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Kohler KSS Manual

Automatic transfer switches
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Service
Automatic Transfer Switches
Models:
KSS/KSP/KGS/KGP
Power Switching Device:
Standard and Bypass/Isolation
30 to 4000 Amperes
Electrical Controls:
MPACt 1500
TP-6461 1/08

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Summary of Contents for Kohler KSS

  • Page 1 Service Automatic Transfer Switches Models: KSS/KSP/KGS/KGP Power Switching Device: Standard and Bypass/Isolation 30 to 4000 Amperes Electrical Controls: MPACt 1500 TP-6461 1/08...

  • Page 3: Table Of Contents

    ..........3.6.3 Solenoid Operation Diagrams, 40--225 Amp Model KSS Open Transition Switches .
  • Page 4 Table of Contents, continued 3.6.5 Solenoid Operation Diagrams, Model KSP Programmed-Transition Models 3.6.6 Solenoid Operation Diagrams, Model KGS Open Transition Bypass/Isolation Switches ........3.6.7 Solenoid Operation Diagrams, 150--400 Amp Model KGP Programmed-Transition Bypass/Isolation Switches...
  • Page 5 Table of Contents, continued Section 6 Component Replacement, Model KSS ..........
  • Page 6 Notes TP-6461 1/08...

  • Page 7: Safety Precautions And Instructions

    Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting DANGER Electromechanical equipment, including generator sets, transfer WARNING switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or Hazardous voltage. maintained. To prevent accidents be Will cause severe injury or death.
  • Page 8 Grounding electrical equipment. Making line auxiliary Heavy Equipment Hazardous voltage cause connections. Hazardous voltage severe injury or death. Electrocution can cause severe injury or death. To WARNING prevent electrical shock deenergize the is possible whenever electricity is present. Ensure you comply with all normal power source before making applicable codes...
  • Page 9 NOTICE NOTICE NOTICE Improper operator handle usage. Foreign material contamination. Electrostatic discharge damage. Use the manual operator handle on the Cover the transfer switch during Electrostatic discharge (ESD) transfer switch maintenance installation to keep dirt, grit, metal drill damages electronic circuit boards. purposes only.
  • Page 10 Notes Safety Precautions and Instructions TP-6461 1/08...

  • Page 11: Introduction

    Number Document Information in this publication represents data available Model KSS/KSP ATS Operation and TP-6447 at the time of print. Kohler Co. reserves the right to Installation Manual change this literature and the products represented Model KGS/KGP Bypass/Isolation Switch TP-6449...

  • Page 12: 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 13: Section 1 Scheduled Maintenance

    Section 1 Scheduled Maintenance Introduction WARNING Regular preventive maintenance ensures safe and reliable operation and extends the life of the transfer switch. Preventive maintenance includes periodic testing, cleaning, inspecting, and replacing of worn or Hazardous voltage. missing components. Section 1.4 contains a service Can cause severe injury or death.

  • Page 14: Inspection And Service

    NOTICE WARNING 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 Hazardous voltage. Screws and nuts are available in different hardness Can cause severe injury or death.

  • Page 15: Internal Inspections And Maintenance

    1.2.2 Internal Inspections and Terminal Tightening. Loose connections on the power circuits can lead to overheating or explosion. Maintenance Tighten all lugs to the torque values shown on the label Internal Inspection. Have an authorized distributor/ on the switch. Tighten engine start, input/output, and dealer perform an annual inspection of the transfer auxiliary connections to the torque indicated on the switch.

  • Page 16: Testing

    Transfer Switch Inspection. Remove the arc chute Testing assemblies or covers at the front of the transfer switch Periodic testing is important in any transfer switch and inspect the main contacts inside the transfer switch. application. It helps to ensure that the generator set will See Figure 1-1 or Figure 1-2.
  • Page 17 4. Calculate the contact resistance using the WARNING following formula: R = V ÷ I Where: V = measured voltage in millivolts Hazardous voltage. Can cause severe injury or death. I = measured current in amps R = calculated resistance in milliohms Only authorized personnel should open the enclosure.

  • Page 18: Service Schedule

    Testing live electrical circuits. Hazardous voltage or 4. If the hi-pot tester indicates wire insulation current can cause severe injury or death. Have trained and breakdown or if the measured resistance is less qualified personnel take diagnostic measurements of live than 1.24 MΩ, isolate the leakage current using an circuits.
  • Page 19 Adjust, Visually Repair, or System Component or Procedure Interval Section Inspect Replace Check Clean Test Electrical System Check for signs of overheating or loose connections: 1.2.2 discoloration of metal, melted plastic, or a burning odor. Check the transfer switch’s external operating mechanism for cleanliness.

  • Page 20: View Maintenance Records

    View Maintenance Records 1.6.3 Reset Default Parameters Check the system voltage and frequecy before selecting Navigate to the View Maintenance Records screen to Reset Default Parameters. Resetting to the default check the last transfer switch maintenance dates and parameters will reset all parameters, including the operation information.

  • Page 21: Reset Data Procedure

    1.6.6 Reset Data Procedure 2. Press the open up arrow button to toggle Yes or No until Yes is displayed. Use the Reset Data menus to set records or parameters back to factory default settings. See Figure 1-6. 3. Press Save to reset the displayed records to the factory defaults.
  • Page 22 Notes Section 1 Scheduled Maintenance TP-6461 1/08...

  • Page 23: Section 2 Controller Troubleshooting

    Section 2 Controller Troubleshooting This section contains troubleshooting information for DANGER the transfer switch controls. When troubleshooting a power system problem, also refer to Section 3, Transfer Switch Troubleshooting, and to the troubleshooting information in the generator set service documentation. Hazardous voltage.

  • Page 24: Controller Backup Battery

    battery needs to be replaced. See Section 4.3.2 for System Ready Main Screen. Press instructions. LD Exer ##/## @ ##:## the View button to step Norm ###V Emer ###V See Section 3.3 for other transfer switch power to the Event History View Test screen.
  • Page 25 Event Description The Controller Has Detected the Following Condition Inhibit Transfer Remote input assigned to inhibit transfer function is active (contact closed). Prevents transfer for maintenance or service. Remote Test External signal (contact closure) connected to a programmable input assigned to remote test. Signals the transfer switch to start a test sequence.

  • Page 26: System Settings

    System Settings Use the procedure in Section 3.3.2 to measure the source voltage, frequency, and phase rotation, and If the ATS does not recognize the source, check that the compare the measured values to the controller settings. source voltage and frequency settings on the controller Follow the instructions in the transfer switch Operation match the actual source parameters.

  • Page 27: Time Delays

    Time Delays Voltage and Frequency Sensing Parameter Default Adjustment Range Check the time delays when troubleshooting problems with transfer switch operation. Undervoltage 90% of pickup 75%--98% dropout Use the View Time Delays screen to check the settings Undervoltage 90% of nominal 85%--100% for the adjustable time delays.

  • Page 28: Common Alarms

    Common Alarms Functions that can be Assigned to Common Alarms Aux Switch Fault * Src E Over Freq Any of the functions listed in Figure 2-8 can be assigned Aux Switch Open * Src E Over Voltage to Common Alarms 1 and 2. Common alarms 1 and 2 Battery Backup Low * Src E Rotation Err * can then be assigned to output functions which activate...

  • Page 29: Warnings And Faults

    Warnings and Faults source position, the engine cooldown time delay executes and the engine start contacts open, allowing When a fault exists, the System Alert indicator lights, a the generator set to shut down. When the fault condition designated output and the common fault output are is corrected, the fault is automatically cleared from the turned on, and an appropriate message is displayed to controller and normal ATS operation continues.

  • Page 30: Fault Reset

    2.7.1 Fault Reset Module Status Change To clear a fault or warning condition and reset the Press Reset. Norm ###V Emer ###V System Alert LED, go to the Main screen and press the Reset View Test down arrow button to open the Reset screen. See Figure 2-9 and Figure 2-11.

  • Page 31: Module Status Conflict

    Set Inputs/Outputs Main Board I/O " " Main Back Module 1 Module 1 Auxiliary I/O Type POB Addr 1 Uninstall Module Status: Lost " " Back Back Save Back Press the down arrow button to step to the next module, if necessary. Figure 2-14 Uninstall Module 6.

  • Page 32: Events And Faults

    Events and Faults The event history log also lists transfers and other normal events not shown in these tables. The event The following tables list the faults and alarms that may history log can be saved to an electronic file. Refer to the be shown on the controller’s display screen or listed in transfer switch Operation/Installation Manual for the event history log.
  • Page 33 Section Fault or Event Message Possible Cause Check Auxiliary Switch Fault or Controller cannot determine the Check wiring and connections to transfer switch position position microswitches. See the Auxiliary Switch Open schematic drawing for connections. Test position microswitch operation. Replace microswitch if necessary. Transfer switch in intermediate position.
  • Page 34 Section Fault or Event Message Possible Cause Check Module Status Change A new accessory module is Press the reset button to open Reset 2.7.2 detected New Module screen. Then press Reset again. A module has been disconnected Check connections from the controller 2.7.2 to the I/O module assembly and at the top of each I/O module.

  • Page 35: Controller Troubleshooting Table

    Controller Troubleshooting Table Also see the transfer switch troubleshooting tables in Section 3. Section Problem Possible Cause Check No LEDs illuminated and/or No power to the transfer switch Check that source switches or circuit — display is blank breakers are closed. Verify that at least one source is 3.3.2 available.
  • Page 36 Notes Section 2 Controller Troubleshooting TP-6461 1/08...

  • Page 37: Section 3 Transfer Switch Troubleshooting

    Section 3 Transfer Switch Troubleshooting Initial Checks Transfer Switch Troubleshooting Table When troubleshooting the transfer switch mechanism, always check for simple causes first: broken or loose The following table lists potential problems with possible wires, corroded contacts, exposure to dirt or foreign causes and suggested remedies.
  • Page 38 Section Problem Possible Cause Check Generator set engine runs when it ATS does not recognize the Check connections. — should not Normal source Check voltage and frequency settings, phase rotation, calibration. Check for open switches or circuit breakers. ATS not in the expected position Check the ATS position LEDs.
  • Page 39 Section Problem Possible Cause Check Exerciser does not run regularly Exerciser not set Use View Exercise Setup screen to ATS O/I/M or at all check exerciser settings. Maintenance DIP switch SW1B Check for Maintenance Mode message — closed on controller display. Check the DIP switch setting.
  • Page 40 Section Problem Possible Cause Check Failure to transfer: Damaged or wrong coil Check for signs of overheating. Measure the coil resistance to check Transfer switch electrical for damaged coil. Replace the coil if it malfunction is damaged. Verify that the coil voltage rating matches the transfer switch voltage rating and source voltage.

  • Page 41: System Power

    System Power DANGER 3.3.1 Verify Power to the ATS If the transfer switch display is off, check for power to the transfer switch. If the utility source is not available, Hazardous voltage. check for emergency power. Follow the voltage check Will cause severe injury or death.

  • Page 42: Contacts

    the manufacturer’s instructions to adjust the 13. Connect the power switching device and controller generator set. The automatic transfer switch wiring harnesses together at the inline disconnect will only function with the rated system voltage plug. and frequency specified on the nameplate. Note: Do not connect or disconnect the controller 7.

  • Page 43: Rectifier Test

    Section 3.6.2. If the coil does not operate correctly, replace it. See Section 6.6 for instructions to test coils on Model KSS switches. Replace the coil if an open circuit or a short circuit is found. TP-6461 1/08...

  • Page 44: Solenoid Operation

    3.6.2 Solenoid Operation On 40--225 amp model KSS standard-transition switches, control contacts SCN and SCE control the This section contains descriptions and diagrams of the amount of time that power is applied to the solenoid coil. solenoid coil operation. For complete diagrams, refer to...

  • Page 45: Switches

    3.6.3 Solenoid Operation Diagrams, 40- -225 Amp Model KSS Standard Transition Switches Source N position, Source N available. The solenoid coil is not energized. COIL Source N position, Source N lost. The coil is energized if Source E is available. The transfer switch is ready to transfer to Source E.

  • Page 46: Switches

    3.6.4 Solenoid Operation Diagrams, 400- -600 Amp Model KSS Standard Transition Switches Source N position, Source N available. The solenoid coil is not energized. COIL Source N position, Source N lost. The coil is energized if Source E is available. The transfer switch is ready to transfer to Source E.

  • Page 47: Solenoid Operation Diagrams, Model Ksp Programmed-Transition Models

    3.6.5 Solenoid Operation Diagrams, Model KSP Programmed-Transition Models Normal to OFF Source N position Source N is lost Emergency available ER is pulsed for 250 ms ATS1 BTS1 to energize trip coil TC. ATS1 AND ATS2: Closed in Normal Open in OFF BTS2 ATS2 OFF to Emergency...
  • Page 48 Emergency to OFF NR1 is pulsed for 250 ms to energize trip coil TC. BTS1 and BTS2: Closed in Emergency ATS1 BTS1 Open in OFF BTS2 ATS2 OFF to Normal NR is pulsed for 250 ms to energize closing coil CC. AX is closed in OFF.

  • Page 49: Solenoid Operation Diagrams, Model Kgs Open Transition Bypass/Isolation Switches

    3.6.6 Solenoid Operation Diagrams, Model KGS Open Transition Bypass/Isolation Switches Normal to Emergency Central voltage C.V. triggers SCR RE to activate coil CE. Emergency to Normal Central voltage C.V. triggers SCR RN to activate coil CN. GM46246 TP-6461 1/08 Section 3 Transfer Switch Troubleshooting...

  • Page 50: Solenoid Operation Diagrams, 150--400 Amp Model Kgp Programmed-Transition Bypass/Isolation Switches

    3.6.7 Solenoid Operation Diagrams, 150- -400 Amp Model KGP Programmed-Transition Bypass/Isolation Switches Normal to Off Off to Emergency GM46248 Section 3 Transfer Switch Troubleshooting TP-6461 1/08...

  • Page 51: Solenoid Operation Diagrams, 150--400 Amp Model Kgp Programmed-Transition Bypass/Isolation Switches, Continued

    Solenoid Operation Diagrams, 150- -400 Amp Model KGP Programmed-Transition Bypass/Isolation Switches, continued Emergency to Off Off to Normal GM46248 TP-6461 1/08 Section 3 Transfer Switch Troubleshooting...

  • Page 52: Solenoid Operation Diagrams, 600--3000 Amp Model Kgp Programmed-Transition Bypass/Isolation Switches

    3.6.8 Solenoid Operation Diagrams, 600- -3000 Amp Model KGP Programmed-Transition Bypass/Isolation Switches Normal to Off Off to Emergency GM46249 Section 3 Transfer Switch Troubleshooting TP-6461 1/08...

  • Page 53: Solenoid Operation Diagrams, 600--3000 Amp Model Kgp Programmed-Transition Bypass/Isolation Switches, Continued

    Solenoid Operation Diagrams, 600- -3000 Amp Model KGP Programmed-Transition Bypass/Isolation Switches, Continued Emergency to Off Off to Normal GM46249 TP-6461 1/08 Section 3 Transfer Switch Troubleshooting...
  • Page 54 Notes Section 3 Transfer Switch Troubleshooting TP-6461 1/08...

  • Page 55: Section 4 Controller Test And Replacement

    Section 4 Controller Test and Replacement User Interface Panel Current (amps) Source setup information The user interface panel is located on the transfer switch door. Figure 4-1 shows the user interface pushbuttons Time and date and LED indicators. Time and date of next scheduled exercise 4.1.1 Display The display also identifies the pushbutton functions,...

  • Page 56: Lamp Test

    LED Indicator Condition Down arrow (closed). Step down to the next Source N Available, Source N is available. screen or scroll through a list. Green Source E Available, Source E is available. Up arrow (closed). Step back to the previous screen.

  • Page 57: Controller Circuit Boards And Connectors

    Controller Circuit Boards and Connectors Logic Board Power Board GM46733 GM21079 With Cover Cover Removed 1. Hinges 11. LED1 (ON = 12VDC) 2. Latch 12. Relays 3. Transfer switch harness connection P1 13. Programmed-transition interface board (PTIB) connection P2 4. RS-485 Modbus connections TB2 (factory connection) 5.

  • Page 58: Controller Power

    Controller Power Check for Line Voltage to the Controller 1. Disconnect power to the transfer switch by opening DANGER circuit breakers or switches. 2. Disconnect the transfer switch wiring harness from the controller at the 24-pin connector. 3. Reapply power to the transfer switch. Hazardous voltage.

  • Page 59: Controller Backup Battery

    4.3.2 Controller Backup Battery 4.3.3 Powering the Controller Directly (Service Kit GM52407) DANGER On occasion it is necessary to supply 120 VAC power directly to the controller for testing. Service Kit GM52407 contains a cable with a transformer to supply power to the controller from a 120 VAC wall outlet.

  • Page 60: Sequence Of Operation

    Sequence of Operation 4.4.2 Preferred Source Loss and Return Following is an explanation of the sequence of operation 4.4.1 Controller Powerup Reset for MPACt 1500 ATS Controller when Preferred Sequence of Operation Source failure is detected. Following is an explanation of the sequence of operation Preferred Source Fails: for the MPACt 1500 ATS Controller when power is initially applied to the controller or a controller reset...

  • Page 61: System Test

    System Test 4.5.2 Loaded System Test A loaded test actually simulates a preferred source Use the system test feature to: failure, except that the engine start time delay is Start and run the generator set, or bypassed. The generator set is signaled to start immediately upon test activation.
  • Page 62 Note: If the standby source fails during a test, the ATS 6. Verify that the generator set starts and the Source will immediately attempt to transfer to the E Available LED lights. preferred source. 7. Verify that the switch transfers the load to Source E. Check the preferred source selection.
  • Page 63 Test Sequence Screens System OK LD Exer ##/## @ ##:## Engine Start in ##:## Norm ###V Emer ###V Norm ###V Emer ###V View Test Main Delay Test Press the Test button. LD# Disc in ##:## Norm ###V Emer ###V Enter Password Time to Enter #:## >...

  • Page 64: Test Sequence Of Operation

    4.5.5 Test Sequence of Operation 6. Load control contacts close. 7. Engine start contacts open. Test Function is Activated (Unloaded) 1. The generator set is signaled to start. Test Function is Deactivated (Loaded) 2. The generator starts and the standby source 1.
  • Page 65 Test started Test ended Standby-to-preferred time delay and pre-transfer Generator set engine start contacts close load control (as programmed*) Load control contacts open Preferred-to-standby time delay and pre-transfer load control time delays (as programmed*) In-phase monitor or transfer to off (as programmed*) Load control contacts open Transfer to preferred source and post-transfer...

  • Page 66: Exercise

    Exercise Exerciser Accessory is activated (Loaded) 1. Exerciser timer begins. Schedule exercise runs through the Set Exercise screen. See the transfer switch Operation and 2. The generator is signaled to start. Installation Manual for instructions. To run the generator set at a time other than a scheduled exercise sequence, 3.
  • Page 67 Loaded EXERCISE timer begins Unloaded EXERCISE timer begins Generator set engine start contacts close Generator set engine start contacts close Generator set engine starts and the Generator set engine starts and the standby source becomes available standby source becomes available Time delay preferred to standby and pre-transfer Load bank control output load control time delays (as programmed*)

  • Page 68: Engine Start

    Engine Start Testing live electrical circuits. Hazardous voltage or current can cause severe injury or death. Have trained and qualified personnel take diagnostic measurements of live The engine start contacts should close when the Normal circuits. Use adequately rated test equipment with electrically source is lost and when the ATS controller starts a test or insulated probes and follow the instructions of the test exercise sequence.

  • Page 69: Controller Dip Switches

    If the generator set engine does not start, check the board. It is not necessary to remove the logic assembly cover to see or adjust the DIP switches. engine start connections to the generator set. Verify that the generator set master switch is in the AUTO position. SW1-1, Password Disable.

  • Page 70: Calibration

    Calibration The transfer switch controls are calibrated at the factory and should not require recalibration in the field. However, if recalibration is necessary, measure the DANGER source voltages as instructed in Section 3.3.2, record measured values, Setup Screen--Calibration to enter the measured values. See Figure 4-15.

  • Page 71: 4.10 Position Microswitch Test

    4.10 Position Microswitch Test Disconnect power to the transfer switch and use an ohmmeter or test lamp to check the operation of the position microswitches. Manually operate the switch and check for continuity across pins 10 and 13 of the connector P1 for Source E and pins 10 and 14 for Source N.

  • Page 72: File Transfer Through The Usb Port

    4.12 File Transfer through the USB instructions to view settings. See Section 4.5 for instructions to run a test. Port Loading Settings when Controller is Replaced The Universal Serial Bus (USB) port on the main logic board allows file transfer to and from a USB mass If the controller needs to be replaced, the configuration storage device (removeable drive).

  • Page 73: 4.12.2 File Transfer

    4.12.2 File Transfer 4.13 Controller Application Program The USB Access screen opens automatically when a device is connected to the controller’s USB port. See The manufacturer occasionally releases new versions Figure 4-19. Select Upload or Download as described of the controller application code. The new code can be below.

  • Page 74: 4.14 Controller Replacement

    4.14 Controller Replacement 4.14.2 Circuit Board and Electronic Component Handling Always check for open switches or circuit breakers, loose connections, or faulty wiring before replacing any Improper removal, installation, transportation, storage, parts. Replace the controller only if the troubleshooting service damage sensitive electronic...

  • Page 75: 4.14.3 Replacement Procedure

    4.14.3 Replacement Procedure Controller Replacement Procedure 1. Move the generator set master switch to the OFF Before removing the old controller, refer to Section position. 4.14.1. It may be possible to download the system settings from the controller to a file that can later be 2.
  • Page 76 15. To replace the entire controller assembly: a. Support the controller assembly and remove four nuts at the corners. b. Carefully remove entire controller assembly, including the user interface panel, which is part of the assembly. c. Replace the entire assembly with a new controller.
  • Page 77 27. Reconnect power to the transfer switch by closing Note: Contactor and ATS serial numbers can only be circuit breakers or switches. entered through Modbus using Monitor III or a customer-supplied Modbus driver and the Note: Power to the controller is required in order to distributor-level password.
  • Page 78 Notes Section 4 Controller Test and Replacement TP-6461 1/08...

  • Page 79: Section 5 Component Replacement, Model Kgs/Kgp

    Section 5 Component Replacement, Model KGS/KGP Introduction Removing Contact Assemblies, 800- -1200 Amp Models This section contains component removal and 1. Remove the machine screws and flat washers that replacement procedures Model KGS/KGP secure the blue plastic switch cover. bypass/isolation switches. This section contains information available at the time of publication.
  • Page 80 8. Slide out the pivot pin. should close at approximately at the same time. The neutral pole should close approximately 9. Remove the bus stud bolt, compression washer, 12.7 mm (1/2 in.) before the other three poles. and clamp bracket. 10.

  • Page 81: 1600--2000 Amp Models

    10. Close the contacts fully. See Figure 5-5. 5.2.2 1600- -2000 Amp Models Removing Contact Assembly, 1600- -2000 Amp Models Refer to Figure 5-1 and Figure 5-6 for the following procedure: 566860 1. Spring gap 3. Adjustment screw 2. Locknuts 4.
  • Page 82 Replacing Contact Assembly 1600- -2000 Amp 6.35 mm (1/4 in.) minimum gap. If not, adjust the arc finger adjustment nut as required. If the Models contacts cannot be brought within specifications, Refer to Figure 5-6 and Figure 5-7 for the following reject the contact assembly.

  • Page 83: 3000 Amp Model

    5.2.3 3000 Amp Model 1. Remove the machine screws and flat washers that secure the blue plastic switch cover. Removing Contact Assembly, 3000 Amp 2. Remove the cover. Model 3. Remove the screws that secure the arc chute. Disconnect both the normal and emergency power sources from the transfer switch before servicing.
  • Page 84 Replacing Contact Assembly, 3000 Amp 4. Install the anchor bars on the load bus assembly with twelve 1/4-20 socket head cap screws. The Model longer cap screws are used on the sides. Torque Refer to Figure 5-7, Figure 5-8, and Figure 5-9 for the the cap screws to 10.2 Nm (90 in.

  • Page 85: Auxiliary Switch Removal And Replacement

    Auxiliary Switch Removal and 4. Disconnect the wires and connect them to the corresponding terminals of the replacement switch Replacement assembly. 5. Install the new auxiliary switch assembly with the two mounting screws. 6. Manually operate the transfer switch to make sure that the new auxiliary switch trips.
  • Page 86 Notes Section 5 Component Replacement, Model KGS/KGP TP-6461 1/08...

  • Page 87: Section 6 Component Replacement, Model Kss

    Section 6 Component Replacement, Model KSS Introduction DANGER This section contains instructions for component replacement on model KSS standard-transition transfer switches. See Section 7 for programmed-transition switches. Hazardous voltage. Will cause severe injury or death. Observe the following safety precautions when...

  • Page 88: Microswitch Replacement

    5. Note the location of the fast-on connectors to the microswitch terminals. See Figure 6-1. 1. End plate Figure 6-2 End Plate (required for assemblies with four microswitches) Figure 6-1 Microswitches Section 6 Component Replacement, Model KSS TP-6461 1/08...

  • Page 89: 600 Amp

    Verify that all power is disconnected before proceeding. 5. Note the location of the fast-on connectors to the Figure 6-5 Microswitch Holding Screws microswitch terminals. See Figure 6-3. 6. Disconnect fast-on connectors. Figure 6-4. TP-6461 1/08 Section 6 Component Replacement, Model KSS...

  • Page 90: Power Panel Replacement

    3. Open the enclosure. 4. Check for zero volts on the normal and emergency power lugs. 5. Remove the tie wraps securing the harness. Figure 6-6 Installing the Power Panel Section 6 Component Replacement, Model KSS TP-6461 1/08...

  • Page 91: Arc Chute Replacement

    1. Prevent all connected generator sets from starting. a. Place the generator set master switch in the Figure 6-8 Movable Contacts (arc chute removed) OFF position. b. Disconnect the battery charger, if equipped. TP-6461 1/08 Section 6 Component Replacement, Model KSS...

  • Page 92: Limit Switch Assembly Replacement

    5. Note the location of the fast-on connections to the SCN/SCE microswitch terminals. 6. Disconnect fast-on connectors. Figure 6-10. Figure 6-9 Manual Operation Handle Inserted Figure 6-10 Microswitch Fast-On Connectors Section 6, Component Replacement, Model KSS Switches TP-6461 1/08...
  • Page 93 5. Note: Do not leave the transfer switch in the Test mode. Figure 6-11 Microswitch Insulator with Label Figure 6-13 Microswitch Installation Figure 6-12 Microswitch TP-6461 1/08 Section 6, Component Replacement, Model KSS Switches...

  • Page 94: Solenoid And Rectifier Replacement

    11. Connect the AC fast-on connections to the AC terminals. Note: The AC terminals are in the upper left and Figure 6-14 Rectifier Connections (DC solenoid lower right hand corners. leads shown disconnected) Section 6, Component Replacement, Model KSS Switches TP-6461 1/08...
  • Page 95 12. Remove tie wraps, as necessary. Figure 6-18 Spring and Plunger Assembly Note: Do not cut the insulation on the wiring. 13. Remove the front bolt of the coil securing the strap. See Figure 6-17. TP-6461 1/08 Section 6, Component Replacement, Model KSS Switches...

  • Page 96: Solenoid And Rectifier Replacement, 400--600 Amp Models

    24. Close the enclosure. 2. Disconnect main power and open the ATS 25. Reconnect power to the ATS. enclosure. 26. Enable the generator set startup. 3. Verify zero volts across each phase. Section 6, Component Replacement, Model KSS Switches TP-6461 1/08...
  • Page 97 The spring in the solenoid assembly exerts substantial force on the 9. Connect AC fast-on connections to AC terminals. coil. Hold the coil assembly securely when removing the screws. TP-6461 1/08 Section 6, Component Replacement, Model KSS Switches...
  • Page 98 1. Mounting screws with washers (4 ea.) 4. Plunger 2. Linkage 5. Rectifier connections 3. Clip location (not visible this view) Figure 6-22 Solenoid Assembly (shown on the bench) Section 6, Component Replacement, Model KSS Switches TP-6461 1/08...
  • Page 99 Reconnect the generator set engine starting batter(ies), negative (--) lead last. c. Reconnect the battery charger, if equipped. 26. Move the generator set master switch to the AUTO position. Figure 6-23 Rectifier Connections and Tie Wraps TP-6461 1/08 Section 6, Component Replacement, Model KSS Switches...
  • Page 100 Notes 100 Section 6, Component Replacement, Model KSS Switches TP-6461 1/08...

  • Page 101: Section 7 Component Replacement, Model Ksp

    Section 7 Component Replacement, Model KSP Introduction Component Replacement, 100- -400 Amp Models This section contains instructions for component replacement on Model KSP programmed-transition 7.2.1 Disassembly, 100- -400 Amps transfer switches. Disassemble the mechanical unit and the current- Illustrations in this section show the transfer switch carrying unit.

  • Page 102: Reassembly, 100--400 Amps

    3. Remove the auxiliary switches. See Figure 7-3. 6226 Figure 7-6 Mechanical Unit 6226 1. Auxiliary switches Figure 7-3 Auxiliary Switches 7.2.2 Reassembly, 100- -400 Amps 4. Loosen four bolts and separate the mechanical unit Reassemble mechanical unit from the current-carrying unit. See Figure 7-4, current-carrying unit.
  • Page 103 2. Replace the ON/OFF indicators and the cover. Note: The ON/OFF indicators are not identical. Locate them as shown in Figure 7-8. 6226 1. Auxiliary switch levers 2. Auxiliary switches Figure 7-9 100 and 200 Amp Models 6226 1. ON/OFF indicators Figure 7-8 Assembled Units 3.

  • Page 104: Printed Circuit Board Replacement, 100--400 Amps

    7.2.3 Printed Circuit Board Replacement, 100- -400 Amps Separate the current-carrying unit from the mechanical unit. See Section 7.2.1. 1. Note the connections (for reconnection later) and disconnect the printed circuit board leads. See Figure 7-11 or Figure 7-12. 2. Disconnect the control switch leads at three terminals.

  • Page 105: Closing Coil Replacement, 100--400 Amps

    7.2.4 Closing Coil Replacement, 4. Loosen the M6 bolt and remove the frame with the coil. See Figure 7-15 and Figure 7-16. 100- -400 Amps 5. Loosen the M12 nut and replace the closing coil. 1. Push the trip button. See Figure 7-16.

  • Page 106: Trip Coil Replacement, 100--400 Amps

    2. Remove two M4 bolts shown in Figure 7-18 and 7.2.6 Trip Coil Replacement, remove the select coil assembly. 100- -400 Amps Note: Remove the select coil first for easier access to the trip coil. See Section 7.2.5. 1. Locate the trip coil. See Figure 7-21. 6226 1.
  • Page 107 3. Remove two M4 bolts that secure the trip coil. See Figure 7-23. 6226 1. Trip shaft 2. M4 bolt 6226 Figure 7-24 Trip Shaft Location 1. Trip coil M4 bolts (2) 2. Trip shaft M4 bolt (and ring, not visible in this view) 3.

  • Page 108: Arc Chute Replacement, 100--400 Amps

    6. Reassemble in reverse order: Align the bosses on the coil with the holes in the L-shaped bracket. Be sure to reinstall the ring on the trip shaft bolt and align the parts so that the ring fits into the hole on the trip lever.

  • Page 109: Shaft Adjustment, 600 Amp Models

    7.3.2 Shaft Adjustment, WARNING 600 Amp Models Note: It is not necessary to remove the movable steel shaft when replacing the closing coil. 1. Turn the large round shaft in (clockwise) until the Spring-loaded parts. mechanism just latches when operated with the Can cause severe personal injury manual handle.

  • Page 110: Trip Coil Replacement, 600 Amp Models

    7.3.4 Trip Coil Replacement, 2. Remove two M4 bolts and replace the trip coil. Retain the small spring for the trip coil lever. See 600 Amp Models Figure 7-33 and Figure 7-34. 1. Note the connections and disconnect the trip coil 3.

  • Page 111: Select Coil Replacement, 600 Amp Models

    7.3.5 Select Coil Replacement, 7.3.6 Printed Circuit Board 600 Amp Models Replacement, 600 Amp Models 1. Note the connections and disconnect the select Note: The individual rectifiers are not replaceable. coil leads from the printed circuit board and the Replace the entire printed circuit board in the control switch.
  • Page 112 1. Remove the insulation plate. See Figure 7-38. 6226 tp6226 1. Remove this rod 1. Insulation plate 2. Fixture 3. M6 nuts or retainers Figure 7-38 600 Amp Contactor Figure 7-39 Fixture or Clamp, 600 Amp Models 2. Attach a clamp or fixture similar to the one shown in Figure 7-39.

  • Page 113: Appendix A Abbreviations

    Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere cubic feet per minute est. estimated ABDC after bottom dead center center of gravity E-Stop emergency stop cubic inch displacement alternating current etc. et cetera (and so forth) analog to digital centerline...
  • Page 114 Motoren-und Turbinen-Union read only memory kilobyte (2 bytes) megawatt rot. rotate, rotating KBus Kohler communication protocol milliwatt revolutions per minute μF kilogram microfarad right side kg/cm kilograms per square N, norm. normal (power source) remote terminal unit...

  • Page 115: Appendix B Screen Summaries

    Appendix B Screen Summaries This section lists the items shown in the View and Setup screens for quick reference. View Screens Main Screen View Maintenance Records System Status Total Min Not Preferred Next Exercise Time and Date Reset Min Not Preferred Normal and Emergency Voltage Total Min in Standby Frequency...
  • Page 116 View Source Setup View Communications Setup ABC/BAC Rotation (3-phase only) Modbus Server TCP Enabled/Disabled System Voltage, Normal/Emergency Modbus Server Port 1 and 2 Enable/Disabled Frequency (Hz), Source N and E Modbus Address Port 1 and 2 Normal Under Voltage PU% and DO% Baud Rate Port 1 and 2 Normal Over Voltage PU% and DO% 9600/19200/57600...
  • Page 117 Set Source Set System Phase Rotation ABC/BAC/Disabled Source Type: Utility/Generator, Generator/Generator, Utility/Utility, Utility/Generator/Generator (3--source system) In-Phase Monitor Enable/Disable Transition Type: Standard/Programmed In-Phase Monitor Angle Rated Current, Amps Set Preferred Source Normal/Emergency 3 Source Engine Start Mode Set Normal (Emergency) Source: Mode1/Mode2 Number of Phases Preferred Source Toggle Enable/Disable...

  • Page 118: Appendix C Noise And Wiring Practices

    Appendix C Noise and Wiring Practices Electrical noise is an unwanted electrical signal that can General Purpose Power Distribution. Circuits to cause errors in measurement, loss of control, medium-power loads such as lighting, offices, light- duty equipment, and small motors such as fans and malfunctions in microprocessor-based control systems, pumps can emit transient, medium levels of broad- errors in data transfer between systems over...

  • Page 119: Appendix D Common Hardware Application Guidelines

    Appendix D Common Hardware Application Guidelines Use the information below and on the following pages to Steps for common hardware application: identify proper fastening techniques when no specific 1. Determine entry hole type: round or slotted. reference for reassembly is made. 2.

  • Page 120: Appendix E General Torque Specifications

    Appendix E General Torque Specifications American Standard Fasteners Torque Specifications Assembled into Assembled into Cast Iron or Steel Torque Torque Aluminum Aluminum Grade 2 Grade 5 Grade 8 Size Measurement Grade 2 or 5 8-32 Nm (in. lb.) (16) (20) —...

  • Page 121: Appendix F Common Hardware Identification

    Appendix F Common Hardware Identification Screw/Bolts/Studs Nuts Hardness Grades Head Styles Nut Styles American Standard Hex Head or Machine Head Hex Head Grade 2 Hex Head or Machine Head Lock or Elastic Grade 5 with Washer Flat Head (FHM) Square Grade 8 Grade 8/9 (Hex Socket Round Head (RHM)

  • Page 122: Appendix G Common Hardware List

    Appendix G Common Hardware List The Common Hardware List lists part numbers and dimensions for common hardware items. American Standard Part No. Dimensions Part No. Dimensions Part No. Dimensions Type Hex Head Bolts (Grade 5) Hex Head Bolts, cont. Hex Nuts X-465-17 1/4-20 x .38 X-6238-14...
  • Page 123 Metric Hex head bolts are hardness grade 8.8 unless noted. Part No. Dimensions Part No. Dimensions Part No. Dimensions Hex Head Bolts (Full Thread), Hex Head Bolts (Partial Thread) Hex Head Bolts (Partial Thread), continued continued M931-05055-60 M5-0.80 x 55 M931-06040-60 M6-1.00 x 40 M933-12016-60...
  • Page 124 Metric, continued Part No. Dimensions Type Hex Nuts M934-03-50 M3-0.50 Standard M934-04-50 M4-0.70 Standard M934-04-B M4-0.70 Brass M934-05-50 M5-0.80 Standard M934-06-60 M6-1.00 Standard M934-06-64 M6-1.00 Std. (green) M6923-06-80 M6-1.00 Spiralock M982-06-80 M6-1.00 Elastic Stop M934-08-60 M8-1.25 Standard M6923-08-80 M8-1.25 Spiralock M982-08-80 M8-1.25 Elastic Stop...
  • Page 126 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-6461 1/08 7 Jurong Pier Road Singapore 619159 E 2008 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455...

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