Kohler KGS Operation And Installation Manual
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Kohler KGS Operation And Installation Manual

Automatic transfer and bypass/isolation switches
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Operation and
Installation
Automatic Transfer and
Bypass/Isolation Switches
Models:
KGS/KGP
150 to 3000 Amperes
TP-6836 4/14a

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Summary of Contents for Kohler KGS

  • Page 1 Operation and Installation Automatic Transfer and Bypass/Isolation Switches Models: KGS/KGP 150 to 3000 Amperes TP-6836 4/14a...

  • Page 2: Product Identification Information

    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.

  • Page 3: Table Of Contents

    Table of Contents Product Identification Information ............. Safety Precautions and Instructions .
  • Page 4 Table of Contents, continued Accessory Modules ........... . 4.3.1 Accessory Module Mounting .

  • Page 5: Safety Precautions And Instructions

    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 Grounding electrical equipment. Servicing transfer switch. Testing live electrical circuits. Hazardous voltage cause Hazardous voltage cause Hazardous voltage or current can severe injury or death. Electrocution severe injury or death. Deenergize all cause severe injury or death. Have is possible whenever electricity is power sources before servicing.
  • Page 7 NOTICE NOTICE Foreign material contamination. Electrostatic discharge damage. Cover the transfer switch during Electrostatic discharge (ESD) installation to keep dirt, grit, metal drill damages electronic circuit boards. chips, and other debris out of the Prevent electrostatic discharge components. Cover the solenoid damage by wearing an approved mechanism during installation.
  • Page 8 Notes Safety Precautions and Instructions TP-6836 4/14...

  • Page 9: Introduction

    Separate manuals contain Information in this publication represents data available service 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...

  • Page 10: Service Assistance

    Phone: (86) 10 6518 7950 KOHLERPower.com. (86) 10 6518 7951 (86) 10 6518 7952 Look at the labels and stickers on your Kohler product Fax: (86) 10 6518 7955 or review the appropriate literature or documents included with the product.

  • Page 11: Section 1 Product Description

    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.

  • Page 12: Model Designation

    380 Volts / 60 Hz 400 Volts / 50 Hz 220 Volts / 60 Hz Note: Some selections are not available for every model. Contact your Kohler distributor for availability. 416 Volts / 50 Hz Section 1 Product Description TP-6836 4/14...

  • Page 13: Section 2 Installation

    Section 2 Installation 2.1 Introduction and/or rough handling is evident, immediately file a damage claim with the transportation company. Kohlerr transfer switches are shipped factory-wired, factory-tested, and ready for installation. 2.2.2 Lifting Have the equipment installed only be trained and WARNING qualified personnel.

  • Page 14: Storage

    2.2.3 Storage switch. Select a mounting site that complies with local electrical code restrictions for the enclosure type. Store the transfer switch in its protective packing until Mount the transfer switch as close to the load and power final installation. Protect the transfer switch at all times sources as possible.

  • Page 15: Seismic Certification

    2.4 Seismic Certification 7. Wide washers must be installed at each anchor location between the anchor head and equipment Automatic transfer switches with seismic certification for tension load distribution. See applicable ADV must be installed according to the instructions in this drawing for specific anchor information and section.

  • Page 16: Manual Operation Check

    2.5 Manual Operation Check NOTICE Improper operator handle usage. Use the manual operator handle on the transfer switch for maintenance purposes only. DANGER Return the transfer switch to the normal position. Remove the manual operator handle, if used, and store it in the place provided on the transfer switch when service is completed.

  • Page 17: Controller Connections

    2.6 Controller Connections The controller is mounted in a plastic housing on the inside of the transfer switch enclosure door. DANGER Figure 2-3 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.

  • Page 18: Controller Input And Output Connections

    2.6.1 Controller Input and Output Connections controller provides connections programmable inputs and two programmable outputs. See Figure 2-3 for the connector location. Each input has a signal and a return connection. The outputs are C form contacts with ratings of 500 mA @ 120 VAC.

  • Page 19: Electrical Wiring

    2.7 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: A protective device such as a molded-case circuit Will cause severe injury or death. breaker or fused disconnect switch MUST be Disconnect all power sources before installed on both sources of incoming power for...

  • Page 20: Generator Engine Start Connection

    Install and test the power cables. Leave sufficient Torque Bolt (Grade 5) Bolt slack in the power leads to reach all of the power in. lb. ft. lb. Size connecting lugs on the power switching device. Test the power conductors before connecting them to the 1/4-20 transfer switch.

  • Page 21: Auxiliary Contact Connections

    2.7.3 Auxiliary Contact Connections Terminals for field connections to the A3 Source 2 auxiliary contacts and the A4 Source 1 auxiliary contacts are also provided. See Figure 2-9 through Figure 2-11. These terminals are clearly marked and are located on the side of the power panel. On 400 amp metal frame units these terminals are located on the bracket above the operator handle.

  • Page 22: Communication And Accessory Connections

    2.8 Communication and Accessory Connections See Section 4 for accessory and communication connection instructions. 2.9 Functional Tests After completion of the mechanical installation and all electrical connections, perform the functional tests described in Section 6. The procedures in Section 6 are required to complete the installation and startup of the transfer switch.

  • Page 23: Section 3 Three-Source Systems

    Section 3 Three-Source Systems Three-Source Systems 3.3 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.

  • Page 24: Three-Source System Connection

    3.5 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 25 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.

  • Page 26: Ats1 And Ats2 System Setup

    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...

  • Page 27: Section 4 Communication And Accessory Connections

    Section 4 Communication and Accessory Connections 4.1 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. Hazardous voltage. Will cause severe injury or death.
  • Page 28 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...

  • Page 29: Ethernet Connection

    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 30 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.

  • Page 31: Accessory Modules

    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.

  • Page 32: Input/Output (I/O) Modules

    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.

  • Page 33: External Battery Supply Module (Ebsm)

    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.

  • Page 34: Alarm Module

    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 module mounting kit is required for installation of the the external battery voltage falls below 11 VDC for a alarm module.
  • Page 35 Alarm Board DIP Switches Alarm Operation, Chicago Alarm Mode There are four DIP switches on the alarm module board. Chicago Alarm mode requires the horn to sound and a Some of the switches are not used. See Figure 4-19. To lamp or LED to light when the switch is in the emergency enable the preferred source selection, set DIP switch 1 (non-preferred) position.

  • Page 36: Load Shed (Forced Transfer To Off)

    Figure 4-23. Use #12--24 AWG wire and tighten to 0.5 Nm (4.4 in. lb.). DANGER 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 37 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-6836 4/14 Section 4 Communication and Accessory Connections...

  • Page 38: Heater

    Heater DANGER Hazardous voltage. Will cause severe injury or death. Disconnect all power sources before opening the enclosure. Servicing the transfer switch. Hazardous voltage can 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.

  • Page 39: Other Accessories

    4.6 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 40 Notes Section 4 Communication and Accessory Connections TP-6836 4/14...

  • Page 41: Section 5 Scheduled Maintenance

    Section 5 Scheduled Maintenance Regular preventive maintenance ensures safe and The transfer switch controller Operation Manual reliable operation and extends the life of the transfer contains the Service Schedule and other maintenance switch. Preventive maintenance includes periodic information. Refer to the Operation Manual shipped testing, cleaning, inspection, and replacement of worn with the transfer switch, or check which controller is or missing components.
  • Page 42 Notes Section 5 Scheduled Maintenance TP-6836 4/14...

  • Page 43: Section 6 Functional Tests And Setup

    Section 6 Functional Tests and Setup 6.1 Introduction 6.3 Voltage Check The voltage, frequency, and phasing of the transfer Be sure to perform all of the functional tests described in switch and the power sources must be the same to this section before putting the transfer switch into avoid damage to loads and the transfer switch.

  • Page 44: Lamp Test

    4. Use a phase rotation meter to check the phase DANGER rotation at the Source N (normal) terminals. Rewire the transfer switch Source N terminals to obtain the correct phase sequence if necessary. Note: The default setting for the phase rotation on the controller is ABC.

  • Page 45: System Setup

    6.6 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.
  • Page 46 Notes Section 6 Functional Tests and Setup TP-6836 4/14...

  • Page 47: Section 7 Bypass/Isolation

    Section 7 Bypass/Isolation 7.1 Introduction Crank Mechanism (600- to 3000-amp switches only). The crank mechanism determines the ATS mode of operation: AUTO, TEST, or isolate. Turn the crank DANGER mechanism clockwise raise counterclockwise to lower the ATS through the three positions.

  • Page 48: Operation Of Bypass/Isolation Switch

    7.3 Operation of Bypass/Isolation In the ISOLATE position, the ATS is completely withdrawn and can be removed from the enclosure for Switch maintenance or service. See Figure 7-4. An automatic transfer switch equipped with a bypass/isolation switch allows withdrawal of the ATS for Bypass emergency testing and/or service without interrupting power to the Emergency...

  • Page 49: Bypassing And Isolating, 150- To 400-Amp Switches

    7.4 Bypassing and Isolating, 1. Check that the ATS is in automatic mode: 150- to 400-Amp Switches a. The ATS location handle is in the AUTO position. See Figure 7-6. Also see the notes after this procedure. b. The manual bypass handle is in the OPEN position.
  • Page 50 6. Reconnecting the ATS: i. Move the ATS location handle to the AUTO position. a. Place the ATS into its drawer slots (front rollers first). j. Turn the disconnect to the AUTO position and move the manual bypass handle to the OPEN b.

  • Page 51: Bypassing And Isolating, 600- To 1200-Amp Switches

    7.5 Bypassing and Isolating, Note: The bypass switch uses safety interlocks to prevent cross phasing. 600- to 1200-Amp Switches c. Move the manual-bypass handle to the See Figure 7-7. Also see the notes after this procedure. BYPASS POSITION. 3. Testing the ATS: DANGER a.
  • Page 52 j. Turn the disconnect switch to the INHIBIT 3. When the ATS is in the TEST or ISOLATE position position. the bypass switch acts as a manual transfer switch to either available source. k. Rotate the crank mechanism until the ATS is in the AUTO position.

  • Page 53: Bypassing And Isolating, 1600- To 3000-Amp Switches

    7.6 Bypassing and Isolating, a. Turn the disconnect switch to the INHIBIT position. 1600- to 3000-Amp Switches b. Position the bypass-selector switch to the See Figure 7-8. Also see the notes after this procedure. same power source as the ATS. Note: The bypass switch uses safety interlocks to DANGER prevent cross phasing.
  • Page 54 5. Removing the ATS: i. Rotate the crank mechanism clockwise until the ATS is in the AUTO position. The ATS must a. Bypass and isolate the ATS as described in the be in the same position as the Bypass switch. previous steps.

  • Page 55: Appendix A Abbreviations

    (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-6836 4/14 Appendix 55...
  • Page 56 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 57 Notes TP-6836 4/14...
  • Page 58 Notes TP-6836 4/14...
  • Page 60 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-6836 4/14a 7 Jurong Pier Road Singapore 619159 E 2014, 2017 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455...

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