Kohler KBS, KBP, KBC Operation And Installation

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Page 1

Operation and

Installation

Automatic Transfer and

Bypass/Isolation Switches

Models:

KBS/KBP/KBC

150 to 4000 Amperes

TP-6835 9/17c

Page 2

Product Identification Information

Product identification numbers determine service parts. Record the product identification numbersin the spaces below immediately after unpacking the products so that the numbers are readily available for future reference. Record field-installed kit numbers after installing the kits.

Transfer Switch Identification Numbers

Record the product identification numbers from the transfer switch nameplate.

Model Designation

Serial Number

Accessories

- Alarm Board

- Battery Module

- California OSHPD Approval

- 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

- IBC Seismic Certification

- Supervised Transfer Switch

- SurgeProtectionDevice(SPD)

Controller Identification

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

Controller Description

Page 3

Table of Contents

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 1 1....................................................

2.2.2 Lifting 11........................................................

2.2.3 Storage 12......................................................

2.2.4 Unpacking 12....................................................

2.3 Installation 13............................................................

2.4 IBC Seismic Certification or California OSHPD Approval 14....................

2.5 Manual Operation Check 15...............................................

2.5.1 Manual Operation, 150--4000 Amp Standard-Transition Model KBS 16..

2.5.2 Manual Operation, 150--4000 Amp Programmed- and Closed-

2.6 Controller Connections 18.................................................

2.6.1 Controller Input and Output Connections 19..........................

2.6.2 Harness Connection 19...........................................

2.6.3 Controller Ground 19..............................................

2.7 Electrical Wiring 20.......................................................

2.7.1 Source and Load Connections 20...................................

2.7.2 Extended Transfer Time Relay (Model KBC only) 22..................

2.7.3 Engine Start Connection 24........................................

2.7.4 Auxiliary Contacts 25.............................................

2.8 Communication and Accessory Connections 25..............................

2.9 Functional Tests 25.......................................................

Section 3 Three-Source Systems 27...........................................................

3.1 Three-Source Systems 27.................................................

3.2 Three Source Engine Start Mode 27........................................

3.2.1 Mode 1 27.......................................................

3.2.2 Mode 2 27.......................................................

3.3 Preferred Source Toggle 27................................................

3.4 Three Source System Test and Exercise 27..................................

3.4.1 Unloaded Test 27.................................................

3.4.2 Loaded Test 27...................................................

3.4.3 Unloaded Exercise 27.............................................

3.4.4 Loaded Exercise 27...............................................

3.5 Three-Source System Connection 28.......................................

3.6 ATS1 and ATS2 System Setup 30..........................................

Section 4 Communication and Accessory Connections 31......................................

4.1 Introduction 31

4.2 Communication Connections 31............................................

4.2.1 USB Port SiteTech Connection 31..................................

4.2.2 Modbus Connection 31............................................

4.2.3 Ethernet Connection 33...........................................

Transition Models KBP and KBC 17.................................

...........................................................

TP-6835 9/17 Table of Contents 3

Page 4

Table of Contents, continued

4.3 Accessory Modules 35....................................................

4.3.1 Accessory Module Mounting 35....................................

4.3.2 Input/Output (I/O) Modules 36......................................

4.3.3 External Battery Supply Module (EBSM) 37..........................

4.3.4 Alarm Module 38.................................................

4.4 Load Shed (Forced Transfer to OFF) 40.....................................

4.5 Heater 42...............................................................

4.6 Other Accessories 43.....................................................

Section 5 Functional Tests and Setup 45.......................................................

5.1 Introduction 45...........................................................

5.2 Manual Operation Test 45.................................................

5.3 Voltage Check 45.........................................................

5.4 Lamp Test 46............................................................

5.5 Automatic Operation Test 46...............................................

5.6 System Setup 47.........................................................

5.7 Exerciser Setup 47.......................................................

5.8 User Interface Cover 47...................................................

5.9 Startup Notification 47.....................................................

Section 6 Scheduled Maintenance 49..........................................................

Section 7 Bypass, Isolation, and Manual Transfer 51............................................

7.1 Introduction 51...........................................................

7.1.1 Bypassing the Transfer Switch 51...................................

7.1.2 Isolating the Transfer Switch 51....................................

7.2 150--600 Amp Models 52..................................................

7.2.1 Bypassing the ATS, 150--600 Amp Models 52........................

7.2.2 Isolating the Transfer Switch, 150--600 Amp Models 55................

7.2.3 Return to Service, 150--600 Amp Models 57..........................

7.2.4 Return Bypass Switch to OPEN, 150--600 Amp Models 59.............

7.2.5 Manual Load Transfer, 150--600 Amp Models 60......................

7.3 800--1200 Amp Models 61.................................................

7.3.1 Bypassing the ATS, 800--1200 Amp Models 61.......................

7.3.2 Isolating the ATS, 800--1200 Amp Models 64.........................

7.3.3 Return to Service, 800--1200 Amp Models 66........................

7.3.4 Return Bypass Switch to OPEN, 800--1200 Amp Models 67............

7.3.5 Manual Load Transfer, 800--1200 Amp Models 68.....................

7.4 1600--4000 Amp Models 69................................................

7.4.1 Bypassing the Transfer Switch, 1600--4000 Amp Models 69............

7.4.2 Isolating the Transfer Switch, 1600--4000 Amp Models 70..............

7.4.3 Removing the Transfer Switch, 1600--4000 Amp Models 71............

7.4.4 Return to Operation, 1600--4000 Amp Models 73.....................

7.4.5 Manual Load Transfer, 1600--4000 Amp Models 75...................

Appendix A Abbreviations 77................................................................

TP-6835 9/17Table of Contents4

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Safety Precautions and Instructions

IMPORTANTSAFETY INSTRUCTIONS.

Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely. Read and follow all safety precautions and instructions. SAVE THESE INSTRUCTIONS.

This manual has several types of safety precautions and instructions: Danger, Warning, Caution, and Notice.

DANGER

Danger indicates the presence of a hazard that will cause severe

personal injury, death,orsubstantial property damage.

WARNING

Warning indicates the presence of a hazard that can cause severe

personal injury, death, or substantial property damage.

CAUTION

Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage.

NOTICE

Notice communicates installation, operation, or maintenance information that is safety related but not hazard related.

Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely. The decals are shown throughout this publication to improve operator recognition. Replace missing or damaged decals.

Accidental Starting

WARNING

Accidental starting. Can cause severe injury or death.

Disconnect the battery cables before working on the generator set. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery.

Disabling the generator set. Accidental starting can cause severe injury or death. Before

working on the generator set or equipment connected to the set, disable the generator set as follows: (1) Move the generator set master switch to the OFF position. (2) Disconnect the power to the battery charger. (3) Remove the battery cables, negative (--) lead first. Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.

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

Disabling the generator set. Accidental starting can cause severe injury or death. Before

working on the generator set or equipment connected to the set, disable the generator set as follows: (1) Press the generator set off/reset button to shut down the generator set. (2) Disconnect the power to the battery charger, if equipped. (3) Remove the battery cables, negative (--) lead first. Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent the starting of the generator set by the remote start/stop switch.

(RDC, DC, RDC2, DC2, Decision-Makerr 3000, 3500 and 6000 Generator Set Controllers)

Disabling the generator set. Accidental starting can cause severe injury or death. Before

working on the generator set or equipment connected to the set, disable the generator set as follows: (1) If the controller is not already in the MAN (manual) mode, press the Controller Mode button and then press the MAN mode button. (2) If the generator set is running, press and hold the Manual--Stop button for at least 2 seconds to stop the generator set. (3) Press the Controller Mode button and then press the controller Off mode button. (4) Disconnect the power to the battery charger, if equipped. (5) Remove the battery cables, negative (--) lead first. Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent the starting of the generator set by the remote start/stop switch.

(Decision-Makerr 8000 Controller)

Hazardous Voltage/ Moving Parts

DANGER

Hazardous voltage. Will cause severe injury or death.

Disconnect all power sources before opening the enclosure.

DANGER

Hazardous voltage. Will cause severe injury or death.

Only authorized personnel should open the enclosure.

TP-6835 9/17 5Safety Precautions and Instructions

Page 6

Grounding electrical equipment. Hazardous voltage will cause severe injury or death. Electrocution is

possible whenever electricity is present. Ensure you comply with all applicable codes and standards. Electrically ground the generator set, transfer switch, and related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the equipment. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.

Removing the transfer switch from bypass/isolation models. Hazardous voltage will cause severe injury or death. Bypass and isolate the transfer

switch before removing it from the enclosure. The bypass/isolation switch is energized. Do not touch the isolation contact fingers or the control circuit terminals.

Short circuits. Hazardous voltage/current will cause severe injury or death. Short circuits can

cause bodily injury and/or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment.

Making line or auxiliary connections. Hazardous voltage will cause severe injury or death. To

prevent electrical shock deenergize the normal power source before making any line or auxiliary connections.

Servicing the transfer switch. Hazardous voltage will cause severe injury or death. Deenergize all power

sources before servicing. Turn off the main circuit breakers of all transfer switch power sources and disable all generator sets as follows: (1) Move all generator set master controller switches to the OFF position. (2) Disconnect power to all battery chargers. (3) Disconnect all battery cables, negative (--) leads first. Reconnect negative(--) leads last when reconnecting the battery cables after servicing. Follow these precautions to prevent the starting of generator sets by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer. Before servicing any components inside the enclosure: (1) Remove all jewelry. (2) Stand on a dry, approved electrically insulated mat. (3) Test

circuits with a voltmeter to verify that they are deenergized.

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

Servicing the transfer switch. Hazardous voltage will cause severe injury or death. Deenergize all power

sources before servicing. Turn off the main circuit breakers of all transfer switch power sources and disable all generator sets as follows: (1) Press the generator set off/reset button to shut down the generator set. (2) Disconnect power to all battery chargers. (3) Disconnect all battery cables, negative (--) leads first. Reconnect negative (--) leads last when reconnecting the battery cables after servicing. Follow these precautions to prevent the starting of generator sets by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer. Before servicing any components inside the enclosure: (1) Remove all jewelry. (2) Stand on a dry, approved electrically insulated mat. (3) Test circuits with a voltmeter to verify that they are deenergized.

(RDC, DC, RDC2, DC2, Decision-Makerr 3000, 3500 and 6000 Generator Set Controllers)

Testing live electrical circuits. Hazardous voltage or current will cause severe injury or death. Have

trained and qualified personnel take diagnostic measurements of live circuits. Use adequately rated test equipment with electrically insulated probes and follow the instructions of the test equipment manufacturer when performing voltage tests. Observe the following precautions when performing voltage tests: (1) Remove all jewelry. (2) Stand on a dry,approved electrically insulated mat. (3) Do not touch the enclosure or components inside the enclosure. (4) Be prepared for the system to operate automatically.

(600 volts and under)

Heavy Equipment

WARNING

Unbalanced weight. Improper lifting can cause severe injury or death and equipment damage.

Use adequate lifting capacity. Never leave the transfer switch standing upright unless it is securely bolted in place or stabilized.

Notice

NOTICE

Improper operator handle usage.

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

NOTICE

Foreign material contamination.

Cover the transfer switch during installation to keep dirt, grit, metal drill chips, and other debris out of the components. Cover the solenoid mechanism during installation. After installation, use the manual operating handle to cycle the contactor to verify that it operates freely. Do not use a screwdriver to force the contactor mechanism.

NOTICE

Electrostatic discharge damage.

Electrostatic discharge (ESD) damages electronic circuit boards. Prevent electrostatic discharge damage by wearing an approved grounding wrist strap when handling electronic circuit boards or integrated circuits. An approved grounding wrist strap provides a high resistance (about 1 megohm), not a direct short,to ground.

TP-6835 9/176 Safety Precautions and Instructions

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Introduction

This manual provides operation and installation instructions for Kohlerr Model KBS/KBP/KBC Bypass/ Isolation Transfer Switches equipped with the Decision-Makerr MPAC 1500 controller.

A separate manual provided with the transfer switch covers the transfer switch controller operation. See List of Related Materials for the document part number.

Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this literature and the products represented without notice and without any obligation or liability whatsoever.

Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury. Read and follow the Safety Precautions and Instructions section at the beginning of this manual. Keep this manual with the equipment for future reference.

The equipment service requirements are very important to safe and efficient operation. Inspect parts often and

perform required service at the p rescribed intervals. See the controller Operation manual for the service schedule. Obtain service from an authorized service distributor/ dealer to keep equipment in top condition.

List of Related Materials

A separate covers the transfer switch controller and related accessories. Separate manuals cover service and parts information for transfer switch power switching devices and electrical controls.

The following table lists the part numbers for related literature.

Literature Item Part Number

Specification Sheet, Decision-Makerr MPAC 1500 Controller

Specification Sheet, Model KBS/KBP/KBC G11-137

Operation Manual, Decision-Makerr MPAC 1500 Controller

Parts Catalog, Transfer Switch and Controller TP-6433

Service Manual, Models KC/KB TP-6920

G11-128

TP-6883

TP-6835 9/17 7Introduction

Page 8

Service Assistance

For professional advice on generator power requirements and conscientious service, please contact your nearest Kohler distributor or dealer.

D Consult the Yellow Pages under the heading

Generators—Electric.

D Visit the Kohler Power Systems website at

KOHLERPower.com.

D Look at the labels and decals on your Kohler product

or review the appropriate literature or documents included with the product.

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

D Outside the US and Canada, call the nearest regional

office.

Headquarters Europe, Middle East, Africa (EMEA)

Kohler Power Systems Netherlands B.V. Kristallaan 1 4761 ZC Zevenbergen The Netherlands Phone: (31) 168 331630 Fax: (31) 168 331631

Asia Pacific

Power Systems Asia Pacific Regional Office Singapore, Republic of Singapore Phone: (65) 6264-6422 Fax: (65) 6264-6455

China

North China Regional Office, Beijing Phone: (86) 10 6518 7950

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

Fax: (86) 10 6518 7955

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

India, Bangladesh, Sri Lanka

India Regional Office Bangalore, India Phone: (91) 80 3366208

(91) 80 3366231

Fax: (91) 80 3315972

Japan, Korea

North Asia Regional Office Tokyo, Japan Phone: (813) 3440-4515 Fax: (813) 3440-2727

TP-6835 9/178 Service Assistance

Page 9

Section 1 Product Description

1.1 Purpose

An automatic transfer switch (ATS) transfers electrical loads from a normal (preferred) source of electrical power to an emergency (standby) source when the normal source falls outside the acceptable electrical parameters.

When the normal ( preferred) source fails, the ATS signals the emergency (standby) source generator set to start. Whenthe emergency (standby) source reaches acceptable levels and stabilizes, the ATS transfers the load from the normal (preferred) source to the emergency (standby) source. The ATS continuously monitors the normal (preferred) source and transfers the load back when the normal (preferred) source returns and stabilizes. After transferring the load back to the normal (preferred) source, the ATS removes the generator start signal, allowing the generator set to shut down.

A bypass/isolation transfer switch allows transfer switch testing and service without interrupting power to the load. The bypass connection is open during normal transfer switch operation. Closing the bypass connection provides a direct connection to either the Normal or Emergency source, bypassing the transfer switch to provide power to the load during transfer switch service. Isolation removes the transfer switch from the power circuit. Procedures in Section 7 explain how to bypass and isolate the transfer switch. Figure 1-1 shows a typical bypass/isolation transfer switch.

Normal (Utility)

Power Switching Device

Power

To Load

Emergency (Generator) Power

Automatic Transfer Switch

Bypass Isolation Switch

Generator

Electrical

Controls

Start Generator

6835

Figure 1-2 Typical ATS Block Diagram

1.2 Nameplate

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

Copy the model designation, serial number, and accessory information from the nameplate to the spaces provided in the Product Identification Information section inside the front cover of this manual for use when requesting service or parts.

Figure 1-2 shows a typical installation block diagram.

Figure 1-1 Bypass/Isolation Switch

TP-6835 9/17 9Section 1 Product Description

Figure 1-3 Typical Transfer Switch Nameplate

GM21291

Page 10

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 defines characteristics and ratings as explained below.

Sample Model Designation: KBS-DMVA-1200S

Model

K: Kohler

Mechanism

B: Bypass/Isolation

Transition

S: Standard

P: Programmed

C: Closed

Controller

Decision-Makerr MPAC 1500, Automatic

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

Current, Amps *

0150 0800 2600

0225 1000 3000

0260 1200 4000

0400 1600

0600 2000

* Some selections are not available on all models.

Connections

S: Standard

F: Front (800 amp only)

Note: Some selections are not available on all models.

Contact your Kohler distributor for availability.

TP-6835 9/1710 Section 1 Product Description

Page 11

Section 2 Installation

2.1 Introduction

An automatic transfer and bypass/isolation switch consists of an upper bypass/isolation switch, a lower transfer switch, and door-mounted controls.

Kohlerr transfer switches are shipped factory-wired, factory-tested, and ready for installation. Have the equipment installed only by trained and qualified personnel, and verify that the installation complies with applicable codes and standards. Switch installation includes the following steps:

D Unpack and inspect the transfer switch upon receipt.

D Verify that the transfer switch voltage and frequency

ratings match the voltages and frequencies of the sources.

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 load circuits.

exterior and interior for shipping damage. If damage and/or rough handling is evident, immediately file a damage claim with the transportation company.

2.2.2 Lifting

WARNING

Unbalanced weight. Improper lifting can cause severe injury or death and equipment damage.

Use adequate lifting capacity. Never leave the transfer switch standing upright unless it is securely bolted in place or stabilized.

See Figure 2-1 or the dimension drawing for the approximate transfer switch weight . Usea spreader bar to lift the transfer switch. Attach the bar only to the enclosure’s mounting holes or lifting brackets; do not lift the unit any other way. Close and latch the enclosure door before moving the unit.

D Connect accessories, if provided.

D Check voltages and operation.

Protect the switch against damage before and during installation.

Note: An approved protective device such a s a

molded-case circuit breaker or fused disconnect switch MUST be installed on both sources of incoming power for circuit protection and use as a disconnect device.

The functional tests in Section 5 are a necessary part of the 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 the transfer switch for signs of shipping damage. Unpack the transfer switch as soon as possible and inspect the

Weight, kg (lb.)

Amps

150--600 431 (950) 431 (950) 431 (950)

800F — 635 (1400) 635 (1400)

600--1200S — 708 (1560) 708 (1560)

1600--2000 — 1070 (2360) 1152 (2540)

2600--3000 — 1240 (2730) 1525 (3360)

4000 — 2087 (4600) 2268 (5000)

2-Pole 3-Pole 4-Pole

Figure 2-1 Approximate Weights with NEMA 1

Enclosures

TP-6835 9/17 11Section 2 Installation

Page 12

2.2.3 Storage

Store the transfer switch in its protective packing until final installation. Protect the transfer switch at all times from moisture, construction grit, and metal chips. Avoid storage in low-temperature and high-humidity areas where moisture could condense on the unit. See Figure 2-2 for acceptable storage temperatures.

Environmental Specifications

Operating Temperature -- 2 0 Cto70C(--4F to 158F)

Storage Temperature -- 4 0 Cto85C(--40F to 185F)

Humidity 5% to 95% noncondensing

Figure 2-2 Environmental Specifications

2.2.4 Unpacking

Allow the equipment to warm to room temperature for at least 24 hours before unpacking to prevent condensation on the electrical apparatus. Use care when unpacking to avoid damaging transfer switch components. Remove dirt and packing material that may have accumulated in the transfer switch or any of its components.

Note: Do not use compressed air to clean the transfer

switch. Cleaning with compressed air can cause debris to lodge in the components and damage the switch.

Open the enclosure door to remove the lag screws that secure the enclosure to the wood skid. Remove any shipping angles before attempting to operate the transfer switch.

1600--4000 Amp Models

Open the lower front door and remove the two front lag screws that secure the transfer switch to the skid. Then remove the lower panel and remove the two rear lag screws securing the enclosure to the wood skid.

Remove any shipping angles, which are identified by a yellow sticker, before attempting to operate the transfer switch. See Figure 2-3.

1. Shipping angles, qty.3; remove

Figure 2-3 Shipping Angles, 1600--3000 Amp

Models

1. Remove two upper shipping brackets

2. Remove two lower shipping brackets

132

Figure 2-4 Shipping Brackets, 4000 Amp Models

TP-6835 9/1712 Section 2 Installation

Page 13

2.3 Installation

NOTICE

Foreign material contamination. Cover the transfer switch

during installation to keep dirt, grit, metal drill chips, and other debris out of the components. Cover the solenoid mechanism during installation. After installation, use the manual operating handle 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 and metric hardware. Use the correct size tools to prevent rounding of the bolt heads and nuts.

Check the system voltage and frequency. Compare the voltage and frequency shown on the transfer switch nameplate to the source voltage and frequency. Do not install the transfer switch if the system voltage and frequency are different from the nominal normal (utility) source voltage and frequency or the nominal emergency source voltage and frequency shown on the generator set nameplate.

Plan the installation. Use the dimensions given on the enclosure dimension (ADV) drawings. Select a mounting site that complies with local electrical code restrictions for the enclosure type. Mount the transfer switch as close to the load and power sources as possible. Allow adequate space to fully open the enclosure and to service the switch. Provide the required clearance for transfer switch drawout. Provide cable bending space and clearance to live metal parts.

Outdoor installations. Transfer switches with NEMA 3R, 4, or 4X enclosures can be installed outdoors. In locations with very high ambient temperatures, installation in a shaded area or a location with the enclosure door facing away from direct sunlight is recommended.

Prepare the foundation. Ensure that the supporting foundation for the enclosure is level and straight. The floor must be flat and level. Refer to the dimension drawing provided with the switch for required clearance. For 1600--4000 amp models, allow at least 0.9 meters (35 inches) to roll out the transfer switch.

For bottom cable entry, if used, install conduit stubs in the foundation. Refer to the enclosure dimension drawing for the conduit stub locations. Provide cable bending space and clearance to live metal parts. When pouring a concrete floor,use interlocking conduit spacer caps or a wood or metal template to maintain proper conduit alignment.

Installation of IBC seismically certified or California OSHPD approved transfer switches. IBC Seismic

certification or California OSHPD approval must be requested when the transfer switch is ordered. See Section 2.4 and the ADV drawings for additional installation requirements for transfer switches with IBC seismic certification or California OSHPD approval. Correctly installed transfer switches with California OSHPD approval also have IBC seismic certification.

Install the transfer switch. Refer to the dimension drawing supplied with the switch and mount the transfer switch according to the details and instructions on the drawing.

When drilling entry holes for any conductors, cover the transfer switch components for protection from metal chips and construction grit.

Note: Do not use compressed air to clean the switch.

Cleaning with compressed air can cause debris to lodge in the components and damage the switch.

TP-6835 9/17 13Section 2 Installation

Page 14

2.4 IBC Seismic Certification or California OSHPD Approval

Automatic transfer switches with IBC seismic certification or California OSHPD approval must be installed according to the instructions in this section. Also refer to ADV-7456, the Certificate of Compliance provided with the ATS, and the installation (ADV) drawings for the transfer switch.

Abbreviations:

6. Anchors used for seismic installation must be designed and rated to resist seismic loading in accordance with ACI 355.2--04 and documented in a report by a reputable testing agency (for example, the Evaluation Service Report issued by the International Code Council).

7. Wide washers must be installed at each anchor location between the anchor head and equipment for tension load distribution. See applicable ADV drawing for specific anchor information and washer dimensions.

ACI: American Concrete Institute

IBC: International Building Coder

Design spectral response acceleration at short

DS:

period, as determined in Section 1615.1.3 of the IBC

: Equipment response modification factor

: Equipment importance factor

: In-structure equipment amplification factor

Refer to the International Building Coder for more information.

General Seismic Installation Notes (for ATS only):

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

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

3. Anchors must be installed in minimum 4000 psi compressive strength normal weight concrete. Concrete aggregate must comply with ASTM C33. Installation in structural lightweight concrete is not permitted unless otherwise approved by the structural engineer of record.

4. Anchors must be installed to the required torque specified by the anchor manufacturer to obtain maximum loading.

5. Anchors must be installed to the anchor spacing required to obtain maximum load and edge distance required to obtain maximum load unless otherwise approved by the structural engineer of record.

8. Equipment installed on a housekeeping pad requires the housekeeping pad thickness to be at least 1.5x the anchor embedment depth.

9. All housekeeping pads must be seismically designed and dowelled or cast into the building structure as approved by the structural engineer of record.

10. Rebar reinforcing in the housekeeping pad is required for all installations.

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

12. Wall-mounted equipment must be installed to a rebar reinforced structural concrete wall that is seismically designed and approved by the engineer of record to resist the added seismic loads from components being anchored to the wall.

13. Floor-mounted equipment (with or without a housekeeping pad) must be installed to a rebar reinforced structural concrete floor that is seismically designed and approved by the engineer of record to resist the added seismic loads from components being anchored to the floor.

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

15. Equipment attached to any structural floor or wall other than those constructed of structural concrete and designed to accept the seismic loads from the mounted equipment are beyond the scope of this specification.

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

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

TP-6835 9/1714 Section 2 Installation

Page 15

2.5 Manual Operation Check

DANGER

Disable the generator set to prevent it from starting and disconnect both power sources before manually operating the switch.

Do not place the transfer switch into service if the contactor does not operate smoothly; contact an authorized distributor/dealer to service the contactor.

Hazardous voltage. Will cause severe injury or death.

Disconnect all power sources before opening the enclosure.

Servicing the transfer switch. Hazardous voltage will cause severe injury or death. Deenergize all power sources

before servicing. Turn off the main circuit breakers of all transfer switch power sources and disable all generator sets as follows: (1) Press the generator set off/reset button to shut down the generator set. (2) Disconnect power to all battery chargers. (3) Disconnect all battery cables, negative (--) leads first. Reconnect negative (--) leads last when reconnecting the battery cables after servicing. Follow these precautions to prevent the starting of generator sets by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer. Before servicing any components inside the enclosure: (1) Remove all jewelry. (2) Stand on a dry, approved electrically insulated mat. (3) Test circuits with a voltmeter to verify that they are deenergized.

NOTICE

Improper operator handle usage. Use the manual operator

handle on the transfer switch for maintenance purposes only. Return the transfer switch to the normal position. Remove the manual operator handle, if used, and store it in the place provided on the transfer switch when service is completed.

Remove any shipping angles, which are identified by a yellow sticker, before attempting to operate the transfer switch.

Note: Bypass and isolate the transfer switch before

using the maintenance handle. See Section 7

for bypass and isolation procedures.

A detachable manual operator handle is provided on the transfer switch for maintenance purposes only. Use the following manual operation procedures to verify that the contactor operates smoothly without binding. On programmed-transition and closed-transition models, check the operation of both the Normal and Emergency operators.

Note: A contactor in normal and serviceable condition

operates smoothly without binding. If the contactor does not operate smoothly, contact an authorized distributor/dealer to service the contactor.

TP-6835 9/17 15Section 2 Installation

Page 16

2.5.1 Manual Operation, 150--4000 Amp Standard-Transition Model KBS

1. Bypass and isolate the transfer switch before using the maintenance handle. See Section 7

for instructions.

2. Remove the maintenance handle from the clips on the left side of the transfer switch frame on 150--800 amp models, or on the lower part of the transfer switch frame for larger models.

3. Attach the maintenance handle:

a. 150--1200 amp switches: See Figure 2-5 or

Figure 2-6. Attach the maintenance handle onto the shaft extension on the left side of the operator.

b. 1600--4000 amp switches: See Figure 2-7.

Slide the hub onto the shaft and insert the maintenance handle into the hole in the hub.

4. Move the maintenance handle up or down as shown to manually operate the transfer switch. It should operate smoothly without any binding. If it does not, check for shipping damage or construction debris.

202

1. Shaft

2. Manual operator handle

Figure 2-6 Manual Operation, 800--1200 Amp

Standard-Transition Switches

5. Return the transfer switch to the NORMAL position.

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

1. Maintenance handle

2. Shaft

Figure 2-5 Manual Operation, 150--600 Amp

Standard-Transition Switches

307a

Turn counterclockwise to

1. Maintenance handle

2. Hub

Emergency.

Turn clockwise to Normal.

Figure 2-7 Manual Operation, 1600--3000 Amp

Standard-Transition Switches

127a

TP-6835 9/1716 Section 2 Installation

Page 17

2.5.2 Manual Operation, 150--4000 Amp Programmed- and ClosedTransition Models KBP and KBC

1. Bypass and isolate the transfer switch before using the maintenance handle. See Section 7

for instructions.

2. Remove the maintenance handle from the clips on the left side of the transfer switch frame on 150--800 amp models, or on the lower part of the transfer switch frame for larger models.

3. Attach the maintenance handle:

a. 150--1200 amp switches: See Figure 2-9.

Attach the maintenance handle onto the shaft extension on the left side of the operator.

b. 1600--4000 amp switches: See Figure 2-8.

Slide the hub onto the shaft and insert the pin. Pull out the shaft to operate the Emergency contacts. Push in the shaft to operate the Normal contacts.

c. Starting with the contactor in the NORMAL

position, use the maintenance handle to move the Normal operator from the CLOSED to the OPEN position.

d. Move the Emergency operator from the OPEN

position to the CLOSED position.

e. Return the Emergency operator to the OPEN

position and the Normal operator to the CLOSED position.

f. Remove the maintenance handle and store it on

the frame in the clips provided.

Turn counterclockwise to OPEN contacts.

Turn clockwise to CLOSE contacts.

Slide hub onto shaft & insert pin

Pull out shaft to operate Emergency contacts.

Push in shaft to operate Normal contacts.

Insert handle into hole

Grasp handle firmly

Figure 2-8 Manual Operation, 1000--4000 Amp

KBP and KBC

140

Handle

Shaft

Handle

Shaft

UPPER SHAFT:

UP opens the Emergency source contacts

DOWN closes the Emergency source contacts

LOWER SHAFT:

UP closes the Normal source contacts

DOWN opens the Normal source contacts

Figure 2-9 Manual Operation, 150--1200 Amp KBP and KBC

195

TP-6835 9/17 17Section 2 Installation

Page 18

2.6 Controller Connections

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

DANGER

Hazardous voltage. Will cause severe injury or death.

Disconnect all power sources before opening the enclosure.

NOTICE

Electrostatic discharge damage. Electrostatic discharge

(ESD) damages electronic circuit boards. Prevent electrostatic discharge damage by wearing an approved grounding wrist strap when handling electronic circuit boards or integrated circuits. An approved grounding wrist strap provides a high resistance (about 1 megohm), not a direct short, to ground.

Figure 2-10 shows the locations of the connectors on the controller. It is not necessary to open the cover to access the Ethernet, Modbusr, and input/output connectors.

Opening the cover. If necessary, open the plastic housing by pushing up on the latch on the bottom of the cover and swinging the cover up and out. The cover is hinged at the top. Lift the cover off the hinges to remove it completely, if necessary.

Note: Always replace the cover before energizing the

transfer switch controls.

1. Standard input/output connection

2. RS-485 connection TB2

3. Connection for optional current sensing kit

4. Optional I/O board connection P16

Figure 2-10 Controller

Modbus is a registered trademark of Schneider Electric.

5. Access openings to optional RJ-45 connector

6. Latch

7. Ground wire

8. Contactor harness connection

GM85884

TP-6835 9/1718 Section 2 Installation

Page 19

2.6.1 Controller Input and Output Connections

The controller p rovides connections for two programmable inputs and two programmable outputs. See Figure 2-10 for the connector location.

Each input has a signal and a return connection. The outputs are C form contacts with ratings of 500 mA @ 120 VAC. See Figure 2-12 for connections. Use #12--24 AWG wire and tighten the connections to

0.5 Nm (4.4 in. lbs.).

Main Board I/O Specifications

Output contact type Isolated form C (SPDT)

Output contact rating 1amp@30VDC,

500 mA @120 VAC

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

Figure 2-11 Main Board I/O Specifications

2.6.3 Controller Ground

Verify that the grounding wire is connected from the controller’s lower left mounting stud to the enclosure. This connection provides proper grounding that does not rely upon the door hinges.

TB1

Output 1 NO

Output 1 C

Output 1 NC

Input 1B

Input 1A

Output 2 NO

Output 2 C

Output 2 NC

Input 2B

Input 2A

NC = normally closed NO = normally open C = common

6866

Figure 2-12 Input and Output Connections

2.6.2 Harness Connection

Verify that the contactor harness is connected at the controller base (or at the controller disconnect switch, if equipped). See Figure 2-13.

1. Contactor Harness Connection

2. Ground Connection

GM85844

Figure 2-13 Contactor Harness and Controller

Ground Connections

Note: Verify that the power is disconnected before

connecting or disconnecting the contactor harness.

TP-6835 9/17 19Section 2 Installation

Page 20

2.7 Electrical Wiring

All internal electrical connections are factory-wired and tested. Field installation includes connecting the sources, loads, generator start circuit(s), and auxiliary circuits, if used.

Note: An approved protective device such a s a

molded-case circuit breaker or fused disconnect switch MUST be installed on both sources of incoming power for circuit protection and used as a disconnect device.

Refer to the wiring diagrams provided with the transfer switch. Observe all applicable national, state, and local electrical codes during installation.

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

It is not necessary to remove the barriers from the bypass switch or transfer switch. If you do remove the barriers, reinstall them carefully.

WARNING

Accidental starting. Can cause severe injury or death.

DANGER

Hazardous voltage. Will cause severe injury or death.

Disconnect all power sources before opening the enclosure.

Making line or auxiliary connections. Hazardous voltage will cause severe injury o r death. To prevent electrical

shock deenergize the normal power source before making any line or auxiliary connections.

Grounding electrical equipment. Hazardous voltage will cause severe injury or death. Electrocution is possible

whenever electricity is present. Ensure you comply with all applicable codes and standards. Electrically ground the generator set and related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the equipment. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.

NOTICE

Foreign material contamination. Cover the transfer switch

Servicing the transfer switch. Hazardous voltage will cause severe injury or death. Deenergize all power sources

2.7.1 Source and Load Connections

Refer to the wiring diagrams furnished with each transfer switch.

Determine the cable size. Refer to transfer switch dimension drawing to determine the cable size and number of cables required for the transfer switch. Make sure that the cables are suitable for use with the lugs on the transfer switch. Watertight conduit hubs may be required for outdoor use.

Drill the entry holes. Cover the transfer switch to protect it from metal chips and construction grit. Then drill entry holes for the conductors at the locations shown on the enclosure drawings. Remove debris from the enclosure with a vacuum cleaner.

TP-6835 9/1720 Section 2 Installation

Page 21

Note: Do not use compressed air to clean the switch.

Cleaning with compressed air can cause debris to lodge in the components and damage the switch.

Install and test the power cables. Leave sufficient slack in the power leads to reach all of the power connecting lugs on the power switching device. Test the power conductors before connecting them to the transfer switch. Installingpower cables in conduit, cable troughs and ceiling-suspended hangers often requires considerable force. Pulling cables can damage insulation and stretch or break the conductor’s strands.

Test the cables after pulling them into position and before they are connected to verify that they are not defective and that they were not damaged during installation.

Connect the cables. Be careful when stripping insulation from the cables; avoid nicking or ringing the conductor. Clean cables with a wire brush to remove surface oxides before connecting them to the terminals. Apply joint compound to the conductors. Wipe away any excess compound. If aluminum conductors are used, follow the conductor manufacturer’s instructions.

Use a compression washer, flat washer, and a minimum grade 5 bolt. Torque the connections to the values in Figure 2-15.

SUITABLE FOR CONTROLOF MOTORS, ELEC DISCHARGE AND TUNGSTEN LAMPS, ELEC HEAT-ING EQPT, WHERE THE SUM OF MOTOR FULL-LOAD AMPSAND AMPS OF OTHER LOADS DOES NOT EXCEED THE SWITCHAMP RATING AND THE TUNGSTEN LOAD DOES NOT EXCEED % OF SWITCH RATING, 240V MAX. WHEN PROTECTED BY ACIRCUIT BREAKER WITHOUT ANADJUSTABLE SHORT--TIMERESPONSE ONLY OR BY FUSES THIS TRANSFER SWITCH IS RATED FOR USE ONA CIRCUIT CAPABLE OF DELIVERING NOT MORE THEN THE RMS SYMM AMPS ATTHE VOLTAGE SHOWN. RMS SYMM

MAX

AMPS

VOLTS

X1000

35 22 600

42 480 GE SGL4,SGP4, TB4, 400

THLC4,TLB4 400 SGLA,SGL6,SGP6,TB6 SKHA,SKL8,SKP8,TKL

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

HHJXD6,HJD6,SCJD6,SHJD6 CLD6,HHLD6,HHLXD6,HLD6, SCLD6,SHLD6 CMD6,HMD6,HND6,MD6,MXD6, SCMD6,SHMD6,SMD6,SND6 800

42 480 SQUARE D LC,LI

42 480 WESTH HKD,KDC,LCL, 400

TRI-- PACLA HLD TRI--PAC NB 800

42 480 ABB S5

42 480 MERLIN GERI N

CJ600

BREAKER/MFR/TYPE

480 ANY

ANY

ANY ANY

100

AMPS

MAX PER NEC PER NEC

600

800

400

600

800

600

800

400

600

400

800

600

Refer to the wiring diagram provided with the switch.

The connection points on the contactor are labeled Normal, Emergency, and Load. Be sure to follow the phase markings (A, B, C, and N). For single-phase systems, connect to A and C.

Note: Connect the source and load phases as

indicated by the markings and drawings to prevent short circuits and to prevent phasesensitive load devices from malfunctioning or operating in reverse.

Tighten the lugs. Verify that all connections are consistent with drawings before tightening the lugs. Tighten all cable lug connections to the torque values shown on the label on the switch. See Figure 2-14 for a typical rating/torque label. Carefullywipe off any excess joint compound after tightening the terminal lugs.

Bus connections. For bus connections, use SAE grade 5 hardware to connect the bus to the terminal plates on the bypass switching device. Wipe off the bus surfaces before connecting. Use a non-flammable solvent to clean the surfaces if they are dirty.

Note: For a reliable connection, the joint must be clean

and tight.

200 480 FUSE ANY CLASS J

USE 75 C MIN. CU/AL WIRE FOR POW ER CONNECTIONS. USE 60 C MIN. CU WIRE FOR CONTROLS.

USE COPPER OR ALUMINUM WIRE

FOR POWER TERMINALS RECOMMENDED TIGHTENING TORQUE 600 IN-- LBS

483500--007

REV

600

1. Torque specification

Figure 2-14 Typical Rating/Torque Label

Bolt Size,

inches

5/16 16.3 12

3/8 27.1 20 1/2 67.8 50 5/8 128.8 95 3/4 210.2 155

Bolt Torque

Nm ft. lb.

Figure 2-15 Tightening Torque for Bus Bars

007

TP-6835 9/17 21Section 2 Installation

Page 22

2.7.2 Extended Transfer Time Relay (Model KBC only)

The extended transfer time relay is standard on closed-transition transfer switches. The relay is provided to prevent paralleling the standby and utility sources for longer than the acceptable time, which is typically 100 ms. The relay is located on the field connection assembly. See Figure 2-17.

The relay starts timing when both sources are connected. If one source fails to disconnect within the set time, the relay energizes and a Fail to Open Source1 (or Source2) fault message will display on the ATS controller. Identify and correct the cause of the source disconnect problem before resetting the fault.

Connect the relay to a shunt trip on the emergency source circuit breaker. Provide 12 or 24 VDC power as required for the relay, as shown in Figure 2-18 or Figure 2-21. Connect the DC power, emergency source circuit breaker trip circuit (TR--EMER), and optional alarm (TR-ALARM) to the field-connection terminal block shown in Figure 2-17. See Figure 2-16 for typical connections and refer to the schematic diagram provided with the transfer switch.

Relay with Time Adjustment Knob

This section applies to the relay equipped with an adjustment knob, shown in Figure 2-17.

Relay specifications are shown in Figure 2-18.

Setting the Time Delay (knob style)

A knob on the relay assembly allows adjustment of the time delay. See Figure 2-17. The relay time delay is adjustable between 100 ms and 10 seconds. The time settings are in percent (%) of the maximum setting, which is 10 seconds, and adjustable in 5% increments. Figure 2-19 shows some sample settings. The typical setting is 1% = 0.1 seconds (100 ms). If it is necessary to set the relay to a longer time, ensure that the time setting is in accordance with applicable codes.

The extended transfer time relay uses an adjustment knob or switches to set the time delay. Compare your equipment to Figure 2-17 and Figure 2-20 to identify the relay used on your transfer switch.

GM89661

Figure 2-16 Typical Relay Connections (see the

schematic diagram for your transfer switch)

1. Extended transfer time relay

2. Field connection terminal block

3. Time adjustment

Figure 2-17 Extended Transfer Time Relay

(knob style)

Relay Specifications

Input Power 24 VDC (customer-supplied)

Output Type Relay contacts, DPDT (2 form C)

Rating

10 amp max. resistive @ 240 VAC

100 mA @ 5 VDC min. load current

Figure 2-18 Relay Specifications (knob style)

TP-6833

Setting* Time

1% 0.1 seconds (100 ms)

50 % 5 seconds

100 % 10 seconds

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

Figure 2-19 Relay Transfer Time Settings

(knob style)

TP-6835 9/1722 Section 2 Installation

Page 23

Relays with Time Adjustment Switches

This section applies to relays equipped with switches for time adjustment, shown in Figure 2-20.

Relay specifications are shown in Figure 2-21.

A three-digit pushbutton switch and a range selection switch on the relay assembly allow adjustment of the transfer time. See Figure 2-20. The relay delay time is adjustable between 0.05 seconds (50 ms)* and 999 minutes. Set the range and the time as shown in Figure 2-22. The recommended setting is

0.10 seconds (100 ms). If it is necessary to set the relay

to a longer time, ensure that the time setting is in accordance with applicable codes.

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

Setting the Time Delay (adjustment switch style)

To set the time delay, select the range based on seconds or minutes and the numbers after the decimal point. Then use the pushbuttons to set the time. Some examples are shown in Figure 2-23.

Relay 12VDC 24VDC

Input Power (customer-supplied)

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

Output Type Relay contacts, DPDT (2 form C)

Rating 10 amp max. resistive @ 240 VAC

12 VDC 24 VDC

Figure 2-21 Relay Specifications

(adjustment switch style)

Time Select Range Select Time Setting

9.99 S 0.01 to 9.99 seconds *

99.9 S 0.1 to 99.9 seconds

001--999

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

999 S 1 to 999 seconds

99.9 M 0.1 to 99.9 minutes

999 M 1 to 999 minutes

Figure 2-22 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 than

50 ms.

Figure 2-23 Examples of Transfer Time Settings

(adjustment switch style)

1. Time select pushbuttons

2. Relay timing LED

3. Range selection switch

Note: See Figure 2-17 for relay location on the field connection

assembly.

IMG_0732

Figure 2-20 Extended Transfer Time Relay

(adjustment switch style)

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

TP-6835 9/17 23Section 2 Installation

Page 24

2.7.3 Engine Start Connection

WARNING

Accidental starting. Can cause severe injury or death.

Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the

generator set or equipment connected to the set, disable the generator set as follows: (1) Press the generator set off/reset button to shut down the generator set. (2) Disconnect the power to the battery charger, if equipped. (3) Remove the battery cables, negative (--) lead first. Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent the starting of the generator set by the remote start/stop switch.

GM58752

2021

1415

1112

Making line or auxiliary connections. Hazardous voltage will cause severe injury o r death. To prevent electrical

shock deenergize the normal power source before making any line or auxiliary connections.

Prevent the generator set from starting b y pressing the OFF button on the generator controller; disconnecting power to the generator engine start battery charger, if installed; and disconnecting all generator engine start battery cables, negative (--) leads first.

Connect the generator set remote starting circuit to the engine start connections located on the field connection terminal block. The terminal block is mounted on the upper right side inside the enclosure on most models. See Figure 2-24. Refer to the generator set installation manual for wire size specifications.

The engine start contact rating is shown below.

Engine Start Contacts

Contact Rating 2 A @ 30 VDC/250 VAC

GM21311

1. Typical terminal block location

2. Decal

3. Engine start contacts 1 and 2

4. Auxiliary contacts (see the schematic diagram for contacts closed on Normal or closed on Emergency)

Figure 2-24 Engine Start and Auxiliary Contact

Terminal Block (typical)

TP-6835 9/1724 Section 2 Installation

Page 25

2.7.4 Auxiliary Contacts

Connect the auxiliary contacts to customer-supplied alarms, remote indicators, or other devices. Auxiliary contacts provide contacts that close when the transfer switch is in the Normal position and contacts that close when the transfer switch is in the Emergency position.

The auxiliary contact rating is shown below.

Auxiliary Contacts

Contact Rating 10 amps @ 32 VDC/250 VAC

Figure 2-25 lists the number of auxiliary contacts provided with each transfer switch.

2.8 Communication and Accessory Connections

See Section 4 for accessory and communication connection instructions.

2.9 Functional Tests

After completion of the mechanical installation and all electrical connections, perform the functional tests described in Section 5. The procedures in Section 5 are required to complete the installation and startup of the transfer switch.

Switch

Rating,

amps

150--400 8, 8 6, 6 5, 5

800--1200 8, 8 7, 7 7, 7

1600--4000 2, 2 7, 7 6, 6

Number of Auxiliary Contacts Indicating

Normal, Emergency

KBS KBP KBC

Figure 2-25 Number of Auxiliary Contacts Available

on Each Switch

Connect to the auxiliary contacts at the field connection terminal block. The terminal block is mounted on the upper right side inside the enclosure on most models. See Figure 2-24. Figure 2-26 shows typical auxiliary contact connections. Refer to the schematic drawing provided with the unit to identify the auxiliary contact terminals for your model transfer switch.

Note: Thecontactsare shown with the transfer switch in

the Normal (Source N) position in all figures and schematic drawings. (Contacts shown closed in the figures are closed on Normal. Contacts shown open in the figures will close on Emergency.)

Follow the wire size and tightening torque specifications shown on the decal on the transfer switch.

Figure 2-26 Auxiliary Contacts, Typical

TP-6835 9/17 25Section 2 Installation

Page 26

Notes

TP-6835 9/1726 Section 2 Installation

Page 27

Section 3 Three-Source Systems

3.1 Three-Source Systems

The Decision-Makerr MPAC 1500 controller is required for three-source systems.

A three-source system provides the means to connect a utility and two generators to a single load. See Figure 3-1. Two generators and two transfer switches are required.

Note: The second transfer switch (ATS2) requires an

external battery supply module (EBSM) to provide power to the controller. See Section 4.3.3.

During normal operation, the utility source supplies the load with power. In the event of a utility failure, generator set G1 or G2 will supply the load as described in Sections 3.2 and 3.3.

3.2 Three Source Engine Start Mode

There are two modes of operation for three-source engine start. Select Mode 1 or Mode 2 on ATS2 as needed for the application.

3.2.1 Mode 1

In mode 1 there will be an attempt to start only the preferred source generator. If the preferred source does not achieve voltage and frequency within a fail to acquire time period, the standby engine start contact will close. The fail to acquire will be indicated. If the standby source subsequently fails to achieve voltage and frequency, a separate fail to acquire standby will be indicated.

3.2.2 Mode 2

In mode 2 both generators receive a start signal simultaneously. The ATS2 will transfer to the first generator set to reach proper voltage and frequency. If the first source to reach available status is the preferred source, the engine start signal to the standby source will open immediately. If the standby source is the first to reach available status, the contactor will transfer to the standby position. When the preferred source generator output reaches available status, the controller will transfer to the preferred source and open the engine start contacts to the standby generator (after the cooldown delay has elapsed).

3.3 Preferred Source Toggle

The preferred source toggle function alternates between the two generator sets each time the three-source function is activated. If G1 is the preferred source during the first run, then G2 will be preferred during the next run. The preferred source selection will continue to alternate between G1 and G2 for each subsequent run.

3.4 Three Source System Test and Exercise

3.4.1 Unloaded Test

Unloaded testing is possible at each transfer switch. Initiating the unloaded test function at ATS1 starts and runs the preferred generator set attached to ATS2. Initiating the unloaded test function at ATS2 starts and runs 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 only possible during a loaded test from ATS1 because the standby generator can only be connected to the load when ATS1 is connected to emergency. To initiate a loaded test of the standby generator set, first use ATS1 to start a loaded test of the preferred source generator set. Then use ATS2 to start a loaded test of the standby generator set.

3.4.3 Unlo aded Exercise

The exercise program in ATS2 controls the operation of each generator. The exercise function does not require interaction with ATS1. If the utility is lost during an unloaded exercise event, the event is canceled and the load is transferred to the preferred generator set.

3.4.4 Loaded Exercise

The exercise program in ATS2 controls the operation of each generator. The loaded exercise event requires synchronization with a loaded exercise from ATS1. Program the ATS1 exercise to start before the ATS2 exercise. Set the ATS2 exercise to end before the ATS1 exercise ends. If the utility is lost during a loaded exercise event, the event is canceled and the load is transferred to the preferred generator set.

TP-6835 9/17 27Section 3 Three-Source Systems

Page 28

3.5 Three-Source System Connection

DANGER

Hazardous voltage. Will cause severe injury or death.

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

a. Connect the ATS2 engine start contacts to the

engine start circuit on generator set 2 (G2).

Note: See the Installation Section for the engine

start contact locations. Engine start contacts are labeled with a decal.

Disconnect all power sources before opening the enclosure.

Servicing the transfer switch. Hazardous voltage will cause severe injury or death. Deenergize all power sources

Making line or auxiliary connections. Hazardous voltage will cause severe injury o r death. To prevent electrical

shock deenergize the normal power source before making any line or auxiliary connections.

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

1. Connect the power sources to the transfer switches as described below. Refer to the transfer switch operation/installation manual or specification sheet for cable sizes. See Figure 3-1 for connections.

a. Connect the utility power source to the normal

side of ATS1.

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

c. Connect the emergency side of ATS1 to the

load side of ATS2.

d. Connect generator set 1 to the normal side of

ATS2.

e. Connect generator set 2 to the emergency side

of ATS2.

b. Connect one ATS1 programmable output from

the controller to one ATS2 main logic board programmable input as shown in Figure 3-2. This I/O connection will be set to Three-Source System Disable.

c. Connect one ATS2 programmable output from

the controller to the engine start connection on generator set 1 (G1). TheATS1 programmable output will be set to Source N Start Signal.

3. Connect battery power. Use #14-28 AWG wire to connect the generator set engine starting battery (or batteries) to the BATT1 terminals on terminal block TB13 on the external battery supply module (EBSM). (Another battery(ies) can be connected to terminals BATT2 but is not required.) Follow the marking on the board for the positive (+) and negative (--) connections. See Figure 4-16 and Figure 4-17.

Note: If the battery connections are reversed, red

LED1 or LED2 will light. Incorrect battery connections can damage the battery module.

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

Note: See Section 4.3.3 for more information on

the EBSM.

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

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

a. Assign ATS2 controller programmable input 1

to Three-Source System Disable.

b. Assign the ATS2 controller programmable

output connected in step 2c. to Source N Start Signal.

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

TP-6835 9/1728 Section 3 Three-Source Systems

Page 29

SINGLE LINE DIAGRAM

G1 G2

ATS 2

ATS 1

LOAD

LEGEND

ATS -- AUTOMATIC TRANSFER SWITCH EBSM -- EXTERNAL BATTERY SUPPLY MODULE G1 -- GENERATOR #1 G2 -- GENERATOR #2 K1 -- NORMAL RELAY K2 -- EMERGENCY RELAY LED1 -- LIGHT EMITTING DIODE (BATTERY 1 REVERSED) LED2 -- LIGHT EMITTING DIODE (BATTERY 1 REVERSED) LED3 -- LIGHT EMITTING DIODE (BATTERY SUPPLYING POWER) MLB -- MAIN LOGIC BOARD P(#) -- CONNECTOR PIOM -- PROGRAMMABLE INPUT/OUTPUT MODULE MLB -- MAIN LOGIC BOARD TB(#) -- TERMINAL BLOCK SW -- SWITCH U -- UTILITY

ENGINE START

N/C

NOTE: THE CLOSED IN EMERGENCY AUXILLIARY CONTACT THAT IS USED IN THE ENGINE START CIRCUIT OF THE ATS MUST BE REMOVED FROM THE CIRCUIT WHEN USED WITH THIS THREE SOURCE CONTROL SCHEME.

REFERENCE ATS WIRING DIAGRAM FOR CONNECTIONS.

Note: ATS2 requires an external battery module

ENGINE START

TO G2

to maintain power to the controller.

OPERATION

WHEN UTILITY FAILS ATS2 STARTS G1. ATS1 TRANSFERS TO THE EMERGENCY POSITION. IF G1 FAILS ATS2 WILL START G2 AND ATS2 WILL TRANSFER TO EMERGENCY. IF G1 RETURNS THEN ATS2 WILL RE--TRANSFER BACK TO NORMAL. ATS1 WILL RE--TRANSFER BACK TO NORMAL AFTER THE UTILITY RETURNS. WHEN THE UTIITY 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 GENSET WHILE THE UTILITY SOURCE IS AVAILABLE.

THE BATTERY SUPPLY MODULE USES UP TO TWO BATTERY INPUTS (9--36VDC) AND PROVIDES A 12V OUTPUT THAT POWERS THE ATS CONTROLLER. THIS IS CONNECTED TO THE CONTROLLER BY SNAPPING IT

TO AN EXISTING I/O MODULE OR THROUGH A HARNESS TO P3 ON THE CONTROLLER (WHEN AN I/O MODULE IS NOT USED). THE BATTERY SUPPLY MODULE WILL CONTINUALLY PROVIDE POWER TO THE CONTROLLER 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 THE NORMALLY OPEN CONTACT OF A PROGRAMMABLE OUTPUT FROM AN INPUT/OUTPUT MODULE TO TURN THE

BATTERY SUPPLY MODULE OFF WHEN A SOURCE IS AVAILABLE.

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

TP-6835 9/17 29Section 3 Three-Source Systems

GM28627B

Page 30

3 Source System Disable

Connect Output 1 terminals TB1-5 and TB1-6 on ATS 1 to Input 1 terminals TB1-1 and TB1-2onATS2.

Assign ATS 1 main logic board output 1 to 3 Source System Disable.

ATS1

ATS1 TB1

on logic board

Assign ATS2 main logic board input 1 to 3 Source System Disable.

Connect one normally closed

G1 ES

output from ATS2 to G1 engine start (ES) connections. Assign to Engine Start Source N.

Connect the ATS2 engine start contacts (on the contactor or the field-connection terminal

ATS2 TB1

on logic board

block) to G2 engine start (ES) connections. SeeFigure3-1.

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

3.6 ATS1 and ATS2 System Setup

ATS2: Set the source type to Util-Gen-Gen. Set the 3 Src Engine Start Mode to Mode 1 or Mode 2 as

Use the System Setup Menu on each transfer switch to

described in Section 3.2.

set the following:

The transfer switch settings are summarized in

ATS1: Set the Source type to Util-Gen.

Figure 3-3.

ATS2

6883

Transfer Switch

ATS 1 Util-Gen Not Required Not Required Not Required

ATS 2 Util-Gen-Gen Mode 1 or Mode 2

Source Type

3 Src Engine Start

Mode

(See Section 3.2)

Preferred

Source Toggle

Enable or Disable

See Section 3.3

Inputs Outputs

Three Source System

Disable

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

Three Source System

Disable

Source N Start Signal

TP-6835 9/1730 Section 3 Three-Source Systems

Page 31

Section 4 Communication and Accessory Connections

4.1 Introduction

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

Also refer to the following documentation for instructions to install, connect, and operate optional accessories.

D Transfer switch wiring diagrams.

D Installation instructions or diagrams provided with

loose accessory kits.

4.2 Communication Connections

The Decision-Makerr MPAC 1500 controller is equipped with a USB port and a Modbus port with an RS-485 connector. An Ethernet communication board is also standard on the MPAC 1500 controller.

4.2.1 USB Port SiteTech Connection

A personal computer and Kohlerr SiteTecht software can be used for changing controller settings. Use a USB cable to connect the controller to a personal computer.

See Figure 4-1 for the USB port location on the front of the controller assembly. Remove the small port cover and use a USB cable with a mini-B connector to connect the controller’s USB port to the computer.

See TP-6701, SiteTech Software Operation Manual, for instructions to use the software. Disconnect the USB cable from the controller and replace the port cover when finished.

4.2.2 Modbus Connection

DANGER

Hazardous voltage. Will cause severe injury or death.

Disconnect all power sources before opening the enclosure.

Servicing the transfer switch. Hazardous voltage will cause severe injury or death. Deenergize all power sources

See Figure 4-2 for the RS-485 Modbus connector location.

Use serial connections to TB2 on the controller to connect the transfer switch to a personal computer for system monitoring, the optional remote annunciator, or a Modbus network. See Figure 4-4.

Notice that a 121 ohm terminating resistor is recommended on the last device in a network. If there is only one device, a terminating resistor may be required depending on the cable distance and communication speed. Long cables and high speeds will increase the need for a terminating resistor.

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

1. USB connection (below port cover)

Figure 4-1 USB Connection for SiteTech

GM85888

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

TP-6835 9/17 31Section 4 Communication and Accessory Connections

Page 32

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

Note: Modbusr applications require a Modbus

software driver written by a trained and qualified systems programmer.

USB port

USB to RS-485 port

converter

Terminating resistor

may be required [

(121 Ohms)

RS-485 *

Out

Device

GM85884

1. RS-485 Modbus connections

2. Access opening for RS-485 cables

Figure 4-2 Modbus Connections (controller cover

removed for illustration only)

Input

GND1

B1 (+)

Cable shield

A1 (--)

USB port

USB to RS-485

port converter

PCPC

Terminating resistor [,

(121 Ohms)

* Use Belden #9841 or equivalent shielded, twisted-pair

communication cable for RS-485 connections. Ground one end of the cable shield. Leave the other end of the cable shield disconnected.

[ Long cables and high communication speeds will require

a terminating resistor. Use 121 ohm resistor X-6058-27.

RS-485 *

In Out

RS-485 *

In Out

RS-485 *

Out

Device

Last

Device

Figure 4-4 Serial Connections

TB2

GND1

B1 (+)

A1 (--)

Cable shield

Output

Customer connections

Figure 4-3 Modbus RS-485 Connections

TP-6835 9/1732 Section 4 Communication and Accessory Connections

Page 33

4.2.3 Ethernet Connection

DANGER

Hazardous voltage. Will cause severe injury or death.

Disconnect all power sources before opening the enclosure.

Servicing the transfer switch. Hazardous voltage will cause severe injury or death. Deenergize all power sources

The Ethernet communication accessory board is required for connection to the Ethernet. The Ethernet communication board is standard on the MPAC 1500 controller. The communication board connects to the controller board as shown in Figure 4-5.

The Ethernet communication board allows the transfer switch to be connected to a building’s Ethernet network to communicate with personal computers connected to the same subnet.

Note: For an ethernet connection, obtain an IP address

and subnet mask number from the local system administrator.

Ethernet Port. The ethernet port is a standard RJ-45 jack. See Figure 4-5 for the location of the Ethernet port. Use Category 5e or better cable to connect the controller to the building’s network.

Use the controller’s Setup menus or a personal computer connected to the controller’s USB port and Kohler SiteTech software to set the communication parameters. The Ethernet communication board may have a default IP address assigned at the factory for test purposes. See Figure 4-6. Change the IP address to an address owned by the user. See the controller operation manual for instructions to set the communication parameters.

The transfer switch controller does not operate as a Modbus-to-Ethernet converter for other devices in a network. For multiple device networks connected to the personal computer through the Ethernet, use a Modbus-to-Ethernet converter for the other devices in the network. See Figure 4-7 and instruction sheet TT-1405, provided with the converter, for connection instructions.

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

GM85884

1. Ethernet communication board with RJ-45 connector

2. Access opening for Ethernet cable

Figure 4-5 Ethernet Board (controller cover

removed for illustration only)

TP-6835 9/17 33Section 4 Communication and Accessory Connections

Page 34

Modbusr TCP/IP

Category 5e

IP xx.xx.xx.02

Note: ThePC and the ATS must be on the same subnet.

Note: A crossover cable can be used to connect the PC

to the ATS controller through the Ethernet port.

Figure 4-6 Remote Network (Ethernet) Connection

Modbusr

TCP/IP

Ethernet Network

Modbusr TCP/IP

Category 5e

Modbusr TCP/IP

Category 5e

MPAC

Controller with

Ethernet comm.

board

IP xx.xx.xx.03

MPAC

Controller with

Ethernet comm.

board

IP xx.xx.xx.03

IP xx.xx.xx.02

Modbusr

TCP/IP

IP xx.xx.xx.01

Figure 4-7 Ethernet Connections to Multiple-Device Network

Modbusr TCP/IP

Category 5e

Converter,

Modbusr/Ethernet

IP xx.xx.xx.05

Terminating resistor

(121 Ohms)

Modbusr

RTU

RS-485

Device

RS-485

Device

RS-485

Last device

TP-6835 9/1734 Section 4 Communication and Accessory Connections

Page 35

4.3 Accessory Modules

4.3.1 Accessory Module Mounting

DANGER

Hazardous voltage. Will cause severe injury or death.

Disconnect all power sources before opening the enclosure.

Servicing the transfer switch. Hazardous voltage will cause severe injury or death. Deenergize all power sources

Mount the accessory modules on the module mounting plate. Starting at the end of the module mounting assembly nearest the cable connection, install any I/O modules first, then install the alarm board, if used. The external battery module, if used, must be the last module. See Figure 4-9. The alarm board has a fixed Modbus address = 5.

Note: Some models may have the I/O module

assembly installed with the cable connection end pointing to the side or the bottom. Regardless of the actual orientation of the assembly, the I/O modules must be installed closest to the cable connection, followed by the alarm module and then the external battery module, if used.

The transfer switch uses a standard bus system for connecting accessory modules to the controller. This bus incorporates a standard serial communication interface for passing data back and forth between the main logic board and the assemblies on the expansion bus.

The module mounting kit holds up to five optional modules. The total current draw of all modules must not exceed 300 mA. See Figure 4-8. Add the current draw for every module installed to determine the total current draw. If an External Battery Module is installed and connected to a battery, there is no current restriction. The External Battery Module, if used, must be the last board 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

1. Cable connection (defined as the TOP regardless of orientation)

2. I/O modules (if equipped)

3. Alarm module (if equipped)

4. External battery module (must be last, if equipped)

5. Mounting plate

Figure 4-9 Module Mounting

GM46258

TP-6835 9/17 35Section 4 Communication and Accessory Connections

Page 36

4.3.2 Input/Output (I/O) Modules

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

1. Input LEDs 7 and 8 for inputs 1 and 2

2. Input connector (see Figure 4-14)

3. Output connector

4. Output LEDs 1--6

GM41093

Figure 4-10 Standard Input/Output Module

Inputs

Available Inputs 2

Input Definition Contact Closure

Current 5mAMax

Connection Type Terminal Strip

Wire Size #14-24 AWG

Max Distance 700 feet

Outputs

Outputs Available 6

Contact Type Form C (SPDT)

Contact Voltage Rating

Connection Type Terminal Strip

Wire Size #14-24 AWG

2A@30VDC 500 mA @ 125 VAC

Figure 4-11 Standard I/O Module Specifications

1. Input LEDs 1 and 2

2. Input connector (see Figure 4-14)

3. Output connector

4. Output LEDs 3--5 for outputs 1, 2, and 3

GM42186

Figure 4-12 High-Power Input/Output Module

Inputs

Available Inputs 2

Input Definition Contact Closure

Current 5mAMax

Connection Type Terminal Strip

Wire Size #14-24 AWG

Max Distance 700 feet

Outputs

Outputs Available 3

Contact Type Form C (SPDT)

12 A @ 24 VDC

Contact Voltage Rating

Connection Type Terminal Strip

Wire Size #14-24 AWG

12 A @ 250 VAC 10 A @ 277 VAC 2 A @ 480 VAC

Environmental Specifications

Temperature -- 4 0 Cto85C(--40F to 185F)

Humidity 35% to 85% noncondensing

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

TP-6835 9/1736 Section 4 Communication and Accessory Connections

Page 37

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

4.3.3 External Battery Supply Module (EBSM)

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

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

Use the address DIP switches on the I/O module to assign a unique (different) address to each module as shown in Figure 4-15. Assign addresses in order from 1 to 4. An LED for each DIP switch lights to indicate that the switch is closed.

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

See the controller operation manual for instructions to assign functions to each input and output. Inputs and outputs can also be assigned using a personal computer with Kohlerr SiteTecht software or over Modbus. See TP-6701, SiteTech Operation Manual, or TP-6113, Modbus Protocol Manual.

INPUT 1

INPUT 2

The external battery supply module kit allows connection to the generator set engine start battery(ies) or other batteries to provide 12 VDC power to the ATS controller. The external battery supply module kit is required for the following applications:

D Systems using extended engine start time

delays. The EBSM provides power to the ATS controller during extended time delays longer than 15 seconds, when neither the Normal nor the Emergency source is available.

D Installations with frequent utility power outages.

The EBSM provides power to the ATS controller when neither source is available, preserving the controller’s backup battery.

D Three-source systems. Three-source systems use

two transfer switches and two standby power sources in addition to the preferred power source. The EBSM provides power to the second ATS controller when the preferred source (connected to ATS1) is supplying the load. See Section 3.1 for instructions to set up a three-source system.

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

Figure 4-14 I/O Module Input Connections

(TB1 or TB10)

Both switches OFF

Address=1 shown

DIP Switch

1 2

Off Off 1

On Off 2

Off On 3

On On 4

Address

Figure 4-15 Address DIP Switch Settings

refGM41093

1. Connector P20

2. LED indicators

3. Battery input connection terminal block TB13

4. 12/24 volt DIP switch SW11-1. OFF=12 VDC, ON = 24 VDC

GM42227-A

Figure 4-16 External Battery Supply Module

TP-6835 9/17 37Section 4 Communication and Accessory Connections

Page 38

The EBSM produces 2 amps at 12 VDC with 9--36 VDC input. The EBSM input is reverse-polarity protected. The EBSM outputs a low battery voltage signal when the external battery voltage falls below 11 VDC for a 12-volt system or 22 VDC for a 24-volt system.

4.3.4 Alarm Module

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

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

The battery voltage selection DIP switch SW11-1allows selection between 12-volt and 24-volt systems for low battery voltage sensing and indication. Connect one or two batteries to the external battery supply module. Use a battery charger to maintain the battery(ies) connected to 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 two batteries to terminal block TB13. (A second battery can be connected but is not required.) Follow the marking on the board for the positive (+) and negative (--) connections. See Figure 4-16 and Figure 4-17.

The functions provided by this board are:

D 90 dB Audible alarm (any alarm function can be

programmed to trigger the audible alarm)

D Chicago alarm operation

D Preferred source selection

D Supervised transfer control (supervised transfer

control switch required)

D Connection for external alarm

The alarm board has a fixed address = 5.

Note: If the battery connections are reversed, red

LED1 or LED2 will light. See Figure 4-16.

2. Set voltage selector switch SW11-1 to 12 or 24VDC. See Figure 4-16 and Figure 4-17. Switch SW11-2 is not used.

Note: The EBSM has no address switches but

must be the last board on the bus.

1. Supervised Transfer Switch Connection, P22

2. External Alarm Connection, TB 14

3. Alarm Indicator, LED1

4. DIP Switches

Figure 4-18 Alarm Module

GM40764

TP-6835 9/1738 Section 4 Communication and Accessory Connections

Page 39

Alarm Board DIP Switches

Audible Alarm Setup

There are four DIP switches on the alarm module board. Some of the switches are not used. See Figure 4-19. To enable the preferred source selection, set DIP switch 1 to ON. If the supervised transfer switch is installed on theATS,setDIPswitch2toON.

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 source selection. To enable the preferred source selection, set DIP switch 1 to ON. Then see the controller operation manual for instructions to select Source N or Source E as the preferred source.

External Alarm

A customer-supplied external alarm horn can be connected to the alarm module at terminal block TB14. Connect to the normally open or normally closed contact as recommended by the alarm manufacturer’s instructions. See Figure 4-20.

Item Specification

Wire Size #12-22 AWG Cu

Contact Voltage Rating

500 mA @ 120 VAC

250 mA @ 240 VAC

The alarm board is equipped with a 90 dB audible alarm. The audible alarm can be set to sound under selected fault conditions. Use the Common Alarms Setup menu to assign functions to the audible alarm. See the controller operation manual for instructions to set Audible Alarm: Y for each function that should trigger the alarm.

Alarm Operation, Normal Mode

In Normal Mode, the horn sounds anytime a fault event happens in the system. The horn continues to sound unless the alarm silence button is pressed. When the fault is cleared, the alarm silence is ended and reset for the next alarm.

Alarm Operation, Chicago Alarm Mode

Chicago Alarm mode requires the horn to sound and a lamp or LED to light when the switch is in the emergency (non-preferred) position. The horn continues to sound unless the alarm silence button is pressed. When the fault is cleared, the alarm silence is ended and reset for the next alarm.

For Chicago Alarm Mode, use the Common Alarm Setup menu to assign the necessary faults and conditions to the audible alarm. See the controller operation manual for instructions to assign common faults. Be sure to assign the Contactor in Standby condition to trigger the audible alarm.

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

Figure 4-20 External Alarm Connection

Specifications

TP-6835 9/17 39Section 4 Communication and Accessory Connections

Page 40

Alarm Silence Mode

In Alarm Silence Mode, the horn is disabled. Alarm Silenced appears on the display and the system alert LED lights.

The Alarm Silenced condition can be assigned to a programmable output. See the controller operation manual for instructions to assign outputs.

4.4 Load Shed (Forced Transfer to OFF)

DANGER

Instructions to Silence the Alarm in Normal and Chicago Alarm Modes

When the alarm is activated, the word Alarm appears on the main display menu above the first button. See Figure 4-21. Press the Alarm button to open the Reset menu. Then press the button labeled Reset to silence the alarm.

System Ready

LD Exer 12/14 @ 16:00

Norm 480V Emer 480V

Alarm View Set Test

Reset

To Silence Alarm

BYReset Main

Reset

Status or Fault Description

Alarm Silenced

BYReset Main

Figure 4-21 Alarm Silence

Hazardous voltage. Will cause severe injury or death.

Disconnect all power sources before opening the enclosure.

Servicing the transfer switch. Hazardous voltage will cause severe injury or death. Deenergize all power sources

The load shed (forced transfer to OFF) accessory must be factory-installed. The load shed accessory is available only on programmed-transition transfer switches. See Figure 4-22 for an illustration of the load shed 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) or input #2 on connector TB1 on the main logic board. See Figure 4-23. Use #12--24 AWG wire and tighten to

0.5 Nm (4.4 in. lb.).

Use the Input/Output setup menu or Kohler SiteTech software to assign the connected input (Main Board Input #1 or #2) to the forced transfer to off function. If the external contact is connected to a different input connection on an optional I/O module, assign the forced transfer to off function to that input.

TP-6835 9/1740 Section 4 Communication and Accessory Connections

Page 41

Figure 4-22 Load Shed Accessory (for

identification)

GM23469

TB1

MLB Input 2

MLB Input 1

(alternate connection)

#12--24 AWG wire

0.5 Nm (4.4 in. lb.)

MPAC Controller Circuit Board

1. Input/output terminal strip TB1

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

GM89713

TP-6835 9/17 41Section 4 Communication and Accessory Connections

Page 42

4.5 Heater

Hazardous voltage. Will cause severe injury or death.

Disconnect all power sources before opening the enclosure.

DANGER

Servicing the transfer switch. Hazardous voltage will cause severe injury or death. Deenergize all power sources

An anti-condensation heater kit is available. The strip heater is controlled by a hygrostat to raise the temperature inside the enclosure above the dew point to prevent condensation. Figure 4-24 shows a typical location of the heater kit components inside the enclosure.

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

Right Side View

GM69824

1. Hygrostat assembly, see Figure 4-25

2. Strip heater with guard

Figure 4-24 Heater Location, Typical

The relative humidity setting on the hygrostat is adjustable from 35% to 95%. A setting of 65% is recommended.

GM71056

1. 120 VAC power connection terminal block

2. Circuit breaker

3. Relative humidity adjustment control

Figure 4-25 Hygrostat Assembly, Typical

TP-6835 9/1742 Section 4 Communication and Accessory Connections

Page 43

4.6 Other Accessories

HYGROSTAT

CIRCUIT

BREAKER

TERMINAL

BLOCK

120 VAC ONLY

CUSTOMER SUPPLIED

Figure 4-26 Heater Connections

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

D Transfer switch wiring diagrams.

D Installation instructions provided with loose

accessory kits.

D Controller Operation Manual. See List of Related

materials in the Introduction section of this manual for document numbers.

HEATER

GM71278

TP-6835 9/17 43Section 4 Communication and Accessory Connections

Page 44

Notes

TP-6835 9/1744 Section 4 Communication and Accessory Connections

Page 45

Section 5 Functional Tests and Setup

5.1 Introduction

Be sure to perform all of the functional tests described in this section before putting the transfer switch into operation.

The functional tests include the following checks:

D Manual Operation Test D Voltage Checks D Lamp Test D Automatic Operation Test

Note: Perform these checks in the order presented to

avoid damaging the ATS.

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

To complete the installation, follow the instructions in this section to:

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

controller.

D Perform the system startup procedures listed on the

startup form.

D Register the unit using the Kohlerr online Warranty

Processing System.

voltage and frequency ratings of the utility source, transfer switch, and generator set, and verify that the ratings are all the same.

Use the voltage check procedure explained in this section to verify that the voltages and phasing of all power sources are compatible with the transfer switch before connecting the power switching device and controller wire harnesses together.

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

Verify the following before proceeding with the functional tests:

D The bypass handle is in the NORMAL position.

D The isolation handle is in the CONN position.

D The transfer switch Normal contacts are closed.

D The transfer switch Emergency contacts are open.

If the handles are not in the correct positions, follow the instructions for bypassing and isolating the switch. See the Table of Contents. Do not force the handles. Electrical interlocks prevent a wrong sequence of operation.

5.2 Manual Operation Test

If you have not already done so, test the contactor manual operation before proceeding to the voltage check and electrical operation test.

Note: Disable the generator set and disconnect the

power by opening the circuit breakers or switches for both sources before manually operating the transfer switch.

Manual operation instructions are given in Section 7. See the Table of Contents to locate the manual operation instructions for your unit.

A contactor in normal and serviceable condition transfers smoothly without binding when operated manually. Do not place the transfer switch into service if the contactor does not operate smoothly without binding; contact an authorized distributor/dealer to service the contactor.

5.3 Voltage Check

Read and understand all instructions on installation drawings and labels on the switch. Note any optional accessories that have been furnished with the switch and review their operation.

Note: Source N is the source connected to the normal

side of the contactor. Source E is the source connected to the emergency side of the contactor. Verify that the source leads are connected to the correct lugs before proceeding.

The voltage check procedure requires the following equipment:

D A digital voltmeter (DVM) with electrically insulated

probes capable of measuring the rated voltage and frequency

D A phase rotation meter

The voltage, frequency, and phasing of the transfer switch and the power sources must be the same to avoid damage to loads and the transfer switch. Compare the

TP-6835 9/17 45Section 5 Functional Tests and Setup

Page 46

DANGER

Hazardous voltage. Will cause severe injury or death.

Only authorized personnel should open the enclosure.

Testing live electrical circuits. Hazardous voltage or current will cause severe injury or death. Have trained and

qualified personnel take diagnostic measurements of live circuits. Use adequately rated test equipment with electrically insulated probes and follow the instructions of the test equipment manufacturer when performing voltage tests. Observe the following precautions when performing voltage tests: (1) Remove all jewelry. (2) Stand on a dry, approved electrically insulated mat. (3) Do not touch the enclosure or components inside the enclosure. (4) Be prepared for the system to operate automatically.

(600 volts and under)

Voltage Check Procedure

1. If Source N is a generator set, move the generator set master switch to the RUN position. The generator 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 (if applicable) terminal voltages and frequency.

Note: The default setting for the phase rotation on

the controller is ABC. If the application uses a phase rotation of BAC, refer to the controller Operation Manual for instructions to change the phase rotation setting on the controller.

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

6. Disconnect Source N by opening upstream circuit breakers or switches.

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

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

9. Close and lock the transfer switch enclosure door.

10. Reconnect both power sources by closing the circuit breakers or switches.

11. Move the generator set master switch to the AUTO position.

Note: If the engine cooldown time delay setting is

not set to zero (default setting), the generator set may start and run until the Time Delay Engine Cooldown (TDEC) ends.

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

a. If Source N is the utility and the measured input

does not match the voltage and frequency shown on the transfer switch nameplate, STOP! Do not proceed further in installation because the transfer switch is not designed for the application—call your distributor/dealer to order the correct transfer switch.

b. If Source N is a generator set and the generator

set output voltage and frequency do not match the nominal system voltage and frequency shown on the transfer switch nameplate, follow the manufacturer’s instructions to adjust the generator set. The automatic transfer switch will only function with the rated system voltage and frequency specified on the nameplate.

4. Use a phase rotation meter to check the phase rotation at the Source N (normal) terminals. Rewire the transfer switch Source N terminals to obtain the correct phase sequence if necessary.

5.4 Lamp Test

Refer to the controller Operation Manual for instructions to perform a lamp test. Verify that all controller LEDs or lamps light during the test.

5.5 Automatic Operation Test

Check the transfer switch’s automatic control system immediately after the voltage check. Refer to the controller Operation Manual for instructions to run the automatic operation test.

Note: Closeand lock the enclosure door before starting

the test procedure.

TP-6835 9/1746 Section 5 Functional Tests and Setup

Page 47

5.6 System Setup

5.8 User Interface Cover

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

The transfer switch is factory-set with default settings for time delays and other parameters. See the controller Operation Manual for instructions to view and change settings, if necessary.

Note: Use caution when changing transfer switch

settings. The source voltage and frequency settings must match the values shown on the transfer switch nameplate.

5.7 Exerciser Setup

Set the exerciser to start and run the generator set at least once a week. See the controller Operation Manual for instructions.

The gasket-sealed, hinged user interface cover prevents unauthorized access to the transfer switch controls and protects the user interface from harsh environmental conditions. The cover is available as an optional accessory for NEMA 1 enclosures.

Use a customer-supplied padlock to lock the cover.

5.9 Startup Notification

Perform the system startup procedure explained on the Startup Notification Form. The Startup Notification Form covers all equipment in the power system. Complete the Startup Notification Form and register the power system using the Kohlerr online Warranty Processing System.

TP-6835 9/17 47Section 5 Functional Tests and Setup

Page 48

Notes

TP-6835 9/1748 Section 5 Functional Tests and Setup

Page 49

Section 6 Scheduled Maintenance

Regular preventive maintenance ensures safe and reliable operation and extends the life of the transfer switch. Preventive maintenance includes periodic testing, cleaning, inspection, and replacement of worn or missing components.

The transfer switch Operation Manual contains the Service Schedule and other maintenance information. Refer to the Operation Manual shipped with the transfer switch, or check which controller is used on your transfer switch and see Figure 6-1 for the Operation Manual part number.

Have maintenance or service performed by a local authorized distributor/dealer. Maintenance and service

Keep records of all maintenance or service. must comply with all applicable codes and standards. See the Service Assistance section in this manual for how to locate a local distributor/dealer.

Operation Manual Part Number

Operation Manual, Decision-Makerr MPAC 1500 Controller

TP-6883

Figure 6-1 Operation Manuals

TP-6835 9/17 49Section 6 Scheduled Maintenance

Page 50

Notes

TP-6835 9/1750 Section 6 Scheduled Maintenance

Page 51

Section 7 Bypass, Isolation, and Manual Transfer

7.1 Introduction

The bypass and isolation handles allow transfer switch testing and service without interrupting power to the load. Read the information and instructions in Sections 7.1.1 and 7.1.2 before proceeding to the bypass and isolation procedures.

Note: To prevent confusion, set the preferred source

selection (available if the ATS is equipped with the optional alarm module) to SOURCE N before beginning the bypass/isolation procedures. See the controller Operation Manual for instructions, if necessary.

7.1.1 Bypassing the Transfer Switch

The bypass handle allows direct connection of the source to the load, bypassing the transfer switch to provide power to the load during transfer switch service.

The bypass connection is open during normal transfer switch operation. Closing the bypass connection provides a direct connection to either the Normal or Emergency source. See Figure 7-1 and Figure 7-2. Check the transfer switch position and bypass to the source that is connected to the automatic transfer switch (ATS) at the time.

The bypass handle positions are labeled Normal and

Emergency. Transfer switches equipped with the alarm

module have a preferred source selection that allows

selection of either source as preferred. The preferred

source selection does not affect the bypass handle

positions. Do not confuse the preferred source with the

source connected to the Normal side of the power

switching device in the following procedures.

7.1.2 Isolating the Transfer Switch

Isolation removes the transfer switch from the power

circuit. Always bypass the transfer switch before

moving the isolation handle to the TEST or OPEN

position. In the TEST position, the isolation contacts

disconnect the transfer switch from the load but

maintain transfer switch connections to the sources,

allowing transfer switch testing without load. See

Figure 7-3. In the OPEN position, the isolation contacts

disconnect the transfer switch from the load and from

both sources, allowing transfer switch service. See

Figure 7-4.

For normal ATS operation, the isolation handle should

be in the CLOSED position. In the CLOSED position,

the ATS isolation contacts are fully engaged with both

sources and the load.

Note: Bypass to the source that is connected to the

load, as indicated by the Transfer Switch Position indicator. Interlocks prevent bypassing to the wrong source; do not force the bypass handle.

Figure 7-1 Bypass to Normal

Figure 7-3 Isolate to Test (load contacts are

disengaged but sources are connected)

Figure 7-4 Isolate to Open (isolation contacts are

all disengaged)

Figure 7-2 Bypass to Emergency

TP-6835 9/17 51Section 7 Bypass, Isolation, and Manual Transfer

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7.2 150--600 Amp Models

Read the information and instructions in Sections 7.1.1 and 7.1.2 before proceeding.

7.2.1 Bypassing the ATS,

150--600 Amp Models

This procedure explains how to bypass the closed transfer switch contacts. Bypassing is required before the transfer switch can be tested or isolated.

D The bypass switch handle must be in the OPEN

position (green window indicator). See Figure 7-5.

D The Isolation Handle must be in the CONN

(connected) position. Check the position window indicator. See Figure 7-6.

D The TS Connected light must be on. See Figure 7-7

and Figure 7-8.

Note: Yo u can only bypass to the same source that is

connected to the transfer switch. A solenoid interlock prevents connection to the wrong source.

Window indicator shows yellow when ATS is bypassed to Emergency.

Window indicator shows green when the ATS is

bypassed.

not

Window indicator shows yellow when ATS is bypassed to Normal.

Position window Isolation handle

Figure 7-6 Isolation Handle in CONN Position

Bypass handle

Figure 7-5 Bypass Handle and Three-Position

Window Indicators

Figure 7-7 Status Lights and Engine Control

TP-6835 9/1752 Section 7 Bypass, Isolation, and Manual Transfer

Page 53

Upper amber light should be on.

TS CONNECTED

TS TEST

TS ISOLATED

Figure 7-8 Status Lights for Transfer Switch

Isolation Contact Position

1. Observe which Transfer Switch Connected To light is on (Normal or Emergency) on the door. This is the position of the transfer switch. See Figure 7-9.

TRANSFER SWITCH

Upper green light is on if Transfer Switch is on Normal.

Lower red light is on if Transfer Switch is on Emergency.

CONNECTED TO NORMAL

CONNECTED TO EMERGENCY

Figure 7-9 Status Lights for Transfer Switch Main

Contact Position

2. Use the following procedures to bypass to the same source as connected to the transfer switch (select Normal or Emergency).

Figure 7-10 shows allowable positions of the bypass switch in relation to positions of the transfer switch (with isolation handle in the Conn [connected] position and TS Connected light on).

The automatic transfer switch can now be put in the TEST or OPEN position. See Section 7.2.2, Isolating the Transfer Switch.

Push in Bypass Handle and turn it counterclockwise.

Bypass Switch

ATS

BYPASS SWITCH

Upper green light comes on

Figure 7-11 Bypass to Normal Diagram

BYPASSED TO NORMAL

BYPASSED TO EMERGENCY

Transfer Switch

Position

Normal Open or Normal

Emergency Open or Emergency

Bypass Switch

can be in either

Figure 7-10 Allowable Bypass Switch Position

Procedure to Bypass to Normal Source

(connect load to normal source)

The Transfer Switch Connected To Normal light is on. The Transfer Switch Connected To Emergency light is off.

Push the bypass handle in and turn it counterclockwise.

Push the bypass handle all the way in, then turn it counterclockwise until Bypass Switch Position shows closed on NORMAL (yellow window indicator). The green Bypassed to Normal light will come on and the amber Not In Automatic light will flash. See Figure 7-11 and Figure 7-12.

Lower window indicator NORMAL shows yellow

Figure 7-12 Status Light and Window Indicator for

Bypassed to Normal Source

TP-6835 9/17 53Section 7 Bypass, Isolation, and Manual Transfer

Page 54

Procedure to Bypass to Emergency Source

(connect load to emergency source)

The Transfer Switch Connected To Emergency light is on. Transfer Switch Connected To Normal light is off.

Turn the bypass handle clockwise.

Turn the Bypass Handle clockwise until bypass switch position shows closed on EMERGENCY (yellow window indicator). See Figure 7-13 and Figure 7-14. The red Bypassed to Emergency light will come on and the amber Not In Automatic light will flash.

The automatic transfer switch can now be put in TEST or OPEN position. See Section 7.2.2, Isolating the Transfer Switch.

Upper window indicator EMERGENCY shows yellow

Figure 7-14 Status Light and Window Indicator for

Bypassed to Emergency Source

Turn Bypass Handle clockwise.

Lower red light comes on

Bypass Switch

ATS

BYPASS SWITCH

BYPASSED TO NORMAL

BYPASSED TO EMERGENCY

Figure 7-13 Bypass to Emergency Diagram

TP-6835 9/1754 Section 7 Bypass, Isolation, and Manual Transfer

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7.2.2 Isolating the Transfer Switch, 150--600 Amp Models

Isolate the transfer switch before performing any service work on the automatic transfer switch (ATS). Refer to Figure 7-15 through Figure 7-18.

1. Bypass the closed automatic transfer switch contacts. See Section 7.2.1, Bypassing ATS.

2. Turn the Isolation Handle counterclockwise (approx. 8 turns) until window shows TEST.See Figure 7-15 and Figure 7-16. The TS Test amber light should come on (Figure 7-16). The ATS can be tested now without load interruption.

Note: In the TEST position the transfer switch solenoid

operator circuit is energized through secondary disconnects.

Turn crank counterclockwise until window shows TEST.

Middle amber light should be on.

Bypass Switch

Automatic Transfer Switch

TS CONNECTED

TS TEST

TS ISOLATED

Position window:

CONN

TEST

ISOLATE

Counterclockwise draws out the transfer switch

Figure 7-15 Isolation Handle Turned to TEST

Figure 7-16 CONNECTED to TEST position

TP-6835 9/17 55Section 7 Bypass, Isolation, and Manual Transfer

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3. Continue turning the Isolation Handle counterclockwise (approx. 6 turns) until the window shows ISOLATE. See Figure 7-17. The amber TS Isolated light should come on. See Figure 7-18.

DANGER

Hazardous voltage. Will cause severe injury or death.

Only authorized personnel should open the enclosure.

Removing the transfer switch from bypass/isolation models. Hazardous voltage will cause severe injury or death. Bypass and isolate the transfer switch before

removing it from the enclosure. The bypass/isolation switch is energized. Do not touch the isolation contact fingers or the control circuit terminals.

WARNING

Position window:

Counterclockwise draws out the transfer switch

ISOLATE

Figure 7-17 Isolation Handle Turned to ISOLATE.

Bypass Switch

Turn crank counterclockwise until window shows ISOLATE.

Automatic Transfer Switch

TS CONNECTED

Unbalanced weight. Improper lifting can cause severe injury or death and equipment damage.

Use adequate lifting capacity. Never leave the transfer switch standing upright unless it is securely bolted in place or stabilized.

Note: The transfer switch weighs about 55 kg (120 lb.)

depending upon the number of poles. Use lifting equipment capable of lifting this weight. Two persons are recommended.

4. Open the lower enclosure door. Pull out both left and right side rails then use the two handles to roll out the transfer switch. It can be safely inspected in this position. The transfer switch can also be removed for easier maintenance operations. See Figure 7-19 or Figure 7-20.

TS TEST

Lower amber light should be on.

TS ISOLATED

Figure 7-18 From TEST to ISOLATE Position

TP-6835 9/1756 Section 7 Bypass, Isolation, and Manual Transfer

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Tab handles

7.2.3 Return to Service, 150--600 Amp Models

This procedure explains how to return the automatic transfer switch (ATS) to service after inspection and maintenance. Observe the bypass switch position indicator and lights.

1. Use the two handles to roll the transfer switch into the enclosure (isolation contacts facing inward) until its crank pins engage the latch plates on both sides. See Figure 7-19 or Figure 7-20. Next push in both side rails and close the enclosure door.

Left rail

Right rail

Figure 7-19 Transfer Switch Isolated and Pulled

Out for Inspection (standard-transition model)

Tab handles

Bypass Switch

Turn crank clockwise until window shows TEST.

Automatic Transfer Switch

Middle amber light should come on.

TS CONNECTED

TS TEST

TS ISOLATED

Figure 7-21 From ISOLATE to TEST Position

Left rail

Right rail

Figure 7-20 Transfer Switch Isolated and Pulled

Out for Inspection (programmed- or closed- transition model)

TP-6835 9/17 57Section 7 Bypass, Isolation, and Manual Transfer

Page 58

3. Observe which bypass switch position window indicator is yellow (NORMAL or EMERGENCY) at the bypass switch handle. This indicates the source connected to the load.

Note: A solenoid interlock prevents you from

closing the isolation contacts until the ATS is in the same position as the bypass switch.

4. Observe which Transfer Switch Connected To light is on (Normal or Emergency) on the door. This is the position of the transfer switch. If it is not in the same position as the bypass handle, change the position of the transfer switch as shown in Figure 7-23.

Position window: TEST

Clockwise draws in the transfer switch

Figure 7-22 Isolation Handle Turned to TEST

WARNING

Hazardous voltage. Can cause severe injury or death.

Close and secure the enclosure door before energizing the transfer switch.

2. Turn the Isolation Handle clockwise (approx. 6 turns) until the window shows TEST and TS TEST light comes on. See Figure 7-21 and Figure 7-22.

Note: The ATS can be tested now without load

interruption.

Operate to NORMAL

Turn Transfer Control switch to Retransfer Delay Bypass.

Connected To Normal light should come on.

* With Normal available, the automatic transfer switch will return

to the Normal position after the retransfer time delay.

Operate to EMERGENCY *

Turn Transfer Control switch to Transfer Test (hold 15 seconds).

Connected To Emergency light comes on.

Figure 7-23 Changing Transfer Switch Position

Note: Do not close the isolation contacts unless

the transfer switch (ATS) and bypass switch are in the same position!

5. When the transfer switch is in the same position as the bypass switch handle, continue turning the isolation handle clockwise (about 8 turns) until the window shows CONN (connected).

Position window: CONN

Clockwise draws in the transfer switch

Figure 7-24 Isolation Handle Turned to CONN

TP-6835 9/1758 Section 7 Bypass, Isolation, and Manual Transfer

Page 59

Bypass Switch

Window indicator shows yellow when ATS is bypassed to Emergency.

Turn crank clockwise until window shows CONN.

Automatic Transfer Switch

Upper amber light should be on.

TS CONNECTED

TS TEST

TS ISOLATED

Figure 7-25 TEST to CONN (Connected) Position

7.2.4 Return Bypass Switch to OPEN, 150--600 Amp Models

This procedure explains how to return the bypass switch handle to the OPEN position. The bypass handle must be in the CLOSED position (yellow indicator on NORMAL or EMERGENCY) and the isolation handle must be in the CONN position (window). See Figure 7-26, Figure 7-27, and Figure 7-28.

Window indicator shows green when the ATS is not bypassed.

Window indicator shows yellow when ATS is bypassed to Normal.

Figure 7-26 Bypass Handle and Position Indicators

Bypass Switch

Turn bypass handle clockwise.

Note: Yo u can only bypass to the same source that is

connected to the ATS. A solenoid interlock prevents incorrect operation.

Figure 7-27 Opening Bypass to Normal

ATS

1. Observe which bypass switch position indicator is yellow (NORMAL or EMERGENCY) at the bypass switch handle. This indicates the source connected to the load. See Figure 7-26.

2. Turn the bypass handle to open the bypass as directed in the following procedures (select Normal or Emergency according to the bypass position indicator).

TP-6835 9/17 59Section 7 Bypass, Isolation, and Manual Transfer

Page 60

Bypass Switch

Turn bypass handle counterclockwise.

ATS

Figure 7-28 Opening Bypass to Emergency

To Open the Bypass when Connected to the Emergency Source

The Transfer Switch Connected To Emergency light is on. The Transfer Switch Connected To Normal light is off.

Turn the handle counterclockwise.

Turn the bypass handle counterclockwise until the bypass switch position shows OPEN (green window indicator). See Figure 7-26. The Bypassed to Emergency light should go off and the Not In Automatic light should go off. The automatic transfer and bypass/ isolation switch should be left in this position.

To Open the Bypass when Connected to the Normal Source

The Transfer Switch Connected To Normal light is on. The Transfer Switch Connected To Emergency light is off.

Turn the handle clockwise.

Turn the bypass handle clockwise until the bypass switch position shows OPEN (green window indicator). See Figure 7-26. The Bypassed to Normal light should go off and the Not In Automatic light should go off. The automatic transfer and bypass/isolation switch should be left in this position.

7.2.5 Manual Load Transfer, 150--600 Amp Models

The following procedure manually transfers the load to the other source if the transfer switch or controller are out of service.

Note: Close and secure the enclosure door before

performing this procedure.

1. Bypass to the connected source. Turn the bypass handle to EMERGENCY or NORMAL. See Section 7.2.1.

2. Turn the isolation handle to the TEST position. See Section 7.2.2.

3. Turn the bypass handle to OPEN, then to the other source. The load will be interrupted.

To return to automatic operation, follow the instructions inSection7.2.3,ReturntoService.

TP-6835 9/1760 Section 7 Bypass, Isolation, and Manual Transfer

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7.3 800--1200 Amp Models

Read the information and instructions in Sections 7.1.1 and 7.1.2 before proceeding.

7.3.1 Bypassing the ATS, 800--1200 Amp Models

This procedure explains how to bypass the closed transfer switch contacts. Bypassing is required before the transfer switch can be tested or isolated.

D The bypass switch handle must be in the OPEN

position (green window indicator). See Figure 7-29.

D The Isolation Handle must be in the CONN

(connected) position. Check the position window indicator. See Figure 7-31.

D The TS Connected light must be on. See Figure 7-30

and Figure 7-32.

Window indicator shows yellow when ATS is bypassed to Emergency.

Position window

CONN

Clockwise – draws in

the transfer switch

Figure 7-31 Isolation Handle in CONN Position

Window indicator shows green when the ATS is not bypassed.

Window indicator shows yellow when ATS is bypassed to Normal.

Figure 7-29 Bypass Handle and Three Position

Window Indicators

Upper amber light should be on.

TS CONNECTED TS TEST

TS ISOLATED

Figure 7-30 Status Lights for Transfer Switch

Isolation Contact Position

Figure 7-32 Status Lights and Engine Control

Note: You can only bypass to the same source that is

connected to the transfer switch. A solenoid interlock prevents connection to the wrong source.

TP-6835 9/17 61Section 7 Bypass, Isolation, and Manual Transfer

Page 62

1. Observe which Transfer Switch Connected To light is on (Normal or Emergency) on the door. This is the position of the transfer switch. See Figure 7-33.

TRANSFER SWITCH

Upper green light is on if Transfer Switch is on Normal.

CONNECTED TO NORMAL

Push in Bypass Handle and turn it counterclockwise.

Bypass Switch

Lower red light is on if Transfer Switch is on Emergency.

CONNECTED TO EMERGENCY

Figure 7-33 Status Lights for Transfer Switch Main

Contact Position

2. Use the following procedures to bypass to the same source as connected to the transfer switch (select Normal or Emergency).

Figure 7-34 shows allowable positions of the bypass switch in relation to positions of the transfer switch (with isolation handle in the Conn [connected] position and TS Connected light on).

Transfer Switch

Position

Normal Open or Normal

Emergency Open or Emergency

Bypass Switch

can be in either

Figure 7-34 Allowable Bypass Switch Position

Procedure to Bypass to Normal Source

(connect load to normal source)

ATS

BYPASS SWITCH

Upper green light comes on

BYPASSED TO NORMAL

BYPASSED TO EMERGENCY

Figure 7-35 Bypass to Normal Diagram

The Transfer Switch Connected To Normal light is on. The Transfer Switch Connected To Emergency light is off.

Push the bypass handle in and turn it counterclockwise.

The automatic transfer switch can now be put in the TEST or OPEN position. See Section 7.3.2, Isolating ATS.

Lower window indicator NORMAL shows yellow

Figure 7-36 Status Light and Window Indicator for

Bypassed to Normal Source

TP-6835 9/1762 Section 7 Bypass, Isolation, and Manual Transfer

Page 63

Procedure to Bypass to Emergency Source

(connect load to emergency source)

The Transfer Switch Connected To Emergency light is on. Transfer Switch Connected To Normal light is off.

Turn the bypass handle clockwise.

Turn the Bypass Handle clockwise until bypass switch position shows closed on EMERGENCY (yellow window indicator). See Figure 7-37 and Figure 7-38. The red Bypassed to Emergency light will come on and the amber Not In Automatic light will flash.

The automatic transfer switch can now be put in TEST or OPEN position. See Section 7.3.2, Isolating ATS.

Upper window indicator EMERGENCY shows yellow

Figure 7-38 Status Light and Window Indicator for

Bypassed to Emergency Source

Turn Bypass Handle clockwise.

Lower red light comes on

Bypass Switch

ATS

BYPASS SWITCH

BYPASSED TO NORMAL

BYPASSED TO EMERGENCY

Figure 7-37 Bypass to Emergency Diagram

TP-6835 9/17 63Section 7 Bypass, Isolation, and Manual Transfer

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7.3.2 Isolating the ATS, 800--1200 Amp Models

Isolate the transfer switch before performing any service work on the automatic transfer switch (ATS). Refer to Figure 7-39 through Figure 7-42.

1. Bypass the closed automatic transfer switch contacts. See Section 7.3.1 for instructions.

2. Turn the Isolation Handle counterclockwise (approx. 8 turns) until window shows TEST.See Figure 7-39. The TS Test amber light should come on (Figure 7-40). The ATS can be tested now without load interruption.

Note: In the TEST position the transfer switch solenoid

operator circuit is energized through secondary disconnects.

Turn crank counterclockwise until window shows TEST.

Middle amber light should be on.

Bypass Switch

Automatic Transfer Switch

TS CONNECTED

TS TEST

TS ISOLATED

Position window:

CONN

TEST

ISOLATE

Counterclockwise – draws

out the transfer switch

Figure 7-39 Isolation Handle Turned to TEST

Figure 7-40 CONNECTED to TEST position

3. Continue turning the Isolation Handle counterclockwise (approx. 6 turns) until the window shows ISOLATE. See Figure 7-41. The amber TS Isolated light should come on (Figure 7-42).

Position window: ISOLATE

Counterclockwise – draws

out the transfer switch

Figure 7-41 Isolation Handle Turned to ISOLATE.

TP-6835 9/1764 Section 7 Bypass, Isolation, and Manual Transfer

Page 65

Turn crank counterclockwise until window shows ISOLATE.

Lower amber light should be on.

Bypass Switch

Automatic Transfer Switch

TS CONNECTED

TS TEST

TS ISOLATED

handles

right railleft rail

Figure 7-43 Transfer Switch Isolated and Pulled

Out for Inspection

WARNING

Figure 7-42 From TEST to ISOLATE Position

DANGER

Hazardous voltage. Will cause severe injury or death.

Only authorized personnel should open the enclosure.

Removing the transfer switch from bypass/isolation models. Hazardous voltage will cause severe injury or death. Bypass and isolate the transfer switch before

removing it from the enclosure. The bypass/isolation switch is energized. Do not touch the isolation contact fingers or the control circuit terminals.

Note: The transfer switch weighs 59--90 kg

(130–200 lb.) depending upon the number of poles.

4. Open the lower enclosure door. Pull out both left and right side rails then use the two handles to roll out the transfer switch. It can be safely inspected in this position. See Figure 7-43.

Unbalanced weight. Improper lifting can cause severe injury or death and equipment damage.

Use adequate lifting capacity. Never leave the transfer switch standing upright unless it is securely bolted in place or stabilized.

5. The transfer switch can also be removed for easier maintenance operations. If it is necessary to lift the transfer switch, use lifting equipment capable of lifting the weight. Two persons are recommended.

TP-6835 9/17 65Section 7 Bypass, Isolation, and Manual Transfer

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7.3.3 Return to Service, 800--1200 Amp Models

This procedure explains how to return the automatic transfer switch (ATS) to service after inspection and maintenance. Observe the bypass switch position indicator and lights.

1. Use the two handles to roll the transfer switch into the enclosure (isolation contacts facing inward) until its crank pins engage the latch plates on both sides. See Figure 7-43. Next push in both side rails and close the enclosure door.

WARNING

Hazardous voltage. Can cause severe injury or death.

Close and secure the enclosure door before energizing the transfer switch.

2. Turn the Isolation Handle clockwise (approx. 6 turns) until the window shows TEST and TS TEST light comes on. See Figure 7-44 and Figure 7-45.

The ATS can be tested now without load interruption.

Bypass Switch

Turn crank clockwise until window shows TEST.

Position window: TEST

Clockwise – draws in

the transfer switch

Figure 7-45 Isolation Handle Turned to TEST

3. Observe which bypass switch position window indicator is yellow (NORMAL or EMERGENCY) at the bypass switch handle. This indicates the source connected to the load.

Note: A solenoid interlock prevents you from closing

the isolation contacts until the ATS is in the same position as the bypass switch.

Operate to NORMAL

Turn Transfer Control switch to Retransfer Delay Bypass.

Connected To Normal light should come on.

* With Normal available, the automatic transfer switch will return

to the Normal position after the retransfer time delay.

Operate to EMERGENCY *

Turn Transfer Control switch to Transfer Test (hold 15 seconds).

Connected To Emergency light comes on.

Automatic Transfer Switch

Middle amber light should come on.

TS CONNECTED

TS TEST

TS ISOLATED

Figure 7-44 From ISOLATE to TEST Position

Figure 7-46 Changing Transfer Switch Position

Note: Do not close the isolation contacts unless the

transfer switch (ATS) and bypass switch are in the same position!

5. When the transfer switch is in the same position as the bypass switch handle, continue turning the isolation handle clockwise (about 8 turns) until the window shows CONN (connected). See Figure 7-47 and Figure 7-48.

TP-6835 9/1766 Section 7 Bypass, Isolation, and Manual Transfer

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7.3.4 Return Bypass Switch to OPEN, 800--1200 Amp Models

Note: You can only bypass to the same source that is

connected to the ATS. A solenoid interlock prevents incorrect operation.

Position window: CONN

Clockwise – draws in

the transfer switch

Figure 7-47 Isolation Handle Turned to CONN

Bypass Switch

Turn crank clockwise until window shows CONN.

Automatic Transfer Switch

Upper amber light should be on.

Figure 7-48 TEST to CONN (Connected) Position

TS CONNECTED

TS TEST

TS ISOLATED

Indicator shows yellow when ATS is bypassed to Emergency.

Indicator shows green when the ATS is not bypassed.

Indicator shows yellow when ATS is bypassed to Normal.

Figure 7-49 Bypass Handle and Position Indicators

Bypass Switch

Turn Bypass Handle clockwise.

ATS

Figure 7-50 Opening Bypass to Normal

TP-6835 9/17 67Section 7 Bypass, Isolation, and Manual Transfer

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Bypass Switch

Turn Bypass Handle counterclockwise.

ATS

Figure 7-51 Opening Bypass to Emergency

To Open the Bypass when Connected to the Emergency Source

The Transfer Switch Connected To Emergency light is on. The Transfer Switch Connected To Normal light is off.

Turn the handle counterclockwise.

Turn the bypass handle counterclockwise until the bypass switch position shows OPEN (green window indicator). See Figure 7-49. The Bypassed to Emergency light should go off and the Not In Automatic light should go off. The automatic transfer and bypass/ isolation switch should be left in this position.

1. Observe which bypass switch position indicator is yellow (NORMAL or EMERGENCY) at the bypass switch handle. This indicates the source connected to the load. See Figure 7-49.

2. Un–Bypass to same source as the bypass switch position as follows (select Normal or Emergency).

To Open the Bypass when Connected to the Normal Source

The Transfer Switch Connected To Normal light is on. The Transfer Switch Connected To Emergency light is off.

Turn the handle clockwise.

Turn the bypass handle clockwise until the bypass switch position shows OPEN (green window indicator). See Figure 7-49. The Bypassed to Normal light should go off and the Not In Automatic light should go off. The automatic transfer and bypass/isolation switch should be left in this position.

7.3.5 Manual Load Transfer, 800--1200 Amp Models

The following procedure manually transfers the load to the other source if the transfer switch or controller are out of service.

Note: Close and secure the enclosure door before

performing this procedure.

1. Bypass to the connected source. Turn the bypass handle to EMERGENCY or NORMAL. See Section 7.3.1.

2. Turn the isolation handle to the TEST position. See Section 7.3.2.

3. Turn the bypass handle to OPEN, then to the other source. The load will be interrupted.

To return to automatic operation, follow the instructions inSection7.3.3,ReturntoService.

TP-6835 9/1768 Section 7 Bypass, Isolation, and Manual Transfer

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7.4 1600--4000 Amp Models

Check the ATS position indicator. Bypass to the connected source (Source N = Normal, Source E =

Read the information and instructions in Sections 7.1.1

Emergency).

and 7.1.2 before proceeding.

Note: Bypass to the source that is connected to the

load, as indicated by the Position LED. Interlocks

7.4.1 Bypassing the Transfer Switch,

prevent incorrect operation.

1600--4000 Amp Models

The bypass handle must be in the OPEN position (green indicator) and the isolation handle must be in the CLOSED position (window) at the start o f the procedure. See Figure 7-52.

The OPEN indicator is green when the ATS is NOT bypassed.

To Bypass to Normal (Source N), push in the handle all the way and turn it clockwise.

To Bypass to Emergency (Source E), pull out the handle all the way and turn it clockwise.

After bypass, the ATS can be put into the Test or Open position. Proceed to Section 7.4.2, Isolating the Transfer Switch.

The EMERGENCY (or SOURCE E) CLOSED indicator is yellow when the ATS is bypassed to the Emergency source (or Source E).

The NORMAL (or Source N) CLOSED indicator is yellow when the ATS is bypassed to the Normal Source (or Source N).

Figure 7-52 Bypass Handle and Position Indicators, 1600--3000 Amp Models

Procedure to Bypass Normal (Source N)

The load is connected to the Normal source. The

Transfer Switch Connected to Normal light is on; the Transfer Switch Connected to Emergency light is off.

1. Push in the bypass handle all the way. See Figure 7-52.

2. Turn the bypass handle clockwise until the NORMAL bypass switch position indicator turns completely yellow. The Not In AUTO indicator will flash.

Bypass Switch

Push in the bypass handle and turn it clockwise.

Procedure to Bypass Emergency (Source E)

The load is connected to Emergency source. The

Transfer Switch Connected to Normal light is off; the Transfer Switch Connected to Emergency light is on.

1. Pull out the bypass handle all the way. See Figure 7-52.

2. Turn the bypass handle clockwise until the CLOSED bypass switch position indicator turns completely yellow. The Not In AUTO indicator will flash.

Pull out the bypass handle and turn it clockwise.

Bypass Switch

ATS

Figure 7-53 Bypass to Normal (Source N)

TP-6835 9/17 69Section 7 Bypass, Isolation, and Manual Transfer

Figure 7-54 Bypass to Emergency (Source E)

ATS

Page 70

7.4.2 Isolating the Transfer Switch, 1600--4000 Amp Models

Bypass the ATS before isolating it. See Section 7.4.1.

2. Continue turning the isolation handle counterclockwise (approx. 7 turns for 1600--3000 amps, 8 turns for 4000 amps) until the position window shows ISOLATE. See Figure 7-57.

Note: Turn the isolation handle until the position shows

clearly through the position window. Do not leave the handle in an intermediate position.

1. Turn the isolation handle counterclockwise (approximately 16 turns for 1600--3000 amps, 12 turns for 4000 amps) until the position window shows TEST. See Figure 7-55 and Figure 7-56. The ATS can be tested now without load interruption.

Note: In the TEST position, the power switching

device solenoid operator circuit is energized through secondary disconnects.

Position

CONN TEST ISOLATE

window

Unfold crank

Bypass Switch

Turn cr ank counterclockwise until window shows ISOLATE.

Automatic Transfer Switch

Figure 7-57 From TEST to ISOLATE Position

Turning the handle counterclockwise draws out the t ransfer switch.

Figure 7-55 Isolation Handle

Bypass Switch

Turn cr ank counterclockwise until window shows TEST.

Automatic Transfer Switch

Figure 7-56 From CONNECTED to TEST Position

TP-6835 9/1770 Section 7 Bypass, Isolation, and Manual Transfer

Page 71

7.4.3 Removing the Transfer Switch, 1600--4000 Amp Models

After the ATS is bypassed and isolated, it can be removed from the enclosure for inspection or service.

DANGER

Hazardous voltage. Will cause severe injury or death.

Only authorized personnel should open the enclosure.

Short circuits. Hazardous voltage/current will cause severe injury or death. Short circuits can cause bodily injury

and/or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment.

Removing the transfer switch from bypass/isolation models. Hazardous voltage can cause severe injury or death. Bypass and isolate the transfer switch before

removing it from the enclosure. The bypass/isolation switch is energized. Do not touch the isolation contact fingers or the control circuit terminals.

Procedure to Remove the Transfer Switch, 1600--4000 Amp Models

1. Open the lower enclosure door.

2. Pull out the side rail carriage, then roll out the transfer switch. See Figure 7-59. It can be safely inspected in this position. The transfer switch can also be removed for maintenance operations.

See Section 2.5 for maintenance handle use.

WARNING

Unbalanced weight. Improper lifting can cause severe injury or death and equipment damage.

Use adequate lifting capacity. Never leave the transfer switch standing upright unless it is securely bolted in place or stabilized.

The transfer switch weights are shown in Figure 7-58. Use an overhead crane or other lifting equipment capable of handling this weight to move the transfer switch.

Size, Amps Weight, kg (lbs.)

1600--3000 160-- 205 kg (350--450 lbs.)

4000 272 kg (600 lbs.)

Figure 7-58 Transfer Switch Weights

136e

Figure 7-59 1000–4000 Amp Transfer Switch

Isolated and Pulled Out for Inspection

Procedure to Remove the Transfer Switch, 4000 Amp Models

3. See Figure 7-60 and follow these steps:

a. Open both lower doors.

b. Pull out the rail support carriage all the way.

c. Remove the left and right clevis and locking

pins. Drop two support legs and reinstall locking and clevis pins (to lock in place).

d. Adjust both legs to extend to the floor.

e. Stand directly in front of transfer switch. Grasp

both handles, and pull straight out.

Note: Detents on the rails prevent the transfer

switch from rolling out unless substantial initial force is applied.

4. The ATS can be safely inspected in this position. The transfer switch can also be removed for maintenance operations.

TP-6835 9/17 71Section 7 Bypass, Isolation, and Manual Transfer

Page 72

1. Handles

2. Locking pin with clevis pin

3. Support leg (fold down and lock; adjust length to touch floor)

4. Rail support carriage

Figure 7-60 4000 Amp Transfer Switch Isolated and Pulled Out for Inspection

136e

TP-6835 9/1772 Section 7 Bypass, Isolation, and Manual Transfer

Page 73

7.4.4 Return to Operation, 1600--4000 Amp Models

This procedure explains how to return the ATS to operation after inspection or service.

1. Observe which bypass switch position indicator is yellow (NORMAL or EMERGENCY). This indicates the source connected to the load.

2. Slide the transfer switch (ATS) into the enclosure (isolation contacts facing inward) until its crank pins engage the latch plates on both sides. On 4000 amp units, substantial force is required to overcome detents on the rails.

Turn cr ank clockwise until window shows TEST.

Bypass Switch

E(B)

N(A)

3. 4000 amp models only: Retract the two support legs and lock them into place.

4. Push in the side rail carriage and then close the enclosure door.

WARNING

Hazardous voltage. Can cause severe injury or death.

Close and secure the enclosure door before energizing the transfer switch.

5. Turn the isolation handle clockwise (approximately 7 turns for 1600--3000 amp units, 8 turns for 4000 amp units) until the window shows TEST. See Figure 7-55 and Figure 7-61. The ATS can be tested now without load interruption.

Note: Turn the isolation handle until the position

shows clearly through the position window. Do not leave the handle in an intermediate position.

ATS

Figure 7-61 Moving from ISOLATE to TEST

Position

6. Observe which bypass switch position indicator is yellow (NORMAL or EMERGENCY). This indicates the source connected to the load.

Note: Solenoid interlocks prevent closing the isolation

contacts unless the transfer switch is in the same position as the bypass switch. Do not force the isolation handle.

7. Observe which Position LED on the controller is illuminated (Normal or Emergency). This is the position of the transfer switch. If the transfer switch is not in the same position as the bypass handle, check the controller display.

a. If a test sequence is running, press the End Test

button. Wait for the transfer switch to change positions and the test sequence to end.

b. If the ATS is not under test, do not proceed to

close the isolation contacts. Turn the isolation handle counterclockwise to the OPEN position and follow the instructions in Section 2.5 to manually operate the transfer switch to match the bypass handle position.

8. When the transfer switch is in the same position as the bypass switch handle, turn the isolation handle clockwise (about 16 turns for 1600--3000 amps, 12 turns for 4000 amps) until the window shows CONN (connected). See Figure 7-62.

TP-6835 9/17 73Section 7 Bypass, Isolation, and Manual Transfer

Page 74

Bypass Switch

Opening the Bypass Contacts

This procedure explains how to return the bypass switch handle to the OPEN position, which opens the bypass contacts so that the ATS controls the connections to the sources and the load.

Turn cr ank

clockwise until window shows CONN (connected).

ATS

Figure 7-62 Moving from TEST to CONNECTED

Position

Now continue with the next instructions to return the bypass handle to the OPEN position.

The OPEN indicator is green when the ATS is NOT bypassed.

1. Verify that the bypass handle is in the CLOSED position (yellow indicator on NORMAL or EMERGENCY) and the isolation handle is in the CONN position (window) before proceeding. If the handles are not in these positions, go back to Section 7.4.4, Return To Operation.

2. Observe which bypass switch position indicator is yellow (NORMAL or EMERGENCY) at the bypass switch handle. This indicates the source connected to the load.

Note: Solenoid interlocks prevent moving the

bypass handle in the wrong direction. Do not force the bypass handle.

The EMERGENCY (or SOURCE E) CLOSED indicator is yellow when the ATS is bypassed to the Emergency source (or Source E).

The NORMAL (or Source N) CLOSED indicator is yellow when the ATS is bypassed to the Normal Source (or Source N).

To open the Bypass to Normal (Source N) contacts, push in the handle all the way and turn it counterclockwise.

To open the Bypass to Emergency (Source E) contacts, pull out the handle all the way and turn it counterclockwise.

Figure 7-63 Bypass Handle and Position Indicators

TP-6835 9/1774 Section 7 Bypass, Isolation, and Manual Transfer

Page 75

3. Open the bypass contacts that are connected to the load as follows (select Normal or Emergency).

Leave the bypass and isolation handles in these positions for automatic operation.

a. If the load is connected to the NORMAL

source, push in the bypass handle and then turn it counterclockwise until the bypass switch position indicator turns green, showing that the bypass contacts are open. See Figure 7-64 and Figure 7-63. The Not in Auto light should be off.

Push in the bypass handle and turn it counterclockwise.

Bypass Switch

ATS

7.4.5 Manual Load Transfer, 1600--4000 Amp Models

This procedure manually transfers the load to the other source if the transfer switch or the controller are out of service.

Hazardous voltage. Can cause severe injury or death.

Close and secure the enclosure door before energizing the transfer switch.

1. Verify that the bypass handle is closed on either

Normal or Emergency. See Section 7.4.1.

2. Verify that the isolation handle is in the TEST or ISOLATE position. See Section 7.4.2.

WARNING

Figure 7-64 Opening Bypass to Normal Contacts

b. If the load is connected to the EMERGENCY

source, pull out the bypass handle and then

turn it counterclockwise until the bypass switch position indicator turns green, showing that the bypass contacts are open. See Figure 7-65. The Not in Auto light should be off.

Pull out

Bypass Switch

bypass handle and turn it counterclockwise.

ATS

3. Turn the bypass handle counterclockwise to OPEN. Then bypass to the other source. See Figure 7-63.

Figure 7-65 Opening Bypass to Emergency

Contacts

TP-6835 9/17 75Section 7 Bypass, Isolation, and Manual Transfer

Page 76

Notes

TP-6835 9/1776 Section 7 Bypass, Isolation, and Manual Transfer

Page 77

Appendix A Abbreviations

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

A, amp ampere ABDC after bottom dead center AC alternating current A/D analog to digital ADC advanced digital control;

adj. adjust, adjustment ADV advertising dimensional

Ah amp-hour AHWT anticipatory high water

AISI American Iron and Steel

ALOP anticipatory low oil pressure alt. alternator Al aluminum ANSI American National Standards

AO anticipatory only APDC Air Pollution Control District API American Petroleum Institute approx. approximate, approximately APU Auxiliary Power Unit AQMD Air Quality Management District AR as required, as requested AS as supplied, as stated, as

ASE American Society of Engineers ASME American Society of

assy. assembly ASTM American Society for Testing

ATDC after top dead center ATS automatic transfer switch auto. automatic aux. auxiliary avg. average AVR automatic voltage regulator AWG American Wire Gauge AWM appliance wiring material bat. battery BBDC before bottom dead center BC battery charger, battery

BCA battery charging alternator BCI Battery Council International BDC before dead center BHP brake horsepower blk. black (paint color), block

blk. htr. block heater BMEP brake mean effective pressure bps bits per second br. brass BTDC before top dead center Btu British thermal unit Btu/min. British thermal units per minute C Celsius, centigrade cal. calorie CAN controller area network CARB California Air Resources Board CAT5 Category 5 (network cable) CB circuit breaker CC crank cycle cc cubic centimeter CCA cold cranking amps ccw. counterclockwise CEC Canadian Electrical Code cert. certificate, certification, certified cfh cubic feet per hour

analog to digital converter

drawing

temperature

Institute

Institute (formerly American Standards Association, ASA)

suggested

Mechanical Engineers

Materials

charging

(engine)

cfm cubic feet per minute CG center of gravity CID cubic inch displacement CL centerline cm centimeter CMOS complementary metal oxide

com communications (port) coml commercial Coml/Rec Commercial/Recreational conn. connection cont. continued CPVC chlorinated polyvinyl chloride crit. critical CSA Canadian Standards

CT current transformer Cu copper cUL Canadian Underwriter’s

CUL Canadian Underwriter’s

cu. in. cubic inch cw. clockwise CWC city water-cooled cyl. cylinder D/A digital to analog DAC digital to analog converter dB decibel dB(A) decibel (A weighted) DC direct current DCR direct current resistance deg.,  degree dept. department dia. diameter DI/EO dual inlet/end outlet DIN Deutsches Institut fur Normung

DIP dual inline package DPDT double-pole, double-throw DPST double-pole, single -throw DS disconnect switch DVR digital voltage regulator

PROM, EEPROM

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

EDI electronic data interchange EFR emergency frequency relay e.g. for example (exempli gratia) EG electronic governor EGSA Electrical Generating Systems

EIA Electronic Industries

EI/EO end inlet/end outlet EMI electromagnetic interference emiss. emission eng. engine EPA Environmental Protection

EPS emergency power system ER emergency relay ES engineering special,

ESD electrostatic discharge est. estimated E-Stop emergency stop etc. et cetera (and so forth)

substrate (semiconductor)

Association

Laboratories

e. V. (also Deutsche Industrie Normenausschuss)

electrically-erasable programmable read-only memory

engine control module

Association

Agency

engineered special

exh. exhaust ext. external F Fahrenheit, female FHM flat head machine (screw) fl. oz. fluid ounce flex. flexible freq. frequency FS full scale ft. foot, feet ft. lb. foot pounds (torque) ft./min. feet per minute ftp file transfer protocol ggram ga. gauge (meters, wire size) gal. gallon gen. generator genset generator set GFI ground fault interrupter

GND, gov. governor gph gallons per hour gpm gallons per minute gr. grade, gross GRD equipment ground gr. wt. gross weight H x W x D height by width by depth HC hex cap HCHT high cylinder head temperature HD heavy duty HET high exhaust temp., high

hex hexagon Hg mercury (element) HH hex head HHC hex head cap HP horsepower hr. hour HS heat shrink hsg. housing HVAC heating, ventilation, and air

HWT high water temperature Hz hertz (cycles per second) IBC International Building Code IC integrated circuit ID inside diameter, identification IEC International Electrotechnical

IEEE Institute of Electrical and

IMS improved motor starting in. inch in. H in. Hg inches of mercury in. lb. inch pounds Inc. incorporated ind. industrial int. internal int./ext. internal/external I/O input/output IP internet protocol ISO International Organization for

J joule JIS Japanese Industry Standard k kilo (1000) Kkelvin kA kiloampere KB kilobyte (2 KBus Kohler communication protocol kg kilogram

ground

engine temp.

conditioning

Commission

Electronics Engineers

O inches of water

Standardization

bytes)

TP-6835 9/17 Appendix 77

Page 78

kg/cm

kgm kilogram-meter kg/m

kilograms per square centimeter

kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm, k kilo-ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt-hour kWm kilowatt mechanical kWth kilowatt-thermal L liter LAN local area network L x W x H length by width by height lb. pound, pounds

lbm/ft

pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display LED light emitting diode Lph liters per hour Lpm liters per minute LOP low oil pressure LP liquefied petroleum LPG liquefied petroleum gas LS left side L

LWL low water level

sound power level, A weighted

LWT low water temperature m meter, milli (1/1000) M mega (10

units), male

cubic meter

/hr. cubic meters per hour /min. cubic meters per minute

when used with SI

mA milliampere man. manual max. maximum MB megabyte (2

bytes) MCCB molded-case circuit breaker MCM one thousand circular mils meggar megohmmeter MHz megahertz mi. mile mil one one-thousandth of an inch min. minimum, minute misc. miscellaneous MJ megajoule mJ millijoule mm millimeter mOhm, mmilliohm MOhm, Mmegohm MOV metal oxide varistor MPa megapascal mpg miles per gallon mph miles per hour MS military standard ms millisecond m/sec. meters per second mtg. mounting MTU Motoren-und Turbinen-Union MW megawatt mW milliwatt F microfarad N, norm. normal (power source) NA not available, not applicable nat. gas natural gas NBS National Bureau of Standards NC normally closed

NEC National Electrical Code NEMA National Electrical

NFPA National Fire Protection

Manufacturers Association

Association Nm newton meter NO normally open no., nos. number, numbers NPS National Pipe, Straight NPSC National Pipe, Straight-coupling NPT National Standard taper pipe

thread per general use NPTF National Pipe, Taper-Fine NR not required, normal relay ns nanosecond OC overcrank OD outside diameter OEM original equipment

manufacturer OF overfrequency opt. option, optional OS oversize, overspeed OSHA Occupational Safety and Health

OSHPD Office of Statewide Health

Administration

Planning and Development

(California) OV overvoltage oz. ounce p., pp. page, pages PC personal computer PCB printed circuit board pF picofarad PF power factor ph.,  phase PHC Phillipsr head Crimptiter

(screw) PHH Phillipsr hex head (screw) PHM pan head machine (screw) PLC programmable logic control PMG permanent magnet generator pot potentiometer, potential ppm parts per million PROM programmable read-only

memory psi pounds per square inch psig pounds per square inch gauge pt. pint PTC positive temperature coefficient PTO power takeoff PVC polyvinyl chloride qt. quart, quarts qty. quantity R replacement (emergency)

power source rad. radiator, radius RAM random access memory RDO relay driver output ref. reference rem. remote Res/Coml Residential/Commercial RFI radio frequency interference RH round head RHM round head machine (screw) rly. relay rms root mean square rnd. round RO read only ROM read only memory rot. rotate, rotating rpm revolutions per minute RS right side RTDs Resistance Temperature

Detectors

RTU remote terminal unit RTV room temperature vulcanization RW read/write SAE Society of Automotive

Engineers scfm standard cubic feet per minute SCR silicon controlled rectifier s, sec. second SI Systeme international d’unites,

International System of Units SI/EO side in/end out sil. silencer SMTP simple mail transfer protocol SN serial number SNMP simple network management

protocol SPDT single-pole, double-throw SPST single-pole, single-throw spec specification specs specification(s) sq. square sq. cm square centimeter sq. in. square inch SMS short message service SS stainless steel std. standard stl. steel tach. tachometer TB terminal block TCP transmission control protocol TD time delay TDC top dead center TDEC time delay engine cooldown TDEN time delay emergency to

normal TDES time delay engine start TDNE time delay normal to

emergency TDOE time delay off to emergency TDON time delay off to normal temp. temperature term. terminal THD total harmonic distortion TIF telephone influence factor tol. tolerance turbo. turbocharger typ. typical (same in multiple

locations) UF underfrequency UHF ultrahigh frequency UIF user interface UL Underwriter’s Laboratories, Inc. UNC unified coarse thread (was NC) UNF unified fine thread (was NF) univ. universal URL uniform resource locator

(web address) US undersize, underspeed UV ultraviolet, undervoltage Vvolt VAC volts alternating current VAR voltampere reactive VDC volts direct current VFD vacuum fluorescent display VGA video graphics adapter VHF very high frequency Wwatt WCR withstand and closing rating w/ with WO write only w/o without wt. weight xfmr transformer

TP-6835 9/1778 Appendix

Page 79

Page 80

TP-6835 9/17c

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

Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6455

Kohler KBS, KBP, KBC Operation And Installation

Specifications and Main Features

Frequently Asked Questions

User Manual