Kohler KCS Operation And Installation
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Kohler KCS Operation And Installation

Automatic transfer switches
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Operation and
Installation
Automatic Transfer Switches
Models:
KCS/KCP/KCC
30 to 4000 Amperes
TP-6833 2/16a

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Summary of Contents for Kohler KCS

  • Page 1 Operation and Installation Automatic Transfer Switches Models: KCS/KCP/KCC 30 to 4000 Amperes TP-6833 2/16a...
  • Page 2 Product Identification Information Product identification numbers determine service parts. Controller Identification Record the product identification numbers in the spaces Record the controller description from the generator set below immediately after unpacking the products so that operation manual, spec sheet, or sales invoice. the numbers are readily available for future reference.

  • Page 3: Table Of Contents

    ........... Manual Operation, Model KCS Standard- Transition Switches .
  • Page 4 Table of Contents, continued Section 4 Communication and Accessory Connections ........Introduction .

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions Accidental Starting Hazardous Voltage/ IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, Moving Parts including generator sets, transfer WARNING switches, switchgear, and accessories, can cause bodily harm and pose DANGER life-threatening danger when improperly installed, operated, maintained. To prevent accidents be aware of potential dangers and act safely.
  • Page 6 Notice Servicing transfer switch. Testing live electrical circuits. Hazardous voltage cause Hazardous voltage or current can severe injury or death. Deenergize all cause severe injury or death. Have NOTICE power sources before servicing. Turn trained and qualified personnel take Improper operator handle usage. off the main circuit breakers of all diagnostic measurements...

  • Page 7: Introduction

    Related Materials for the document part number. Specification Sheet, Decision-Makerr G11-127 Information in this publication represents data available MPAC 1200 Controller at the time of print. Kohler Co. reserves the right to Specification Sheet, Decision-Makerr G11-128 MPAC 1500 Controller change this literature and the products represented...

  • Page 8: Service Assistance

    Visit the Kohler Power Systems website at Phone: (86) 21 6288 0500 KOHLERPower.com. Fax: (86) 21 6288 0550 Look at the labels and stickers on your Kohler product India, Bangladesh, Sri Lanka or review the appropriate literature or documents India Regional Office included with the product.

  • Page 9: Section 1 Product Description

    Section 1 Product Description 1.1 Purpose Normal Emergency (Utility) (Generator) An automatic transfer switch (ATS) transfers electrical Power Power Generator loads from a normal (preferred) source of electrical Start Generator power to an emergency (standby) source when the normal source falls outside the acceptable electrical Power Electrical parameters.

  • Page 10: Model Designation

    0400 2000 Decision-Makerr MPAC 1500, Automatic 0104 0600 2600 Decision-Makerr MPAC 1500, Non-Automatic 0150 0800 3000 * Non-automatic controls are available on Models KCS and KCP 0200 1000 4000 only. 0230 1200 Voltage/Frequency Connections 208 Volts / 60 Hz 440 Volts / 60 Hz...

  • Page 11: Section 2 Installation

    Weight kg (lb.) installation. 2-Pole 3-Pole 4-Pole Amps Note: A protective device such as a molded-case circuit Model KCS breaker or fused disconnect switch MUST be 30--200 (62) (65) (68) installed on both sources of incoming power for 52 (115)

  • Page 12: Storage

    2.2.3 Storage Plan the installation. Use the dimensions given on the enclosure dimension (ADV) drawings. Select a Store the transfer switch in its protective packing until mounting site that complies with local electrical code final installation. Protect the transfer switch at all times restrictions for the enclosure type.

  • Page 13: Seismic Certification

    2.4 Seismic Certification accordance with ACI 355.2--04 and documented in a report by a reputable testing agency (for Automatic transfer switches with seismic certification example, the Evaluation Service Report issued by must be installed according to the instructions in this the International Code Council).

  • Page 14: Manual Operation, Model Kcs Standard- Transition Switches

    2.5 Manual Operation, Model KCS 2. Turn the attached handle to manually operate the transfer switch. See Figure 2-3. It should operate Standard- Transition Switches smoothly without any binding. If it does not, check for shipping damage or construction debris.
  • Page 15 Note: If Normal and Emergency connections are reversed, this operation is also reversed. Figure 2-6 Maintenance Handle Positions, 1. Maintenance handle 225--1200 Amp Model KCS 2. Storage clip(s) Figure 2-4 Detachable Handle Storage (typical) TP-6833 2/16 Section 2 Installation...
  • Page 16 OPEN or CLOSED 127a 1. Emergency contact position indicator 3. Slide hub onto shaft 2. Normal contact position indicator 4. Insert maintenance handle until spring is fully compressed Figure 2-8 Manual Operation, 1600--4000 Amp Model KCS Section 2 Installation TP-6833 2/16...

  • Page 17: Manual Operation, Model Kcp Programmed-Transition Switches

    2.6 Manual Operation, Model KCP Programmed-Transition Switches Insert the maintenance Programmed-transition switches have two operators, handle into the hub. Normal and Emergency, on the left side of the contactor assembly. Mechanical interlocks prevent closing both operators at the same time. Refer to Figure 2-9 for typical locations of the Normal and Emergency operators.

  • Page 18: Transition Transfer Switches

    2.6.1 Manual Operation Test Procedure, 4. Return the Emergency operator to the open position and the Normal operator to the closed 150- -1200 Amp Programmed- position. Transition Transfer Switches 5. Remove the maintenance handle and store it in the Refer to Figure 2-10 through Figure 2-12 during the place provided on the switch.
  • Page 19 Transfer Switch Position Interlocked Weights Maintenance Handle Shaft Indicators Weight E : O upper contacts open Lobe Normal Lobe N : C lower contacts closed Weight E : O upper contacts open Load Disconnected N : O lower contacts open Down E : C upper contacts closed...

  • Page 20: Transition Transfer Switches

    2.6.2 Manual Operation Test Procedure, 5. Grasp the handle firmly with both hands and rotate down: 1600- -4000 Amp Programmed- Transition Transfer Switches a. Rotate counterclockwise to open the contacts. Check the operation of both operators by following the b. Rotate clockwise to close the contacts. instructions below for both the Normal and Emergency operators.

  • Page 21: Manual Operation, Model Kcc Closed-Transition Switches

    Manual Operation, Model Position indicators on the right side of the contactor assembly show the positions of the operators. See KCC Closed-Transition Figure 2-14. Switches 2.7.1 Manual Operation Test Procedure, DANGER 150- -1200 Amp Model KCC Refer to Figure 2-14 through Figure 2-16 during the following procedure.
  • Page 22 ATS Position Handle Indicators Insert the maintenance handle into the hub: E = O upper contacts open Normal N = C lower contacts closed E = C upper contacts closed 150--600 Amps 800--1200 Amps Emergency N = O Handle storage location lower contacts open EMERGENCY OPERATOR...

  • Page 23: Manual Operation Procedure, 1600--4000 Amp Model Kcc

    2.7.2 Manual Operation Procedure, 5. Grasp the handle firmly with both hands and rotate down: 1600- -4000 Amp Model KCC a. Rotate counterclockwise to open the contacts. Check the operation of both operators by following the instructions below for both the Normal and Emergency b.

  • Page 24: Controller Connections

    2.8 Controller Connections The controller is mounted in a plastic housing on the inside of the transfer switch enclosure door. DANGER Figure 2-18 shows the locations of the connectors on the controller. It is not necessary to open the cover to access the Ethernet, Modbusr, and input/output connectors.

  • Page 25: Controller Input And Output Connections

    2.8.1 Controller Input and Output 2.8.2 Harness Connection Connections Verify that the contactor harness is connected at the controller base (or at the controller disconnect switch, if controller provides connections equipped). See Figure 2-21. programmable inputs and two programmable outputs. See Figure 2-18 for the connector location and Note: Verify that the power is disconnected before Figure 2-19 for the I/O connection specifications.

  • Page 26: Electrical Wiring

    2.9 Electrical Wiring DANGER 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. Hazardous voltage. Note: A protective device such as a molded-case circuit Will cause severe injury or death. breaker or fused disconnect switch MUST be Disconnect all power sources before installed on both sources of incoming power for...
  • Page 27 Install and test the power cables. Leave sufficient Tighten the lugs. Verify that all connections are slack in the power leads to reach all of the power consistent with drawings before tightening the lugs. connecting lugs on the power switching device. Test the Tighten all cable lug connections to the torque values power conductors before connecting them to the shown on the label on the switch.

  • Page 28: Extended Transfer Time Relay (Model Kcc Only)

    2.9.2 Extended Transfer Time Relay Relay with Time Adjustment Knob (Model KCC only) This section applies to the relay equipped with an adjustment knob, shown in Figure 2-26. Relay The extended transfer time relay is standard on specifications are shown in Figure 2-27. closed-transition transfer switches.
  • Page 29 Relays with Time Adjustment Switches Relay 12VDC 24VDC Input Power This section applies to relays equipped with switches for 12 VDC 24 VDC (customer-supplied) time adjustment, shown in Figure 2-29. Relay specifications are shown in Figure 2-30. Relay Marking A1M-0999M-466 A1M-0999M-462 Output Type Relay contacts, DPDT (2 form C) A three-digit time selection switch and a range selection...

  • Page 30: Engine Start Connection

    2.9.3 Engine Start Connection WARNING Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working generator set. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery. Disabling the generator set.

  • Page 31: Auxiliary Contacts

    2.9.4 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. Refer to the wiring diagrams provided with the transfer switch for auxiliary contact connection information.

  • Page 32: Communication And Accessory Connections

    2.10 Communication and Accessory Connections See Section 4 for accessory and communication connection instructions. 2.11 Functional Tests After completion of the mechanical installation and all electrical connections, perform the functional tests described in Section 5. The procedures in Section 5 are required to complete the installation and startup of the transfer switch.

  • Page 33: Section 3 Three-Source Systems

    Section 3 Three-Source Systems Three-Source Systems 3.3 Preferred Source Toggle The Decision-Makerr MPAC 1500 controller is required The preferred source toggle function alternates for three-source systems. between the two generator sets each time the three-source function is activated. If G1 is the preferred A three-source system provides the means to connect a source during the first run, then G2 will be preferred utility and two generators to a single load.

  • Page 34: Three-Source System Connection

    3.5 Three-Source System commands for generator sets 1 and 2. Observe the polarity of all connections shown in Figure 3-2. Connection Use wire sizes from #14 AWG to #20 AWG for EBSM and I/O module connections. DANGER a. Connect the ATS2 engine start contacts to the engine start circuit on generator set 2 (G2).
  • Page 35 SINGLE LINE DIAGRAM ATS2 ATS1 ENGINE START TO G2 NOTE: THE CLOSED IN EMERGENCY AUXILLIARY ENGINE START CONTACT THAT IS USED IN THE ENGINE START CIRCUIT OF THE ATS MUST BE REMOVED FROM THE CIRCUIT WHEN USED WITH THIS THREE SOURCE CONTROL SCHEME. REFERENCE ATS WIRING DIAGRAM FOR CONNECTIONS.

  • Page 36: Ats1 And Ats2 System Setup

    ATS1 3 Source System Disable Connect Output 1 terminals TB1-5 and TB1-6 on ATS 1 to Input 1 terminals TB1-1 and TB1-2 on ATS2. Assign ATS 1 main logic board output 1 to 3 Source System ATS1 TB1 Disable. on logic board Assign ATS2 main logic board ATS2 input 1 to 3 Source System...

  • Page 37: Section 4 Communication And Accessory Connections

    Section 4 Communication and Accessory Connections 4.1 Introduction 4.2.2 Modbus Connection This section explains the connection of communication DANGER cables and factory-installed accessories. Also refer to the following documentation for instructions to install, connect, and operate optional accessories. Transfer switch wiring diagrams. Hazardous voltage.
  • Page 38 Use Modbus RTU (remote terminal unit) protocol for communication through the serial port. A map of the Modbus codes for this controller is available. Contact RS-485 * USB port your local distributor/dealer. USB to RS-485 port Device Note: Modbusr applications require Modbus converter...

  • Page 39: Ethernet Connection

    USB port and before servicing. Turn off the main circuit breakers of all Kohler SiteTech software to set the communication transfer switch power sources and disable all generator sets parameters. The Ethernet communication board may...
  • Page 40 Ethernet MPAC Modbusr TCP/IP Modbusr TCP/IP Network Controller with Category 5e Category 5e Ethernet comm. board IP xx.xx.xx.03 Note: The PC and the ATS must be on the same subnet. IP xx.xx.xx.02 Note: A crossover cable can be used to connect the PC to the ATS controller through the Ethernet port.

  • Page 41: Accessory Modules

    Accessory Modules 4.3.1 Accessory Module Mounting Mount the accessory modules on the module mounting DANGER plate. Starting at the end of the module mounting assembly nearest the cable connection, install any I/O modules first, then install the alarm board, if used. The external battery module, if used, must be the last module.

  • Page 42: Input/Output (I/O) Modules

    4.3.2 Input/Output (I/O) Modules Two types of input/output modules are available. The standard I/O Module has two inputs and six outputs. The high-power I/O module has two inputs and three outputs. See Figure 4-10 through Figure 4-13 for I/O module illustrations and specifications. GM42186 1.

  • Page 43: External Battery Supply Module (Ebsm)

    4.3.3 External Battery Supply Module Use 14-24 AWG cable to connect to inputs and outputs. See Figure 4-14. (EBSM) LEDs on the module circuit board light to indicate that The external battery supply module kit allows each input or output is active. connection to the generator set engine start battery(ies) or other batteries to provide 12 VDC power to the ATS Note: Each I/O module must have unique address.

  • Page 44: Alarm Module

    4.3.4 Alarm Module The EBSM produces 2 amps at 12 VDC with 9--36 VDC input. The EBSM input is reverse-polarity protected. See Figure 4-18 for the optional alarm module. The EBSM outputs a low battery voltage signal when the module mounting kit is required for installation of the external battery voltage falls below 11 VDC for a 12-volt alarm module.
  • Page 45 Alarm Board DIP Switches Alarm Operation, Chicago Alarm Mode There are four DIP switches on the alarm module board. Chicago Alarm mode requires the horn to sound and a Some of the switches are not used. See Figure 4-19. To lamp or LED to light when the switch is in the emergency enable the preferred source selection, set DIP switch 1 (non-preferred) position.

  • Page 46: Load Shed (Forced Transfer To Off)

    Figure 4-23. Use #12--24 AWG wire and tighten to 0.5 Nm (4.4 in. lb.). DANGER Use the Input/Output setup menu or Kohler SiteTech software to assign the connected input (Main Board Input #1 or #2) to the forced transfer to off function. If the...
  • Page 47 MLB Input 2 (alternate connection) Input 1 #12--24 AWG wire 0.5 Nm (4.4 in. lb.) GM89713 MPAC Controller Circuit Board 1. Input/output terminal strip TB1 Figure 4-23 Forced Transfer to Off Input Connection (for factory-installed load shed kits) TP-6833 2/16 Section 4 Communication and Accessory Connections...

  • Page 48: Heater

    35% to 95%. A setting of 65% is recommended. Because of space limitations in the smaller enclosures, 30--200 Amp Model KCS switches can include either an enclosure heater or a surge protection device (SPD), GM71056 but not both.

  • Page 49: Other Accessories

    4.6 Other Accessories Refer to the following documentation for instructions to HYGROSTAT install, connect, and operate optional accessories. Transfer switch wiring diagrams. Installation instructions provided with loose accessory kits. CIRCUIT BREAKER Controller Operation Manual. See List of Related materials in the Introduction section of this manual for document numbers.
  • Page 50 Notes Section 4 Communication and Accessory Connections TP-6833 2/16...

  • Page 51: Section 5 Functional Tests And Setup

    Section 5 Functional Tests and Setup 5.1 Introduction 5.3 Voltage Check The voltage, frequency, and phasing of the transfer Be sure to perform all of the functional tests described in switch and the power sources must be the same to avoid this section before putting the transfer switch into damage to loads and the transfer switch.

  • Page 52: Lamp Test

    4. Use a phase rotation meter to check the phase DANGER 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 controller is ABC.

  • Page 53: System Setup

    5.6 System Setup User Interface Cover Set the controller’s current time and date. See the The gasket-sealed, hinged user interface cover controller Operation Manual for instructions. prevents unauthorized access to the transfer switch controls and protects the user interface from harsh The transfer switch is factory-set with default settings for environmental conditions.
  • Page 54 Notes Section 5 Functional Tests and Setup TP-6833 2/16...

  • Page 55: Appendix A Abbreviations

    (2 bytes) est. estimated Canadian Electrical Code KBus Kohler communication protocol E-Stop emergency stop cert. certificate, certification, certified kilogram etc. et cetera (and so forth) cubic feet per hour TP-6833 2/16 Appendix 55...
  • Page 56 kg/cm kilograms per square National Bureau of Standards remote terminal unit centimeter normally closed room temperature vulcanization kilogram-meter National Electrical Code read/write kg/m kilograms per cubic meter NEMA National Electrical Society of Automotive kilohertz Manufacturers Association Engineers kilojoule NFPA National Fire Protection scfm standard cubic feet per minute Association...
  • Page 57 Notes TP-6833 2/16...
  • Page 58 Notes TP-6833 2/16...
  • Page 60 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KOHLERPower.com Kohler Power Systems Asia Pacific Headquarters TP-6833 2/16a 7 Jurong Pier Road Singapore 619159 E 2014, 2016 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455...

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