosure Dimensions Drawing, 1600--2000 Amp, NEMA Type 3R, E33+ and S340+ Logic 28 Diagrams and Drawings TP-5660 11/98...
  • Page 37 ADV-5989-A Enclosure Dimensions Drawing, 1600--2000 Amp, NEMA Type 3R, M340+ Logic TP-5660 11/98 Diagrams and Drawings 29...
  • Page 38 ADV-6242-B Enclosure Dimensions Drawing, 2500--3000 Amp, NEMA Type 1 30 Diagrams and Drawings TP-5660 11/98...
  • Page 39 ADV-6241-A Enclosure Dimensions Drawing, 2500--3000 Amp, NEMA Type 3R, E33+ and S340+ Logic TP-5660 11/98 Diagrams and Drawings 31...
  • Page 40 ADV-6240-A Enclosure Dimensions Drawing, 2500--3000 Amp, NEMA Type 3R, M340+ Logic 32 Diagrams and Drawings TP-5660 11/98...
  • Page 41 TO LOAD FROM NORMAL FROM EMERGENCY SOURCE SOURCE MECHANISM P1--10 P1--9 P1--23 P1--24 P1--34 P1--35 P1--36 INNER NORMAL EMERG. PANEL AUXILIARY CONTACTS P1--18 P1--3 15A, 240VAC SN--1 A4--1 A4--1 A4--1 P1--22 P1--8 SN--2 NA NC A4--2 A4--2 A4--2 SE--1 A3--1 A3--1 A3--1 A3--2...
  • Page 42 TO LOAD FROM NORMAL FROM EMERGENCY SOURCE SOURCE MECHANISM P1--10 P1--9 P1--23 P1--24 P1--34 P1--35 P1--36 NORMAL EMERG. 307R 209R SN--1 INNER AUXILIARY CONTACTS PANEL 15A, 240VAC P1--18 P1--3 A4--1 SN--2 A4--1 A4--1 P1--8 P1--22 SE--1 A4--2 NA NC 206R 306R A4--2 A4--2...
  • Page 43 TO LOAD FROM EMERGENCY FROM NORMAL SOURCE SOURCE P1--10 P1--9 P1--8 P1--22 P1--23 P1--24 MECHANISM AUXILIARY CONTACTS 15A, 240VAC P1--35 P1--36 P1--34 A4--1 P1--18 CN/0 A4--1 A4--1 400R A4--2 SCNO P1--33 P1--2 INNER A4--2 A4--2 PANEL A3--1 401R A3--1 A3--1 A3--2 SCEO P1--17...
  • Page 44 TO LOAD FROM EMERGENCY FROM NORMAL SOURCE SOURCE MECHANISM P1--10 P1--9 P1--23 P1--24 P1--35 P1--36 P1--34 NORMAL EMERG. INNER 206R 306R PANEL SN--1 P1--18 P1--3 AUXILIARY CONTACTS P1--8 AC RE 15A, 240VAC P1--22 SN--2 208R 307R A4--1 A4--1 A4--1 TO T3 SE--1 NA NC 406R...
  • Page 45 321096-C Schematic Diagram, S340+ Logic, 600--1200 Amp TP-5660 11/98 Diagrams and Drawings 37...
  • Page 46 321097-A Schematic Diagram, S340+ Logic, 1600--3000 Amp 38 Scheduled Maintenance TP-5660 11/98...
  • Page 47 346311- Schematic Diagram, S340+ Logic, 120 VAC, 40--260 Amp with Programmed Transition TP-5660 11/98 Diagrams and Drawings 39...
  • Page 48 353185- Schematic Diagram, S340+ Logic, 208 VAC, 40--260 Amp with Programmed Transition 40 Scheduled Maintenance TP-5660 11/98...
  • Page 49 353184- Schematic Diagram, S340+ Logic, 240 and 480 VAC, 40--260 Amp with Programmed Transition TP-5660 11/98 Diagrams and Drawings 41...
  • Page 50 353183- Schematic Diagram, S340+ Logic, 380 and 416 VAC, 40--260, Amp with Programmed Transition 42 Scheduled Maintenance TP-5660 11/98...
  • Page 51 353182- Schematic Diagram, S340+ Logic, 600 VAC, 40--260 Amp with Programmed Transition TP-5660 11/98 Diagrams and Drawings 43...
  • Page 52 321098-B Schematic Diagram, S340+ Logic, 400 Amp with Programmed Transition 44 Scheduled Maintenance TP-5660 11/98...
  • Page 53 321099-B Schematic Diagram, S340+ Logic, 600--3000 Amp with Programmed Transition TP-5660 11/98 Diagrams and Drawings 45...
  • Page 54 321287-C Schematic Diagram, M340+ Logic 600--1200 Amp 46 Diagrams and Drawings TP-5660 11/98...
  • Page 55 321301-B Schematic Diagram, M340+ Logic, 1600--3000 Amp TP-5660 11/98 Diagrams and Drawings 47...
  • Page 56 346312- Schematic Diagram, M340+ Logic, 120 VAC, 40--260 Amp with Programmed Transition 48 Diagrams and Drawings TP-5660 11/98...
  • Page 57 353174- Schematic Diagram, M340+ Logic, 208 VAC, 40--260 Amp with Programmed Transition TP-5660 11/98 Diagrams and Drawings 49...
  • Page 58 353175- Schematic Diagram, M340+ Logic, 240 and 480 VAC, 40--260 Amp with Programmed Transition 50 Diagrams and Drawings TP-5660 11/98...
  • Page 59 353176- Schematic Diagram, M340+ Logic, 380 and 416 VAC, 40--260 Amp with Programmed Transition TP-5660 11/98 Diagrams and Drawings 51...
  • Page 60 353177- Schematic Diagram, M340+ Logic, 600 VAC, 40--260 Amp with Programmed Transition 52 Diagrams and Drawings TP-5660 11/98...
  • Page 61 321300-B Schematic Diagram, M340+ Logic, 400 Amp with Programmed Transition TP-5660 11/98 Diagrams and Drawings 53...
  • Page 62 321286-A Schematic Diagram, M340+ Logic, 600--3000 Amp with Programmed Transition 54 Diagrams and Drawings TP-5660 11/98...

  • Page 63: Section 6. Installation

    Section 6. Installation Kohler automatic transfer switches are shipped factory See Figure 6-1 for the approximate weight of each wired and tested, ready for installation. Installation of transfer switch covered in this manual. Use a spreader the switch consists of the following.

  • Page 64: Unpacking

    6.1.3 Unpacking such as a wall. When mounting these units either way, plumb the enclosure to ensure that the door hinges are Unpack the transfer switch immediately after receipt vertical to avoid any distortion of the enclosure or door. and inspect for shipping damage. Failure to perform an For floor mounting, bolt the mounting feet to the floor immediate inspection impedes recovery of losses and shim the mounting feet as needed to plumb the...
  • Page 65 Disabling the generator set. Accidental starting can DANGER 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 power to the battery charger. 3) Remove battery cables, negative (--) lead first.

  • Page 66: Ac Power Connections

    Installing accessories transformer assembly. compressed air to clean the switch because it can cause Hazardous voltage can cause severe injury or death. To debris to lodge in the components and cause damage. prevent the possibility of electrical shock, disconnect harness Use watertight conduit hubs approved for outdoor use plug before installing any accessories which will be connected for installing the transfer switch outdoors.

  • Page 67: Generator Start Connection

    position; disconnecting power to the generator engine Torque Socket Size Socket Size start battery charger, if installed; and disconnecting all Across Flat Across Flat in. lbs. ft. lbs. generator engine start battery cables, negative (--) leads first. 5/32 11.3 3/16 13.6 Connect the generator set remote starting circuit to the 7/32...

  • Page 68: Functional Tests

    cables, negative (--) leads last; and reconnect power to 3. Move the generator set master switch to the OFF position to inhibit generator set starting. the generator engine start battery chargers, if installed. 4. Manually transfer the load to the emergency 6.6 Functional Tests source.

  • Page 69: Automatic Operation Test

    6.6.2 Automatic Operation Test 12. Follow generator manufacturer’ s instructions to adjust the generator output voltage Test the transfer switch’ s automatic control system. See and frequency to match the nominal system the logic controller operation and installation manual for voltage and frequency shown on the transfer the test procedure.
  • Page 70 Notes 62 Installation TP-5660 11/98...

  • Page 71: Appendix A. Glossary Of Abbreviations

    Appendix A. Glossary of Abbreviations Abbreviations are used throughout this manual. Normally in the text they will appear in complete form with the abbreviation following in parenthesis the first time they are used. After that they will appear in the abbreviated form. The commonly used abbreviations are shown below.
  • Page 72 Fax 920-459-1646 (U.S.A. Sales), Fax 920-459-1614 (International) For the nearest sales and service outlet in U.S.A. and Canada Phone 1-800-544-2444 KohlerrPower Systems Asia Pacific Headquarters TP-5660 11/98 7 Jurong Pier Road Singapore 619159 Phone (65)264-6422, Fax (65)264-6455 E Kohler Co.1994, 1997, 1998. All rights reserved.

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