automatic transfer switches - kohler co....6 safety precautions and instructions tp-6833 2/16...

Models:

KCS/KCP/KCC30 to 4000 Amperes

TP-6833 2/16a

Operation andInstallation

Automatic Transfer Switches

Product Identification Information

Product identification numbers determine service parts.Record the product identification numbers in the spacesbelow immediately after unpacking the products so thatthe numbers are readily available for future reference.Record field-installed kit numbers after installing thekits.

Transfer Switch Identification Numbers

Record the product identification numbers from thetransfer switch nameplate.

Model Designation

Serial Number

Accessories

- Alarm Board

- Battery Module

- Controller Disconnect Switch

- Current Monitoring

- Digital Meter

- Heater

- I/O Module, Standard (max. 4) qty:

- I/O Module, High Power (max. 4) qty:

- Load Shed

- Line-Neutral Monitoring

- Seismic Certification

- Supervised Transfer Switch

- Surge Protection Device (SPD)

-

-

-

-

-

-

Controller Identification

Record the controller description from the generator setoperation manual, spec sheet, or sales invoice.

Controller Description

Table of Contents

TP-6833 2/16 Table of Contents 3

Safety Precautions and Instructions 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .List of Related Materials 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Assistance 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 1 Product Description 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1 Purpose 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2 Nameplate 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3 Model Designation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2 Installation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1 Introduction 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2 Receipt of Unit 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.1 Inspection 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2.2 Lifting 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2.3 Storage 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2.4 Unpacking 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 Installation 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4 Seismic Certification 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5 Manual Operation, Model KCS Standard- Transition Switches 14. . . . . . . . . . . . . . .

2.5.1 Manual Operation, 30--200 Amp Standard-Transition Switches 14. . . . . . .2.5.2 Manual Operation, 225--4000 Amp Standard-Transition Switches 14. . . .

2.6 Manual Operation, Model KCP Programmed-Transition Switches 17. . . . . . . . . . . .2.6.1 Manual Operation Test Procedure, 150--1200 Amp Programmed-

Transition Transfer Switches 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6.2 Manual Operation Test Procedure, 1600--4000 Amp Programmed-

Transition Transfer Switches 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7 Manual Operation, Model KCC Closed-Transition Switches 21. . . . . . . . . . . . . . . . . .

2.7.1 Manual Operation Test Procedure, 150--1200 Amp Model KCC 21. . . . . .2.7.2 Manual Operation Procedure, 1600--4000 Amp Model KCC 23. . . . . . . . .

2.8 Controller Connections 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.8.1 Controller Input and Output Connections 25. . . . . . . . . . . . . . . . . . . . . . . . . .2.8.2 Harness Connection 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.8.3 Controller Ground 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9 Electrical Wiring 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.9.1 Source and Load Connections 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.9.2 Extended Transfer Time Relay (Model KCC only) 28. . . . . . . . . . . . . . . . . .2.9.3 Engine Start Connection 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.9.4 Auxiliary Contacts 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.10 Communication and Accessory Connections 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11 Functional Tests 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 3 Three-Source Systems 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1 Three-Source Systems 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2 Three Source Engine Start Mode 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.1 Mode 1 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2.2 Mode 2 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Preferred Source Toggle 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4 Three Source System Test and Exercise 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.1 Unloaded Test 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4.2 Loaded Test 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4.3 Unloaded Exercise 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4.4 Loaded Exercise 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 Three-Source System Connection 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.6 ATS1 and ATS2 System Setup 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents, continued

TP-6833 2/16Table of Contents4

Section 4 Communication and Accessory Connections 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1 Introduction 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2 Communication Connections 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.1 USB Port SiteTech Connection 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2.2 Modbus Connection 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2.3 Ethernet Connection 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Accessory Modules 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3.1 Accessory Module Mounting 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3.2 Input/Output (I/O) Modules 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3.3 External Battery Supply Module (EBSM) 43. . . . . . . . . . . . . . . . . . . . . . . . . .4.3.4 Alarm Module 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 Load Shed (Forced Transfer to OFF) 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5 Heater 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.6 Other Accessories 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 5 Functional Tests and Setup 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1 Introduction 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2 Manual Operation Test 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3 Voltage Check 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.4 Lamp Test 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.5 Automatic Operation Test 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.6 System Setup 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.7 Exerciser Setup 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.8 User Interface Cover 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.9 Startup Notification 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A Abbreviations 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TP-6833 2/16 5Safety Precautions and Instructions

Safety Precautions and Instructions

IMPORTANTSAFETY INSTRUCTIONS.Electromechanical equipment,including generator sets, transferswitches, switchgear, and accessories,can cause bodily harm and poselife-threatening danger whenimproperly installed, operated, ormaintained. To prevent accidents beaware of potential dangers and actsafely. Read and follow all safetyprecautions and instructions. SAVETHESE INSTRUCTIONS.

Thismanual has several types of safetyprecautions and instructions: Danger,Warning, Caution, and Notice.

DANGER

Danger indicates the presence of ahazard that will cause severepersonal injury, death, orsubstantialproperty damage.

WARNING

Warning indicates the presence of ahazard that can cause severepersonal injury, death, orsubstantialproperty damage.

CAUTION

Caution indicates the presence of ahazard that will or can cause minorpersonal injury or property damage.

NOTICENotice communicates installation,operation, or maintenance informationthat is safety related but not hazardrelated.

Safety decals affixed to the equipmentin prominent places alert the operatoror service technician to potentialhazards and explain how to act safely.The decals are shown throughout thispublication to improve operatorrecognition. Replace missing ordamaged decals.

Accidental Starting

Accidental starting.Can cause severe injury or death.

Disconnect the battery cables beforeworking on the generator set.Remove the negative (--) lead firstwhen disconnecting the battery.Reconnect the negative (--) lead lastwhen reconnecting the battery.

WARNING

Disabling the generator set.Accidental starting can causesevere injury or death. Beforeworking on the generator set orconnected equipment, disable thegenerator set as follows: (1) Move thegenerator set master switch to the OFFposition. (2) Disconnect the power tothe battery charger. (3) Remove thebattery cables, negative (--) lead first.Reconnect the negative (--) lead lastwhen reconnecting the battery. Followthese precautions to prevent starting ofthe generator set by an automatictransfer switch, remote start/stopswitch, or engine start command fromaremote computer.

(Decision-Makerr 3+ and 550Generator Set Controllers)

Disabling the generator set.Accidental starting can causesevere injury or death. Beforeworking on the generator set orequipment connected to the set,disable the generator set as follows:(1) Press the generator set off/resetbutton to shut down the generator set.(2) Disconnect the power to the batterycharger, if equipped. (3) Remove thebattery cables, negative (--) lead first.Reconnect the negative (--) lead lastwhen reconnecting the battery. Followthese precautions to prevent thestarting of the generator set by theremote start/stop switch.

(RDC, DC, RDC2, DC2,Decision-Makerr 3000, 3500 and6000 Generator Set Controllers)

Hazardous Voltage/Moving Parts

Hazardous voltage.Will cause severe injury or death.

Disconnect all power sources beforeopening the enclosure.

DANGER


Only authorized personnel shouldopen the enclosure.

DANGER

Grounding electrical equipment.Hazardous voltage can causesevere injury or death. Electrocutionis possible whenever electricity ispresent. Ensure you comply with allapplicable codes and standards.Electrically ground the generator set,transfer switch, and related equipmentand electrical circuits. Turn off themaincircuit breakers of all power sourcesbefore servicing the equipment. Nevercontact electrical leads or applianceswhen standing in water or on wetground because these conditionsincrease the risk of electrocution.

Short circuits. Hazardousvoltage/current can cause severeinjury or death. Short circuits cancause bodily injury and/or equipmentdamage. Do not contact electricalconnections with tools or jewelry whilemaking adjustments or repairs.Remove all jewelry before servicing theequipment.

Making line or auxiliaryconnections. Hazardous voltagecan cause severe injury or death. Toprevent electrical shock deenergize thenormal power source before makingany line or auxiliary connections.

TP-6833 2/166 Safety Precautions and Instructions

Servicing the transfer switch.Hazardous voltage can causesevere injuryor death. Deenergizeallpower sources before servicing. Turnoff the main circuit breakers of alltransfer switch power sources anddisable all generator sets as follows:(1) Move all generator set mastercontroller switches to theOFFposition.(2) Disconnect power to all batterychargers. (3) Disconnect all batterycables, negative (--) leads first.Reconnect negative (--) leads lastwhenreconnecting the battery cables afterservicing. Follow these precautions toprevent the starting of generator setsby an automatic transfer switch, remotestart/stop switch, or engine startcommand from a remote computer.Before servicing any componentsinside the enclosure: (1) Remove alljewelry. (2) Stand on a dry, approvedelectrically insulated mat. (3) Testcircuits with a voltmeter to verify thatthey are deenergized.

(Decision-Makerr 3+ and 550Generator Set Controllers)

Servicing the transfer switch.Hazardous voltage can causesevere injuryor death. Deenergizeallpower sources before servicing. Turnoff the main circuit breakers of alltransfer switch power sources anddisable all generator sets as follows:(1) Press the generator set off/resetbutton to shut down the generator set.(2) Disconnect power to all batterychargers. (3) Disconnect all batterycables, negative (--) leads first.Reconnect negative (--) leads lastwhenreconnecting the battery cables afterservicing. Follow these precautions toprevent the starting of generator setsby an automatic transfer switch, remotestart/stop switch, or engine startcommand from a remote computer.Before servicing any componentsinside the enclosure: (1) Remove alljewelry. (2) Stand on a dry, approvedelectrically insulated mat. (3) Testcircuits with a voltmeter to verify thatthey are deenergized.

(RDC, DC, RDC2, DC2,Decision-Makerr 3000, 3500 and6000 Generator Set Controllers)

Testing live electrical circuits.Hazardous voltage or current cancause severe injury or death. Havetrained and qualified personnel takediagnostic measurements of livecircuits. Use adequately rated testequipment with electrically insulatedprobes and follow the instructions of thetest equipment manufacturer whenperforming voltage tests. Observe thefollowing precautions when performingvoltage tests: (1) Remove all jewelry.(2) Standonadry, approvedelectricallyinsulated mat. (3) Do not touch theenclosure or components inside theenclosure. (4) Be prepared for thesystem to operate automatically.(600 volts and under)

Airborne particles.Can cause severe injury orblindness.

Wear protective goggles and clothingwhen using power tools, hand tools,or compressed air.

WARNING

Heavy Equipment

Unbalanced weight.Improper lifting can cause severeinjury or death and equipmentdamage.

Use adequate lifting capacity.Never leave the transfer switchstanding upright unless it is securelybolted in place or stabilized.

WARNING

NoticeNOTICE

Improper operator handle usage.Use the manual operator handle on thetransfer switch for maintenancepurposes only. Return the transferswitch to the normal position. Removethe manual operator handle, if used,and store it in the place provided on thetransfer switch when service iscompleted.

NOTICEForeign material contamination.Cover the transfer switch duringinstallation to keep dirt, grit, metal drillchips, and other debris out of thecomponents. Cover the solenoidmechanism during installation. Afterinstallation, use the manual operatinghandle to cycle the contactor to verifythat it operates freely. Do not use ascrewdriver to force the contactormechanism.

NOTICEElectrostatic discharge damage.Electrostatic discharge (ESD)damages electronic circuit boards.Prevent electrostatic dischargedamage by wearing an approvedgrounding wrist strap when handlingelectronic circuit boards or integratedcircuits. An approved grounding wriststrap provides a high resistance (about1 megohm), not a direct short, toground.

TP-6833 2/16 7Introduction

Introduction

This manual provides operation and installationinstructions for the followingKohlerrAutomaticTransferSwitches (ATS):

D Model KCS standard-transition any breaker ATS

D Model KCP programmed-transition any breaker ATS

D Model KCC closed-transition any breaker ATS

The transfer switch is equippedwith one of the followingKohlerr transfer switch controllers:

D Decision-Makerr MPAC 1200 controller

D Decision-Makerr MPAC 1500 controller

A separate manual provided with the transfer switchcovers the transfer switch controller operation. See Listof Related Materials for the document part number.

Information in this publication represents data availableat the time of print. Kohler Co. reserves the right tochange this literature and the products representedwithout notice and without any obligation or liabilitywhatsoever.

Read this manual and carefully follow all proceduresand safety precautions to ensure proper equipmentoperation and to avoid bodily injury. Readand follow theSafety Precautions and Instructions section at thebeginning of this manual. Keep this manual with theequipment for future reference.

The equipment service requirements are very importantto safe and efficient operation. Inspect parts often andperform required service at the prescribed intervals.See the controller Operation manual for the serviceschedule. Obtain service from an authorized servicedistributor/ dealer to keep equipment in top condition.

List of Related Materials

A separate manual covers the transfer switch controllerand related accessories. Separate manuals containservice and parts information for transfer switch powerswitching devices and electrical controls.

The following table lists the part numbers for relatedliterature.

Literature Item Part Number

Specification Sheet, Decision-MakerrMPAC 1200 Controller G11-127

Specification Sheet, Decision-MakerrMPAC 1500 Controller G11-128

Specification Sheet, Model KCS/KCP/KCC G11-129

Operation Manual, Decision-MakerrMPAC 1200 Controller TP-6866

Operation Manual, Decision-MakerrMPAC 1500 Controller TP-6883

Parts Catalog, Transfer Switch and Controller TP-6433

Service Manual, Model KC/KB TP-6920

TP-6833 2/168 Service Assistance

Service Assistance

For professional advice on generator powerrequirementsandconscientiousservice, pleasecontactyour nearest Kohler distributor or dealer.

D Consult the Yellow Pages under the headingGenerators—Electric.

D Visit the Kohler Power Systems website atKOHLERPower.com.

D Lookat the labels and stickers on yourKohler productor review the appropriate literature or documentsincluded with the product.

D Call toll free in the US and Canada 1-800-544-2444.

D Outside theUSandCanada, call the nearest regionaloffice.

Headquarters Europe, Middle East, Africa(EMEA)Kohler Power Systems Netherlands B.V.Kristallaan 14761 ZC ZevenbergenThe NetherlandsPhone: (31) 168 331630Fax: (31) 168 331631

Asia PacificPower Systems Asia Pacific Regional OfficeSingapore, Republic of SingaporePhone: (65) 6264-6422Fax: (65) 6264-6455

ChinaNorth China Regional Office, BeijingPhone: (86) 10 6518 7950

(86) 10 6518 7951(86) 10 6518 7952

Fax: (86) 10 6518 7955

East China Regional Office, ShanghaiPhone: (86) 21 6288 0500Fax: (86) 21 6288 0550

India, Bangladesh, Sri LankaIndia Regional OfficeBangalore, IndiaPhone: (91) 80 3366208

(91) 80 3366231Fax: (91) 80 3315972

Japan, KoreaNorth Asia Regional OfficeTokyo, JapanPhone: (813) 3440-4515Fax: (813) 3440-2727

Latin AmericaLatin America Regional OfficeLakeland, Florida, USAPhone: (863) 619-7568Fax: (863) 701-7131

TP-6833 2/16 9Section 1 Product Description

Section 1 Product Description

1.1 Purpose

An automatic transfer switch (ATS) transfers electricalloads from a normal (preferred) source of electricalpower to an emergency (standby) source when thenormal source falls outside the acceptable electricalparameters.

When the normal (preferred) source fails, the ATSsignals the emergency (standby) source generator setto start. When theemergency (standby) source reachesacceptable levels and stabilizes, the ATS transfers theload from the normal (preferred) source to theemergency (standby) source. The ATS continuouslymonitors the normal (preferred) source and transfersthe load back when the normal (preferred) sourcereturnsandstabilizes. After transferring the loadback tothe normal (preferred) source, the ATS removes thegenerator start signal, allowing the generator set to shutdown.

Figure 1-2 shows a typical installation block diagram.

Figure 1-1 Automatic Transfer Switch

Figure 1-2 Typical ATS Block Diagram

PowerSwitchingDevice

To Load

Automatic Transfer Switch

ElectricalControls

Normal(Utility)Power

Emergency(Generator)Power

Generator

Start Generator

TS-003

1.2 Nameplate

A nameplate attached to the controller cover on theinside of the enclosure door includes a modeldesignation, a serial number, ratings, and otherinformation about the transfer switch. See Figure 1-3.The serial number is also shown on a label inside thetransfer switch enclosure.

Copy the model designation, serial number, andaccessory information from thenameplate to thespacesprovided in the Product Identification Informationsection inside the front cover of thismanual for usewhenrequesting service or parts.

GM21291

Figure 1-3 Typical Transfer Switch Nameplate

TP-6833 2/1610 Section 1 Product Description

1.3 Model Designation

Model Controls Voltage Poles Enclosure Current Rating ConnectionsMechanism Transition

Record the transfer switch model designation in the boxes. The transfer switch model designation definescharacteristics and ratings as explained below.

Sample Model Designation: KCS-DNTA-0400S

Model

K: Kohler

Mechanism

C: Standard (Any Breaker)

Transition

S: Standard

P: Programmed

C: Closed

Controller

A: Decision-Makerr MPAC 1200, Automatic

B: Decision-Makerr MPAC 1200, Non-Automatic

D: Decision-Makerr MPAC 1500, Automatic

F: Decision-Makerr MPAC 1500, Non-Automatic

* Non-automatic controls are available on Models KCS and KCPonly.

Voltage/Frequency

C: 208 Volts /60 Hz K: 440 Volts /60 Hz

D: 220 Volts /50 Hz M: 480 Volts /60 Hz

F: 240 Volts /60 Hz N: 600 Volts /60 Hz

G: 380 Volts /50 Hz P: 380 Volts /60 Hz

H: 400 Volts /50 Hz R: 220 Volts /60 Hz

J: 416 Volts /50 Hz

Number of Poles/Wires

N: 2 Poles /3 Wires, Solid Neutral

T: 3 Poles /4 Wires, Solid Neutral

V: 4 Poles /4 Wires, Switched Neutral

W: 4 Poles /4 Wires, Overlapping Neutral

Enclosure

A: NEMA 1 D: NEMA 4

B: NEMA 12 F: NEMA 4X

C: NEMA 3R G: Open Unit

Current, Amps

0030 0260 1600

0070 0400 2000

0104 0600 2600

0150 0800 3000

0200 1000 4000

0230 1200

Connections

S: Standard

F: Front (1600 and 2000 amp only)

Note: Some selections are not available for every model.Contact your Kohler distributor for availability.

TP-6833 2/16 11Section 2 Installation

Section 2 Installation

2.1 Introduction

Kohlerr transfer switches are shipped factory-wired,factory-tested, and ready for installation. Have theequipment installed only by trained and qualifiedpersonnel, and verify that the installation complies withapplicable codes and standards. Switch installationincludes the following steps:

D Unpack and inspect the transfer switch upon receipt.

D Verify that the transfer switch voltage and frequencyratings match the voltages and frequencies of thesources.

D Install the transfer switch.

D Check the manual operation.

D Connect the controller harness and ground lead.

D Connect the generator set engine start leads.

D Connect the normal power source (utility),emergency power source (generator set), and loadcircuits.

D Connect accessories, if provided.

D Check voltages and operation.

Protect the switch against damage before and duringinstallation.

Note: Aprotective device suchasamolded-case circuitbreaker or fused disconnect switch MUST beinstalled on both sources of incoming power forcircuit protection and used as a disconnectdevice.

The functional tests in Section 5 are a necessary part ofthe installation. Be sure to perform the functional tests,which include voltage checks and operation tests,before putting the transfer switch into service.

2.2 Receipt of Unit

2.2.1 Inspection

At the time of delivery, inspect the packaging and thetransfer switch for signs of shipping damage. Unpackthe transfer switch as soon as possible and inspect theexterior and interior for shipping damage. If damage

and/or rough handling is evident, immediately file adamage claim with the transportation company.

2.2.2 Lifting

Unbalanced weight.Improper lifting can cause severeinjury or death and equipmentdamage.

Use adequate lifting capacity.Never leave the transfer switchstanding upright unless it is securelybolted in place or stabilized.

WARNING

Refer to Figure 2-1 for the approximate weight of thetransfer switch in a Type 1 enclosure. For otherenclosures, refer to the dimension drawing. Use aspreader bar to lift the transfer switch. Attach the baronly to the enclosure’s mounting holes or liftingbrackets; do not lift the unit any other way. Close andlatch the enclosure door before moving the unit.

Amps

Weight kg (lb.)

2-Pole 3-Pole 4-Pole

Model KCS

30--200 28 (62) 30 (65) 31 (68)

230 52 (115) 56 (123) 59 (131)

260--600 179 (395) 183 (403) 188 (414)

800--1000 220 (485) 231 (510) 238 (525)

1200 — 356 (785) 379 (835)

1600--2000 — 472 (1040) 494 (1090)

2600--3000 — 649 (1430) 679 (1495)

4000 — 975 (2149) 1056 (2328)

Models KCP and KCC

150--600 179 (395) 183 (403) 188 (414)

800--1000 220 (485) 231 (510) 238 (525)

1200 — 463 (1020) 485 (1070)

1600--2000 — 533 (1175) 556 (1225)

2600--3000 — 735 (1620) 765 (1685)

4000 — 975 (2149) 1056 (2328)

Figure 2-1 Approximate Weights, Type 1 Enclosures

TP-6833 2/1612 Section 2 Installation

2.2.3 Storage

Store the transfer switch in its protective packing untilfinal installation. Protect the transfer switch at all timesfrommoisture, construction grit, andmetal chips. Avoidstorage in low-temperature and high-humidity areaswhere moisture could condense on the unit. SeeFigure 2-2 for acceptable storage temperatures.

Environmental Specifications

Operating Temperature --20C to 70C (--4F to 158F)

Storage Temperature --40C to 85C (--40F to 185F)

Humidity 5% to 95% noncondensing

Figure 2-2 Environmental Specifications

2.2.4 Unpacking

Allow the equipment to warm to room temperature for atleast 24 hours before unpacking to preventcondensation on the electrical apparatus. Use carewhen unpacking to avoid damaging transfer switchcomponents. Remove dirt and packing material thatmayhaveaccumulated in the transfer switchor anyof itscomponents.

Note: Do not use compressed air to clean the switch.Cleaning with compressed air can cause debristo lodge in the components and damage theswitch.

For 600--800 amp transfer switches, remove the lagscrews that secure the transfer switch to the shippingskid. For 1000--4000 amp transfer switches, open theenclosure door to remove the lag screws that secure thetransfer switch to the skid.

2.3 Installation

NOTICEForeign material contamination. Cover the transfer switchduring installation to keep dirt, grit, metal drill chips, and otherdebris out of the components. Cover the solenoidmechanismduring installation. After installation, use themanual operatinghandle to cycle the contactor to verify that it operates freely.Do not use a screwdriver to force the contactor mechanism.

The transfer switch may use both American Standard andmetric hardware. Use the correct size tools to preventrounding of the bolt heads and nuts.

Check the system voltage and frequency. Comparethe voltage and frequency shown on the transfer switchnameplate to the source voltage and frequency. Do notinstall the transfer switch if the system voltage andfrequency are different from the nominal normal (utility)source voltage and frequency or the nominalemergency source voltage and frequency shown on thegenerator set nameplate.

Plan the installation. Use the dimensions given on theenclosure dimension (ADV) drawings. Select amounting site that complies with local electrical coderestrictions for the enclosure type. Mount the transferswitch as close to the load and power sources aspossible. Allow adequate space to fully open theenclosure and to service the switch. Provide cablebending space and clearance to live metal parts.

Outdoor installations. Transfer switches withNEMA 3R, 4, or 4X enclosures can be installedoutdoors. In locations with very high ambienttemperatures, installation in a shaded area or a locationwith the enclosure door facing away from direct sunlightis recommended.

Prepare the foundation. Ensure that the supportingfoundation for the enclosure is level and straight. Forbottom cable entry, if used, install conduit stubs in thefoundation. Refer to the enclosure dimension drawingfor the conduit stub locations. When pouring a concretefloor, use interlocking conduit spacer caps or a wood ormetal template to maintain proper conduit alignment.

Installation of seismically certified transferswitches. Seismic certification must be requestedwhen the transfer switch is ordered. See Section 2.4and the transfer switch dimension (ADV) drawings foradditional installation requirements for transfer switcheswith seismic certification.

Install the ATS. Mount 30- through 400-amp transferswitches to a wall or other rigid vertical supportingstructure. Clearance holes through the back of eachenclosure are provided for mounting. Level theenclosure and use shims if needed to make it plumb.Verify that the door hinges are vertical to avoid distortionof the enclosure or door.

Bolt 600- through 4000-amp automatic transferswitches directly to floor mounting pads. Use shims ifneeded to plumb the enclosure. Verify that the doorhinges are vertical to avoid distortion of the enclosure ordoor.


2.4 Seismic Certification

Automatic transfer switches with seismic certificationmust be installed according to the instructions in thissection. Also refer to ADV-7456, the Certificate ofCompliance provided with the ATS, and the installation(ADV) drawings for the transfer switch.

Abbreviations:

ACI: American Concrete Institute

IBC: International Building Coder

SDS: Design spectral response acceleration at shortperiod, as determined in Section 1615.1.3 ofthe IBC

Rp: Equipment response modification factor

Ip: Equipment importance factor

ap: In-structure equipment amplification factor

Refer to the International Building Coder for moreinformation.

General Seismic Installation Notes:

1. Anchors used for seismic installation must bedesigned in accordance with ACI 355.2--04.Suggested manufacturers include Simpson,Ramset, and Hilti.

2. Anchors must be installed to a minimumembedment of 8x the anchor diameter.

3. Anchors must be installed in minimum 4000 psicompressive strength normal weight concrete.Concrete aggregate must comply with ASTMC33.Installation in structural lightweight concrete is notpermitted unless otherwise approved by thestructural engineer of record.

4. Anchors must be installed to the required torquespecified by the anchor manufacturer to obtainmaximum loading.

5. Anchors must be installed to the anchor spacingrequired to obtain maximum load and edgedistance required to obtain maximum load unlessotherwise approved by the structural engineer ofrecord.

6. Anchors used for seismic installation must bedesigned and rated to resist seismic loading in

accordancewith ACI 355.2--04 and documented ina report by a reputable testing agency (forexample, the Evaluation Service Report issued bythe International Code Council).

7. Wide washers must be installed at each anchorlocation between the anchor head and equipmentfor tension load distribution. See applicable ADVdrawing for specificanchor informationandwasherdimensions.

8. Equipment installed on a housekeeping padrequires the housekeeping pad thickness to be atleast 1.5x the anchor embedment depth.

9. All housekeeping pads must be seismicallydesigned and dowelled or cast into the buildingstructure as approved by the structural engineer ofrecord.

10. Rebar reinforcing in the housekeeping pad isrequired for all installations.

11. Concrete and rebar reinforcing must be designedin accordance with ACI 318--05.

12. Wall mounted equipment must be installed to arebar reinforced structural concrete wall that isseismically designed and approved by theengineer of record to resist the added seismicloads fromcomponents being anchored to thewall.

13. Floor mounted equipment (with or without ahousekeeping pad) must be installed to a rebarreinforced structural concrete floor that isseismically designed and approved by theengineer of record to resist the added seismicloads from components being anchored to thefloor.

14. When installing to a floor or wall, rebar interferencemust be considered.

15. Equipment attached to any structural floor otherthan those constructed of structural concrete anddesigned to accept the seismic loads from themounted equipment are beyond the scope of thisspecification.

16. Installation to light-weight concrete over steeldecking is beyond the scope of this specification.

17. Installation to concrete block or cinder block wallsis beyond the scope of this specification.


2.5 Manual Operation, Model KCSStandard- Transition Switches



DANGER

Servicing the transfer switch. Hazardous voltage cancause severe injury or death. Deenergize all power sourcesbefore servicing. Turn off the main circuit breakers of alltransfer switch power sources and disable all generator setsas follows: (1) Press the generator set off/reset button to shutdown the generator set. (2) Disconnect power to all batterychargers. (3) Disconnect all battery cables, negative (--) leadsfirst. Reconnect negative (--) leads last when reconnecting thebattery cables after servicing. Follow these precautions toprevent the starting of generator sets by an automatic transferswitch, remote start/stop switch, or engine start commandfrom a remote computer. Before servicing any componentsinside the enclosure: (1) Remove all jewelry. (2) Stand on adry, approved electrically insulatedmat. (3) Test circuits with avoltmeter to verify that they are deenergized.

Note: A manual operation handle is provided on thetransfer switch for maintenance purposes only. Donot use the manual operation handle to transferthe load with the power connected.

Use the manual operation handle to check the manualoperation before energizing the transfer switch. Use thefollowingmanual operation procedures to verify that thecontactor operates smoothly without binding.

Note: A contactor in normal and serviceable conditionoperates smoothly without binding. Do not placethe transfer switch into service if the contactordoes not operate smoothly; contact anauthorized distributor/dealer to service thecontactor.

2.5.1 Manual Operation, 30--200 AmpStandard-Transition Switches

The 30--200 amp standard-transition models have anattached manual operating handle. See Figure 2-3.

Manual Operation Test Procedure, 30--200 AmpTransfer Switches

1. Disable the generator set to prevent starting anddisconnect all power sources before manuallyoperating the transfer switch.

2. Turn the attached handle to manually operate thetransfer switch. See Figure 2-3. It should operatesmoothly without any binding. If it does not, checkfor shipping damage or construction debris.

3. Return the transfer switch to the Normal position.

1

127a

1. Handle

Figure 2-3 Manual Operation Handle, 30--200 AmpModel KCS

2.5.2 Manual Operation, 225--4000 AmpStandard-Transition Switches



DANGER

NOTICEImproper operator handle usage. Use the manual operatorhandle on the transfer switch for maintenance purposes only.Return the transfer switch to the normal position. Remove themanual operator handle, if used, and store it in the placeprovided on the transfer switch when service is completed.

The 225--4000 amp standard-transition models use adetachable manual operating handle.

Manual Operation Test Procedure, 225--1200 AmpStandard-Transition Transfer Switches


2. Remove the maintenance handle from the clip(s)on the left side of the transfer switch frame. SeeFigure 2-4.


3. 225--600 amp switches: See Figure 2-5. Insertthemaintenancehandle into thehole in theshaft onthe left side of the operator.

800--1200 amp switches: See Figure 2-7. Insertthemaintenance handle into the hole in themoldedhub on the left side of the operator.

4. Move the maintenance handle up or down asshown to manually operate the transfer switch. Itshould operate smoothly without any binding. If itdoes not, check for shipping damage orconstruction debris. See Figure 2-6.


6. Remove the maintenance handle and store it on theframe in the clips provided.

Note: Verify that the maintenance handle has beenremoved before proceeding.

202

1. Maintenance handle2. Storage clip(s)

1

2

Figure 2-4 Detachable Handle Storage (typical)

3

283

1. Handle2. Hub3. Position indicators (right side of contactor):

O = open, C = closed

1

2

N

E

N

E

Figure 2-5 Manual Operation, 225--600 AmpModel KCS

ATS Position Handle Indicators

Normal

Up E : Oupper contacts open

N : Clower contacts closed

Emergency

Down

E : Cupper contacts closed

N : Olower contacts open

Note: If Normal and Emergency connections are reversed,this operation is also reversed.

Figure 2-6 Maintenance Handle Positions,225--1200 Amp Model KCS


202

2

1

1. Maintenance handle2. Hub

1

Figure 2-7 Manual Operation, 800--1200 AmpModel KCS

Manual Operation Test Procedure, 1600--4000 AmpStandard-Transition Transfer Switches


2. Remove the maintenance handle from the clip(s)on the left side of the transfer switch frame. SeeFigure 2-4.

3. See Figure 2-8. Slide the hub onto the shaft andinsert the maintenance handle into the hole in thehub until the spring is fully compressed.

4. Move the maintenance handle as shown tomanually operate the transfer switch. It shouldoperate smoothlywithout anybinding. If it doesnot,check for shipping damage or construction debris.


6. Remove the maintenance handle and store it on thetransfer switch in the clips provided.

Note: Verify that the maintenance handle has beenremoved before proceeding.

Position indicators onLEFT side of contactorshow contacts OPEN orCLOSED

4

127a

3

1. Emergency contact position indicator2. Normal contact position indicator

3. Slide hub onto shaft4. Insert maintenance handle until spring is fully compressed

1

2

Figure 2-8 Manual Operation, 1600--4000 Amp Model KCS


2.6 Manual Operation, Model KCPProgrammed-TransitionSwitches

Programmed-transition switches have two operators,Normal and Emergency, on the left side of the contactorassembly. Mechanical interlocks prevent closing bothoperators at the same time. Refer to Figure 2-9 fortypical locations of the Normal and Emergencyoperators.

Programmed-transition models use a detachablemanual operating handle. Position indicators on theright side of the contactor assembly show the positionsof the operators. See Figure 2-10.



DANGER



UP opens theEmergency sourcecontacts

DOWN closes theEmergency sourcecontacts

UPPER SHAFT

UP closes theNormal sourcecontacts

DOWN opens theNormal sourcecontacts

LOWER SHAFT

Emergency Operator(shown open)

Normal Operator(shown closed)

Insert the maintenancehandle into the hub.

Handle storage location

Figure 2-9 Model KCP Manual Operation (typical)


2.6.1 Manual Operation Test Procedure,150--1200 Amp Programmed-Transition Transfer Switches

Refer to Figure 2-10 through Figure 2-12 during thefollowing procedure.

Check the operation of both operators by following theinstructions below for both the Normal and Emergencyoperators in the following sequence:


2. Starting with the contactor in the Normal position,use the maintenance handle to move the Normaloperator from the closed to the open position.

3. Move the Emergency operator from the openposition to the closed position.

4. Return the Emergency operator to the openposition and the Normal operator to the closedposition.

5. Remove themaintenance handle and store it in theplace provided on the switch.

1. Emergency contact indicator2. Normal contact indicator

1

2

O = Open; C = Closed

Figure 2-10 Position Indicators

Transfer Switch Position Interlocked Shafts Maintenance Handle Shaft Indicators

Normal

E

N LinkContact shafts

Hub

Hub

Up

E : O

upper contacts open

N : C

lower contacts closed

Up

LoadDisconnected

E

N

Up

E : O

upper contacts open

N : O

lower contacts open

Down

Emergency

E

N

Down

E : C

upper contacts closed

N : O

lower contacts open

Down

Note: The link between contact shafts prevents closing both N and E contacts.The hub and contact shaft turn in opposite directions through a cam follower mechanism.

Note: If Normal and Emergency connections are reversed, this operation is also reversed.

Figure 2-11 Maintenance Handle Positions, 150--600 Amp Model KCP Only. ALL POWER MUST BE OFF !


Transfer Switch Position Interlocked Weights Maintenance Handle Shaft Indicators

Normal

E

N

Lobe Lobe

Weight

Weight Hub

Hub

Up

E : O

upper contacts open

N : C

lower contacts closed

Up

LoadDisconnected

E

N

Up

E : O

upper contacts open

N : O

lower contacts open

Down

Emergency

E

N

Down

E : C

upper contacts closed

N : O

lower contacts open

Down

Note: If Normal and Emergency connections are reversed this operation is also reversed.

Note: The lobes prevent closing both N and E contacts at the same time.

Figure 2-12 Maintenance Handle Positions, 800--1200 Amp Model KCP Only. ALL POWER MUST BE OFF !


2.6.2 Manual Operation Test Procedure,1600--4000 Amp Programmed-Transition Transfer Switches

Check the operation of both operators by following theinstructions below for both the Normal and Emergencyoperators. Refer to Figure 2-13 during this procedure.


2. Install the hub onto the shaft and insert the pin.

3. Insert the manual operating handle into the sidehole on the hub until the spring is fully compressed.

4. Push in or pull out the hub to engage the oppositesource contacts:

a. Pull out the shaft to engage the emergencysource contacts.

b. Push in the shaft to engage the normal sourcecontacts.

5. Grasp the handle firmly with both hands and rotatedown:

a. Rotate counterclockwise to open the contacts.

b. Rotate clockwise to close the contacts.

6. Repeat steps 4 and 5 on the other transfer switch.

7. Return the CN transfer switch to the C (closed)position. Return the CE transfer switch to the O(open) position.Remove themanual operator handleand store it on the transfer switch in the placeprovided.

3

129

1. Emergency contacts position indicator2. Normal contacts position indicator3. Hub. Slide onto the shaft and insert the pin.4. Manual operating handle. Insert until spring is fully compressed.

OPEN orCLOSED

Contact positionindicators (left side)

1

2

4

Pull out shaft for emergency contacts; push in fornormal contacts.

Rotate handle down, clockwise to close orcounterclockwise to open contacts.

Turn counterclockwise to OPEN contacts.

Turn clockwise to CLOSE contacts.

Figure 2-13 Manual Operation, 1600--4000 Amp Model KCP


2.7 Manual Operation, ModelKCC Closed-TransitionSwitches



DANGER



Note: A manual operation handle is provided on thetransfer switch for maintenance purposes only. Donot use the manual operation handle to transferthe load with the power connected.

Use the manual operation handle to check the manualoperation before energizing the transfer switch. Checkthe operation of both the Normal and Emergencyoperators.

A contactor in normal and serviceable conditionoperates smoothlywithout binding. Do not place thetransfer switch into service if the contactor does notoperate smoothly; contact an authorizeddistributor/dealer to service the contactor.

Closed-transition switches have two operators, NormalandEmergency. Refer toFigure 2-9 for typical locationsof the Normal and Emergency operators.

Position indicators on the right side of the contactorassembly show the positions of the operators. SeeFigure 2-14.

2.7.1 Manual Operation Test Procedure,150--1200 Amp Model KCC

Refer to Figure 2-14 through Figure 2-16 during thefollowing procedure.

Check the operation of both operators for both theNormal and Emergency contacts in the followingsequence:


2. Locate the maintenance handle stored on the leftside of the transfer switch frame.

3. Starting with the contactor in the Normal position,use the maintenance handle to move the Normaloperator from the closed to the open position.

4. Move the Emergency operator from the openposition to the closed position.

5. Return the Emergency operator to the openposition and the Normal operator to the closedposition. Observe that thewindow indicators showthe upper shaftO (emergency open) and the lowershaft C (normal closed). See Figure 2-14.

6. Remove themaintenance handle and store it in theclips provided on the switch.

1. Emergency contact indicator2. Normal contact indicator

1

2

O = Open; C = Closed

Figure 2-14 Indicators, Model KCC


UP opens theEmergency sourcecontacts

DOWN closes theEmergency sourcecontacts

Upper Shaft

UP closes theNormal sourcecontacts

DOWN opens theNormal sourcecontacts

Lower Shaft:

EMERGENCYOPERATOR(shown open)

NORMALOPERATOR(shown closed)

Insert the maintenance handle into the hub:

800--1200 Amps150--600 Amps

Handle storage location

Figure 2-15 Transfer Switch Manual Operation,150 -- 1200 Amp Model KCC (typical)

ATS Position Handle Indicators

Normal

E = Oupper contacts open

N = Clower contacts closed

Emergency

E = Cupper contacts closed

N = Olower contacts open

Figure 2-16 Maintenance Handle Positions, ModelKCC. ALL POWER MUST BE OFF !


2.7.2 Manual Operation Procedure,1600--4000 Amp Model KCC

Check the operation of both operators by following theinstructions below for both the Normal and Emergencyoperators. Refer to Figure 2-17 during this procedure.


2. Install the hub onto the shaft and insert the pin.

3. Insert the manual operating handle into the sidehole on the hub until the spring is fully compressed.

4. Push in or pull out the hub to engage the oppositesource contacts:

a. Pull out the shaft to engage the emergencysource contacts.

b. Push in the shaft to engage the normal sourcecontacts.

5. Grasp the handle firmly with both hands and rotatedown:

a. Rotate counterclockwise to open the contacts.

b. Rotate clockwise to close the contacts.

6. Repeat steps 4 and 5 on the other transfer switch.

7. Return the CN transfer switch to the C (closed)position. Return the CE transfer switch to the O(open) position.Remove themanual operator handleand store it on the transfer switch in the placeprovided.

3

129

1. Emergency contacts position indicator2. Normal contacts position indicator3. Hub. Slide onto the shaft and insert the pin.4. Manual operating handle. Insert until spring is fully compressed.

OPEN orCLOSED

Contact positionindicators (left side)

1

2

4

Pull out shaft for emergency contacts; push in fornormal contacts.

Rotate handle down, clockwise to close orcounterclockwise to open contacts.

Turn counterclockwise to OPEN contacts.

Turn clockwise to CLOSE contacts.

Figure 2-17 Transfer Switch Manual Operation, 1600--4000 Amps


2.8 Controller Connections



DANGER

NOTICEElectrostatic discharge damage. Electrostatic discharge(ESD) damages electronic circuit boards. Preventelectrostatic discharge damage by wearing an approvedgrounding wrist strap when handling electronic circuit boardsor integrated circuits. An approved grounding wrist strapprovides a high resistance (about 1 megohm), not a directshort, to ground.

The controller is mounted in a plastic housing on theinside of the transfer switch enclosure door.

Figure 2-18 shows the locations of the connectors onthe controller. It is not necessary to open the cover toaccess the Ethernet, Modbusr, and input/outputconnectors.

Opening the cover. If necessary, open the plastichousing by pushing up on the latch on the bottom of thecover and swinging the cover up and out. The cover ishinged at the top. Lift the cover off the hinges to removeit completely, if necessary.

Note: Always replace the cover before energizing thetransfer switch controls.

6

1. Standard input/output connection2. RS-485 connection TB23. Connection for optional current sensing kit4. Optional I/O module connection P16

5. Access openings to optional RJ-45 connector6. Latch7. Ground wire8. Contactor harness connection

5

GM85884

1

3

8

7

24

Figure 2-18 Controller

Modbus is a registered trademark of Schneider Electric.


2.8.1 Controller Input and OutputConnections

The controller provides connections for twoprogrammable inputs and two programmable outputs.See Figure 2-18 for the connector location andFigure 2-19 for the I/O connection specifications.

Each input has a signal and a return connection. Theoutputs are C form contacts with ratings of500 mA@ 120 VAC. See Figure 2-20 for connections.Use #12--24 AWG wire and tighten the connections to0.5 Nm (4.4 in. lbs.).

For additional input and output connections, optionalinput/output modules are available. See Section 4.3 forinstructions.

Main Board I/O Specifications

Output contact type Isolated form C (SPDT)

Output contact rating 1 amp @ 30 VDC,500 mA @120 VAC

I/O terminals wire size #12--24 AWG

Figure 2-19 Main Board I/O Specifications

6866

Input 1A

Input 1BInput 2A

Input 2B

Output 1 NC

Output 1 C

Output 1 NO

Output 2 NC

Output 2 C

Output 2 NO

TB1

NC = normally closedNO = normally openC = common

12

61

7

Figure 2-20 Input and Output Connections

2.8.2 Harness Connection

Verify that the contactor harness is connected at thecontroller base (or at the controller disconnect switch, ifequipped). See Figure 2-21.

Note: Verify that the power is disconnected beforeconnecting or disconnecting the contactorharness.

2.8.3 Controller Ground

Verify that the grounding wire is connected from thecontroller’s lower left mounting stud to the enclosure.This connection provides proper grounding that doesnot rely upon the door hinges.

2

1. Contactor Harness Connection2. Ground Connection

1

GM85844

Figure 2-21 Contactor Harness and ControllerGround Connections


2.9 Electrical Wiring

All internal electrical connections are factory-wired andtested. Field installation includes connecting thesources, loads, generator start circuit(s), and auxiliarycircuits, if used.

Note: Aprotective device suchasamolded-case circuitbreaker or fused disconnect switch MUST beinstalled on both sources of incoming power forcircuit protection and used as a disconnectdevice.

Refer to the wiring diagrams provided with the transferswitch. Observeall applicable national, state, and localelectrical codes during installation.

Install DC, control, and communication system wiringin separate conduit from AC power wiring.

It is not necessary to remove pole covers from thetransfer switch for cabling. If you do remove them,reinstall them carefully.



WARNING




DANGER

Making line or auxiliary connections. Hazardous voltagecan cause severe injury or death. To prevent electricalshock deenergize the normal power source beforemaking anyline or auxiliary connections.

Grounding electrical equipment. Hazardous voltage cancause severe injury or death. Electrocution is possiblewhenever electricity is present. Ensure you comply with allapplicable codes and standards. Electrically ground thegenerator set and related equipment and electrical circuits.Turn off the main circuit breakers of all power sources beforeservicing the equipment. Never contact electrical leads orappliances when standing in water or on wet ground becausethese conditions increase the risk of electrocution.

NOTICEForeign material contamination. Cover the transfer switchduring installation to keep dirt, grit, metal drill chips, and otherdebris out of the components. Cover the solenoidmechanismduring installation. After installation, use themanual operatinghandle to cycle the contactor to verify that it operates freely.Do not use a screwdriver to force the contactor mechanism.

2.9.1 Source and Load Connections

Determine the cable size. Refer to the transfer switchdimension drawing to determine the cable size andnumber of cables required for the transfer switch. Makesure that the cables are suitable for usewith the transferswitch lugs. Watertight conduit hubs may be requiredfor outdoor use.

Drill the entry holes. Cover the transfer switch toprotect it from metal chips and construction grit. Thendrill entry holes for the conductors at the locationsshown on the enclosure drawings. Remove debris fromthe enclosure with a vacuum cleaner.

Note: Do not use compressed air to clean the switch.Cleaning with compressed air can cause debristo lodge in the components and damage theswitch.


Install and test the power cables. Leave sufficientslack in the power leads to reach all of the powerconnecting lugs on the power switching device. Test thepower conductors before connecting them to thetransfer switch. Installing power cables in conduit, cabletroughs and ceiling-suspended hangers often requiresconsiderable force. Pulling cables can damageinsulation and stretch or break the conductor’s strands.

Test the cables after pulling them into position andbefore they are connected to verify that they are notdefective and that they were not damaged duringinstallation.

Install the cable spacers provided with 30--200 ampswitches as shown in Figure 2-22.

1

1. Cable spacers1

127

Figure 2-22 Cable Spacers for 30--200 Amp Switches

Connect the cables. Be careful when strippinginsulation from the cables; avoid nicking or ringing theconductor. Clean cables with a wire brush to removesurface oxides before connecting them to the terminals.Apply joint compound to the connections of anyaluminum conductors.

Refer to the wiring diagram provided with the switch.

The connection points on the contactor are labeledNormal, Emergency, and Load. Be sure to follow thephase markings (A, B, C, and N). For single-phasesystems, connect to A and C.

Note: Connect the source and load phases asindicated by the markings and drawings toprevent short circuits and to prevent phase-sensitive load devices from malfunctioning oroperating in reverse.

Tighten the lugs. Verify that all connections areconsistent with drawings before tightening the lugs.Tighten all cable lug connections to the torque valuesshown on the label on the switch. (See Figure 2-24 for atypical rating/torque label.) Carefully wipe off anyexcess joint compound after tightening the terminallugs.

For load connections to bus bars, use a compressionwasher, flat washer, and a minimum grade 5 bolt andtorque the connections to the values in Figure 2-23.

Bolt Size, inches

Bolt Torque

ft. lb. Nm

1/4 7 9.55/16 12 16.33/8 20 27.11/2 50 67.85/8 95 128.83/4 155 210.2

Figure 2-23 Tightening Torque for Bus Bars

USE COPPER OR ALUMINUM WIREFOR POWER TERMINALS

RECOMMENDED TIGHTENING

200 480 FUSE ANY CLASS J

TORQUE 600 IN--LBS

AMPS AT THE VOLTAGE SHOWN.

BREAKER/MFR/TYPE

DELIVERING NOT MORE THEN THE RMS SYMMRATED FOR USE ON A CIRCUIT CAPABLE OFONLY OR BY FUSES THIS TRANSFER SWITCH ISWITHOUT AN ADJUSTABLE SHORT--TIME RESPONSEWHEN PROTECTED BY A CIRCUIT BREAKERSWITCH RATING, 240V MAX.TUNGSTEN LOAD DOES NOT EXCEED % OFNOT EXCEED THE SWITCH AMP RATING AND THELOAD AMPS AND AMPS OF OTHER LOADS DOESING EQPT, WHERE THE SUM OF MOTOR FULL--DISCHARGE AND TUNGSTEN LAMPS, ELEC HEAT--SUITABLE FOR CONTROL OF MOTORS, ELEC

RMS SYMM

VOLTSMAX

X1000AMPS

MAXAMPS

42 480 GE SGL4,SGP4,TB4, 400THLC4,TLB4 400

SKHA,SKL8,SKP8,TKLSGLA,SGL6,SGP6,TB6

800600

42 480 I--T--E CJD6,HHJD6, 400

CLD6,HHLD6,HHLXD6,HLD6,HHJXD6,HJD6,SCJD6,SHJD6

600400

CMD6,HMD6,HND6,MD6,MXD6,SCLD6,SHLD6

800600

SCMD6,SHMD6,SMD6,SND6 800

MH42 480 SQUARE D LC,LI

800600

42 480 WESTH HKD,KDC,LCL, 400

HLDTRI--PAC LA

600400

TRI--PAC NB 800

100

3522 600

480 ANYANY

ANYANY

ANYANY

PER NECPER NEC

483500--007BREV

USE 75 C MIN. CU/AL WIRE FOR POWERCONNECTIONS. USE 60 C MIN. CU WIRE FORCONTROLS.

600

42 480 MERLIN GERIN

42 480 ABB S5

CJ600

S6400

600

800

007

1

1. Torque specification

Figure 2-24 Typical Rating/Torque Label


2.9.2 Extended Transfer Time Relay(Model KCC only)

The extended transfer time relay is standard onclosed-transition transfer switches. The relay isprovided to prevent paralleling the standby and utilitysources for longer than the acceptable time, which istypically 100 ms. The relay is located on the fieldconnection assembly. See Figure 2-26.

The relay starts timing when both sources areconnected. If one source fails to disconnect within theset time, the relay energizes and aFail toOpenSource1(or Source2) fault message will display on the ATScontroller. Identify and correct the cause of the sourcedisconnect problem before resetting the fault.

Connect the relay to a shunt trip on the emergencysource circuit breaker. Provide 12 or 24 VDC power asrequired for the relay, as shown in Figure 2-27 orFigure 2-30. Connect theDCpower, emergencysourcecircuit breaker trip circuit (TR--EMER), and optionalalarm (TR-ALARM) to the field-connection terminalblock shown in Figure 2-26. See Figure 2-25 for typicalconnections and refer to the schematic diagramprovided with the transfer switch.

The extended transfer time relay uses an adjustmentknob or switches to set the time delay. Compare yourequipment to Figure 2-26 andFigure 2-29 to identify therelay used on your transfer switch.

GM89661

Figure 2-25 Typical Relay Connections (see theschematic diagram for your transferswitch)

Relay with Time Adjustment Knob

This section applies to the relay equipped with anadjustment knob, shown in Figure 2-26. Relayspecifications are shown in Figure 2-27.

Setting the Time Delay (knob style)

A knob on the relay assembly allows adjustment of thetime delay. See Figure 2-26. The relay time delay isadjustable between 100 ms and 10 seconds. The timesettings are in percent (%) of the maximum setting,which is 10 seconds, and adjustable in 5% increments.Figure 2-28 shows some sample settings. The typicalsetting is 1% = 0.1 seconds (100 ms). If it is necessaryto set the relay to a longer time, ensure that the timesetting is in accordance with applicable codes.

1. Extended transfer time relay2. Field connection terminal block3. Time adjustment

1

TP-6833

2

3

Figure 2-26 Extended Transfer Time Relay(knob style shown)

Relay Specifications

Input Power 24 VDC (customer-supplied)

Output Type Relay contacts, DPDT (2 form C)

Rating10 amp max. resistive @ 240 VAC100 mA @ 5 VDC min. load current

Figure 2-27 Relay Specifications (knob style)

Setting* Time

1 % 0.1 seconds (100 ms)

50 % 5 seconds

100 % 10 seconds

* Settings above 1% are adjustable in 5% increments.

Figure 2-28 Examples of Transfer Time Settings(knob style)


Relays with Time Adjustment Switches

This section applies to relays equippedwith switches fortime adjustment, shown in Figure 2-29. Relayspecifications are shown in Figure 2-30.

A three-digit time selection switch and a range selectionswitch on the relay assembly allow adjustment of thetime delay. See Figure 2-29. The relay time delay isadjustable between 0.05 seconds (50 ms)* and 999minutes. Set the range and the time as shown inFigure 2-31. The typical setting is 0.10 seconds (100ms). If it is necessary to set the relay to a longer time,ensure that the time setting is in accordance withapplicable codes.

A timing light on the relay flashes during the time delayand turns on continuously after time out.

Setting the Time Delay (adjustment switch style)

Toset the timedelay, select the rangebasedonsecondsor minutes and the numbers after the decimal point.Then use the pushbuttons to set the time. Someexamples are shown in Figure 2-32.

1. Time select pushbuttons2. Relay timing LED3. Range selection switch

Note: See Figure 2-26 for relay location on the field connectionassembly.

3

IMG_0732

1

2

Figure 2-29 Extended Transfer Time Relay(adjustment switch style)

* Settings less than 0.05 s (50 ms) are not recommended.

Relay 12VDC 24VDC

Input Power(customer-supplied) 12 VDC 24 VDC

Relay Marking A1M-0999M-466 A1M-0999M-462

Output Type Relay contacts, DPDT (2 form C)

Rating 10 amp max. resistive @ 240 VAC

Figure 2-30 Relay Specifications(adjustment switch style)

Time Select Range Select Time Setting

001--999

9.99 S 0.01 to 9.99 seconds *

99.9 S 0.1 to 99.9 seconds

999 S 1 to 999 seconds

99.9 M 0.1 to 99.9 minutes

999 M 1 to 999 minutes

* Settings less than 0.05 s (50 ms) are not recommended.

Figure 2-31 Relay Transfer Time Settings(adjustment switch style)

Range Time Select Time Setting

9.99 S 010 0.10 seconds (100 ms) [

99.9 S 001 00.1 seconds (100 ms) [

999 S 001 1 second

99.9 M 025 2.5 minutes

999 M 020 20 minutes

[ 100 ms is the typical setting. Do not use settings less than50 ms.

Figure 2-32 Examples of Transfer Time Settings(adjustment switch style)


2.9.3 Engine Start Connection



WARNING

Disabling the generator set. Accidental starting cancause severe injury or death. Before working on thegenerator set or equipment connected to the set, disable thegenerator set as follows: (1) Press the generator set off/resetbutton to shut down the generator set. (2) Disconnect thepower to the battery charger, if equipped. (3) Remove thebattery cables, negative (--) lead first. Reconnect the negative(--) lead last when reconnecting the battery. Follow theseprecautions to prevent the starting of the generator set by theremote start/stop switch.

Prevent the generator set from starting by pressing theOFF button on the generator controller; disconnectingpower to the generator engine start battery charger, ifinstalled; and disconnecting all generator engine startbattery cables, negative (--) leads first.

Connect the generator set remote starting circuit to theengine start connections. On 30--200 amp models, theengine start terminals are located on the transfer switchcontactor assembly and labeled with a decal. SeeFigure 2-33. On larger models, the engine startcontacts and auxiliary contacts are located on thefield-connection terminal block. See Figure 2-36 for thelocation of the engine start contacts. Refer to thegenerator set installation manual for wire sizespecifications.

Engine Start Contacts

Contact Rating 2 A@ 30 VDC/250 VAC

1. Engine start contacts 14 and 15

6126

14

15

16 (Do not use)

1

Figure 2-33 Engine Start Contacts, 30--200 AmpSwitches


2.9.4 Auxiliary Contacts

Connect the auxiliary contacts to customer-suppliedalarms, remote indicators, or other devices. Auxiliarycontacts provide contacts that close when the transferswitch is in the Normal position and contacts that closewhen the transfer switch is in the Emergency position.Refer to the wiring diagrams provided with the transferswitch for auxiliary contact connection information.

Figure 2-34 lists the number of contacts available byATS model and size (amps). See Figure 2-35 throughFigure 2-37 for contact locations.

Follow thewire size and tightening torque specificationsshown on the decal on the transfer switch.

Auxiliary Position Indicating Contacts(rated 10 amps @ 32 VDC/250 VAC)

SwitchRating, amps

Number of Contacts IndicatingNormal, Emergency

Number of Contacts IndicatingNormal, Emergency

KCS KCP KCC

30--150 2, 2 — —

150--230 2, 2 8, 8 8, 8

230 (600 V) 8, 8 8, 8 8, 8

260--600 8, 8 8, 8 8, 8

800-1200 8, 8 8, 8 8, 8

1600--4000 8, 8 7, 7 7, 7

Figure 2-34 Auxiliary Contacts

1

1. Auxiliary contacts 10--13 and 29--32 (contacts shown withcontactor in Normal position)

6126

GM4627812

13 11

10

31

32 30

29

Figure 2-35 Auxiliary Contacts, 30--230 Amp TransferSwitches


1

1. Typical terminal block location2. Decal3. Engine start contacts4. Auxiliary contacts (see the schematic diagram for contacts

closed on Normal or closed on Emergency)

GM21298

GM21311

4

3

12

456

789

101112

131415

161718

192021

2224

252627

23

2

Figure 2-36 Engine Start and Auxiliary ContactTerminal Block, 230--4000 Amp TransferSwitches

GM89645

Figure 2-37 Typical Auxiliary Contact Connection,230--4000 Amp Transfer Switches (seeFigure 2-36 and schematic diagram)

2.10 Communication andAccessory Connections

See Section 4 for accessory and communicationconnection instructions.

2.11 Functional Tests

After completion of the mechanical installation and allelectrical connections, perform the functional testsdescribed in Section 5. The procedures in Section 5 arerequired to complete the installation and startup of thetransfer switch.

TP-6833 2/16 33Section 3 Three-Source Systems

Section 3 Three-Source Systems

3.1 Three-Source Systems

TheDecision-MakerrMPAC 1500 controller is requiredfor three-source systems.

A three-source systemprovides themeans to connect autility and two generators to a single load. SeeFigure 3-1. Two generators and two transfer switchesare required.

Note: The second transfer switch (ATS2) requires anexternal battery supply module (EBSM) toprovide power to the controller. SeeSection 4.3.3.

During normal operation, the utility source supplies theloadwith power. In theevent of a utility failure, generatorset G1 or G2 will supply the load as described inSections 3.2 and 3.3.

3.2 Three Source Engine StartMode

There are two modes of operation for three-sourceengine start. Select Mode 1 or Mode 2 on ATS2 asneeded for the application.

3.2.1 Mode 1

In mode 1 there will be an attempt to start only thepreferredsourcegenerator. If thepreferredsourcedoesnotachievevoltageand frequencywithin a fail toacquiretime period, the standby engine start contact will close.The fail to acquire will be indicated. If the standbysource subsequently fails to achieve voltage andfrequency, a separate fail to acquire standby will beindicated.

3.2.2 Mode 2

In mode 2 both generators receive a start signalsimultaneously. The ATS2 will transfer to the firstgenerator set to reach proper voltage and frequency. Ifthe first source to reach available status is the preferredsource, the engine start signal to the standby sourcewillopen immediately. If the standby source is the first toreach available status, the contactor will transfer to thestandby position. When the preferred source generatoroutput reaches available status, the controller willtransfer to the preferred source and open the enginestart contacts to the standby generator (after thecooldown delay has elapsed).

3.3 Preferred Source Toggle

The preferred source toggle function alternatesbetween the two generator sets each time thethree-source function is activated. If G1 is the preferredsource during the first run, then G2 will be preferredduring the next run. The preferred source selection willcontinue to alternate between G1 and G2 for eachsubsequent run.

3.4 Three Source System Test andExercise

3.4.1 Unloaded Test

Unloaded testing is possible at each transfer switch.Initiating the unloaded test function at ATS1 starts andruns the preferred generator set attached to ATS2.Initiating the unloaded test function at ATS2 starts andruns the standby generator set.

3.4.2 Loaded Test

Loaded testing is also allowed at each transfer switch.Loaded testing of the standby generator set is onlypossible during a loaded test from ATS1 because thestandby generator can only be connected to the loadwhen ATS1 is connected to emergency. To initiate aloaded test of the standby generator set, first use ATS1to start a loaded test of the preferred source generatorset. Then use ATS2 to start a loaded test of the standbygenerator set.

3.4.3 Unloaded Exercise

The exercise program in ATS2 controls the operation ofeach generator. The exercise function does not requireinteraction with ATS1. If the utility is lost during anunloaded exercise event, the event is canceled and theload is transferred to the preferred generator set.

3.4.4 Loaded Exercise

The exercise program in ATS2 controls the operation ofeach generator. The loaded exercise event requiressynchronization with a loaded exercise from ATS1.Program the ATS1 exercise to start before the ATS2exercise. Set theATS2 exercise to end before theATS1exercise ends. If the utility is lost during a loadedexercise event, the event is canceled and the load istransferred to the preferred generator set.

TP-6833 2/1634 Section 3 Three-Source Systems

3.5 Three-Source SystemConnection



DANGER


Making line or auxiliary connections. Hazardous voltagecan cause severe injury or death. To prevent electricalshock deenergize the normal power source beforemaking anyline or auxiliary connections.

See Figure 3-1 and Figure 3-2 for connections duringthe following steps.

1. Connect the power sources to the transferswitches as described below. Refer to the transferswitch operation/installationmanual or specificationsheet for cable sizes. See Figure 3-1 forconnections.

a. Connect the utility power source to the normalside of ATS1.

b. Connect the load to the load side of ATS1.

c. Connect the emergency side of ATS1 to theload side of ATS2.

d. Connect generator set 1 to the normal side ofATS2.

e. Connect generator set 2 to the emergency sideof ATS2.

2. Three-source systems require the following input/output connections to control the engine start

commands for generator sets 1and2. Observe thepolarity of all connections shown in Figure 3-2.Use wire sizes from #14 AWG to #20 AWG forEBSM and I/O module connections.

a. Connect the ATS2 engine start contacts to theengine start circuit on generator set 2 (G2).

Note: See the Installation Section for the enginestart contact locations. Engine startcontacts are labeled with a decal.

b. Connect one ATS1 programmable output fromthe controller to one ATS2 main logic boardprogrammable input as shown in Figure 3-2.This I/O connection will be set to Three-SourceSystem Disable.

c. Connect one ATS2 programmable output fromthe controller to the engine start connection ongenerator set 1 (G1). TheATS1programmableoutput will be set to Source N Start Signal.

3. Connect battery power. Use #14-28 AWG wire toconnect the generator set engine starting battery(or batteries) to the BATT1 terminals on terminalblock TB13 on the external battery supply module(EBSM). (Another battery(ies) can be connectedto terminals BATT2 but is not required.) Follow themarking on the board for the positive (+) andnegative (--) connections. See Figure 4-16 andFigure 4-17.

Note: If the battery connections are reversed, redLED1 or LED2 will light. Incorrect batteryconnections can damage the batterymodule.

4. Set voltage selector switch SW11-1 on the batterymodule (EBSM) to 12 or 24VDC.

Note: See Section 4.3.3 for more information onthe EBSM.

5. Assign the ATS1 programmable output connectedin step 2b. to Three-Source System Disable.

6. Assign the following inputs and outputs for thesecond transfer switch.

a. Assign ATS2 controller programmable input 1to Three-Source System Disable.

b. Assign the ATS2 controller programmableoutput connected in step 2c. to Source N StartSignal.

TP-6833 2/16 35Section 3 Three-Source Systems

GM28627B

U

N

L

LOAD

E

ENGINE START

SINGLE LINE DIAGRAM

N/C

G1 G2

N

L

E

ENGINE START

ATS2

ATS1

TO G2

NOTE: THE CLOSED IN EMERGENCY AUXILLIARY

CONTACT THAT IS USED IN THE ENGINE START CIRCUIT

OF THE ATS MUST BE REMOVED FROM THE CIRCUITWHEN USED WITH THIS THREE SOURCE CONTROL SCHEME.

REFERENCE ATS WIRING DIAGRAM FOR CONNECTIONS.

LEGEND

EBSM -- EXTERNAL BATTERY SUPPLY MODULE

LED1 -- LIGHT EMITTING DIODE (BATTERY 1 REVERSED)LED2 -- LIGHT EMITTING DIODE (BATTERY 1 REVERSED)LED3 -- LIGHT EMITTING DIODE (BATTERY SUPPLYING POWER)MLB -- MAIN LOGIC BOARDP(#) -- CONNECTOR

MLB -- MAIN LOGIC BOARDPIOM -- PROGRAMMABLE INPUT/OUTPUT MODULE

TB(#) -- TERMINAL BLOCKSW -- SWITCH

K1 -- NORMAL RELAYK2 -- EMERGENCY RELAY

OPERATION

WHEN UTILITY FAILS ATS2 STARTS G1. ATS1 TRANSFERS TO THE EMERGENCY POSITION. IF G1 FAILS ATS2WILL START G2 AND ATS2 WILL TRANSFER TO EMERGENCY. IF G1 RETURNS THEN ATS2 WILL RE--TRANSFERBACK TO NORMAL. ATS1 WILL RE--TRANSFER BACK TO NORMALAFTER THE UTILITY RETURNS. WHEN THEUTIITY IS AVAILABLE, THE BATTERY SUPPLY MODULE WILL PROVIDE POWER TO THE CONTROLLER ON ATS2.THE 3 SOURCE SYSTEM DISABLE INPUT AND OUTPUT WILL PREVENT ATS2 FROM STARTING EITHER GENSETWHILE THE UTILITY SOURCE IS AVAILABLE.

THE BATTERY SUPPLY MODULE USES UP TO TWO BATTERY INPUTS (9--36VDC) AND PROVIDES A 12VOUTPUT THAT POWERS THE ATS CONTROLLER. THIS IS CONNECTED TO THE CONTROLLER BY SNAPPING ITTO AN EXISTING I/O MODULE OR THROUGH A HARNESS TO P3 ON THE CONTROLLER (WHEN AN I/OMODULE IS NOT USED). THE BATTERY SUPPLY MODULE WILL CONTINUALLY PROVIDE POWER TO THECONTROLLER UNLESS THE ON/OFF INPUT ON THE BATTERY SUPPLY MODULE IS ENABLED.THE ON/OFF INPUT ON TB1 OF THE BATTERY SUPPLY MODULE CAN BE USED IN CONJUNCTION WITH THENORMALLY OPEN CONTACT OF A PROGRAMMABLE OUTPUT FROM AN INPUT/OUTPUT MODULE TO TURN THEBATTERY SUPPLY MODULE OFF WHEN A SOURCE IS AVAILABLE.

ATS -- AUTOMATIC TRANSFER SWITCH

G1 -- GENERATOR #1G2 -- GENERATOR #2

U -- UTILITY

Note: ATS2 requires an external battery moduleto maintain power to the controller.

Figure 3-1 Three-Source System Transfer Switch and Source Connections

TP-6833 2/1636 Section 3 Three-Source Systems

6883

12

61

7

ATS1

ATS2

Connect Output 1 terminalsTB1-5 and TB1-6 on ATS 1 toInput 1 terminals TB1-1 andTB1-2 on ATS2.

Assign ATS 1 main logic boardoutput 1 to 3 Source SystemDisable.

Assign ATS2 main logic boardinput 1 to 3 Source SystemDisable.

Connect one normally closedoutput from ATS2 to G1 enginestart (ES) connections. Assign toEngine Start Source N.

12

61

7

ATS2 TB1on logic board

ATS1 TB1on logic board

G1 ES

3 Source System Disable

Connect the ATS2 engine start contacts (onthe contactor or the field-connection terminalblock) to G2 engine start (ES) connections.See Figure 3-1.

Figure 3-2 Input and Output Connections for Three-Source Systems

3.6 ATS1 and ATS2 System Setup

Use the System Setup Menu on each transfer switch toset the following:

ATS1: Set the Source type to Util-Gen.

ATS2: Set the source type to Util-Gen-Gen. Set the3 Src Engine Start Mode to Mode 1 or Mode 2 asdescribed in Section 3.2.

The transfer switch settings are summarized inFigure 3-3.

TransferSwitch Source Type

3 Src Engine StartMode

PreferredSource Toggle Inputs Outputs

ATS1 Util-Gen Not Required Not Required Not RequiredThree Source System

Disable

ATS2 Util-Gen-Gen Mode 1 or Mode 2(See Section 3.2)

Enable or DisableSee Section 3.3

Three Source SystemDisable

Source N Start Signal

Figure 3-3 Transfer Switch Settings for Three-Source Systems

TP-6833 2/16 37Section 4 Communication and Accessory Connections

Section 4 Communication and Accessory Connections

4.1 Introduction

This section explains the connection of communicationcables and factory-installed accessories.

Also refer to the followingdocumentation for instructionsto install, connect, and operate optional accessories.

D Transfer switch wiring diagrams.

D Installation instructions or diagrams provided withloose accessory kits.

4.2 Communication Connections

The Decision-Makerr MPAC 1200 and MPAC 1500controllers are equipped with a USB port and aModbusport with an RS-485 connector. An Ethernetcommunication board is standard on the MPAC 1500controller and optional on the MPAC 1200 controller.

4.2.1 USB Port SiteTech Connection

A personal computer and Kohlerr SiteTecht softwarecanbeused for changing controller settings. UseaUSBcable to connect the controller to a personal computer.

See Figure 4-1 for the USB port location on the front ofthe controller assembly. Remove the small port coverand use aUSBcable with amini-B connector to connectthe controller’s USB port to the computer.

See TP-6701, SiteTech Software OperationManual, forinstructions to use the software. Disconnect the USBcable from the controller and replace the port coverwhen finished.

1. USB connection (below port cover) GM85888

1

Figure 4-1 USB Connection for SiteTech(MPAC 1500 controller shown)

4.2.2 Modbus Connection



DANGER


See Figure 4-2 for the RS-485 Modbus connectorlocation.

Use serial connections to TB2 on the controller toconnect the transfer switch to a personal computer forsystem monitoring, the optional remote annunciator, ora Modbus network. See Figure 4-4.

Notice that a 121 ohm terminating resistor isrecommended on the last device in a network. If there isonly one device, a terminating resistor may be requireddepending on the cable distance and communicationspeed. Long cables and high speeds will increase theneed for a terminating resistor.

The serial port is an isolated RS-485 port withconnection speeds of 9.6, 19.2, and 57.6 kbps. Useshielded twisted-pair cable to connect to the RS-485connectors on the controller’s terminal strip TB2 forserial connections. For connection to a PC, use a USBto RS-485 converter.

Connect the Modbus input and output to the terminalsshown in Figure 4-3. Use #12-24 AWG shielded,twisted-pair wire. Belden cable #9841 or equivalent isrecommended. Connect one end of the shield toground. Leave the other end of the shield disconnected.Tighten the connections to 0.5 Nm (4.4 in. lb.).

TP-6833 2/1638 Section 4 Communication and Accessory Connections

Use Modbus RTU (remote terminal unit) protocol forcommunication through the serial port. A map of theModbus codes for this controller is available. Contactyour local distributor/dealer.

Note: Modbusr applications require a Modbussoftware driver written by a trained and qualifiedsystems programmer.

1. RS-485 Modbus connections2. Access opening for RS-485 cables

GM85884

1

2

Figure 4-2 Modbus Connections (controller coverremoved for illustration only)

TB2

A1(--)

B1(+)

GND1

3

6

1

4

A1(--)

B1(+)

GND1

Customer connections

Input

Output

Cable shield

Cable shield

Figure 4-3 Modbus RS-485 Connections

USB to RS-485 portconverter

RS-485 *USB port

Device

USB port

Device

LastDevice

RS-485

*

RS-485 *

Device

Terminating resistor [,(121 Ohms)

USB to RS-485port converter

Terminating resistormay be required [

(121 Ohms)

In

Out

In

In

In

Out

Out

Out

PCPC

PC

* Use Belden #9841 or equivalent shielded, twisted-paircommunication cable for RS-485 connections. Groundone end of the cable shield. Leave the other end of thecable shield disconnected.

[ Long cables and high communication speeds will requirea terminating resistor. Use 121 ohm resistor X-6058-27.

RS-485

*Figure 4-4 Serial Connections


4.2.3 Ethernet Connection



DANGER


The Ethernet communication accessory board isrequired for connection to the Ethernet. The Ethernetcommunication board is standard on the MPAC 1500controller. It is anoptional accessory for theMPAC 1200controller. The communication board connects to thecontroller board as shown in Figure 4-5.

1. Ethernet communication board with RJ-45 connector2. Access opening for Ethernet cable

GM85884

1

12

Figure 4-5 Ethernet Board (controller coverremoved for illustration only)

The Ethernet communication board allows the transferswitch to be connected to a building’s Ethernet networkto communicate with personal computers connected tothe same subnet.

Note: For an ethernet connection, obtain an IP addressand subnet mask number from the local systemadministrator.

Ethernet Port. The ethernet port is a standard RJ-45jack. SeeFigure 4-5 for the locationof theEthernet port.UseCategory5eorbetter cable toconnect thecontrollerto the building’s network.

Use the controller’s Setup menus or a personalcomputer connected to the controller’s USB port andKohler SiteTech software to set the communicationparameters. The Ethernet communication board mayhave a default IP address assigned at the factory for testpurposes. See Figure 4-6. Change the IP address toan address owned by the user. See the controlleroperation manual for instructions to set thecommunication parameters.

The transfer switch controller does not operate as aModbus-to-Ethernet converter for other devices in anetwork. Formultiple device networks connected to thepersonal computer through the Ethernet, use aModbus-to-Ethernet converter for the other devices inthe network. See Figure 4-7 and instruction sheetTT-1405, provided with the converter, for connectioninstructions.

The controller can communicate with up to five (5)simultaneous TCP/IP (ethernet) connections. Thesefive connections do not include the RS-485 serial port.In the extreme case, five users may be communicatingwith the controller via TCP/IP network connections andanother may be communicating through the serial port,for a total of six (6) communication channels. As thecontroller is asked to communicate with more andmoreoutside devices, the communication will slow down.


PCIP xx.xx.xx.02

EthernetNetwork

Modbusr TCP/IPCategory 5e


Note: ThePCand theATSmust be on the samesubnet.

Note: A crossover cable can be used to connect the PCto the ATS controller through the Ethernet port.

MPACController withEthernet comm.

boardIP xx.xx.xx.03

Figure 4-6 Remote Network (Ethernet) Connection

MPACController withEthernet comm.

boardIP xx.xx.xx.03

PCIP xx.xx.xx.02

Device

Last device

RS-485

Converter,Modbusr/EthernetIP xx.xx.xx.05 RS-485

ModbusrTCP/IP

ModbusrTCP/IP

EthernetNetwork

PCIP xx.xx.xx.01

Terminating resistor(121 Ohms)

Device

Device

RS-485

Device

ModbusrRTU

RS-485



Figure 4-7 Ethernet Connections to Multiple-Device Network


4.3 Accessory Modules



DANGER


This section provides specifications and fieldconnection information for factory-installed accessorymodules. If themodules are not factory-installed, followthe instructions provided with the kits to install themounting assembly and modules.

The transfer switch uses a standard bus system forconnecting accessory modules to the controller. Thisbus incorporates a standard serial communicationinterface for passing data back and forth between themain logic board and the assemblies on the expansionbus.

The module mounting kit holds up to five optionalmodules. The total current draw of all modulesmust notexceed 300 mA. See Figure 4-8. Add the current drawfor every module installed to determine the total currentdraw. If an External Battery Module is installed andconnected to a battery, there is no current restriction.The External Battery Module, if used, must be the lastboard on the bus.

Module Current Draw Specifications, mA

Alarm Module 75

Standard I/O Module 75

High Power I/O Module 100

Figure 4-8 Option Board Types

4.3.1 Accessory Module Mounting

Mount the accessory modules on the module mountingplate. Starting at the end of the module mountingassembly nearest the cable connection, install any I/Omodules first, then install the alarm board, if used. Theexternal battery module, if used, must be the lastmodule. See Figure 4-9. The alarm board has a fixedModbus address = 5.

Note: Some models may have the I/O moduleassembly installed with the cable connection endpointing to the side or the bottom. Regardless ofthe actual orientation of the assembly, the I/Omodules must be installed closest to the cableconnection, followed by the alarm module andthen the external battery module, if used.

1. Cable connection (defined as the TOP regardless oforientation)

2. I/O modules (if equipped)3. Alarm module (if equipped)4. External battery module (must be last, if equipped)5. Mounting plate

1

GM46258

3

5

2

2

2

4

Figure 4-9 Module Mounting


4.3.2 Input/Output (I/O) Modules

Two types of input/output modules are available. Thestandard I/O Module has two inputs and six outputs.The high-power I/O module has two inputs and threeoutputs. See Figure 4-10 through Figure 4-13 for I/Omodule illustrations and specifications.

1. Input LEDs 7 and 8 for inputs 1 and 22. Input connector (see Figure 4-14)3. Output connector4. Output LEDs 1--6

1

GM41093

2

3

4

Figure 4-10 Standard Input/Output Module

Inputs

Available Inputs 2

Input Definition Contact Closure

Current 5 mA Max

Connection Type Terminal Strip

Wire Size #14-24 AWG

Max Distance 700 feet

Outputs

Outputs Available 6

Contact Type Form C (SPDT)

Contact Voltage Rating2 A @ 30 VDC500 mA @ 125 VAC



Figure 4-11 Standard I/O Module Specifications

1. Input LEDs 1 and 22. Input connector (see Figure 4-14)3. Output connector4. Output LEDs 3--5 for outputs 1, 2, and 3

2

GM42186

1

3

4

Figure 4-12 High-Power Input/Output Module

Inputs

Available Inputs 2

Input Definition Contact Closure

Current 5 mA Max



Max Distance 700 feet

Outputs

Outputs Available 3

Contact Type Form C (SPDT)

Contact Voltage Rating

12 A @ 24 VDC12 A @ 250 VAC10 A @ 277 VAC2 A @ 480 VAC



Environmental Specifications

Temperature --40C to 85C (--40F to 185F)

Humidity 35% to 85% noncondensing

Figure 4-13 High-Power I/O Module Specifications


Use 14-24 AWG cable to connect to inputs and outputs.See Figure 4-14.

LEDs on the module circuit board light to indicate thateach input or output is active.

Note: Each I/O module must have unique address.

Use the address DIP switches on the I/O module toassign a unique (different) address to each module asshown in Figure 4-15. Assign addresses in order from1to 4. An LED for each DIP switch lights to indicate thatthe switch is closed.

The alarm module’s fixed address is 5. The batterymodule’s fixed address is 6.

See the controller operation manual for instructions toassign functions to each input and output. Inputs andoutputs can also be assigned using a personalcomputer with Kohlerr SiteTecht software or overModbus. See TP-6701, SiteTech Operation Manual, orTP-6113, Modbus Protocol Manual.

refGM41093

INPUT 1INPUT 2

Figure 4-14 I/O Module Input Connections(TB1 or TB10)

Both switches OFF

Address=1 shown

DIP Switch

Address1 2

Off Off 1

On Off 2

Off On 3

On On 4

Figure 4-15 Address DIP Switch Settings

4.3.3 External Battery Supply Module(EBSM)

The external battery supply module kit allowsconnection to the generator set engine start battery(ies)or other batteries to provide 12 VDC power to the ATScontroller. The external battery supply module kit isrequired for the following applications:

D Systems using extended engine start timedelays. The EBSM provides power to the ATScontroller during extended time delays longer than 15seconds, when neither the Normal nor theEmergency source is available.

D Installations with frequent utility power outages.TheEBSMprovidespower to theATScontrollerwhenneither source is available, preserving thecontroller’sbackup battery.

D Three-source systems. Three-source systems usetwo transfer switchesand twostandbypower sourcesin addition to the preferred power source. The EBSMprovides power to the second ATS controller whenthe preferred source (connected to ATS1) issupplying the load. SeeSection 3.1 for instructions toset up a three-source system.

The external battery supply module kit includes oneexternal battery supply circuit board and the circuitboard mounting components. See Figure 4-16.

GM42227-A1. Connector P202. LED indicators3. Battery input connection terminal block TB134. 12/24 volt DIP switch SW11-1. OFF=12 VDC, ON = 24 VDC

1

3

2

4

Figure 4-16 External Battery Supply Module


The EBSMproduces 2 amps at 12 VDCwith 9--36 VDCinput. The EBSM input is reverse-polarity protected.TheEBSMoutputsa lowbattery voltagesignalwhen theexternal battery voltage falls below 11 VDC for a 12-voltsystem or 22 VDC for a 24-volt system.

A module mounting kit is required for installation of theexternal battery supply module. See Section 4.3.1.Obtain a module mounting kit if one is not alreadyinstalled and follow the instructions provided with thekits to install the mounting assembly and modules.

The battery voltage selectionDIP switch SW11-1 allowsselection between 12-volt and 24-volt systems for lowbattery voltage sensing and indication. Connect one ortwobatteries to the external battery supplymodule. Usea battery charger tomaintain the battery(ies) connectedto the EBSM.

DIP Switch SW11-1 Setting Battery Voltage

OFF 12 VDC

ON 24 VDC

Figure 4-17 Battery Voltage Selection

EBSM Connection and Voltage Setting

1. Use #14-28 AWG wire to connect one or twobatteries to terminal blockTB13. (A secondbatterycan be connected but is not required.) Follow themarking on the board for the positive (+) andnegative (--) connections. See Figure 4-16 andFigure 4-17.

Note: If the battery connections are reversed, redLED1 or LED2 will light. See Figure 4-16.

2. Set voltage selector switch SW11-1 to 12 or24VDC. See Figure 4-16 and Figure 4-17. SwitchSW11-2 is not used.

Note: The EBSM has no address switches butmust be the last board on the bus.

4.3.4 Alarm Module

See Figure 4-18 for the optional alarm module. Amodule mounting kit is required for installation of thealarm module. See Section 4.3.1.

The functions provided by this board are:

D 90 dB Audible alarm (any alarm function can beprogrammed to trigger the audible alarm)

D Chicago alarm operation

D Preferred source selection

D Supervised transfer control (supervised transfercontrol switch required)

D Connection for external alarm

The alarm board has a fixed address = 5.

1. Supervised Transfer Switch Connection, P222. External Alarm Connection, TB 143. Alarm Indicator, LED14. DIP Switches

1

GM40764

2

34

Figure 4-18 Alarm Module


Alarm Board DIP Switches

There are fourDIP switches on the alarmmodule board.Someof the switchesare not used. SeeFigure 4-19. Toenable the preferred source selection, set DIP switch 1to ON. If the supervised transfer switch is installed onthe ATS, set DIP switch 2 to ON.

DIP Switch Function

1 Preferred source selection

2 Supervised transfer enable

3 Not used

4 Not used

Figure 4-19 Alarm Board DIP Switches

Preferred Source Selection

The alarm module is required for preferred sourceselection. To enable the preferred source selection, setDIP switch 1 to ON. Then see the controller operationmanual for instructions to select Source N or Source Eas the preferred source.

External Alarm

A customer-supplied external alarm horn can beconnected to the alarm module at terminal block TB14.Connect to thenormally openor normally closedcontactas recommended by the alarm manufacturer’sinstructions. See Figure 4-20.

Item Specification

Wire Size #12-22 AWG Cu

Contact Voltage Rating500 mA @ 120 VAC

250 mA @ 240 VAC

Figure 4-20 External Alarm ConnectionSpecifications

Audible Alarm Setup

Thealarmboard is equippedwith a 90dBaudible alarm.The audible alarm can be set to sound under selectedfault conditions. Use the Common Alarms Setup menuto assign functions to the audible alarm. See thecontroller operation manual for instructions to setAudibleAlarm:Y for each function that should trigger thealarm.

Alarm Operation, Normal Mode

In Normal Mode, the horn sounds anytime a fault eventhappens in the system. The horn continues to soundunless the alarm silence button is pressed. When thefault is cleared, the alarm silence is ended and reset forthe next alarm.

Alarm Operation, Chicago Alarm Mode

Chicago Alarm mode requires the horn to sound and alampor LED to lightwhen the switch is in the emergency(non-preferred) position. The horn continues to soundunless the alarm silence button is pressed. When thefault is cleared, the alarm silence is ended and reset forthe next alarm.

For Chicago Alarm Mode, use the Common AlarmSetup menu to assign the necessary faults andconditions to the audible alarm. See the controlleroperation manual for instructions to assign commonfaults. Be sure to assign the Contactor in Standbycondition to trigger the audible alarm.

A remote alarm or indicator light can also be connectedto the alarm board to indicate the alarm condition, asdescribed previously. See External Alarm.

Alarm Silence Mode

In Alarm Silence Mode, the horn is disabled. AlarmSilenced appears on the display and the system alertLED lights.

The Alarm Silenced condition can be assigned to aprogrammable output. See the controller operationmanual for instructions to assign outputs.

Instructions to Silence the Alarm in Normal andChicago Alarm Modes

When the alarm is activated, thewordAlarmappears onthe main display menu above the first button. SeeFigure 4-21. Press the Alarm button to open the Resetmenu. Then press the button labeled Reset to silencethe alarm.

ResetTo Silence Alarm

B Y Reset Main

System ReadyLD Exer 12/14 @ 16:00Norm 480V Emer 480V

Alarm View Set Test

Reset

Status or Fault DescriptionAlarm Silenced

B Y Reset Main

Figure 4-21 Alarm Silence


4.4 Load Shed(Forced Transfer to OFF)



DANGER


The load shed (forced transfer to OFF) accessory mustbe factory-installed. The load shed accessory isavailable only on programmed-transition transferswitches. See Figure 4-22 for an illustration of the loadshed acessory.

The load shed function requires an external signal(contact closure) to initiate transfer to the OFF position.

Connect the external contact to input #1 (if available) orinput #2 on connector TB1 on themain logic board. SeeFigure 4-23. Use #12--24 AWG wire and tighten to0.5 Nm (4.4 in. lb.).

Use the Input/Output setup menu or Kohler SiteTechsoftware to assign the connected input (Main BoardInput #1 or #2) to the forced transfer to off function. If theexternal contact is connected to a different inputconnection on an optional I/Omodule, assign the forcedtransfer to off function to that input.

GM23469

Figure 4-22 Load Shed Accessory (foridentification)


GM89713

1. Input/output terminal strip TB1

1

TB1

12

61

7MLB Input 2(alternateconnection)

#12--24 AWG wire0.5 Nm (4.4 in. lb.)

MLBInput 1

MPAC Controller Circuit Board

Figure 4-23 Forced Transfer to Off Input Connection (for factory-installed load shed kits)


4.5 Heater



DANGER


An anti-condensation heater kit is available. The stripheater is controlled by a hygrostat to raise thetemperature inside theenclosureabove thedewpoint toprevent condensation. Figure 4-24 shows a typicallocation of the heater kit components inside theenclosure.

The installer must connect 120 VAC power to theterminal block near the hygrostat. See Figure 4-25 andFigure 4-26. Theheater and hygrostat are connected topower through a 15-amp circuit breaker.

The relative humidity setting on the hygrostat isadjustable from 35% to 95%. A setting of 65% isrecommended.

Because of space limitations in the smaller enclosures,30--200 AmpModel KCS switches can include either anenclosure heater or a surge protection device (SPD),but not both.

1. Hygrostat assembly, see Figure 4-252. Strip heater with guard

1

GM69824

2

Right Side View

Figure 4-24 Heater Location, Typical

1. 120 VAC power connection terminal block2. Circuit breaker3. Relative humidity adjustment control

GM71056

3

2

1

Figure 4-25 Hygrostat Assembly, Typical


GM71278

HYGROSTAT

HEATER

CIRCUITBREAKER

TERMINALBLOCK

120 VAC ONLYCUSTOMER SUPPLIED

Figure 4-26 Heater Connections

4.6 Other Accessories

Refer to the following documentation for instructions toinstall, connect, and operate optional accessories.

D Transfer switch wiring diagrams.

D Installation instructions provided with looseaccessory kits.

D Controller Operation Manual. See List of Relatedmaterials in the Introduction section of thismanual fordocument numbers.


Notes

TP-6833 2/16 51Section 5 Functional Tests and Setup

Section 5 Functional Tests and Setup

5.1 Introduction

Be sure to performall of the functional tests described inthis section before putting the transfer switch intooperation.

The functional tests include the following checks:

D Manual Operation TestD Voltage ChecksD Lamp TestD Automatic Operation Test

Note: Perform these checks in the order presented toavoid damaging the ATS.

Read all instructions on the labels affixed to theautomatic transfer switch before proceeding.

To complete the installation, follow the instructions inthis section to:

D Set the time, date, and exercise schedule on thecontroller.

D Perform the system startup procedures listed on thestartup form.

D Register the unit using the Kohlerr online WarrantyProcessing System.

5.2 Manual Operation Test

If you have not already done so, test the contactormanual operation before proceeding to the voltagecheck and electrical operation test.

Note: Disable the generator set and disconnect thepower byopening the circuit breakersor switchesfor both sources before manually operating thetransfer switch.

Follow the instructions in the Installation Section tocheck the transfer switch manual operation.

A contactor in normal and serviceable conditiontransfers smoothly without binding when operatedmanually. Do not place the transfer switch into service ifthe contactor does not operate smoothly withoutbinding; contact an authorized distributor/dealer toservice the contactor.

5.3 Voltage CheckThe voltage, frequency, and phasing of the transferswitchand thepower sourcesmust be thesame toavoiddamage to loads and the transfer switch. Compare thevoltage and frequency ratings of the utility source,transfer switch, and generator set, and verify that theratings are all the same.

Use the voltage check procedure explained in thissection to verify that the voltages and phasing of allpower sources are compatible with the transfer switchbefore connecting the power switching device andcontroller wire harnesses together.

Follow the instructions provided with the generator setto prepare the generator set for operation.

Read and understand all instructions on installationdrawings and labels on the switch. Note any optionalaccessories that have been furnished with the switchand review their operation.

Note: Source N is the source connected to the normalside of the contactor. Source E is the sourceconnected to the emergency side of thecontactor. Verify that the source leads areconnected to the correct lugs before proceeding.

The voltage check procedure requires the followingequipment:

D A digital voltmeter (DVM) with electrically insulatedprobes capable of measuring the rated voltage andfrequency

D A phase rotation meter

TP-6833 2/1652 Section 5 Functional Tests and Setup


Only authorized personnel shouldopen the enclosure.

DANGER

Testing live electrical circuits. Hazardous voltage orcurrent can cause severe injury or death. Have trained andqualified personnel take diagnostic measurements of livecircuits. Use adequately rated test equipment with electricallyinsulated probes and follow the instructions of the testequipment manufacturer when performing voltage tests.Observe the following precautions when performing voltagetests: (1) Remove all jewelry. (2) Stand on a dry, approvedelectrically insulated mat. (3) Do not touch the enclosure orcomponents inside the enclosure. (4) Be prepared for thesystem to operate automatically.(600 volts and under)

Voltage Check Procedure

1. If Source N is a generator set, move the generatorset master switch to the RUN position. Thegenerator set should start.

2. Close the Source N circuit breaker or switch.

3. Use a voltmeter to check the Source N (normal)phase-to-phase and phase-to-neutral (ifapplicable) terminal voltages and frequency.

a. If Source N is the utility and themeasured inputdoes not match the voltage and frequencyshown on the transfer switch nameplate,STOP! Do not proceed further in installationbecause the transfer switch is not designed forthe application—call your distributor/dealer toorder the correct transfer switch.

b. If SourceN is a generator set and the generatorset output voltage and frequency do not matchthe nominal system voltage and frequencyshown on the transfer switch nameplate, followthe manufacturer’s instructions to adjust thegenerator set. The automatic transfer switchwill only function with the rated system voltageand frequency specified on the nameplate.

4. Use a phase rotation meter to check the phaserotationat theSourceN (normal) terminals. Rewirethe transfer switchSourceN terminals to obtain thecorrect phase sequence if necessary.

Note: The default setting for the phase rotation onthe controller is ABC. If the application usesa phase rotation of BAC, refer to thecontroller Operation Manual for instructionsto change the phase rotation setting on thecontroller.

5. If the source is a generator set, stop the generatorset by moving the master switch to the OFFposition.

6. Disconnect Source N by opening upstream circuitbreakers or switches.

7. Repeat steps 1 through 5 for Source E. Thenproceed to step 8.

8. Disconnect both sources to the transfer switch byopening the circuit breakers or switches.

9. Close and lock the transfer switch enclosure door.

10. Reconnect both power sources by closing thecircuit breakers or switches.

11. Move the generator setmaster switch to the AUTOposition.

Note: If the engine cooldown time delay setting isnot set to zero (default setting), thegenerator set may start and run until theEngine Cooldown Time Delay ends.

12. Perform the lamp test and then proceed to theautomatic operation test.

5.4 Lamp Test

Refer to the controller OperationManual for instructionsto perform a lamp test. Verify that all controller LEDs orlamps light during the test.

5.5 Automatic Operation TestCheck the transfer switch’s automatic control systemimmediately after the voltage check. Refer to thecontroller Operation Manual for instructions to run theautomatic operation test.

Note: Close and lock the enclosure door before startingthe test procedure.

TP-6833 2/16 53Section 5 Functional Tests and Setup

5.6 System Setup

Set the controller’s current time and date. See thecontroller Operation Manual for instructions.

The transfer switch is factory-setwith default settings fortime delays and other parameters. See the controllerOperation Manual for instructions to view and changesettings, if necessary.

Note: Use caution when changing transfer switchsettings. The source voltage and frequencysettings must match the values shown on thetransfer switch nameplate.

5.7 Exerciser Setup

Set the exerciser to start and run the generator set atleast once aweek. See the controller OperationManualfor instructions.

Transfer switches equipped with the Decision-MakerrMPAC 750 controller may also use the optionalprogrammable exerciser. Refer to the instructionsprovided with the exerciser to schedule additionalloaded or unloaded exercise runs.

5.8 User Interface Cover

The gasket-sealed, hinged user interface coverprevents unauthorized access to the transfer switchcontrols and protects the user interface from harshenvironmental conditions. The cover is available as anoptional accessory for NEMA 1 enclosures. NEMA 3Renclosures include the cover as standard equipment.

Use a customer-supplied padlock to lock the cover.

5.9 Startup NotificationPerform the system startup procedure explained on theStartup Notification Form. The Startup NotificationForm covers all equipment in the power system.Complete the Startup Notification Form and register thepower system using the Kohlerr online WarrantyProcessing System.

TP-6833 2/1654 Section 5 Functional Tests and Setup

Notes

TP-6833 2/16 Appendix 55

Appendix A Abbreviations

The following list contains abbreviations that may appear in this publication.

A, amp ampereABDC after bottom dead centerAC alternating currentA/D analog to digitalADC advanced digital control;

analog to digital converteradj. adjust, adjustmentADV advertising dimensional

drawingAh amp-hourAHWT anticipatory high water

temperatureAISI American Iron and Steel

InstituteALOP anticipatory low oil pressurealt. alternatorAl aluminumANSI American National Standards

Institute (formerly AmericanStandards Association, ASA)

AO anticipatory onlyAPDC Air Pollution Control DistrictAPI American Petroleum Instituteapprox. approximate, approximatelyAPU Auxiliary Power UnitAQMD Air Quality Management DistrictAR as required, as requestedAS as supplied, as stated, as

suggestedASE American Society of EngineersASME American Society of

Mechanical Engineersassy. assemblyASTM American Society for Testing

MaterialsATDC after top dead centerATS automatic transfer switchauto. automaticaux. auxiliaryavg. averageAVR automatic voltage regulatorAWG American Wire GaugeAWM appliance wiring materialbat. batteryBBDC before bottom dead centerBC battery charger, battery

chargingBCA battery charging alternatorBCI Battery Council InternationalBDC before dead centerBHP brake horsepowerblk. black (paint color), block

(engine)blk. htr. block heaterBMEP brake mean effective pressurebps bits per secondbr. brassBTDC before top dead centerBtu British thermal unitBtu/min. British thermal units per minuteC Celsius, centigradecal. calorieCAN controller area networkCARB California Air Resources BoardCAT5 Category 5 (network cable)CB circuit breakerCC crank cyclecc cubic centimeterCCA cold cranking ampsccw. counterclockwiseCEC Canadian Electrical Codecert. certificate, certification, certifiedcfh cubic feet per hour

cfm cubic feet per minuteCG center of gravityCID cubic inch displacementCL centerlinecm centimeterCMOS complementary metal oxide

substrate (semiconductor)com communications (port)coml commercialComl/Rec Commercial/Recreationalconn. connectioncont. continuedCPVC chlorinated polyvinyl chloridecrit. criticalCSA Canadian Standards

AssociationCT current transformerCu coppercUL Canadian Underwriter’s

LaboratoriesCUL Canadian Underwriter’s

Laboratoriescu. in. cubic inchcw. clockwiseCWC city water-cooledcyl. cylinderD/A digital to analogDAC digital to analog converterdB decibeldB(A) decibel (A weighted)DC direct currentDCR direct current resistancedeg., degreedept. departmentdia. diameterDI/EO dual inlet/end outletDIN Deutsches Institut fur Normung

e. V. (also Deutsche IndustrieNormenausschuss)

DIP dual inline packageDPDT double-pole, double-throwDPST double-pole, single-throwDS disconnect switchDVR digital voltage regulatorE2PROM, EEPROM

electrically-erasableprogrammable read-onlymemory

E, emer. emergency (power source)ECM electronic control module,

engine control moduleEDI electronic data interchangeEFR emergency frequency relaye.g. for example (exempli gratia)EG electronic governorEGSA Electrical Generating Systems

AssociationEIA Electronic Industries

AssociationEI/EO end inlet/end outletEMI electromagnetic interferenceemiss. emissioneng. engineEPA Environmental Protection

AgencyEPS emergency power systemER emergency relayES engineering special,

engineered specialESD electrostatic dischargeest. estimatedE-Stop emergency stopetc. et cetera (and so forth)

exh. exhaustext. externalF Fahrenheit, femaleFHM flat head machine (screw)fl. oz. fluid ounceflex. flexiblefreq. frequencyFS full scaleft. foot, feetft. lb. foot pounds (torque)ft./min. feet per minuteftp file transfer protocolg gramga. gauge (meters, wire size)gal. gallongen. generatorgenset generator setGFI ground fault interrupter

GND, groundgov. governorgph gallons per hourgpm gallons per minutegr. grade, grossGRD equipment groundgr. wt. gross weightH x W x D height by width by depthHC hex capHCHT high cylinder head temperatureHD heavy dutyHET high exhaust temp., high

engine temp.hex hexagonHg mercury (element)HH hex headHHC hex head capHP horsepowerhr. hourHS heat shrinkhsg. housingHVAC heating, ventilation, and air

conditioningHWT high water temperatureHz hertz (cycles per second)IBC International Building CodeIC integrated circuitID inside diameter, identificationIEC International Electrotechnical

CommissionIEEE Institute of Electrical and

Electronics EngineersIMS improved motor startingin. inchin. H2O inches of waterin. Hg inches of mercuryin. lb. inch poundsInc. incorporatedind. industrialint. internalint./ext. internal/externalI/O input/outputIP internet protocolISO International Organization for

StandardizationJ jouleJIS Japanese Industry Standardk kilo (1000)K kelvinkA kiloampereKB kilobyte (210 bytes)KBus Kohler communication protocolkg kilogram

TP-6833 2/1656 Appendix

kg/cm2 kilograms per squarecentimeter

kgm kilogram-meterkg/m3 kilograms per cubic meterkHz kilohertzkJ kilojoulekm kilometerkOhm, k kilo-ohmkPa kilopascalkph kilometers per hourkV kilovoltkVA kilovolt amperekVAR kilovolt ampere reactivekW kilowattkWh kilowatt-hourkWm kilowatt mechanicalkWth kilowatt-thermalL literLAN local area networkL x W x H length by width by heightlb. pound, poundslbm/ft3 pounds mass per cubic feetLCB line circuit breakerLCD liquid crystal displayLED light emitting diodeLph liters per hourLpm liters per minuteLOP low oil pressureLP liquefied petroleumLPG liquefied petroleum gasLS left sideLwa sound power level, A weightedLWL low water levelLWT low water temperaturem meter, milli (1/1000)M mega (106 when used with SI

units), malem3 cubic meterm3/hr. cubic meters per hourm3/min. cubic meters per minutemA milliampereman. manualmax. maximumMB megabyte (220 bytes)MCCB molded-case circuit breakerMCM one thousand circular milsmeggar megohmmeterMHz megahertzmi. milemil one one-thousandth of an inchmin. minimum, minutemisc. miscellaneousMJ megajoulemJ millijoulemm millimetermOhm, mmilliohmMOhm, MmegohmMOV metal oxide varistorMPa megapascalmpg miles per gallonmph miles per hourMS military standardms millisecondm/sec. meters per secondmtg. mountingMTU Motoren-und Turbinen-UnionMW megawattmW milliwattF microfaradN, norm. normal (power source)NA not available, not applicablenat. gas natural gas

NBS National Bureau of StandardsNC normally closedNEC National Electrical CodeNEMA National Electrical

Manufacturers AssociationNFPA National Fire Protection

AssociationNm newton meterNO normally openno., nos. number, numbersNPS National Pipe, StraightNPSC National Pipe, Straight-couplingNPT National Standard taper pipe

thread per general useNPTF National Pipe, Taper-FineNR not required, normal relayns nanosecondOC overcrankOD outside diameterOEM original equipment

manufacturerOF overfrequencyopt. option, optionalOS oversize, overspeedOSHA Occupational Safety and Health

AdministrationOV overvoltageoz. ouncep., pp. page, pagesPC personal computerPCB printed circuit boardpF picofaradPF power factorph., phasePHC Phillipsr head Crimptiter

(screw)PHH Phillipsr hex head (screw)PHM pan head machine (screw)PLC programmable logic controlPMG permanent magnet generatorpot potentiometer, potentialppm parts per millionPROM programmable read-only

memorypsi pounds per square inchpsig pounds per square inch gaugept. pintPTC positive temperature coefficientPTO power takeoffPVC polyvinyl chlorideqt. quart, quartsqty. quantityR replacement (emergency)

power sourcerad. radiator, radiusRAM random access memoryRDO relay driver outputref. referencerem. remoteRes/Coml Residential/CommercialRFI radio frequency interferenceRH round headRHM round head machine (screw)rly. relayrms root mean squarernd. roundRO read onlyROM read only memoryrot. rotate, rotatingrpm revolutions per minuteRS right sideRTDs Resistance Temperature

Detectors

RTU remote terminal unitRTV room temperature vulcanizationRW read/writeSAE Society of Automotive

Engineersscfm standard cubic feet per minuteSCR silicon controlled rectifiers, sec. secondSI Systeme international d’unites,

International System of UnitsSI/EO side in/end outsil. silencerSMTP simple mail transfer protocolSN serial numberSNMP simple network management

protocolSPDT single-pole, double-throwSPST single-pole, single-throwspec specificationspecs specification(s)sq. squaresq. cm square centimetersq. in. square inchSMS short message serviceSS stainless steelstd. standardstl. steeltach. tachometerTB terminal blockTCP transmission control protocolTD time delayTDC top dead centerTDEC time delay engine cooldownTDEN time delay emergency to

normalTDES time delay engine startTDNE time delay normal to

emergencyTDOE time delay off to emergencyTDON time delay off to normaltemp. temperatureterm. terminalTHD total harmonic distortionTIF telephone influence factortol. toleranceturbo. turbochargertyp. typical (same in multiple

locations)UF underfrequencyUHF ultrahigh frequencyUIF user interfaceUL Underwriter’s Laboratories, Inc.UNC unified coarse thread (was NC)UNF unified fine thread (was NF)univ. universalURL uniform resource locator

(web address)US undersize, underspeedUV ultraviolet, undervoltageV voltVAC volts alternating currentVAR voltampere reactiveVDC volts direct currentVFD vacuum fluorescent displayVGA video graphics adapterVHF very high frequencyW wattWCR withstand and closing ratingw/ withWO write onlyw/o withoutwt. weightxfmr transformer

TP-6833 2/16 57

Notes

TP-6833 2/1658

Notes

KOHLER CO. Kohler, Wisconsin 53044Phone 920-457-4441, Fax 920-459-1646For the nearest sales/service outlet in theUS and Canada, phone 1-800-544-2444KOHLERPower.com

Kohler Power SystemsAsia Pacific Headquarters7 Jurong Pier RoadSingapore 619159Phone (65) 6264-6422, Fax (65) 6264-6455E 2014, 2016 by Kohler Co. All rights reserved.

TP-6833 2/16a

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