Automatic transfer switches, power switching device: standard, open-transition 30 to 4000 amps, programmed-transition 150 to 4000 amps, electrical controls
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.
Safety Precautions and Instructions IMPORTANT SAFETY Safety decals affixed to the equipment Battery in prominent places alert the operator INSTRUCTIONS. Electromechanical or service technician to potential equipment, including generator sets, hazards and explain how to act safely. WARNING transfer switches, switchgear, and The decals are shown throughout this accessories, can cause bodily harm publication...
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Battery electrolyte is a diluted Battery short circuits. Explosion DANGER sulfuric acid. Battery acid can cause can cause severe injury or death. severe injury or death. Battery acid Short circuits can cause bodily injury can cause blindness and burn skin. and/or equipment damage.
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Installing battery charger. Servicing transfer switch. Testing live electrical circuits. Hazardous voltage cause Hazardous voltage cause Hazardous voltage or current can severe injury death. severe injury or death. Deenergize all cause severe injury or death. Have ungrounded battery charger may power sources before servicing.
Moving Parts Notice NOTICE Foreign material contamination. NOTICE Cover the transfer switch during WARNING installation to keep dirt, grit, metal drill Hardware damage. The transfer chips, and other debris out of the switch both American components. Cover the solenoid Standard and metric hardware. Use mechanism during installation.
Information in this publication represents data available transfer switch model number from the transfer switch at the time of print. Kohler Co. reserves the right to nameplate and verify that the it matches the model change this literature and the products represented...
Visit the Kohler Power Systems website at Phone: (86) 21 6288 0500 KohlerPowerSystems.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...
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.
1.3 Model Code Record the transfer switch model designation in the boxes below. The transfer switch model designation defines characteristics and ratings as explained in the accompanying chart. Model Mechanism Transition Controls Voltage Poles Enclosure Current Rating Connections Kohlerr r r r Model Designation Key SAMPLE MODEL DESIGNATION This chart explains the Kohlerr transfer switch model designation system.
Section 2 Installation 2.1 Introduction 2.2.2 Lifting Kohlerr transfer switches are shipped factory-wired, WARNING 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: Unbalanced weight.
For 600--800 amp transfer switches, remove the lag Weight kg (lb.) screws that secure the transfer switch to the shipping 2-Pole 3-Pole 4-Pole Amps skid. For 1000--4000 amp transfer switches, open the 30--200 (17) (20) (23) enclosure door to remove the lag screws that secure the 225--400 (37) (45)
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.
2.4.2 Manual Operation, 225- -4000 Amp Open-Transition Switches DANGER Hazardous voltage. Will cause severe injury or death. Disconnect all power sources before opening the enclosure. The 225--4000 amp open-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.
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.
2.5 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. Will cause severe injury or death. Note: Do not connect the wiring harness to the controller until instructed to do so in the voltage Disconnect all power sources before check procedure, Section 3.7.2.
2.5.1 AC Power Connections Test the cables after pulling them into position and before they are connected to verify that they are not Determine the cable size. Refer to the table in defective and that they were not damaged during Figure 2-15 to determine the cable size and number of installation.
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Connect the cables. Be careful when stripping SUITABLE FOR CONTROL OF MOTORS, ELEC insulation from the cables; avoid nicking or ringing the DISCHARGE AND TUNGSTEN LAMPS, ELEC HEAT-- ING EQPT, WHERE THE SUM OF MOTOR FULL-- conductor. Clean cables with a wire brush to remove LOAD AMPS AND AMPS OF OTHER LOADS DOES NOT EXCEED THE SWITCH AMP RATING AND THE TUNGSTEN LOAD DOES NOT EXCEED...
2.5.2 Engine Start Connection The generator engine start contacts are rated 2 amps @ 30 VDC/250 VAC. 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.
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GM21298 GM21311 1. Typical terminal block location 2. Decal 3. Engine start contacts 1 and 2 1. Engine start contacts 14 and 15 4. Auxiliary contacts 4--27 (see the schematic diagram for 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...
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.
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.
Section 3 Setup and Test 3.1 Introduction voltage and frequency pickup and dropout, and other system parameters. To view and change the system This section explains the setup and test of the transfer settings, personal computer running switch. Follow the instructions in this section after MPAC-1000t Setup Program is required.
LED Illumination Steady Slow Flash Rapid Flash LED Indicator Color Exercise Amber Unloaded exercise is Loaded exercise is When exercise button is pressed and running. running. held, rapid flashing indicates the exercise has been started and set. Rapid flashing at any other time indicates that the exerciser is inhibited by the DIP switch setting.
3.3 Controller Main Logic Board DANGER 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.
3.3.1 Main Logic Board DIP Switch two live sources. When the output is activated, the contact opens for the programmed length of time before Settings transfer (default setting=3 seconds) to allow controlled DIP switches on the main logic board control the test and disconnection of selected loads.
Tighten the connections to 0.5 Nm Other Inputs and Outputs. Other input and output (4.4 in. lbs.). functions can be assigned to the programmable TB1 Note: Contact Kohler Co. for information about terminals. Refer to Section 6 for lists of available Modbusr communication protocol.
3.4 Programmed-Transition 3.5 System Settings and Time Interface Board (PTIB) Delays The system can be operated using the factory settings Programmed-transition model transfer switches use a listed in the following sections. programmed-transition contactor programmed-transition interface board (PTIB). Use the Setup Program to change the controller time PTIB is mounted on the inside of the enclosure door.
3.5.2 Time Delays 3.7 Functional Test The factory settings for the time delays are shown in The functional test includes three checks: Figure 3-13. Manual Operation Test Voltage Checks The pre-transfer time delays operate only when both sources are available. These delays allow time to Automatic Operation Test disconnect selected loads before transfer.
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Note: Source N is the source connected to the normal 6. Use a voltmeter to check the Source N (normal) side of the contactor. Source E is the source phase-to-phase phase-to-neutral connected to the emergency side of the applicable) terminal voltages and frequency. contactor.
16. Reconnect both power sources by closing the Automatic Operation Test Procedure circuit breakers or switches. 1. Check the controller LED indicators to verify that 17. Move the generator set master switch to the AUTO the Position N and Source N Available indicators position.
Note: The generator set may have an engine The exerciser can be set without starting the generator cooldown time delay that causes the set, if necessary. Use the following procedure. generator set engine to run after the transfer switch engine start signal is removed. Exerciser Setting Procedure This completes the functional test.
Section 4 Operation 4.1 Introduction alternate source. The system considers a phase lost if its phase is 45 degrees from the rotation setting. The This section contains descriptions and flowcharts for controller logs loss of phase events in the event history. typical transfer switch operating sequences.
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Normal (preferred) power source returns 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) Time delay off-to-preferred (programmed-transition only) Transfer to normal (preferred) source Post-transfer load control (as programmed*) Time delay engine cooldown (TDEC) (as programmed*) Engine start signal removed...
4.2.2 System Test When the standby source is available and the time delay preferred-to-standby expires, the ATS transfers the load A system test simulates a preferred source failure and if the test DIP switch is set for a loaded test. performs the transfer sequence.
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Test started Time delay engine start (TDES) Test ended Generator set engine start contacts close Standby-to-preferred time delay Pre-transfer load control (as programmed*) Pre-transfer load control (as programmed*) Preferred-to-standby time delay In-phase monitor or transfer to off (as programmed*) In-phase monitor or transfer to off (as programmed*) Transfer to preferred source Transfer to standby source...
4.2.3 Exerciser Exercise Mode. The exerciser is factory-set to operate in switch input mode, which uses the Exercise button on Activate the exerciser after ATS installation by pressing the user interface to start, stop, and set the exerciser, and holding the exercise button until the exercise LED and the 1 week/2 week DIP switch to determine the flashes quickly.
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Load Bank Control. The load bank control output can Exercise button pressed or scheduled be used to apply a load to the generator set during the exercise signaled to begin exercise. The load bank control output provides a contact closure that can be used to signal the load bank controller to operate.
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LED Indicators Load Exercise Available Position Position Available Position Control (flashing) Loaded Exercise Preferred-to-Standby Time Delay Pre-Transfer to Standby Load Control Off-to-Standby Time Delay (programmed-transition only) In-Phase Synch (as programmed; N/A for programmed-transition models.) (flashing) Post-Transfer to Standby Load Control Pre-Transfer to Preferred Load Control Off-to-Preferred Time Delay (programmed-transition only)
4.2.4 Peak Shave/Area Protection Peak Shave/Area Protection Operation Sequence signal received by controller The peak shave input signals the transfer switch to start the generator set and transfer to the standby source. Immediate generator set engine start The engine start (TDES) time delay is ignored. When the peak shave input is removed, the system Pre-transfer load control (as programmed) transfers back to preferred (if available) and removes...
4.2.5 Pre- and Post-Transfer Load The timelines in Figure 4-13 illustrate the pre-transfer time delay sequence using the default settings. (The Control Sequence default settings for the post-transfer signals are equal to The pre-transfer and post-transfer load control time zero.) The default setting for the preferred-to-standby delays operate during transfer between two live time delay is 1 second, and the default setting for the sources, such as during a loaded test sequence or a...
4.3 Faults 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. 4.3.1 Service Required LED The following faults cause the Service Required LED to 4.3.4 Failure to Transfer flash, indicating that immediate service is required:...
Section 5 Scheduled Maintenance 5.1 Introduction DANGER 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 Hazardous voltage. or missing components. Section 5.4 contains a service Will cause severe injury or death.
Grounding the transfer switch. Hazardous voltage can reliability of the emergency power system. Press the cause severe injury or death. Electrocution is possible Test button on the controller front panel to start and end whenever electricity is present. Open main circuit breakers of the test.
Note: Do not use compressed air to clean the transfer Wire or cable insulation deterioration, cuts, or switch because it can cause debris to lodge in the abrasion components and damage the switch. Signs overheating loose connections: Tighten loose external hardware. Replace any worn, discoloration of metal, melted plastic, or a burning odor missing,...
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, Repair, Visually System Component or Procedure Check Replace Clean...
Section 6 Accessories 6.1 Introduction This section describes the installation and/or operation of the following accessories: MPAC Setup Program Control Switches: Preferred source switch Supervised transfer switch In-phase monitor Programmable inputs and outputs: Main logic board terminal strip ADV-6698A 1. Preferred source switch and supervised transfer control switch Input/output modules location Figure 6-1 Control Switch Locations...
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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.
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Preferred Source Switch Position Item Assignment 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...
6.3.2 Supervised Transfer Control cannot be converted in the field. The supervised transfer control switch cannot be removed from Switch non-automatic switches in the field. supervised transfer control switch Test and Peak Shave Operation. When the (AUTO/MANUAL/TRANSFER switch) supervised transfer control switch on an automatic three-position, key-operated switch that allows manual system is in the MANUAL position, pressing the Test control of load transfers.
6.4 In-Phase Monitor 6.5 Programmable Inputs and Outputs Transfer switches are shipped with the in-phase monitor disabled. The factory settings are shown in Figure 6-6. Programmable inputs and outputs are available through Use the Setup Program to enable the in-phase monitor the controller main logic board terminal strip and and adjust the settings, if necessary.
6.5.1 Programmable Input/Output (I/O) Programmable Output Type Modules Preferred Source Available Monitor 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 Position Monitor communications.
6.5.2 I/O Module Connection Optional input/output (I/O) modules are connected to controller 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.
6.5.3 I/O Module Address Each I/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 controller harness.
modules are connected and the address DIP switches position. The load shed (forced transfer to off) are set correctly. Check the diagnostic LED to verify that accessory is available only for programmed-transition the module is receiving power and communicating with transfer switches.
6.8 Battery Charger 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 The GM22502 is a 3-stage electronic battery charger goggles, rubber gloves, and boots when servicing the battery. designed for 12 or 24 VDC systems.
234.4 FUSE HOLDER (2) 47.6 AGC--10 10A 215.9 33.3 FASTBLOW FUSE RED LIGHT GREEN LIGHT #10--32 TERMINALS TYP. (4) 6” LEAD LENGTH REF (CHARGER BODY TO INSERTION END OF CONNECTOR) GM22502-A 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.
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Battery Charger Connection Procedure 7. Determine whether the generator set electrical system uses 12 or 24 volts. This information is shown on the generator set nameplate. DANGER 8. 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.
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Battery Charger Disconnection Procedure DANGER Hazardous voltage. Will cause severe injury or death. Disconnect all power sources before opening the enclosure. 1. Before opening the transfer switch enclosure, disconnect power to the transfer switch by opening switches or circuit breakers to the transfer switch. 6126 2.
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 Indicators Green Operating Condition...
Bulk Absorption Float (Red LED On) (Red LED On) (Red/Green LEDs On) (Green LED On) DC Amps gi267712 Figure 6-26 Charging Method, 24 VDC 3 A Configuration 6.8.3 Battery Charger Troubleshooting Problem Cause Solution Red LED stays on for One or more defective or damaged Load test the battery and replace if necessary.
6.8.4 Battery Charger Specifications Figure 6-28 lists the battery charger specifications. Output Charging 12 Volts DC (min.) at 6 Amps 24 Volts DC (min.) at 3 Amps Maintaining 13.30 Volts DC at 0.1 Amps Input 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...
Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere cont. continued ABDC after bottom dead center CPVC chlorinated polyvinyl chloride alternating current crit. critical analog to digital cathode ray tube analog to digital converter Canadian Standards Association adj.
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liters per hour GND, ground liters per minute gov. governor low oil pressure gallons per hour liquefied petroleum gallons per minute liquefied petroleum gas grade, gross left side equipment ground sound power level, A weighted gr. wt. gross weight low water level H x W x D height by width by depth low water temperature hex cap...
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p., pp. page, pages SPDT single--pole, double--throw personal computer SPST single--pole, single--throw printed circuit board spec, specs specification(s) picofarad square power factor Æ sq. cm square centimeter ph., phase sq. in. square inch Phillips head crimptite (screw) stainless steel Phillips hex head (screw) std.
* 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 w Programmed-transition models only ] Optional front-connected service limited to 85,000 amps for specific and any breaker ratings.
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Ratings with Specific Manufacturers’ Circuit Breakers Open- 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 Switch Switch Rating,...
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Codes and Standards The ATS meets or exceeds the requirements of the EN61000-4-5 Surge Immunity Class 4 (voltage sensing and programmable inputs only) following specifications: EN61000-4-4 Fast Transient Immunity Underwriters Laboratories UL 508, Standard for Severity Level 4 Industrial Control Equipment IEC Specifications for EMI/EMC Immunity: Underwriters Laboratories UL 1008, Standard for Automatic Transfer Switches...
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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 TP-6126 8/02b 7 Jurong Pier Road Singapore 619159 E 2002 by Kohler Co. All rights reserved. Phone (65)264-6422, Fax (65)264-6455...
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