Page 1
Operation and Installation Automatic Transfer and Bypass/Isolation Switches Models: KBS/KBP/KBC 150 to 4000 Amperes TP-6835 9/17c...
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.
Safety Precautions and Instructions Accidental Starting Disabling generator set. IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, Accidental starting cause including generator sets, transfer severe injury or death. Before WARNING switches, switchgear, and accessories, working on the generator set or can cause bodily harm and pose equipment connected to the set, life-threatening danger...
Page 6
Heavy Equipment Grounding electrical equipment. circuits with a voltmeter to verify that Hazardous voltage will cause severe they are deenergized. injury or death. Electrocution is (Decision-Makerr 3+ and 550 WARNING possible whenever electricity Generator Set Controllers) present. Ensure you comply with all applicable codes standards.
Separate manuals cover service Information in this publication represents data available and parts information for transfer switch power at the time of print. Kohler Co. reserves the right to switching devices and electrical controls. change this literature and the products represented...
Phone: (86) 10 6518 7950 KOHLERPower.com. (86) 10 6518 7951 (86) 10 6518 7952 Look at the labels and decals on your Kohler product Fax: (86) 10 6518 7955 or review the appropriate literature or documents included with the product.
Section 1 Product Description 1.1 Purpose Emergency Normal (Utility) (Generator) Power An automatic transfer switch (ATS) transfers electrical 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 Electrical parameters.
Front (800 amp only) 400 Volts / 50 Hz 220 Volts / 60 Hz Note: 416 Volts / 50 Hz Some selections are not available on all models. Contact your Kohler distributor for availability. Section 1 Product Description TP-6835 9/17...
Section 2 Installation Introduction exterior and interior for shipping damage. If damage and/or rough handling is evident, immediately file a An automatic transfer and bypass/isolation switch damage claim with the transportation company. consists of an upper bypass/isolation switch, a lower transfer switch, and door-mounted controls.
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. Figure 2-2 for acceptable storage temperatures.
Installation Prepare the foundation. Ensure that the supporting foundation for the enclosure is level and straight. The NOTICE floor must be flat and level. Refer to the dimension drawing provided with the switch for required clearance. Foreign material contamination. Cover the transfer switch For 1600--4000 amp models, allow at least 0.9 meters during installation to keep dirt, grit, metal drill chips, and other debris out of the components.
IBC Seismic Certification or 6. Anchors used for seismic installation must be designed and rated to resist seismic loading in California OSHPD Approval accordance with ACI 355.2--04 and documented in a report by a reputable testing agency (for Automatic transfer switches with seismic...
Manual Operation Check Disable the generator set to prevent it from starting and disconnect both power sources before manually operating the switch. DANGER Do not place the transfer switch into service if the contactor does not operate smoothly; contact an authorized distributor/dealer to service the contactor.
2.5.1 Manual Operation, 150- -4000 Amp Standard-Transition Model KBS 1. Bypass and isolate the transfer switch before using the maintenance handle. See Section 7 for instructions. 2. Remove the maintenance handle from the clips on the left side of the transfer switch frame on 150--800 amp models, or on the lower part of the transfer switch frame for larger models.
2.5.2 Manual Operation, 150- -4000 Amp d. Move the Emergency operator from the OPEN position to the CLOSED position. Programmed- and Closed- Transition Models KBP and KBC e. Return the Emergency operator to the OPEN position and the Normal operator to the 1.
Controller Connections The controller is mounted in a plastic housing on the inside of the transfer switch enclosure door. DANGER Figure 2-10 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.
2.6.1 Controller Input and Output 2.6.3 Controller Ground Connections Verify that the grounding wire is connected from the controller’s lower left mounting stud to the enclosure. controller provides connections This connection provides proper grounding that does programmable inputs and two programmable outputs. not rely upon the door hinges.
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: An approved protective device such as a Will cause severe injury or death. molded-case circuit breaker or fused disconnect Disconnect all power sources before switch MUST be installed on both sources of...
Page 21
Note: Do not use compressed air to clean the switch. Use a compression washer, flat washer, and a minimum Cleaning with compressed air can cause debris grade 5 bolt. Torque the connections to the values in to lodge in the components and damage the Figure 2-15.
2.7.2 Extended Transfer Time Relay Relay with Time Adjustment Knob (Model KBC only) This section applies to the relay equipped with an adjustment knob, shown in Figure 2-17. extended transfer time relay standard closed-transition transfer switches. The relay is provided to prevent paralleling the standby and utility sources for longer Relay specifications are shown in Figure 2-18.
Page 23
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 2-20. Relay Marking A1M-0999M-466 A1M-0999M-462 Relay specifications are shown in Figure 2-21. Output Type Relay contacts, DPDT (2 form C) A three-digit pushbutton switch and a range selection...
2.7.3 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.
2.8 Communication and 2.7.4 Auxiliary Contacts Accessory Connections Connect the auxiliary contacts to customer-supplied alarms, remote indicators, or other devices. Auxiliary See Section 4 for accessory and communication contacts provide contacts that close when the transfer connection instructions. switch is in the Normal position and contacts that close when the transfer switch is in the Emergency position.
Section 3 Three-Source Systems Three-Source Systems 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.
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 29
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.
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...
Section 4 Communication and Accessory Connections 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 32
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...
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 34
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.
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.
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.
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.
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 39
Alarm Board DIP Switches Audible Alarm Setup There are four DIP switches on the alarm module board. The alarm board is equipped with a 90 dB audible alarm. Some of the switches are not used. See Figure 4-19. To The audible alarm can be set to sound under selected enable the preferred source selection, set DIP switch 1 fault conditions.
Figure 4-23. Use #12--24 AWG wire and tighten to 0.5 Nm (4.4 in. lb.). 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 41
GM23469 Figure 4-22 Load Shed Accessory (for identification) 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-6835 9/17 Section 4 Communication and Accessory Connections...
Heater DANGER Hazardous voltage. Will cause severe injury or death. Disconnect all power sources before opening the enclosure. Servicing the transfer switch. Hazardous voltage will cause severe injury or death. Deenergize all power sources before servicing. Turn off the main circuit breakers of all transfer switch power sources and disable all generator sets as follows: (1) Press the generator set off/reset button to shut down the generator set.
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 44
Notes Section 4 Communication and Accessory Connections TP-6835 9/17...
Section 5 Functional Tests and Setup Introduction voltage and frequency ratings of the utility source, transfer switch, and generator set, and verify that the Be sure to perform all of the functional tests described in ratings are all the same. this section before putting the transfer switch into Use the voltage check procedure explained in this operation.
Note: The default setting for the phase rotation on DANGER the controller is ABC. If the application uses a phase rotation of BAC, refer to the controller Operation Manual for instructions to change the phase rotation setting on the controller. Hazardous voltage.
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.
Section 6 Scheduled Maintenance Regular preventive maintenance ensures safe and The transfer switch Operation Manual contains the reliable operation and extends the life of the transfer Service Schedule and other maintenance information. switch. Preventive maintenance includes periodic Refer to the Operation Manual shipped with the transfer testing, cleaning, inspection, and replacement of worn switch, or check which controller is used on your transfer or missing components.
Section 7 Bypass, Isolation, and Manual Transfer Introduction The bypass handle positions are labeled Normal and Emergency. Transfer switches equipped with the alarm The bypass and isolation handles allow transfer switch module have a preferred source selection that allows testing and service without interrupting power to the selection of either source as preferred.
150- -600 Amp Models Read the information and instructions in Sections 7.1.1 and 7.1.2 before proceeding. 7.2.1 Bypassing the ATS, 150- -600 Amp Models This procedure explains how to bypass the closed transfer switch contacts. Bypassing is required before the transfer switch can be tested or isolated. The bypass switch handle must be in the OPEN position (green window indicator).
Page 53
The automatic transfer switch can now be put in the TEST or OPEN position. See Section 7.2.2, Isolating Upper amber light TS CONNECTED the Transfer Switch. should be on. TS TEST Bypass Switch Push in TS ISOLATED Bypass Handle and turn it Figure 7-8 Status Lights for Transfer Switch...
Page 54
Procedure to Bypass to Emergency Source (connect load to emergency source) The Transfer Switch Connected To Emergency light is on. Transfer Switch Connected To Normal light is off. Upper window indicator EMERGENCY shows yellow Turn the bypass handle clockwise. Turn the Bypass Handle clockwise until bypass switch position shows closed on EMERGENCY (yellow window indicator).
7.2.2 Isolating the Transfer Switch, Bypass Switch 150- -600 Amp Models Isolate the transfer switch before performing any service work on the automatic transfer switch (ATS). Refer to Figure 7-15 through Figure 7-18. 1. Bypass the closed automatic transfer switch Turn crank counter- contacts.
Page 56
3. Continue turning Isolation Handle DANGER counterclockwise (approx. 6 turns) until the window shows ISOLATE. See Figure 7-17. The amber TS Isolated light should come on. See Figure 7-18. Hazardous voltage. Will cause severe injury or death. Only authorized personnel should open the enclosure.
7.2.3 Return to Service, Tab handles 150- -600 Amp Models This procedure explains how to return the automatic transfer switch (ATS) to service after inspection and maintenance. Observe the bypass switch position indicator and lights. 1. Use the two handles to roll the transfer switch into the enclosure (isolation contacts facing inward) until its crank pins engage the latch plates on both sides.
Page 58
3. Observe which bypass switch position window indicator is yellow (NORMAL or EMERGENCY) at the bypass switch handle. This indicates the source connected to the load. Note: A solenoid interlock prevents you from closing the isolation contacts until the ATS is in the same position as the bypass switch.
Bypass Switch Window indicator shows yellow when ATS is bypassed to Emergency. Turn crank clockwise Window indicator until shows green when window the ATS is not shows bypassed. CONN. Window indicator Automatic Transfer Switch shows yellow when ATS is bypassed to Normal.
To Open the Bypass when Connected to the Bypass Switch Emergency Source Turn The Transfer Switch Connected To Emergency light is bypass on. The Transfer Switch Connected To Normal light is handle off. counter- clockwise. Turn the handle counterclockwise. Turn the bypass handle counterclockwise until the bypass switch position shows OPEN (green window indicator).
800- -1200 Amp Models Read the information and instructions in Sections 7.1.1 and 7.1.2 before proceeding. 7.3.1 Bypassing the ATS, 800- -1200 Amp Models This procedure explains how to bypass the closed transfer switch contacts. Bypassing is required before the transfer switch can be tested or isolated. The bypass switch handle must be in the OPEN position (green window indicator).
Page 62
1. Observe which Transfer Switch Connected To light Bypass Switch Push in is on (Normal or Emergency) on the door. This is Bypass the position of the transfer switch. See Figure 7-33. Handle and turn it counter- TRANSFER SWITCH clockwise. Upper green light is on if CONNECTED Transfer Switch is on...
Page 63
Procedure to Bypass to Emergency Source (connect load to emergency source) The Transfer Switch Connected To Emergency light is on. Transfer Switch Connected To Normal light is off. Upper window indicator EMERGENCY shows yellow Turn the bypass handle clockwise. Turn the Bypass Handle clockwise until bypass switch position shows closed on EMERGENCY (yellow Figure 7-38 Status Light and Window Indicator for...
7.3.2 Isolating the ATS, Bypass Switch 800- -1200 Amp Models Isolate the transfer switch before performing any service work on the automatic transfer switch (ATS). Refer to Figure 7-39 through Figure 7-42. 1. Bypass the closed automatic transfer switch Turn crank counter- contacts.
Page 65
Bypass Switch handles Turn crank counter- clockwise until window shows ISOLATE. Automatic Transfer Switch left rail right rail TS CONNECTED Figure 7-43 Transfer Switch Isolated and Pulled Out for Inspection TS TEST Lower amber light TS ISOLATED should be on. WARNING Figure 7-42 From TEST to ISOLATE Position...
7.3.3 Return to Service, 800- -1200 Amp Models This procedure explains how to return the automatic transfer switch (ATS) to service after inspection and maintenance. Observe the bypass switch position indicator and lights. 1. Use the two handles to roll the transfer switch into the enclosure (isolation contacts facing inward) until its crank pins engage the latch plates on both sides.
7.3.4 Return Bypass Switch to OPEN, 800- -1200 Amp Models This procedure explains how to return the bypass switch handle to the OPEN position. The bypass handle must be in the CLOSED position (yellow indicator on NORMAL or EMERGENCY) and the isolation handle must be in the CONN position (window).
To Open the Bypass when Connected to the Bypass Switch Emergency Source Turn The Transfer Switch Connected To Emergency light is Bypass on. The Transfer Switch Connected To Normal light is Handle off. counter- clockwise. Turn the handle counterclockwise. Turn the bypass handle counterclockwise until the bypass switch position shows OPEN (green window indicator).
1600- -4000 Amp Models Check the ATS position indicator. Bypass to the connected source (Source N = Normal, Source E = Read the information and instructions in Sections 7.1.1 Emergency). and 7.1.2 before proceeding. Note: Bypass to the source that is connected to the load, as indicated by the Position LED.
7.4.2 Isolating the Transfer Switch, 2. Continue turning isolation handle counterclockwise (approx. 7 turns for 1600--3000 1600- -4000 Amp Models amps, 8 turns for 4000 amps) until the position Bypass the ATS before isolating it. See Section 7.4.1. window shows ISOLATE. See Figure 7-57. Note: Turn the isolation handle until the position shows Bypass Switch clearly through the position window.
7.4.3 Removing the Transfer Switch, Procedure to Remove the Transfer Switch, 1600- -4000 Amp Models 1600- -4000 Amp Models 1. Open the lower enclosure door. After the ATS is bypassed and isolated, it can be removed from the enclosure for inspection or service. 2.
Page 72
136e 1. Handles 3. Support leg (fold down and lock; adjust length to touch floor) 2. Locking pin with clevis pin 4. Rail support carriage Figure 7-60 4000 Amp Transfer Switch Isolated and Pulled Out for Inspection Section 7 Bypass, Isolation, and Manual Transfer TP-6835 9/17...
7.4.4 Return to Operation, 1600- -4000 Bypass Switch E (B) Amp Models This procedure explains how to return the ATS to operation after inspection or service. Turn crank 1. Observe which bypass switch position indicator is clockwise yellow (NORMAL or EMERGENCY). This until indicates the source connected to the load.
Page 74
Opening the Bypass Contacts Bypass Switch This procedure explains how to return the bypass switch handle to the OPEN position, which opens the bypass contacts so that the ATS controls the connections to the sources and the load. 1. Verify that the bypass handle is in the CLOSED position (yellow indicator on NORMAL or Turn crank clockwise until...
3. Open the bypass contacts that are connected to Leave the bypass and isolation handles in these the load as follows (select Normal or Emergency). positions for automatic operation. a. If the load is connected to the NORMAL 7.4.5 Manual Load Transfer, source, push in the bypass handle and then 1600- -4000 Amp Models turn it counterclockwise until the bypass switch...
Page 76
Notes Section 7 Bypass, Isolation, and Manual Transfer TP-6835 9/17...
(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-6835 9/17 Appendix 77...
Page 78
kg/cm kilograms per square National Electrical Code remote terminal unit centimeter NEMA National Electrical room temperature vulcanization kilogram-meter Manufacturers Association read/write kg/m kilograms per cubic meter NFPA National Fire Protection Society of Automotive Association kilohertz Engineers newton meter kilojoule scfm standard cubic feet per minute normally open kilometer...
Page 80
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-6835 9/17c 7 Jurong Pier Road Singapore 619159 E 2014, 2016, 2017 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455...
Need help?
Do you have a question about the KBS and is the answer not in the manual?
Questions and answers