Product identification numbers determine service parts.
Record the product identification numbers in 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
- IBC Seismic Certification
- I/O Module, Standard (max. 4) qty:
- I/O Module, High Power (max. 4) qty:
- Load Shed
- Line-Neutral Monitoring
- Supervised Transfer Switch
- SurgeProtectionDevice(SPD)
-
-
-
-
Controller Identification
Record the controller description from the generator set
operation manual, spec sheet, or sales invoice.
Controller Description
Table of Contents
Safety Precautions and Instructions5........................................................
Appendix A Abbreviations45................................................................
TP-7191 4/21Table of Contents4
Safety Precautions and Instructions
IMPORT ANT SAFETY INSTRUCTIONS.
Electromechanicalequipment,
including generator sets, transfer
switches, switchgear, and accessories,
can cause bodily harm and pose
life-threateningdangerwhen
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 hasseveral types of safety
precautions and instructions: Danger,
Warning, Caution, and Notice.
DANGER
DANGERindicatesahazardous
situation which, if not avoided, will
result in death or serious injury.
WARNING
WARNING indicates a hazardous
situation which, if not avoided, could
result in death or serious injury.
CAUTION
CAUTION indicatesa hazardous
situation which, if not avoided, could
result in minor or moderate injury.
NOTICE
NOTICE is used to address practices
not related to physical injury.
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
publicationtoimproveoperator
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.
Disablingthegeneratorset.
Accidentalstartingcancause
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
switchtotheOFFposition.
(2) Disconnect the power to the battery
charger.(3) Remove the battery
cables,negative(- )leadfirst.
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)
Disablingthegeneratorset.
Accidentalstartingcancause
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)
Disablingthegeneratorset.
Accidentalstartingcancause
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
batterycharger,ifequipped.
(5) Removethebatterycables,
negative (- ) lead first. Reconnect the
negative(- )leadlastwhen
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-7191 4/215Safety Precautions and Instructions
Grounding electrical equipment.
Hazardous voltagewill cause severe
injury or death.Electrocution is
possiblewheneverelectricityis
present. Ensure you comply with all
applicablecodesandstandards.
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.
Shortcircuits.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
makingadjustmentsorrepairs.
Remove all jewelry before servicing the
equipment.
Makinglineorauxiliary
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.
Servicingthetransferswitch.
Hazardous voltagewill 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
generatorsetmastercontroller
switchesto the OFF position.(2)
Disconnect powerto allbattery
chargers. (3) Disconnect all battery
cables,negative (- )leadsfirst.
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)
Servicingthetransferswitch.
Hazardous voltagewill 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) Pressthe
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)
Testingliveelectricalcircuits.
Hazardous voltage or current will
cause severe injury or death. Have
trained and qualified personnel take
diagnosticmeasurementsoflive
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
transferswitchformaintenance
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 switchwhen serviceis
completed.
TP-7191 4/216Safety Precautions and Instructions
NOTICE
Foreignmaterialcontamination.
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.
Electrostaticdischarge(ESD)
damages electronic circuit boards.
Preventelectrostaticdischarge
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-7191 4/217Safety Precautions and Instructions
Notes
TP-7191 4/218Safety Precautions and Instructions
Introduction
This manual provides installation instructions for the
Kohlerr Model KSSB Automatic Transfer Switch (ATS).
Model KSSB transfer switches are equipped with the
Kohler MPACr 1200 controller.
Model KSSB is used in some places in this manual to
indicate that this document applies to an updated
version of the model KSS automatic transfer switch. The
letter B is NOT used in the model designation or Quick
Ship (QS) specification numbers used for ordering the
product.
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 prescribed 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 Literature
A separate manual covers the transfer switch controller
and related accessories. The Service Manual contains
service instructions for transfer switch power switching
devices and electrical controls.
The following table lists the part numbers for related
literature.
Kohler Asia Pacific Headquarters
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-7191 4/2110 Service Assistance
Section 1 Product Description
1.1Purpose
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. When the emergency (standby) source reaches
acceptable levels and stabilizes, the ATS transfers the
load from the normal (preferred) source to the
emergency (standby) source. The AT S 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.
Figure 1-2 shows a typical installation block diagram.
Normal
(Utility)
Power
Switching
Device
Power
Emergency
(Generator)
Power
Automatic Transfer Switch
To Load
Generator
Start Generator
Electrical
Controls
TS-003
Figure 1-2 Typical ATS Block Diagram
1.2Nameplate
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.
Figure 1-1 Automatic Transfer Switch
Copy the model designation, serial number, and
accessory information from the nameplate to the spaces
provided in the Product Identification Information
section inside the frontcover of this manual for use when
requesting service or parts.
Record the transfer switch model designation in the boxes. The transfer switch model designation defines
characteristics and ratings as explained below.
Poles
Note: The letter B is not used after KSS in the model designation shown on the ATS nameplate or used for
ordering the product.
Sample Model Designation: KSS-AMTA-0400S
Model
K:Kohler
Mechanism
S:Standard (Specific Breaker)
Transiti on
S:Standard
Controller
A:
Decision-Makerr MPAC 1200, Automatic
B:
Decision-Makerr MPAC 1200, Non-Automatic
Voltage/Frequency
C:208 Volts / 60 HzK:440 Volts/60 Hz
D:220 Volts / 50 HzM:480 Volts /60 Hz
F:240 Volts / 60 HzN:600 Volts / 60 Hz
G:380 Volts/50 HzP:380 Volts /60 Hz
H:400 Volts / 50 HzR:220 Volts / 60 Hz
J:416 Volts / 50 HzS:400 Volts/60 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 1D:NEMA 4
B:NEMA 12F:NEMA 4X
C:NEMA 3RG:Open Unit
Current, Amps
003002000600
007002300800
010402601000
015004001200
Connections
S:Standard
Note: Some selections are not available for every model.
Contact your Kohler distributor for availability.
TP-7191 4/2112 Section 1 Product Description
Section 2 Installation
2.1Introduction
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 Connectthenormalpowersource(utility),
emergency power source (generator set), and load
circuits.
D Connect accessories, if provided.
D Check voltages and operation.
2.2Receipt of Unit
2.2.1Inspection
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
exterior and interior for s hipping damage. If damage
and/or rough handling is evident, immediately file a
damage claim with the transportation company.
2.2.2Lifting
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.
Protect the switch against damage before and during
installation.
Note: A protective device such as 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.
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.
Refer to Figure 2-1 for the approximate weight of the
transfer switch in a Type 1 enclosure. For open units and
other enclosures, refer to the dimension drawing. Use a
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.
Weight kg (lb.)
Amps
30- 20028(62)30(65)31(68)
230
(208- 480V)
230(600V)
260- 600
800220(485)231(510)238(525)
1000—231(510)238(525)
1200—356(785)379(835)
2-Pole3-Pole4-Pole
52(115)56 (123)59(131)
179(395)183(403)188(414)
Figure 2-1 Approximate Weights, Type 1 Enclosures
TP-7191 4/2113Section 2 Installation
2.2.3Storage
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.
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 cable
bending space and clearance to live metal parts.
Environmental Specifications
Operating Temperature-20Cto70C(-4Fto158F)
Storage Temperature-40Cto85C(-40Fto185F)
Humidity5% to 95% noncondensing
Figure 2-2 Environmental Specifications
2.2.4Unpacking
Allow the equipment to warm to room temperature for at
least24 hoursbeforeunpackingtoprevent
condensation on the electrical apparatus. Use care
when unpacking to avoid damaging transfer switch
components. Remove d irt 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 switch.
Cleaning with compressed air can cause debris
to lodge in the components and damage the
switch.
For 600- 800 amp transfer switches, remove the lag
screws that secure the transfer switch to the shipping
skid. For 1000- 1200 amp transfer switches, open the
enclosure door to remove the lag screws that secure the
transfer switch to the skid.
2.3Installation
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.
Outdoorinstallations.Transferswitcheswith
NEMA 3R, 4, or 4X enclosures can be installed
outdoors. Inlocations withvery highambient
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. Refer
to the applicable enclosure outline drawing for all
mounting details including door opening space.
For bottom cable entry, if used, install conduit stubs in
the foundation. Refer to the enclosure dimension
drawing f or the conduit stub locations. When pouring a
concrete floor, use interlocking conduit spacer caps or a
wood or metal template to maintain proper conduit
alignment.
Installationofseismicallycertifiedtransfer
switches. Seismic certification must be requested
when the transfer switch is ordered. See Section 2.4 and
thetransferswitchdimension(ADV)drawingsfor
additional installation requirements for transfer switches
with seismic certification.
Install the ATS. Mount 30- through 600-amp transfer
switches to a wall or other rigid vertical supporting
structure. Clearance holes through the back of each
enclosure are provided for mounting. Level the
enclosure and use shims if needed to make it plumb.
Verify that the door hinges are vertical to avoid d istortion
of the enclosure or door.
Bolt 800- through 1200-amp automatic transfer
switches directly to floor mounting pads. Use shims if
needed to plumb the enclosure. Verify that the door
hinges are vertical to avoid distortion of the enclosure or
door.
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 voltageand frequencyor thenominal
emergency source voltage and frequency shown on the
generator set nameplate.
TP-7191 4/2114 Section 2 Installation
2.4IBC Seismic Certification
Automatic transfer switches with seismic certification
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:
ACI: American Concrete Institute
IBC: International Building Coder
Design spectral response acceleration at short
S
DS:
period, as determined in Section 1615.1.3 of
the IBC
:Equipment response modification factor
R
p
:Equipment importance factor
I
p
:In-structure equipment amplification factor
a
p
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.
SuggestedmanufacturersincludeSimpson,
Ramset, and Hilti.
2. Anchorsmust be installed to aminimum
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.
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.
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
reinforcedstructural concretefloorthatis
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-7191 4/2115Section 2 Installation
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