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Kohler G220 Service And Parts

Automatic transfer switches
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Service and Parts
Automatic Transfer Switches
Models:
G220
Electrical Controls:
Solid-State
Power Switching Device:
Contactors:
100 and 200 Amperes
TP-6322 9/04

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Summary of Contents for Kohler G220

  • Page 1 Service and Parts Automatic Transfer Switches Models: G220 Electrical Controls: Solid-State Power Switching Device: Contactors: 100 and 200 Amperes TP-6322 9/04...

  • Page 2: Product Identification Information

    Product Identification Information Transfer Switch Identification Numbers Record the product identification numbers from the transfer switch nameplate. Model Designation Serial Number Accessory Number Accessory Description...

  • Page 3: Table Of Contents

    Table of Contents Product Identification Information ..........Inside front cover Safety Precautions and Instructions .
  • Page 4 ..........Contactor G220 .

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions IMPORTANT SAFETY Accidental Starting Battery electrolyte is a diluted INSTRUCTIONS. Electromechanical sulfuric acid. Battery acid can cause equipment, including generator sets, severe injury or death. Battery acid WARNING transfer switches, switchgear, and can cause blindness and burn skin. accessories, can cause bodily harm Always wear...
  • Page 6 Hazardous Voltage/ Servicing transfer switch. Short circuits. Hazardous Hazardous voltage cause voltage/current can cause severe Electrical Shock severe injury or death. Deenergize all injury or death. Short circuits can power sources before servicing. Open cause bodily injury and/or equipment DANGER the main circuit breakers of all transfer damage.
  • Page 7 Moving Parts NOTICE NOTICE When replacing hardware, do not Foreign material contamination. WARNING substitute with inferior grade Cover the transfer switch during hardware. Screws and nuts are installation to keep dirt, grit, metal drill available in different hardness ratings. chips, and other debris out of the indicate hardness, American...
  • Page 8 Notes Safety Precautions and Instructions TP-6322 9/04...

  • Page 9: Introduction

    The following Information in this publication represents data available table lists the available literature part numbers. at the time of print. Kohler Co. reserves the right to change this literature and the products represented Part...

  • Page 10: Service Assistance

    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...

  • Page 11: Section 1 General

    TRANSFER SWITCH FOR EMERGENCY SYSTEMS mechanically latches in the selected position. ENCLOSURE contactor also includes a provision for manual operation KOHLER CO. KOHLER WI, USA in emergency nonpowered conditions. MODEL SERIAL NO. ACCESSORIES: AMPS...

  • Page 12: Model Number

    SAMPLE PART NUMBER This chart explains the Kohlerr transfer switch model number code. The sample model number shown is for a Model G220 automatic transfer switch that uses a 250-volt maximum contactor G220-164233-0100 power switching device with solid-state electrical controls rated at 240 volts, 60 hertz, 1 phase, 2 pole, and 3 wires in a NEMA Type 3R enclosure with a current rating of 100 amperes.

  • Page 13: Section 2 Operation

    Section 2 Operation 2. Disconnect both the normal and emergency power DANGER sources by opening circuit breakers or switches leading to the transfer switch. 3. Open the enclosure and check that the contactor wiring harness is connected to the electrical Hazardous voltage.

  • Page 14: Automatic Operation

    2.2 Automatic Operation restored before TDES ends, the controller resets the time delay. If the normal power failure persists and The ATS controller monitors the normal and emergency TDES ends, the controller issues a signal to start the power sources and determines when a power source standby (emergency) generator to produce the has failed or is acceptable and controls the system emergency power source by closing the engine-start...

  • Page 15: Exerciser Function

    contactor mechanism’s inertia carries it through the top DANGER of the cycle and into the normal position. The contactor is mechanically latched in the normal position until the next normal power source failure. The controller starts a time delay called time delay engine cooldown (TDEC). TDEC allows the engine and generator to run unloaded Hazardous voltage.

  • Page 16: Exerciser Power Requirements

    starts the generator automatically when the normal DANGER power source fails. Replace the enclosure cover on the ATS enclosure and tighten the screws that hold it in place after viewing or making changes to the exerciser switch setting. Hazardous voltage. Will cause severe injury or death.

  • Page 17: External Test Switch

    4. Slide the large end of the manual operation handle 2.5 External Test Switch over the manual operation lever on the left side of the contactor. See Figure 2-3. Move the handle up A provision on the main controller circuit board allows to place the transfer switch in the Normal Source the connection of a customer-supplied, normally closed position, or down to place the contactor in the...
  • Page 18 Notes Section 2 Operation TP-6322 9/04...

  • Page 19: Section 3 Scheduled Maintenance

    Section 3 Scheduled Maintenance Scheduled preventive maintenance ensures safe and DANGER reliable operation and extends the life of the transfer switch. Preventive maintenance includes periodic testing, cleaning, inspecting, and replacing of worn or missing components. Hazardous voltage. A local authorized distributor/dealer can provide Will cause severe injury or death.

  • Page 20: Inspection And Service

    Servicing the transfer switch. Hazardous voltage can 3.1.1 General Inspection cause severe injury or death. Deenergize all power sources before servicing. Open the main circuit breakers of all transfer External Inspection. Keep the transfer switch clean switch power sources and disable all generator sets as and in good condition by performing a weekly general follows: (1) Move all generator set master controller switches external inspection of the transfer switch for any...
  • Page 21 Lubrication. The outer mechanism of the contactor is Terminal Tightening. Loose connections on the lubricated for the life of the contactor and requires no power circuits can lead to overheating or explosion. further lubrication under normal use. If the outer Tighten all contactor terminal lugs to 200 in.

  • Page 22: Testing

    Figure 3-3 Contact Cover and Retainer, Model source and signals the generator set to shut down after a G220 cooldown period. Section 3 Scheduled Maintenance TP-6322 9/04...

  • Page 23: Other Tests

    3.2.3 Other Tests accuracy. Look for approximately 0.1 mV per ampere of load current. DANGER 2. The highest voltage on a phase should be within 1.5 times the lowest voltage measured on other phases of the same source. This factor is high because all lines may not be exactly balanced, the construction of each contactor circuit may be Hazardous voltage.

  • Page 24: Service Schedule

    3.3 Service Schedule Follow the service schedule below for the recommended service intervals. Have all service performed by an authorized distributor/dealer except for items designated by an X. Visually System Component or Procedure Section Inspect Check Change Clean Test Interval Electrical System Check for signs of overheating or loose connections: 3.1.2...

  • Page 25: Section 4 Troubleshooting

    Section 4 Troubleshooting This section contains transfer switch troubleshooting WARNING information. Only trained qualified personnel following all applicable codes and standards should attempt to service the transfer switch covered by this manual. Improper repairs can be hazardous and lead to additional repairs.

  • Page 26: General Notes On Connections

    4.1 General Notes on Connections DANGER Many service problems are caused by faulty connections due to corrosion, loose terminals, and damaged wiring or connectors. With all power supplies disconnected, perform the following general checks Hazardous voltage. while troubleshooting. Will cause severe injury or death. Unplug connectors and check terminals and leads Disconnect all power sources before for corrosion.
  • Page 27 Problem Possible Cause Corrective Action ATS fails to operate No power to the transfer Close circuit breakers leading from power sources to the and no LEDs are lit switch/controller. transfer switch. Troubleshoot power to the system. See Section 4.2. Generator set does Generator set master switch is in the Place the generator set master switch in the AUTO position.
  • Page 28 A-353529 1. Normal source line voltage terminal strip TB1 12. VR1, +5 VDC 2. PCB jumper JP2 (cut to install test switch) 13. Exerciser switch wiring harness connector P2 3. Terminal strip TB2 14. Power supply and relay status terminal strip TB5 4.

  • Page 29: Ac System Voltages

    4.4.1 AC System Voltages on voltage regulator VR1 located near the center of the controller circuit board. It may be necessary to 1. Disconnect all power sources and check that the scrape the +5VDC terminal slightly with the test controller is connected to the contactor assembly probe due to the conformal coating on the circuit wiring harness at connector P1.

  • Page 30: Exerciser Circuits

    Engine Start Circuit Troubleshooting Note: When engine start circuit troubleshooting is complete, disconnect all power sources and 1. Disconnect all power sources and wait at least five reconnect the exerciser switch wiring harness to minutes. connector P2, and the engine start wires to terminals ES3 and ES4 on TB3 on the controller 2.

  • Page 31: Contactor Operation

    4.7.2 Solenoid Troubleshooting a. Place the exerciser switch in the Enable The solenoid coils on model G220 switches require position and check for open circuits between 120 VAC for operation. The rectifier is sealed inside the terminals J2-2 to J2-1 and J2-3.

  • Page 32: Scn And Sce Contacts

    Normal position. See Figure 4-6. position. See Figure 4-5. Contact SCN is closed in GM25944 Figure 4-5 G220 Contactor in Normal Position, No Power Present GM25944 Figure 4-6 G220 Contactor in Emergency Position, No Power Present Section 4 Troubleshooting...
  • Page 33 GM25944 Figure 4-7 G220 Contactor in the Emergency Position, Emergency Present, Normal Returns, TDEN Ends, Transferring to the Normal Position GM25944 Figure 4-8 G220 Contactor in the Normal Position, Normal Fails, Emergency Available, TDNE Ends, Transferring to the Emergency Position...

  • Page 34: Nr/Er Relays, Coils, And Controller Circuitry

    4.7.5 NR/ER Relays, Coils, and to be applied between terminals J1-15 and neutral, replace the controller assembly. Controller Circuitry 9. If the NA LED is lit, NR is energized, and 120 volts Use the following steps to troubleshoot controller appears between J1-15 and neutral but the circuits when voltage is not appearing on terminals AC1 contactor does not transfer to the normal position, and AC2 of the bridge rectifier BR to energize the...

  • Page 35: Emergency Source Sensing

    4. Apply the normal power source and wait for TDEC. 2. Reconnect the emergency source and check for If the NA LED does not light, see Section 4.10. If nominal line voltage on phase EA-EC between the NA LED lights and the ES LED does not light or terminals P1-3 and P1-6 on the controller the engine-start contact does not open within assembly.

  • Page 36: Normal Source Sensing

    4.10 Normal Source Sensing b. If the voltage on phase NA-NC on P1 on the controller exceeds the single-phase pickup Follow this section when the system fails to recognize voltage specification in Figure 4-10 then the NA LED on the controller assembly should light; the normal power source as available by lighting the NA replace the controller assembly if the LED does LED, or when it fails to recognize normal power source...

  • Page 37: Section 5 Drawings And Diagrams

    Section 5 Drawings and Diagrams Diagram or Drawing Drawing Number Page Enclosure Dimensions ..........ADV-6834 .
  • Page 38 Figure 5-1 Enclosure Dimension Drawing, ADV-6834 Section 4 Drawings and Diagrams TP-6322 9/04...
  • Page 39 Figure 5-2 Wiring Diagram, 100 and 200 Ampere, GM25943-B TP-6322 9/04 Section 4 Drawings and Diagrams...
  • Page 40 Figure 5-3 Schematic Diagram, 100 and 200 Amperes, GM25944-C Section 4 Drawings and Diagrams TP-6322 9/04...

  • Page 41: Section 6 Service Part Replacement

    Section 6 Service Part Replacement Use the instructions in this section for transfer switch Servicing the transfer switch. Hazardous voltage can cause severe injury or death. Deenergize all power sources service part replacement. See Section 7 for service before servicing. Open the main circuit breakers of all transfer parts.

  • Page 42: Before And After Servicing Components

    After Service Follow these instructions after servicing WARNING the transfer switch. 1. Reinstall barriers. 2. Remove debris from the enclosure. 3. See Section 2.1 for startup instructions. Unbalanced weight. Improper lifting can cause severe injury or death and equipment 6.2 Contactor Assembly damage.

  • Page 43: Solenoid Assembly

    2. Coil bracket 5. Core plate 3. Assembly mounting 6. Steel core screws and nuts 7. Washer Figure 6-3 Coil Assembly Parts tp5992 1. Remove screws, 2 locations Figure 6-1 Solenoid Assembly, Model G220, Typical TP-6322 9/04 Section 6 Service Part Replacement...

  • Page 44: Reassembly, 200 Amp Models

    6.3.3 Reassembly, 200 Amp Models 1. Position the coil in the bracket with the tab on the top of the coil and operating circuit terminal oriented as shown in Figure 6-4 for the Normal source coil or in Figure 6-5 for the Emergency source coil.

  • Page 45: Microswitch Replacement

    6.4 Microswitch Replacement Procedures shown are for the microswitch at the Emergency source coil. Use the same procedures for the microswitch at the Normal source coil. Perform the switch replacement procedures on one source side at a time. To replace the microswitch at the Normal source coil, first move the contactor to the Emergency source position.

  • Page 46: 200 Amp Models

    2. Remove the microswitch mounting screw and 6.4.2 200 Amp Models microswitch. See Figure 6-10 and Figure 6-11. 1. Remove the microswitch mounting screw and 3. Install the new microswitch. Push the microswitch microswitch. See Figure 6-12. mounting screw in the direction of the arrow shown 2.

  • Page 47: Controller Pcb Removal

    Don’t bend or drop the circuit board or any of its 6.5.2 Controller PCB Installation components. 1. Position the circuit board over the push-on PCB Don’t strike the circuit board or any of its components standoffs on the mounting plate. with a hard object.

  • Page 48: Other Service Part Installation

    6.6.2 Other Service Part Installation 3. Reconnect wiring to the same locations from which they where removed, torquing terminals to the 1. Position the part(s) in place in the same manner specifications given in the maintenance section of that the old part was installed. Support the back of this manual.

  • Page 49: Section 7 Service Parts

    Section 7 Service Parts Use this section to locate and identify serviceable parts 7.1.2 Leads for the transfer switch model covered by this manual. Fabricate replacement leads using the same type of wire as the old leads. Add terminals and lead markers at 7.1 General Information each end of the new lead.

  • Page 50: Contactor G220

    7.2 Contactor G220 Model G220 GM29885 Qty. Qty. 100 200 Item Part Number Description 100 200 Item Part Number Description Contactor assembly, Screw, pan head M7985A-04020-20 GM29860 100 A, 2 pole (includes machine items 2--18) Washer, plain, .156 ID x...

  • Page 51: Controls

    7.3 Controls DP-295000 Quantity by Characteristic 3 Phase 208 V 220 V 240 V Item Part Number Description 1-Phase 362107 Three-phase module, 208 V 362138 Three-phase module, 220 V 362108 Three-phase module, 240 V X-71-2 Nut, hex machine screw, 6-32 —...

  • Page 52: Decals

    Item Part Number Description 362112 Decal, ATS rating 297556 Decal, torque 362129 Decal, engine start 362176 Decal, danger X-6246-13 Decal, KOHLER POWER SYSTEMS 273746 Decal, TRANSFER SWITCH 362145 Decal, exerciser ATS 298777 Envelope, manual 362144 Decal, logic ATS 362130 Decal, NEMA 3R rating ATS...

  • Page 53: Enclosure, Nema Type 1

    7.5 Enclosure, NEMA Type 1 SECTION A- -A DP-295000 Item Part Number Description X-67-52 Screw, hex washer, thread-forming (16) 353617 Panel, ATS, top and bottom (2) 353616 Box, ATS Nut, hex, 10-32 (4) 353615 Cover, ATS 362126 Lug, terminal, copper X-22-11 Washer, lock, .262 ID x .469 in.

  • Page 54: Enclosure, Nema Type 3R

    7.6 Enclosure, NEMA Type 3R SECTION A- -A DP-295000 Item Part Number Description 362441 Enclosure (includes 353613, 353614, and 353708) 353613 Nut, hex, 10-32 (4) X-67-52 Screw, hex washer, thread-forming, 10-32 x 0.500 (2) 353614 Cover 353708 Hasp 362126 Lug, terminal, copper X-81-8 Nut, hex, 1/4-20 X-22-11...

  • Page 55: Neutral Lug, 100 Amp

    7.7 Neutral Lug, 100 Amp DP-295000 Item Part Number Description 233269 Insulator, panel (2) 295304 Bracket, mounting X-25-40 Washer, plain, .281 ID x .625 in. OD (2) X-22-11 Washer, lock, .262 ID x .469 in. OD (2) X-465-6 Bolt, 1/4-20 x .50 (2) 295303 Lug, terminal, aluminum (3) X-22-9...

  • Page 56: Neutral Lug, 200 Amp

    7.8 Neutral Lug, 200 Amp DP-295000 Item Part Number Description 233269 Insulator, panel (2) 297713 Bracket, mounting X-25-40 Washer, plain, .281 ID x .625 in. OD (2) X-22-11 Washer, lock, .262 ID x .469 in. OD (7) 297712 Lug, terminal (3) X-465-6 Bolt, 1/4-20 x .50 (5) 7.9 Auxiliary Switch...

  • Page 57: Appendix A Abbreviations

    Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere cubic feet per minute exh. exhaust ABDC after bottom dead center center of gravity ext. external alternating current cubic inch displacement Fahrenheit, female analog to digital centerline fglass.
  • Page 58 kilo (1000) MTBF mean time between failure round head machine (screw) kelvin MTBO mean time between overhauls rly. relay kiloampere mtg. mounting root mean square kilobyte (2 bytes) megawatt rnd. round kilogram milliwatt read only memory µF kg/cm kilograms per square microfarad rot.

  • Page 59: Appendix B Common Hardware Application Guidelines

    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.

  • Page 60: Appendix C General Torque Specifications

    Appendix C General Torque Specifications Use the following torque specifications when service oiled threads. Increase values by 15% for nonplated literature instructions give no specific torque values. threads. All torque values are +0%/--10%. The charts list values for new plated, zinc phosphate, or American Standard Fasteners Torque Specifications Assembled into Assembled into Cast Iron or Steel...

  • Page 61: Appendix D Common Hardware Identification

    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)

  • Page 62: Appendix E Common Hardware List

    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...
  • Page 63 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 64 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 68 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-6322 9/04 7 Jurong Pier Road Singapore 619159 E 2004 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455...

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