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Service Automatic Transfer Switches Models: Power Switching Device: Molded Case Circuit Breakers (MCCB) or Switches Insulated Case Circuit Breakers (ICCB) or Switches 100 to 4000 Amperes Electrical Controls: MPACr 1500 TP-6745 7/10...
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.
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Making line auxiliary Heavy Equipment Notice connections. Hazardous voltage can cause severe injury or death. To NOTICE WARNING prevent electrical shock deenergize the Hardware damage. The transfer normal power source before making switch both American any line or auxiliary connections. Standard and metric hardware.
Document Part Number Document Information in this publication represents data available MPACt 1500 Controller Operation at the time of print. Kohler Co. reserves the right to TP--6714 Manual change this literature and the products represented Model KEP ATS Operation/Installation without notice and without any obligation or liability...
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.
Section 1 Scheduled Maintenance 1.1 Introduction DANGER Regular preventive maintenance ensures safe and reliable operation and extends the life of the transfer switch. Preventive maintenance includes periodic testing, cleaning, inspecting, and replacing of worn or Hazardous voltage. missing components. Section 1.5 contains a service Will cause severe injury or death.
Short circuits. Hazardous voltage/current can cause 1.2 General Inspection severe injury or death. Short circuits can cause bodily injury and/or equipment damage. Do not contact electrical External Inspection. Inspect the transfer switch connections with tools or jewelry while making adjustments or weekly.
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Other evidence of wear, damage, deterioration, or Signs of Overheating. Replace components damaged malfunction of the transfer switch or its components by overheating and locate the cause of the overheating. Overheating could be caused by loose power Cleaning. Use a vacuum cleaner or a dry cloth or brush connections, overloading, or a short circuit in the to remove contaminants from internal components.
1.3.2 Mechanical Interlocks and without binding. If lubricating the outer mechanism of the transfer switch does not eliminate binding, replace Linkages the transfer switch assembly. Verify that mechanical interlocking is correct (i.e. one Periodically oil the enclosure door locks and screws. power switching device must be well open before the other closes).
1.4 Testing DANGER Periodic testing is important in any transfer switch application. It helps to ensure that the generator set will start and the transfer switch mechanisms and control circuits will operate when needed. Hazardous voltage. Will cause severe injury or death. 1.4.1 Weekly Generator Set Exercise Only authorized personnel should...
1.5 Service Schedule Follow service schedule below authorized distributor/dealer inspect the switch annually recommended service intervals. The transfer switch and perform all service marked by a D. operator can perform tasks marked by an X. Have an Adjust, Visually Repair, or System Component or Procedure Interval Section...
Service Disconnect Switch Important notes about service disconnect operation: DANGER Service disconnect transfers to the emergency source, disconnecting the load from the utility source ONLY. On service entrance transfer switches, the line side Hazardous voltage. lugs are active at all times. Will cause severe injury or death.
1.6.1 Service Disconnect Procedure 1.6.2 Service Reconnect Procedure DANGER The service disconnect switch has two positions: AUTO and SERVICE DISCONNECT. Follow the procedures in this section carefully and observe the safety precautions when performing service disconnect before maintenance or service. Watch the LED indicators on the ATS controller to check the ATS position and source Hazardous voltage.
Service Reconnect Procedure (when Normal Control Circuit Isolation source is NOT available) Switch Manually operate the ATS to the Normal position before The two-position control circuit isolation switch removes returning the generator set to service, as described in utility power from the ATS controller assembly. the procedure below.
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Control Circuit Isolation Procedure DANGER Hazardous voltage. Will cause severe injury or death. Only authorized personnel should open the enclosure. 1. Perform the service disconnect procedure in Section 1.6.1. Note: There is still power to the controller assembly after the service disconnect is completed.
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Control Circuit Reconnect Procedure a. Reconnect the battery cables, negative lead (when normal source is NOT available) last. Do not return the generator set to service until instructed b. Reconnect power to the battery charger. to do so in the procedure below. c.
Section 2 Troubleshooting 2.1 Initial Checks DANGER When troubleshooting a problem, check the following things first. Check the Service Required LED and the transfer switch controller display for fault or warning Hazardous voltage. Will cause severe injury or death. indications. If a fault or warning is indicated, proceed to Section 2.9.
From the main screen, step to View Event History and 2.3 Data Log Files display recent events as shown in Figure 2-1. Possible event descriptions are listed in Figure 2-2. The data log files listed in this section are available on MPACt 1500 controllers with version 2.0.0 or later If a fault condition or alarm is displayed, proceed to application code.
2.4 System Power 2.4.2 Source Voltage, Frequency, and Phase Rotation Checks 2.4.1 Verify Power to ATS The voltage, frequency, and phasing of the transfer switch and the power sources must be the same to avoid If the transfer switch display is off, check for power to the damage to loads and the transfer switch.
Voltage, Frequency, and Phase Rotation Check 2.5 System Settings Procedure If the ATS does not recognize the source, check that the 1. Ensure that all downstream loads are switched off. source voltage and frequency settings on the controller match the actual source parameters. 2.
Use the procedure in Section 2.4.2 to measure the Voltage Sensing source voltage, frequency, and phase rotation, and Adjustment Parameter Default compare the measured values to the controller settings. Range Follow the instructions in the transfer switch operation Undervoltage dropout 90% of pickup 75%--98% and installation manual to change the controller settings...
2.6 Time Delays 2.7 Reset Data Check the time delays when troubleshooting problems Be sure to read and understand the information in this with transfer switch operation. section before resetting. Use the View Time Delays screen to check the settings 2.7.1 Reset Maintenance Records for the adjustable time delays.
2.7.6 Reset Data Procedure File Name Description Parameter settings Use the Reset Data menus to set records or parameters MPAC1500_#######.cfg (configuration) back to factory default settings. See Figure 2-11. presentyymmdd.his Event history 1. Use the black arrow buttons to step to the desired alarm_settings.alm Common alarms screen.
2.8 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.
2.8.1 Fault Reset Module Connection (new or reconnected module) Installing or reconnecting one or more accessory To clear a fault or warning condition and reset the modules triggers the Module Status Change message. System Alert LED, go to the Main screen and press the down arrow button to open the Reset screen.
Disconnected Module Other Module Status Change Conditions If one or more accessory modules are disconnected A Module Status Change message that cannot be from the controller, the message Module Status Change cleared as described above may indicate a failure of the appears.
See the transfer switch operation/installation manual for If the common alarm is activated, the specific condition instructions to assign programmable inputs and outputs that triggered the alarm will be shown on the ATS to I/O modules or assign functions to the audible alarm controller display screen.
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Fault or Event Message Section Possible Cause Check Overfrequency, Frequency settings Check that the system frequency setting matches the actual Underfrequency source frequency (50 or 60 Hz). Check the over/underfrequency pickup and dropout settings. See Section 2.5.2 and the Setup Program Operation Manual. Check that the frequency debounce setting is long enough to prevent nuisance faults caused by brief frequency variations.
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Fault or Event Message Section Possible Cause Check Failure to Acquire Generator set did See Failure to Start Generator Set, below. Standby not start Open circuit breaker Check and close ATS source and generator set circuit breakers. — ATS does not Check source voltage, frequency, phase rotation settings and 2.4.2 recognize the...
2.10 Troubleshooting Table The following table lists potential problems with possible Always follow the safety precautions at the beginning of causes and suggested remedies. Section numbers in this manual when troubleshooting and servicing the the last column refer to other sections of this manual. transfer switch.
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Section Problem Possible Cause Check Generator set Generator Generator set master switch not in Move the generator set master switch to the AUTO engine runs when it set manuals AUTO position. Wait for the generator set engine should not cooldown delay, if necessary. (continued) Other generator set problem Disconnect the engine start leads from the ATS.
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Section Problem Possible Cause Check Transfer to Loaded test or exercise sequence Check the controller display for indication that a generator source is active. test or exercise sequence is active. without a power Utility power switching device has Identify and correct the cause of the tripped circuit ATS O/I/M failure in the utility tripped due to an over current...
2.11 MPAC 1500 Controller Incorrect voltage sensing Troubleshooting Flowcharts Blank display This section contains troubleshooting flowcharts for the Slow or no transfer to utility MPACt 1500 ATS controller. Use these instructions to diagnose problems with the MPACt 1500 ATS Strange characters on display or controller lockup controller and identify the parts that require service or Refer to the operation/installation manual and wiring replacement, rather than replacing the entire controller...
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Note: To prevent damage to the controller and the device, NEVER MPAC 1500 AC voltage sensing is incorrect. remove or reapply devices while the controller is energized. Follow the safety precautions during this troubleshooting procedure. Check the system voltage programmed into the controller. Does the controller Check the voltage rating system voltage match the...
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Note: To prevent damage to the controller and the device, NEVER MPAC 1500 remove or reapply devices while the controller is energized. Follow controller display is the safety precautions during this troubleshooting procedure. blank. Verify power to the ATS. Trace leads back to the Check AC line voltage at P1-12(A) contactor and sensing Are any LEDs on the...
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Figure 2-21 Transfer Troubleshooting, Part 1 Section 2 Troubleshooting TP-6745 7/10...
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Figure 2-22 Transfer Troubleshooting, Part 2 TP-6745 7/10 Section 2 Troubleshooting...
Section 3 Controller Test and Replacement 3.1 User Interface Panel 3.1.2 LED Indicators LEDs on the user interface indicate power switching The user interface panel is located on the transfer switch device position, source availability, faults, and other door. Figure 3-1 shows the user interface pushbuttons conditions.
3.1.4 Pushbuttons Down arrow (closed). Step down to the next The user interface panel has four pushbuttons below the screen or scroll through a list. display. Pushbutton functions are shown above each Up arrow (closed). Step back to the previous button in the last line of the display and can change from screen.
3.3 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.
3.4 Sequence of Operation 3.4.1 Controller Powerup Reset Sequence of Operation Following is an explanation of the sequence of operation for the MPACt 1500 ATS Controller when power is initially applied to the controller or a controller reset occurs. 1. Controller self test is executed. 2.
3.4.2 Preferred Source Loss and Return 9. Load control contacts close as post-transfer load control time delays expire. Following is an explanation of the sequence of operation when Preferred Source failure is detected. Preferred Source Returns: 1. Transfer time delay standby-to-preferred expires Preferred Source Fails: and load control contacts open as pretransfer load 1.
3.5 Operation Diagrams Service entrance models stop in the OFF position for a programmed length of time during transfer. On MCCB This section contains descriptions and diagrams of the models, the K2 relay closes after the Off time delay, power switching device operation. For complete applying power to the circuit breaker motor operator and diagrams, refer to the schematic diagrams provided with...
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Transfer, Normal to Off: Note: The K1 and K2 relays on the MPAC 1500 Utility source is lost. Controller relay controller board are energized for only 250 K2 closes, energizing M to open the milliseconds to initiate transfer. utility source circuit breaker. Transfer, Off to Emergency: After the Off time delay, controller relay K2 closes, energizing M to close the generator...
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Transfer, Emergency to Off: Note: The K1 and K2 relays on the MPAC 1500 Utility source returns. Controller relay K1 closes, controller board are energized for only 250 energizing M to open the generator circuit breaker. milliseconds to initiate transfer. Transfer, Off to Utility: Controller relay K1 closes, energizing M to close the utility circuit breaker.
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Transfer, Normal to Off: Note: Controller relays K1 and K2 and PTIB Utility source is lost. relays K1’ and K2’ are energized for only Controller relay K2 closes, 250 milliseconds to initiate transfer. energizing the UBO motor operator to open the utility breaker.
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Transfer, Emergency to Note: Controller relays K1 and K2 and PTIB Off: relays K1’ and K2’ are energized for only Utility power returns. 250 milliseconds to initiate transfer. PTIB relay K1’ closes, energizing the GBO motor operator to open the generator breaker. Transfer, Off to Normal: Controller relay K1 closes, energizing the...
3.6 System Test the preferred source is available, the test will be terminated, and the transfer switch will immediately Use the system test feature to: transfer to the preferred source position, bypassing all time delays except the off-position requirements in a Start and run the generator set, or programmed-transition system.
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Note: Close and lock the enclosure door before starting 5. Press the Start button. the test procedure. 6. Verify that the generator set starts and the Source E Available LED lights. DANGER 7. Verify that the switch transfers the load to Source E: a.
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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 #:## >...
3.6.5 Test Sequence of Operation 8. Load control contacts close. 9. 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.
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Test started Test ended Transfer time delay standby-to-preferred Generator set engine start contacts close and pretransfer load control * Transfer time delay preferred-to-standby and Load control contacts open pretransfer load control time delays * Emergency breaker or switch opens Load control contacts open Off-to-preferred time delay Utility breaker opens.
3.7 Exercise Exercise Sequence is Activated (Loaded) 1. Exerciser timer begins. Schedule exercise runs through the Set Exercise screen. See the transfer switch operation and 2. Engine start contacts close, signaling the installation manual for instructions. To run the generator generator set to start.
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Emergency Source Fails (Normal Source is Exercise Sequence is deactivated (Loaded) available) 1. Pretransfer load control sequences time out. 1. Exerciser is deactivated. 2. Load control contacts open. 2. Immediate failure to acquire standby alarm. 3. Emergency breaker or switch opens. 3.
3.9 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.
If the generator set engine does not start, check the board. It is not necessary to remove the logic assembly engine start connections to the generator set. Verify that cover to see or adjust the DIP switches. the generator set master switch is in the AUTO position. SW1-1, Password Disable.
Testing live electrical circuits. Hazardous voltage or current can cause severe injury or death. Have trained and qualified personnel take diagnostic measurements of live circuits. Use adequately rated test equipment with electrically insulated probes and follow the instructions of the test equipment manufacturer when performing voltage tests.
3.12 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.
3.14 File Transfer through USB Port Configuration files from one transfer switch can be saved to a mass storage device and then loaded onto The Universal Serial Bus (USB) port on the main logic other transfer switches for quick setup of multiple board allows file transfer to and from a USB mass switches.
Loading Settings when Controller is Replaced 3. Use the down button to scroll through the list of available files. If the controller needs to be replaced, the configuration file from the old controller (if available) can be loaded 4. When the desired file is displayed, press the Sel onto the new controller for quick setup.
3.16 Controller Replacement 3.16.2 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...
3.16.3 Replacement Procedure Controller Replacement Procedure 1. Move the generator set master switch to the OFF Before removing the old controller, refer to Section position. 3.16.1. It may be possible to download the system settings from the controller to a file that can later be 2.
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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.
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25. Check the controller’s DIP switch settings and Verify operation. adjust them if necessary. See Section 3.10, 31. Reconnect the generator set engine starting Controller DIP Switches. battery, negative (--) lead last. 26. Close and lock the transfer switch enclosure door. 32.
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Figure 4-3 Wiring Diagrams, NT and NW circuit breakers TP-6745 7/10 Section 4 ICCB Power Switching Device Diagrams...
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Figure 4-4 Wiring Diagram NT Breaker for 800 A and 1200 A 3- and 4-Pole ICCB Models Section 4 ICCB Power Switching Device Diagrams TP-6745 7/10...
(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-6745 7/10 Appendix 79...
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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...
Appendix B 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.
Appendix C General Torque Specifications American Standard Fasteners Torque Specifications Assembled into Assembled into Cast Iron or Steel Aluminum Torque Measurement Grade 2 Grade 5 Grade 8 Size Grade 2 or 5 8-32 Nm (in. lb.) (16) (20) — 10-24 Nm (in.
Appendix D 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)
Appendix E 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...
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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...
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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...
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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-6745 7/10 7 Jurong Pier Road Singapore 619159 E 2010 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455...
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