Kohler KUS, KUP Spec Sheet

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Models:

KUS/KUP

70 to 4000 Amperes

Service Entrance Rated

Automatic Transfer Switches

TP-7280 1/24

Operation and

Installation

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Product Identification Information

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: ____________________________________________________________

Controller Identification

Record the controller description from the transfer switch operation manual, spec sheet, or sales invoice. Controller Description________________________________________________________

Accessories

 Alarm Board  Controller Disconnect Switch  Current Monitoring  Digital Meter  Engine Start Circuit Monitor  Heater  IBC Seismic Certification  I/O Module, Standard (max. 4) qty: ____________________________  I/O Module, High Power (max. 4) qty: __________________________  Load Shed  Surge Protection Device (SPD)  User Interface Cover  ________________________________________________________  ________________________________________________________  ________________________________________________________  ________________________________________________________

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TP-7280 1/24 3

Table of Contents

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

Introduction ................................................................................................................................................................................ 9

Service Assistance................................................................................................................................................................... 10

Section 1. Product Description ............................................................................................................................... 11

1.1 General Description ................................................................................................................................................ 11

1.2 Overcurrent Protection ........................................................................................................................................... 12

1.3 Nameplate .............................................................................................................................................................. 13

1.4 Model Designation ................................................................................................................................................. 14

Section 2. Installation .............................................................................................................................................. 15

2.1 Introduction ............................................................................................................................................................ 15

2.2 Receipt of Unit ........................................................................................................................................................ 15

2.2.1 Inspection................................................................................................................................................. 15

2.2.2 Lifting ....................................................................................................................................................... 16

2.2.3 Storage .................................................................................................................................................... 17

2.2.4 Unpacking ................................................................................................................................................ 17

2.3 Installation .............................................................................................................................................................. 18

2.3.1 IBC Seismic Certification ......................................................................................................................... 18

2.4 Manual Operation, Model KUS Standard-Transition Switches ............................................................................... 20

2.4.1 Manual Operation, 70-225 Amp Standard-Transition Switches ............................................................... 20

2.4.2 Manual Operation, 225A/600V and 250-4000 Amp Standard-Transition Switches .................................. 21

2.5 Manual Operation, Model KUP Programmed-Transition Switches ......................................................................... 24

2.5.1 Manual Operation Test Procedure, 150-1200 Amp Programmed-Transition Transfer Switches .............. 25

2.5.2 Manual Operation Test Procedure, 1600-4000 Amp Programmed-Transition Transfer Switches ............ 28

2.6 Controller Connections ........................................................................................................................................... 29

2.6.1 Controller Input and Output Connections ................................................................................................. 30

2.6.2 Harness Connection ................................................................................................................................ 30

2.6.3 Controller Ground .................................................................................................................................... 31

2.7 Service Disconnect Circuit Connections ................................................................................................................. 31

2.8 External Battery Supply Module (EBSM) ................................................................................................................ 33

2.9 Electrical Wiring ..................................................................................................................................................... 34

2.9.1 Source and Load Connections ................................................................................................................. 35

2.9.2 Engine Start Connection .......................................................................................................................... 38

2.9.3 Auxiliary Contacts ................................................................................................................................ .... 40

2.10 Communication and Accessory Connections ......................................................................................................... 42

2.11 Functional Tests ..................................................................................................................................................... 42

Section 3. Three-Source Systems ................................ ................................................................ .......................... 43

3.1 Three-Source Systems ........................................................................................................................................... 43

3.2 Three Source Engine Start Mode ........................................................................................................................... 43

3.2.1 Mode 1 ..................................................................................................................................................... 43

3.2.2 Mode 2 ..................................................................................................................................................... 43

3.3 Preferred Source Toggle ........................................................................................................................................ 43

3.4 Three Source System Test and Exercise ............................................................................................................... 44

3.4.1 Unloaded Test .......................................................................................................................................... 44

3.4.2 Loaded Test ............................................................................................................................................. 44

3.4.3 Unloaded Exercise ................................................................................................................................... 44

3.4.4 Loaded Exercise ...................................................................................................................................... 44

3.5 Three-Source System Connection ......................................................................................................................... 46

3.6 ATS1 and ATS2 System Setup .............................................................................................................................. 50

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Section 4. Communication and Accessory Connections ..................................................................................... 51

4.1 Introduction ............................................................................................................................................................ 51

4.2 Communication Connections ................................................................................................................................. 51

4.2.1 USB Port SiteTech Connection ................................................................................................................ 51

4.2.2 Modbus Connection ................................................................................................................................. 52

4.2.3 Ethernet Connection ................................................................................................................................ 54

4.3 Accessory Modules ................................................................................................................................................ 56

4.3.1 Accessory Module Mounting .................................................................................................................... 56

4.3.2 Input/Output (I/O) Modules....................................................................................................................... 58

4.3.3 External Battery Supply Module (EBSM) ................................................................................................. 61

4.3.4 Alarm Module ........................................................................................................................................... 61

4.4 Load Shed (Forced Transfer to OFF) ..................................................................................................................... 63

4.5 Heater .................................................................................................................................................................... 65

4.6 Engine Start Circuit Monitoring System .................................................................................................................. 67

4.7 Other Accessories .................................................................................................................................................. 67

Section 5. Scheduled Maintenance ........................................................................................................................ 69

Section 6. Functional Tests and Setup .................................................................................................................. 71

6.1 Introduction ............................................................................................................................................................ 71

6.2 Manual Operation Test ........................................................................................................................................... 71

6.3 Voltage Check ........................................................................................................................................................ 72

6.4 Lamp Test .............................................................................................................................................................. 73

6.5 Automatic Operation Test ....................................................................................................................................... 74

6.6 System Setup ......................................................................................................................................................... 74

6.7 Exerciser Setup ...................................................................................................................................................... 74

6.8 User Interface Cover .............................................................................................................................................. 74

6.9 Startup Notification ................................................................................................................................................. 74

Section 7. Operation ................................................................................................................................................ 75

7.1 Transfer Switch Operation ...................................................................................................................................... 75

7.1.1 Normal Operation ..................................................................................................................................... 75

7.1.2 Overcurrent Trip ....................................................................................................................................... 75

7.1.3 Energy Reduction Maintenance Setting (ERMS) System ........................................................................ 76

7.2 Service Disconnect Switch Operation .................................................................................................................... 79

7.2.1 Service Disconnect Procedure ................................................................................................................. 80

7.2.2 Service Reconnect Procedure ................................................................................................................. 81

7.3 Controller Disconnect Switch Operation ................................................................................................................. 83

Appendix A. Abbreviations ......................................................................................................................................... 85

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TP-7280 1/24 5

Safety Precautions and Instructions

Read and follow all safety precautions and instructions. SAVE THESE INSTRUCTIONS.

IMPORTANT SAFETY 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 a hazardous 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 indicates a 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 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-Maker® 3+ and 550 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.

(APM402, APM603, RDC2, and Decision-Maker® 3000, 3500, and 6000 Controllers)

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

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.

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-Maker® 8000 Controller)

Hazardous Voltage/Moving Parts

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.

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-Maker® 3+ and 550 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.

(APM402, APM603, RDC, DC, RDC2, DC2, Decision-Maker® 3000, 3500 and 6000 Controllers)

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TP-7280 1/24 7

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.

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Page 9

TP-7280 1/24 9

Introduction

This manual provides operation and installation instructions for the following Kohler® Contactor-based Service Entrance Rated Automatic Transfer Switches (ATS):

• Model KUS standard-transition service entrance rated ATS.

• Model KUP programmed-transition service entrance rated ATS.

The transfer switch is equipped with the Kohler® Decision-Maker® MPAC 1500 transfer switch 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 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. Separate manuals contain service information for transfer switch power switching devices and electrical controls. For replacement parts, refer to the Kohler Power Parts online parts system.

The following table lists the part numbers for related literature.

Literature Item

Part Number

Specification Sheet, Decision-Maker® MPAC 1500 Controller

G11-128

Specification Sheet, Model KUS/KUP ATS

G11-153

Operation Manual, Decision-Maker® MPAC 1500 Controller

TP-6883

Installation Manual, Model KUS/KUP

TP-7280

Wiring Diagram Manual, Model KUS/KUP

TP-7281

Service Manual, Model KUS/KUP

TP-7282

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Service Assistance

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

• Visit the Kohler Co. website at KOHLERPower.com.

• Look at the labels and decals on your Kohler product

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

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

• Outside the US and Canada, call the nearest

regional office.

Headquarters Europe, Middle East, Africa (EMEA)

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

Asia Pacific

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

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Section 1. Product Description

1.1 General Description

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.

Model KUS/KUP automatic transfer switches employ a contactor-based power switching unit and the Kohler Decision Maker® 1500 controller to automatically transfer system load to a generator supply in the event of a utility supply failure. 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 ATS continuously monitors the Normal (preferred) source. When the Normal (preferred) source returns and stabilizes, the ATS transfers the load back to Normal. After transferring the load back to Normal (preferred), the ATS removes the generator start signal, allowing the generator set to shut down.

Model KUS/KUP service entrance rated transfer switches have integral overcurrent protection with a shunt trip module supplied for the utility source as standard equipment. This allows installation at the point of service entrance and eliminates the need to have a separate upstream utility source circuit breaker or disconnect. Refer to the Overcurrent Protection Section for more information.

Figure 1 shows examples of some typical service entrance rated ATSs. The utility circuit breaker location varies for different models.

Figure 2 shows a typical installation block diagram.

Figure 1 Typical Service Entrance-Rated Automatic Transfer Switches

70-225 Amps

1600-3000 Amps

800-1200 Amps

1. Utility Circuit Breaker

2. Service Disconnect Switch

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Figure 2 Service Entrance Rated ATS Block Diagram

1.2 Overcurrent Protection

Model KUS/KUP service entrance rated transfer switches have an integral overcurrent protection with shunt trip supplied on the utility source as standard. An upstream overcurrent protection device is required for the generator source. The type of overcurrent protection varies with ATS amperage size and optional features specified. Transfer switches rated 70A through 200A use nonadjustable thermal-magnetic type trip units (standard) or electronic trip units (optional). Transfer switches rated 250A through 4000A use adjustable electronic type with long time and instantaneous trip unit elements. Ground fault protection is standard on 1000 Amp and larger units. See the Model KUS/KUP Specification Sheet for available circuit breaker sizes and trip types.

For overcurrent trip and circuit breaker reset information, see the Operation Section of this document.

Generator

Emergency

(Generator)

Circuit Breaker

Automatic Transfer Switch

Normal (Utility)

Power

Electrical

Controls

To Load

Power Switching Device (Contactor)

TP-7280

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TP-7280 1/24 13

1.3 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 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 3 Typical Transfer Switch Nameplate

GM21291

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1.4 Model Designation

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

Sample Model Designation: KUS-DNTA-0400S-XS

Model

Enclosure

Kohler

A: NEMA 1

D: NEMA 4

B: NEMA 12

F: NEMA 4X

Mechanism

C: NEMA 3R

Service Entrance, Utility

Current, Amps

Transition

0070

0250

1600

Standard

0100

0400

2000

Programmed

0150

0600

2600

0200

0800

3000

Controller

0225

1200

4000

Decision-Maker® MPAC 1500, Automatic

Connections

Voltage/Frequency

S: Standard

208 Volts /60 Hz

440 Volts /60 Hz

220 Volts /50 Hz

480 Volts /60 Hz

Utility Disconnect

240 Volts /60 Hz

600 Volts /60 Hz

U: 80% TM

380 Volts /50 Hz

380 Volts/60 Hz

V: 100% TM

400 Volts/50 Hz

220 Volts/60 Hz

W: 80% ET

416 Volts /50 Hz

400 Volts/60 Hz

X: 100% ET

Number of Poles/Wires

Fault Level

2 Poles/3 Wires, Solid Neutral

S: Standard

3 Poles/4 Wires, Solid Neutral

H: High Fault

4 Poles/4 Wires, Switched Neutral

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

Model

Mechanism

Transition Poles

Enclosure

Current

Rating

Connections

Utility

Disconnect Fault Level

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TP-7280 1/24 15

Section 2. Installation

2.1 Introduction

Kohler® 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:

• Unpack and inspect the transfer switch upon receipt.

• Verify that the transfer switch voltage and frequency ratings match the voltages and frequencies of the sources.

• Install the transfer switch.

• Check the manual operation.

• Connect the controller harness and ground lead.

• Connect the generator set engine start leads.

• Connect the normal power source (utility), emergency power source (generator set), and load circuits.

• Connect accessories, if provided.

• Check voltages and operation.

Protect the switch against damage before and during installation. The functional tests in the functional tests and setup section 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 exterior and interior for shipping damage. If damage and/or rough handling is evident, immediately file a damage claim with the transportation company.

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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

Refer to Figure 4 for the approximate weight of the transfer switch in a Type 1 enclosure. 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.

Model

Amps

NEMA Type

Weight kg (lb.)

2-Pole

3-Pole

4-Pole

KUS

70-225

66 (145)

67 (148)

69 (151)

90 (199)

92 (202)

93 (205)

137 (302)

138 (305)

140 (308)

225-600

223 (492)

227 (500)

232 (511)

237 (522)

240 (530)

245 (541)

245 (540)

249 (549)

254 (560)

800-1200

488 (1075)

497 (1095)

519 (1145)

501 (1105)

510 (1125)

533 (1175)

517 (1140)

526 (1160)

549 (1210)

1600-2000

—

846 (1865)

875 (1930)

—

982 (2165)

1011 (2230)

2500-3000

—

891 (1965)

921 (2030)

—

1027 (2265)

1057 (2330)

4000

—

1581 (3485)

1662 (3665)

—

1762 (3885)

1844 (4065)

KUP

150-600

230 (507)

234 (515)

188 (526)

243 (537)

247 (545)

188 (556)

245 (540)

249 (549)

188 (560)

800-1200

499 (1100)

512 (1130)

238 (1184)

512 (1130)

526 (1160)

238 (1214)

528 (1165)

542 (1195)

485 (1249)

1600-2000

—

907 (2000)

556 (2065)

—

1043 (2300)

1073 (2365)

2500-3000

—

977 (2155)

1007 (2220)

—

1113 (2455)

1143 (2520)

4000

—

1667 (3675)

1748 (3855)

—

1848 (4075)

1930 (4255)

Figure 4 Approximate Weights

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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 5 for acceptable storage temperatures.

Environmental Specifications

Operating Temperature

-20°C to 70°C (-4°F to 158°F)

Storage Temperature

-40°C to 85°C (-40°F to 185°F)

Humidity

5% to 95% noncondensing

Figure 5 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 switch. Cleaning with compressed air can cause debris to lodge in the components and damage the switch.

Check for and remove lag screws that secure the transfer switch to the shipping skid. Lag screws may be found on the outside or the inside of the enclosure.

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2.3 Installation NOTICE

Foreign material contamination. Cover the transfer switch during installation to keep dirt, grit, metal drill chips, and other debris

NOTICE

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 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. 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 for 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.

Installation of IBC seismically certified transfer switches. IBC seismic certification must be requested when the transfer switch is ordered. See the IBC Seismic Certification section and the transfer switch dimension (ADV) drawings for additional installation requirements for transfer switches with IBC seismic certification.

Install the ATS. Mount 70-through 225-amp (except 225A/600V) 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 distortion of the enclosure or door.

Bolt 225A/600V and 250-amp or larger 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.

2.3.1 IBC 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 Code® SDS: Design spectral response acceleration at short period, as determined in Section 1615.1.3 of the IBC Rp: Equipment response modification factor Ip: Equipment importance factor ap: In-structure equipment amplification factor Refer to the International Building Code® for more information.

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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.

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 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.

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2.4 Manual Operation, Model KUS Standard-Transition Switches

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 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.

Note: A manual operation handle is provided on the transfer switch for maintenance purposes only. Do not use the manual operation handle to transfer the load with the power connected.

Use the manual operation handle to check the manual operation before energizing the transfer switch. Use the following manual operation procedures to verify that the contactor operates smoothly without binding.

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

2.4.1 Manual Operation, 70-225 Amp Standard-Transition Switches

The 70-225 amp standard-transition models have an attached manual operating handle. See Figure 6. Note:

For 225A/600V models, see the Manual Operation, 225A/600V and 250-4000 Amp Standard-Transition Switches section.

Manual Operation Test Procedure, 70-225 Amp Transfer Switches

1. Disable the generator set to prevent starting, open the line circuit breaker on the generator set, and perform the service disconnect procedure to disconnect all power sources before manually operating the transfer switch.

2. To manually operate the transfer switch, turn the attached handle by hand. See Figure 6. The maintenance handle turns in the opposite direction of the weight. It should operate smoothly without any binding. If it does not, check for shipping damage or construction debris.

3. Return the transfer switch to the Normal position.

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TP-7280 1/24 21

Figure 6 Manual Operation Handle, 70-225 Amp Model KUS

2.4.2 Manual Operation, 225A/600V and 250-4000 Amp Standard-Transition Switches

DANGER

Hazardous voltage. Will cause severe injury or death.

Disconnect all power sources before opening the enclosure.

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.

The 250-4000 amp standard-transition models use a detachable manual operating handle.

Manual Operation Test Procedure, 225A/600V and 250-1200 Amp Standard-Transition Transfer Switches

1. Disable the generator set to prevent starting and disconnect all power sources before manually operating the transfer switch.

2. Remove the maintenance handle from the clip(s) on the left side of the transfer switch frame. See Figure 7.

3. 225 (600V) and 250--600 amp switches: See Figure 8. Insert the maintenance handle into the hole in the shaft on the left side of the operator.

800-1200 amp switches: See Figure 9. Insert the maintenance handle into the hole in the molded hub on the left side of the operator.

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. See Figure 10.

5. Return the transfer switch to the Normal position.

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

Note: Verify that the maintenance handle has been removed before proceeding.

Handle

Position indicators

Floating weight

Weight

229

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22 TP-7280 1/24

Figure 7 Detachable Handle Storage (typical)

Figure 8 Manual Operation, 250-600 Amp Model KUS

Storage clip(s)

Maintenance handle

202

Handle

Position indicators (right side of contactor):

O = open, C = closed

283

Hub

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TP-7280 1/24 23

Figure 9 Manual Operation, 800-1200 Amp Model KUS

ATS Position

Handle

Indicators

Normal

E : O

Upper contacts open

N : C

lower contacts closed

Emergency

E : C

Upper contacts closed

N : O

lower contacts open

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

Figure 10 Maintenance Handle Positions, 260-1200 Amp Model KUS

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

1. Disable the generator set to prevent starting and disconnect all power sources before manually operating the transfer switch.

2. Remove the maintenance handle from the clip(s) on the left side of the transfer switch frame. See Figure 7.

3. See Figure 11. Insert the maintenance handle into the hole in the molded hub.

4. Move the maintenance handle 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.

5. Return the transfer switch to the Normal position.

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

Note: Verify that the maintenance handle has been removed before proceeding.

Maintenance handle

202

Hub

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24 TP-7280 1/24

Figure 11 Manual Operation, 1600-4000 Amp Model KUS

2.5 Manual Operation, Model KUP Programmed-Transition Switches

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 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.

Programmed-transition switches have two operators, Normal and Emergency, on the left side of the contactor assembly. Mechanical interlocks prevent closing both operators at the same time. Refer to Figure 12 for typical locations of the Normal and Emergency operators.

Programmed-transition models use a detachable manual operating handle. Position indicators on the right side of the contactor assembly show the positions of the operators. See the figure titled: Position Indicators.

Insert maintenance handle until spring is fully compressed

127a

Emergency contact

position indicator

Slide hub onto shaft

Normal contact position indicator

Position indicators on LEFT side of contactor show contacts OPEN or CLOSED

Turn counterclockwise to Emergency.

Turn clockwise to Normal.

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TP-7280 1/24 25

Figure 12 Model KCP Manual Operation (typical)

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

Refer to Figure 13 through Figure 15 during the following procedure. Check the operation of both operators by following the instructions below for both the Normal and Emergency operators in the

following sequence:

1. Disable the generator set to prevent starting and disconnect all power sources before manually operating the transfer switch.

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

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

4. Return the Emergency operator to the open position and the Normal operator to the closed position.

5. Remove the maintenance handle and store it in the place provided on the switch.

Figure 13 Position Indicators

Handle storage location

Emergency Operator (shown open)

Insert the maintenance handle into the hub.

UPPER SHAFT UP opens the

Emergency source contacts

DOWN closes the Emergency source contacts

Normal Operator (shown open)

LOWER SHAFT UP closes the Normal source contacts

DOWN opens the Normal source contacts

Emergency contact indicator Normal contact indicator

O = Open; C = Closed

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26 TP-7280 1/24

Transfer Switch Position

Interlocked Shafts

Maintenance Handle

Shaft Indicators

Normal

E : O

upper contacts open

N : C

lower contacts closed

Load Disconnected

E : O

upper contacts open

N : O

lower contacts open

Emergency

E : C

upper contacts closed

N : O

lower contacts open

Note:

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

Note:

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

Figure 14 Maintenance Handle Positions, 150-600 Amp Model KUP Only. ALL POWER MUST BE OFF !

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TP-7280 1/24 27

Transfer Switch Position

Interlocked Shafts

Maintenance Handle

Shaft Indicators

Normal

E : O

upper contacts open

N : C

lower contacts closed

Load Disconnected

E : O

upper contacts open

N : O

lower contacts open

Emergency

E : C

upper contacts closed

N : O

lower contacts open

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

Note:

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

Figure 15 Maintenance Handle Positions, 800-1200 Amp Model KUP Only. ALL POWER MUST BE OFF !

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

Check the operation of both operators by following the instructions below for both the Normal and Emergency operators. Refer to Figure 16 during this procedure.

1. Disable the generator set to prevent starting and disconnect all power sources before manually operating the transfer switch.

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

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

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

a. Pull out the shaft to engage the emergency source contacts. b. Push in the shaft to engage the normal source contacts.

5. Grasp the handle firmly with both hands and rotate down:

a. Rotate counterclockwise to open the contacts. b. Rotate clockwise to close the contacts.

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

7. Return the CN transfer switch to the C (closed) position. Return the CE transfer switch to the O (open) position. Remove the manual operator handle and store it on the transfer switch in the place provided.

Figure 16 Manual Operation, 1600-4000 Amp Model KUP

Hub. Slide onto the shaft and insert the pin.

Manual operating handle. Insert until spring is fully compressed.

129

Emergency contacts position

indicator

Normal contacts position indicator

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

Rotate handle down, clockwise to close or counterclockwise to open contacts.

Turn counterclockwise to OPEN contacts.

Turn clockwise to CLOSE contacts.

Contact position indicators (left side)

OPEN

CLOSED

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TP-7280 1/24 29

2.6 Controller Connections

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

The controller is mounted in a plastic housing on the inside of the transfer switch enclosure door. Figure 17 shows the locations of the connectors on the controller. It is not necessary to open the cover to access the Ethernet,

Modbus®, 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.

Figure 17 Controller

Modbus is a registered trademark of Schneider Electric.

Connection for optional current sensing kit

Access openings to optional RJ-45 connector

GM85884

Optional I/O module connection P16

RS-485 connection TB2

Standard input/output connection Latch

Ground wire

Contactor harness connection

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30 TP-7280 1/24

2.6.1 Controller Input and Output Connections

The controller provides connections for two programmable inputs and two programmable outputs. On service entrance KUS and KUP models, one input and two outputs are factory connected and must not be changed.

Each input has a signal and a return connection. The outputs are C form contacts with ratings of 500 mA @ 120 VAC. See Figure 19 for connections. Use #12-24 AWG wire and tighten the connections to 0.5 Nm (4.4 in. lbs.).

See the controller illustration in a previous section for the connector locations and Figure 18 for the I/O connection specifications. For additional input and output connections, optional input/output modules are available. See the Accessory Modules section for instructions.

Main Board I/O Specifications

Output contact type

Isolated form C (SPDT)

Output contact rating

1 amp@30 VDC, 500 mA @120 VAC

I/O terminals wire size

#12-24 AWG

Figure 18 Main Board I/O Specifications

Figure 19 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 the figure titled: Contactor Harness and Controller Ground Connections.

Note: Verify that the power is disconnected before connecting or disconnecting the contactor harness.

Output 2 C

Output 2 NO

NC = normally closed NO = normally open C = common

TB1

6866

Output 2 NC

Output 1 NO

Output 1 C

Output 1 NC

Input 2B

Input 2A

Input 1B

Input 1A

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TP-7280 1/24 31

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.

Figure 20 Contactor Harness and Controller Ground Connections

2.7 Service Disconnect Circuit Connections

The External Battery Supply Module is factory-supplied on every unit to maintain power to the controller, provide the proper status indication (Not in Auto, Service Disconnect), and power the Source Disconnect light. The service disconnect circuit is connected to the factory-installed External Battery Supply Module.

The service disconnect circuit terminal block is mounted on the inside of the enclosure door. See Figure 21.

• Connect one 12 VDC battery to the service disconnect circuit terminals 1 and 2; see Figure 22Figure 21. The battery may be the generator set engine starting battery or another battery provided for this purpose. The battery must be connected to a battery charger to ensure that DC power is always available.

• Connect terminals 3 and 4 to the generator set controller’s fault relay.

• Terminals 5 through 7 provide additional form C contacts to indicate the state of the service disconnect relay. These

connections are for customer-supplied equipment and are optional.

When the operator moves the service disconnect switch to the Service Disconnect position, the ATS controller energizes the shunt trip coil, which trips (opens) the utility circuit breaker. The shunt trip relay is also connected to an input on the ATS controller. When the switch is in the Service Disconnect position, the relay closes to signal a fault which prevents the generator set from starting. The ATS remains in the Normal position.

Turning the service disconnect switch back to AUTO will allow the generator set to be reset (at the generator set controller) and the engine to start. The ATS will transfer the load to Emergency. Then the Utility breaker can be reset. Normal time delays and retransfer to normal would occur. The Utility breaker cannot be reset if the service disconnect switch is not in the AUTO position.

Contactor Harness Connection

Ground Connection

GM85844

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32 TP-7280 1/24

Figure 21 Service Disconnect Circuit Connection Location, Typical (on the inside of the ATS enclosure door)

Figure 22 Service Disconnect Circuit Connections

GM117957

Service disconnect circuit terminal block location, typical

Inside of enclosure door shown

GM120212

Connect to generator

fault relay

Optional connection

Connect 12 VDC battery

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TP-7280 1/24 33

2.8 External Battery Supply Module (EBSM)

The external battery supply module connects to the generator set engine start battery or other battery to provide 12 VDC power to the ATS controller when neither the Normal nor the Emergency source is available. An external battery supply module (EBSM) is standard, factory-installed equipment for the KUS/KUP service entrance transfer switches. The EBSM is factory-connected to the service entrance circuit breaker shunt trip circuit.

The installer must connect a 12 VDC battery (typically the generator set engine starting battery) to the shunt trip circuit as described in the Shunt Trip Circuit Section of this document.

The EBSM produces 2 amps at 12 VDC with 9-36 VDC input. The EBSM input is reverse-polarity protected. If the battery connections are reversed, red LED1 or LED2 will light. See Figure 21 for the location of the LED indicators.

The EBSM outputs a low battery voltage signal when the external battery voltage falls below 11 VDC for a 12-volt system. The battery voltage selection DIP switch SW11-1 allows selection between 12-volt and 24-volt systems for low battery voltage

sensing and indication. See Figure 23 and Figure 21. Confirm that voltage selector switch SW11-1 is set to OFF (12 VDC).

DIP Switch SW11-1 Setting

Battery Voltage

OFF

12 VDC

24 VDC

Figure 23 Battery Voltage Selection Note:

The EBSM has no address switches but must be the last accessory module board on the bus. See the Accessory Module Mounting section for more information, if needed.

Figure 24 External Battery Supply Module

LED indicators

Battery input connection terminal block TB13

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

Connector P20

GM42227-A

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2.9 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: 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.

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 pole covers from the transfer switch for cabling. If you do remove them, reinstall them carefully.

WARNING

Accidental starting. Can cause severe injury or death.

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.

DANGER

Hazardous voltage. Will cause severe injury or death.

Disconnect all power sources before opening the enclosure.

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.

NOTICE

Foreign material contamination. Cover the transfer switch during installation to keep dirt, grit, metal drill chips, and other debris

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2.9.1 Source and Load Connections

Note: Refer to the transfer switch dimension drawing to identify the connection points for the Normal and Emergency source and load connections.

Determine the cable size. Refer to the 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 transfer switch lugs. 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.

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. Refer to the transfer switch dimension drawing for connecting lug locations. Connect the utility source cables to the service entrance circuit breaker, which is located in a separate compartment from the power switching device. The utility circuit breaker is factory-connected to the Normal source side of the contactor. Connect the emergency source and load cables to the power switching device.

Figure 25 Typical Utility Power Connections to the Service Entrance Circuit Breaker (see the ADV drawing for your model) Leave sufficient slack in the power leads to reach all of the power connecting lugs on the utility source side circuit breaker and

the power switching device. Test the power conductors before connecting them to the transfer switch. Installing power 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.

150-600 Amp Models

70-225 Amp Models

ADV-9984

Normal Power

Connection

Normal Power Connection

ADV-9983

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36 TP-7280 1/24

Install the cable spacers provided with 70-225 amp KUS transfer switches as shown in Figure 26.

Figure 26 Cable Spacers for 70-225 KUS Amp Switches 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 connections of any aluminum conductors.

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 phase sensitive load devices from malfunctioning or operating in reverse.

Tighten the lugs. Verify that all connections are consistent with drawings before tightening the lugs. Tighten the utility source cables to the torque values shown on the circuit breaker. Tighten all emergency source and load cable lug connections to the torque values shown on the label on the transfer switch. (See Figure 28 for a typical rating/torque label.) Carefully wipe off any excess joint compound after tightening the terminal lugs.

For load connections to bus bars, use a compression washer, flat washer, and a minimum grade 5 bolt and torque the connections to the values in Figure 27.

Bolt Size, inches

Bolt Torque

ft. lb.

1/4 7 9.5

5/16

16.3

3/8

27.1

1/2

67.8

5/8

128.8

3/4

155

210.2

Figure 27 Tightening Torque for Bus Bars

Cable spacers

127

1 ½ inch approximate

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TP-7280 1/24 37

Figure 28 Typical Rating/Torque Label

Torque specification

007

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38 TP-7280 1/24

2.9.2 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.

Prevent the generator set from starting by 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. On 70-200 amp models, the engine start terminals are located on the transfer switch contactor assembly and labeled with a decal. See Figure 29. On larger models, the engine start contacts and auxiliary contacts are located on the field-connection terminal block. See Figure 30 or the transfer switch dimension drawing for the location of the engine start contacts. Refer to the generator set installation manual for wire size specifications.

Engine Start Contacts

Contact Rating

2 A@30 VDC/250 VAC

Figure 29 Engine Start Contacts, 70-225 Amp KUS Switches

Engine start contacts 14 and 15 16 (do not use)

6126

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Figure 30 Field Connection Terminal Block Locations, Typical

225-600 Amp Switches

Field connection terminal block location

1600-3000 Amp Switches

ref ADV-9984

ref ADV-9986

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2.9.3 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.

Figure 31 lists the number of contacts available by ATS model and size (amps).

• On 70-225 Amp units, the contacts are located on the right side of the contactor. See Figure 32.

• On 225 A/600 V and 250-4000Amp units, the contacts are located on the field connection terminal block. See the figure

titled: Field Connection Terminal Block Locations, Typical. See Figure 34 for typical connections.

Refer to the wiring diagrams provided with the transfer switch for specific auxiliary contact connection information. Follow the wire size and tightening torque specifications shown on the decal on the transfer switch.

Auxiliary Position Indicating Contacts

(rated 10 amps @ 32 VDC/480 VAC)

Switch Rating, amps

Number of Contacts Indicating

Normal, Emergency

KUS

KUP

70-150

2, 2 — 150-225

2, 2

8, 8

225 (600 V)

8, 8

260-600

8, 8

800-1200

8, 8

1600-4000

8, 8

7, 7

Figure 31 Auxiliary Contacts

Figure 32 Auxiliary Contacts, 70-225 Amp Transfer Switches

STANDARD

1. Auxiliary contacts (contacts shown with contactor in Normal position)

STANDARD

OPTIONAL

6126

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TP-7280 1/24 41

Figure 33 Field Connection Terminal Block

Figure 34 Typical Auxiliary Contact Connection, 225- 4000 Amp Transfer Switches (see schematic diagram)

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

Engine start contacts TBF-1 and TBF-2

ref GM14691

COMMON

GM115517

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2.10 Communication and Accessory Connections

See the Communication and Accessory Connections section for accessory and communication connection instructions.

2.11 Functional Tests

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

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Section 3. Three-Source Systems

3.1 Three-Source Systems

The Decision-Maker® 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 the figure titled: Three-

Source System Diagram and Operation. 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 the External Battery Supply Module (EBSM) section.

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 the Three Source Engine Start Mode and Preferred Source Toggle sections.

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.

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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 Unloaded 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.

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TP-7280 1/24 45

Figure 35 Three-Source System Diagram and Operation

refGM52678

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

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3.5 Three-Source System 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 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.

See Figure 36 and Figure 37 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 36 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.

2. Three-source systems require the following input/ output connections to control the engine start commands for generator sets 1 and 2. Observe the polarity of all connections shown in Figure 37. 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. b. Connect one ATS1 programmable output from the controller to one ATS2 main logic board programmable

input as shown in Figure 37. 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). The ATS1 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 more details and illustrations for the External Battery Supply Module (EBSM) in the EBSM Section of this manual.

Note: If the battery connections are reversed, red LED1 or LED2 will light. Incorrect battery connections can damage the battery module.

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TP-7280 1/24 47

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

See the External Battery Supply Module (EBSM) section 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.

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Figure 36 Three-Source System Controller Connections

refGM52678

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TP-7280 1/24 49

Figure 37 Input and Output Connections for Three-Source Systems

3 Source System Disable

6883

Connect the ATS2 engine start contacts (on the contactor or the fieldconnection terminal block) to G2 engine start (ES) connections. See

Figure 36

G1 ES

ATS1 TB1 on logic board

ATS2 TB1 on logic board

Connect Output 1 terminals TB1-5 and TB1-6 on ATS 1 to Input 1 terminals TB1-1 and TB1-2 on ATS2.

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

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

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

ATS1

ATS2

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50 TP-7280 1/24

3.6 ATS1 and ATS2 System Setup

Use the System Setup Menu on each transfer switch to set the following: ATS1: Set the Source type to Util-Gen. ATS2: Set the source type to Util-Gen-Gen. Set the 3 Src Engine Start Mode to Mode 1 or Mode 2 as described in the Three

Source Engine Start Mode section. The transfer switch settings are summarized in Figure 38.

Transfer Switch

Source Type

3 Src Engine Start

Mode

Preferred Source

Toggle

Inputs

Outputs

ATS1

Util-Gen

Not Required

Three Source

System Disable

ATS2

Util-Gen-Gen

Mode 1 or Mode 2

Enable or Disable

Three Source

System

Source N Start

Signal

Figure 38 Transfer Switch Settings for Three-Source Systems

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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.

• Transfer switch wiring diagrams.

• Installation instructions or diagrams provided with loose accessory kits.

4.2 Communication Connections

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

4.2.1 USB Port SiteTech Connection

A personal computer and Kohler® SiteTech™ software can be used for changing controller settings. Use a USB cable to connect the controller to a personal computer.

See Figure 39 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.

Figure 39 USB Connection for SiteTech (MPAC 1500 controller shown)

USB connection (below port cover)

GM85888

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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 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.

See Figure 40 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 42. 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.

Connect the Modbus input and output to the terminals shown in Figure 41. 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.).

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: Modbus® applications require a Modbus software driver written by a trained and qualified systems programmer.

Figure 40 Modbus Connections (controller cover removed for illustration only)

Access opening for RS-485 cables

RS-485 Modbus connections

GM85884

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TP-7280 1/24 53

Figure 41 Modbus RS-485 Connections

TB2

Cable shield

Input

─ ─ ─ ─ Customer connections

Cable shield

Output

USB to RS-485 port converter

USB port

 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 Device

Out

Terminating resistor may be required †, (121 Ohms)

In Device

Out

In Device

Out

In Last Device

Terminating resistor may be required †, (121 Ohms)

USB port

RS-485 *

USB to RS-485 port converter

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Figure 42 Serial Connections

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 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.

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 43.

Figure 43 Ethernet Board (controller cover removed for illustration only)

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 43 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 44. 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 45 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

Ethernet communication board with RJ-45 connector

Access opening for Ethernet cable

GM85884

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TP-7280 1/24 55

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.

Figure 44 Remote Network (Ethernet) Connection

Figure 45 Ethernet Connections to Multiple-Device Network

Ethernet

Network

MPAC Controller with

Ethernet comm. board IP xx.xx.xx.03

Note: The PC 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.

Modbus® TCP/IP

Category 5e

Modbus® TCP/IP

Category 5e

IP xx.xx.xx.02

Ethernet Network

MPAC Controller with Ethernet comm. board IP xx.xx.xx.03

Terminating resistor (121 Ohms)

Device

Last Device

RS-485

Converter,

Modbus®/Ethernet

IP xx.xx.xx.05

Modbus®

RTU

RS-485

Modbus® TCP/IP

Category 5e

Modbus® TCP/IP

Category 5e

Modbus® TCP/IP

Category 5e

IP xx.xx.xx.02

IP xx.xx.xx.01

Modbus®

TCP/IP

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4.3 Accessory Modules

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 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.

This section provides specifications and field connection information for factory-installed accessory modules. If the modules are not factory-installed, follow the instructions provided with the kits to install the mounting assembly and modules.

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 46. 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

Standard I/O Module

High Power I/O Module

100

Figure 46 Option Board Types

4.3.1 Accessory Module Mounting

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 47. 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.

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TP-7280 1/24 57

Figure 47 Module Mounting

Cable connection (defined as the TOP regardless of orientation)

I/O modules (if equipped)

GM46258

I/O modules (if equipped)

Alarm module (if equipped)

Mounting plate

External battery module (must be last, if equipped)

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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 48 through Figure 51 for I/O module illustrations and specifications.

Figure 48 Standard Input/Output Module

Inputs

Available Inputs

Input Definition

Contact Closure

Current

5 mA Max

Connection Type

Terminal Strip

Wire Size

#14-24 AWG

Max Distance

700 feet

Outputs

Outputs Available

Contact Type

Form C (SPDT)

Contact Voltage Rating

2 A @ 30 VDC 500 mA @ 125 VAC

Connection Type

Terminal Strip

Wire Size

#14-24 AWG

Figure 49 Standard I/O Module Specifications

Output LEDs 1-6

Output connector

GM41093

Input connector (Figure 52)

Input LEDs 7 and 8 for inputs 1 and 2

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TP-7280 1/24 59

Figure 50 High-Power Input/Output Module

Inputs

Available Inputs

Input Definition

Contact Closure

Current

5 mA Max

Connection Type

Terminal Strip

Wire Size

#14-24 AWG

Max Distance

700 feet

Outputs

Outputs Available

Contact Type

Form C (SPDT)

Contact Voltage Rating

12 A @ 24 VDC 12 A @ 250 VAC 10 A @ 277 VAC 2 A @ 480 VAC

Connection Type

Terminal Strip

Wire Size

#14-24 AWG

Environmental Specifications

Temperature

-40C to 85C (-104F to 185F)

Humidity

35% to 85% noncondensing

Figure 51 High-Power I/O Module Specifications Use 14-24 AWG cable to connect to inputs and outputs. See Figure 52. 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 53.

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 Kohler® SiteTech™ software or over Modbus. See TP-6701, SiteTech Operation Manual, or TP-6113, Modbus Protocol Manual.

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

Output connector

GM42186

Input connector (Figure 52)

Input LEDs 1 and 2

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Figure 52 I/O Module Input Connections (TB1 or TB10)

DIP Switch

Address

Off

Off 1 On

Off 2 Off

On 3 On

Figure 53 Address DIP Switch Settings

refGM41093

INPUT 1

INPUT 2

Address=1 shown

Both switches OFF

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TP-7280 1/24 61

4.3.3 External Battery Supply Module (EBSM)

The External Battery Supply Module is standard factory-installed equipment on Model KUS and KUP service entrance transfer switches. The installer must connect the generator set engine starting batteries or other batteries to the EBSM. See the installation section for instructions.

4.3.4 Alarm Module

See Figure 54 for the optional alarm module. A module mounting kit is required for installation of the alarm module. See the Accessory Module Mounting section.

The functions provided by this board are:

• 90 dB Audible alarm (any alarm function can be programmed to trigger the audible alarm)

• Chicago alarm operation

• Preferred source selection

• Supervised transfer control (supervised transfer control switch not available for Models KUS/KUP)

• Connection for external alarm

The alarm board has a fixed address = 5.

Figure 54 Alarm Module

Alarm Board DIP Switches

There are four DIP switches on the alarm module board. Some of the switches are not used. See Figure 55. To enable the preferred source selection, set DIP switch 1 to ON. If the supervised transfer switch is installed on the ATS, set DIP switch 2 to ON.

DIP Switch

Function

Preferred source selection

Supervised transfer enable

Not used

Figure 55 Alarm Board DIP Switches

Alarm Indicator, LED1

DIP Switches

External Alarm Connection, TB 14

Supervised Transfer Switch Connection, P22 (N/A KUS/KUP)

GM40764

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62 TP-7280 1/24

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 56.

Item

Specification

Wire Size

#12-22 AWG Cu

Contact Voltage Rating

500 mA @ 120 VAC

250 mA @ 240 VAC

Figure 56 External Alarm Connection Specifications

Audible Alarm Setup

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.

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.

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 57. Press the Alarm button to open the Reset menu. Then press the button labeled Reset to silence the alarm.

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TP-7280 1/24 63

Figure 57 Alarm Silence

4.4 Load Shed (Forced Transfer to OFF)

DANGER

Hazardous voltage. Will cause severe injury or death.

Disconnect all power sources before opening the enclosure.

The load shed (forced transfer to OFF) accessory is available for programmed-transition and closed-transition transfer switches. The load shed accessory is available factory-installed or as a loose kit. For kit installation, refer to the Installation Instructions provided with the kit.

See Figure 58 for an illustration of the load shed accessory.

Connection and Setup

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 59. Use #12-24 AWG wire and tighten to 0.5 Nm (4.4 in. lb.).

Alternatively, the external contact can be connected to an input connection on an optional I/O module. Use the Input/Output setup menu or Kohler SiteTech software to assign the connected input (Main Board Input #1 or #2, or an

input on the I/O module) to the forced transfer to off function.

▼ ▲ Reset Main

System Ready

LD Exer 12/14 @ 16:00

Norm 480V Emer 480V

Reset

To Silence Alarm

Alarm View Set Test

▼ ▲ Reset Main

Reset

Status or Fault Description

Alarm Silenced

Page 64

64 TP-7280 1/24

Figure 58 Load Shed Accessory (for identification)

Figure 59 Forced Transfer to Off Input Connection (for factory-installed load shed kits)

GM23469

Input/output terminal strip TB1

GM89713

#12-24 AWG wire 0.5 Nm (4.4 in. lb.)

MLB Input 2 (alternate

connection)

MLB Input 2

TB1

MPAC Controller Circuit Board

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TP-7280 1/24 65

4.5 Heater

DANGER

Hazardous voltage. Will cause severe injury or death.

Disconnect all power sources before opening the enclosure.

An anti-condensation heater kit is available. The strip heater is controlled by a hygrostat to raise the temperature inside the enclosure above the dewpoint to prevent condensation. Figure 60 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 61 and Figure 62. The heater and hygrostat are connected to power through a 15-amp circuit breaker.

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

Figure 60 Heater Location, Typical

Hygrostat assembly, see Figure 61 Strip heater with guard

Right Side View

GM69824

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66 TP-7280 1/24

Figure 61 Hygrostat Assembly, Typical

Figure 62 Heater Connections

Circuit breaker

Relative humidity adjustment control

GM71056

120 VAC power connection terminal block (or transformer for some kits)

GM71278C

Page 67

TP-7280 1/24 67

4.6 Engine Start Circuit Monitoring System

The optional Engine Start Circuit Monitoring System forwards engine start signals while continuously monitoring for wiring faults (open or short circuits) as required by the electrical code NEC 700.10. If the generator module receives an engine start signal or detects any faults, it will send the start signal to the generator and provide an alarm.

See the installation instructions provided with the kit.

4.7 Other Accessories

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

• Transfer switch wiring diagrams.

• Installation instructions provided with loose accessory kits.

• Controller Operation Manual. See List of Related materials in the Introduction section of this manual for document

numbers.

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68 TP-7280 1/24

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TP-7280 1/24 69

Section 5. 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.

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

The transfer switch controller Operation Manual contains the Service Schedule and other maintenance information. Refer to the Operation Manual shipped with the transfer switch or see Figure 63 for the Operation Manual part number.

Keep records of all maintenance or service.

Operation Manual

Part Number

Operation Manual, Decision-Maker® MPAC 1500 Controller

TP-6883

Figure 63 Operation Manual

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70 TP-7280 1/24

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TP-7280 1/24 71

Section 6. Functional Tests and Setup

6.1 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:

• Manual Operation Test

• Voltage Checks

• Lamp Test

• 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:

• Set the time, date, and exercise schedule on the controller.

• Perform the system startup procedures listed on the startup form.

• Register the unit using the Kohler® online Warranty Processing System.

6.2 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.

Follow the instructions in the Installation Section to check the transfer switch manual operation. 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.

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72 TP-7280 1/24

6.3 Voltage Check

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 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. 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:

• A digital voltmeter (DVM) with electrically insulated probes capable of measuring the rated voltage and frequency

• A phase rotation meter

DANGER

Hazardous voltage. Will cause severe injury or death.

Only authorized personnel should open the enclosure.

Page 73

TP-7280 1/24 73

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.

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.

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 Engine Cooldown Time Delay ends.

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

6.4 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.

Page 74

74 TP-7280 1/24

6.5 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: Close and lock the enclosure door before starting the test procedure.

6.6 System Setup

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.

6.7 Exerciser Setup

To maximize the reliability of the emergency power system, set the exerciser to start and run the generator set at the intervals and load conditions recommended by the generator set manufacturer. See the controller Operation Manual for instructions.

Transfer switches equipped with the Decision-Maker® MPAC 750 controller may also use the optional programmable exerciser. Refer to the instructions provided with the exerciser to schedule additional loaded or unloaded exercise runs.

6.8 User Interface Cover

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. NEMA 3R enclosures include the cover as standard equipment.

Use a customer-supplied padlock to lock the cover.

6.9 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 Kohler® online Warranty Processing System.

Page 75

TP-7280 1/24 75

Section 7. Operation

7.1 Transfer Switch Operation

7.1.1 Normal Operation

Under normal conditions, the load is energized from the utility supply. If the utility power fails, the ATS signals the generator to start (engine start contacts close). The generator controller must be in AUTO mode. The load will be energized by the running generator.

When utility power is restored, the load is transferred back to the utility source and the engine start signal is removed (contacts open). If the generator set is in SUTO mode, the engine will stop. There may be a cooldown period before the engine stops. Refer to the controller operation manual for the sequence of operation.

In the normal operating mode, the service disconnect switch must be in the AUTO position. See the Service Disconnect Operation section for service disconnect instructions.

7.1.2 Overcurrent Trip

If the utility source circuit breaker trips open due to an overcurrent condition, the ATS controller will initiate an engine start signal and initiate transfer of the load to the generator supply. A Source1 breaker trip fault will be displayed on the ATS controller. The utility source will be locked out and the load will remain on the generator supply until the fault is manually reset.

Note: Contact your local distributor/dealer to identify and correct the cause of the overcurrent condition before resetting the fault.

The utility circuit breaker is located on the front of the ATS. On NEMA Type 1 enclosures, the circuit breaker can be reset without opening the ATS enclosure. For other enclosure types, open the outer enclosure door to access the circuit breaker handle. See Figure 64 for typical circuit breaker locations. To reset the circuit breaker, move the handle to OFF (0), and then ON (I). Some breakers have a handle that can fold down when not in use. Lift the handle before moving it to OFF. Fold the handle back down after moving it to ON.

After resetting the tripped breaker, check the controller display for fault messages. See the ATS controller operation manual for instructions to reset the fault. See the List of Related Materials in the Introduction section for the manual part number.

Figure 64 Utility Circuit Breaker Locations, Typical

70-225 Amps

1600-3000 Amps

150-600 Amps

Utility Circuit Breaker

Page 76

76 TP-7280 1/24

7.1.3 Energy Reduction Maintenance Setting (ERMS) System

DANGER

Hazardous voltage. Will cause severe injury or death.

This equipment must be installed and serviced by qualified electrical personnel.

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.

The Energy Reduction Maintenance Setting (ERMS) system is available as optional, factory-installed equipment on 1200 Amp and larger model KUS and KUP service entrance rated automatic transfer switches (ATS). The ERMS system is used to reduce the arc flash incident energy (AFIE) during energized service.

The system can help provide compliance with NEC requirements for arc flash reduction. Refer to the NEC and follow all applicable codes and regulations during the ATS installation.

The ERMS system is available on MicroLogic P or H trip units with the blue ERMS label shown in Figure 65. See the KUS/KUP Specification Sheet for circuit breaker information.

Figure 65 ERMS Label on Circuit Breaker Trip Unit The ERMS module is manufactured by the circuit breaker manufacturer and is used to reduce the tripping threshold and clearing

time. The ERMS is installed and wired at the factory according to the circuit breaker manufacturer’s instructions. Factory connections are shown in Figure 67 for reference only. No customer connections to the system are required.

The following components are mounted on the ATS enclosure door as shown in Figure 66.

• ERMS Maintenance Mode ON/OFF selector switch.

• Maintenance mode indicator light. The light is ON when the circuit breaker is in ERMS mode.

The I/O Module factory setting = 3; do not change this setting.

NHA67346

Page 77

TP-7280 1/24 77

ERMS System Operation Description

When the ERMS switch is “ON” (circuit breaker is in maintenance mode), the circuit breaker’s ERMS instantaneous pickup is

set to the pre-programmed level which is less than the normal instantaneous pickup setting as set by the rotary switch setting (Ii). As a result, the potential for nuisance tripping increases. Nuisance tripping can be caused by a motor starting, transformer inrush, or some other momentary power disturbance.

For more information, refer to the ERMS system manufacturer’s literature included with the transfer switch.

ERMS Operation Instructions

1. Turn the ERMS maintenance mode switch to ON before performing service or maintenance on the transfer switch or downstream equipment.

Note: Utility source voltage is still present! The ERMS system does not disconnect power or trip/open the utility circuit breaker.

2. After the service procedures are complete, turn the switch OFF for normal system operation.

Note: Be sure to follow all safety precautions and instructions, including instructions to disconnect power and/or disable the generator set, when performing maintenance and service procedures on the power system or connected equipment.

Figure 66 ERMS System Components

GM120996

DETAIL A

ERMS Status Indicator

ERMS Maintenance Switch

Page 78

78 TP-7280 1/24

Figure 67 ERMS wiring ( factory-installed)

GM121000

NOTES:

1. The I/O Module is factory-set to APP value 3 for ERMS application.

Page 79

TP-7280 1/24 79

7.2 Service Disconnect Switch Operation

The two-position service disconnect switch trips the utility-side circuit breaker using the shunt trip. The service disconnect switch and utility disconnected lamp are located on the front door or front panel. See Figure 58 for the

typical service disconnect switch location. The switch has two positions, AUTO and SERVICE DISCONNECT.

• When the switch is in the AUTO position, the ATS is in normal operation mode

• When the switch is in the SERVICE DISCONNECT position, the ATS service entrance breaker is shunt-tripped and

open. The lamp is illuminated, and the controller display shows SERVICE DISCONNECT.

Note: The ATS does not signal the generator set to start when the utility-side breaker is tripped.

Figure 68 Service Disconnect Switch Location (typical)

Important notes about service disconnect operation:

• On service entrance transfer switches, the line side lugs are always powered.

• Service disconnect removes power from the load and transfer is inhibited. Power will not be restored to the load until

the switch is returned to AUTO.

• The engine start signal is not activated by the service disconnect procedure.

• Moving the switch to the SERVICE DISCONNECT position during a test or exercise sequence ends the test or exercise

sequence. The engine stops immediately without running a cooldown cycle.

• Controller power. To remove the controller for maintenance or service without interrupting the power to the load, an optional Controller Disconnect Switch is required. See the Controller Disconnect Switch Operation section for instructions.

ADV-9983

Utility disconnected lamp

Service disconnect switch

Decal Detail

Page 80

80 TP-7280 1/24

DANGER

Hazardous voltage. Will cause severe injury or death.

Only authorized personnel should open the enclosure.

WARNING

Accidental starting. Can cause severe injury or death.

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.

7.2.1 Service Disconnect Procedure

The service disconnect switch has two positions: AUTO and SERVICE DISCONNECT. Follow the procedures in this section carefully and observe the safety precautions when performing a service disconnect before maintenance or service. Watch the LED indicators on the ATS controller to check the ATS position and source status during the procedures.

Note: The service disconnect procedure removes power from the load, but utility power is still present at the transfer switch normal side lugs whenever the utility source is available.

Service Disconnect when the Transfer Switch is in NORMAL

Use this procedure if utility power is connected and the transfer switch is in the Normal position.

1. Move the service disconnect control switch located on the door of the transfer switch to the SERVICE DISCONNECT position. This opens the utility circuit breaker through the shunt trip circuit and sends a fault to the generator set controller.

2. Verify the following:

• The utility (normal) breaker is open.

• The generator set controller displays a fault message and the generator set is not running.

• The ATS controller display shows SERVICE DISCONNECTED

• The Utility Disconnected light is illuminated and the NOT IN AUTO LED is flashing.

Note: The External Battery Supply Module (EBSM) allows the generator set battery to continue to supply DC power to the ATS controller after the Utility source is disconnected. The EBSM (sometimes referred to as the Battery Option Board, BOB) is factory-installed standard equipment on KUS and KUP models.

3. Attach a safety lockout padlock to the service disconnect control switch to prevent unauthorized reconnection of utility power. Verify the transfer switch door is closed and locked. If the door is not locked, turn and remove the door key.

4. Use a voltmeter to verify that power is disconnected from the load before servicing connected equipment.

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TP-7280 1/24 81

Service Disconnect when the Transfer Switch is in EMERGENCY

Use this procedure if the transfer switch is in the Emergency position.

2. The engine start signal is removed.

3. Wait for the generator set to shut down. The generator set may continue to run for several minutes to cool the engine.

4. Verify the following:

• The utility (normal) breaker is open.

• The generator set controller displays a fault message and the generator set is not running.

• The ATS controller display shows SERVICE DISCONNECTED

• The Utility Disconnected light is illuminated and the NOT IN AUTO LED is flashing.

5. Attach a safety lockout padlock to the service disconnect control switch to prevent unauthorized reconnection of utility power. Verify the transfer switch door is closed and locked. If the door is not locked, turn and remove the door key.

6. Use a voltmeter to verify that power is disconnected from the load before servicing connected equipment.

7.2.2 Service Reconnect Procedure

Service reconnect procedure with Normal source available

1. Remove the padlock from the service disconnect control switch and move the service disconnect switch to the AUTO position. The Service Disconnect light on the door should turn off. The MPAC 1500 ATS controller will resume normal operation.

2. Manually reset the utility-side circuit breaker by moving the breaker handle to fully OFF and then ON.

3. If the ATS controller displays shows “FAILURE TO ACQUIRE,” proceed to step 4. Otherwise, go to step 5.

4. Reset the fault on the ATS controller. See the Decision-Maker® MPAC 1500 Operation Manual for instructions, if necessary.

5. If the ATS is not in the normal position, it will transfer to the normal source.

6. Reset the fault on the generator set controller. See the generator controller Operation Manual for instructions to reset the fault and prepare the generator set for operation. Then place the generator set controller in AUTO

7. Verify that the ATS controller display shows normal source available and ATS in normal position.

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82 TP-7280 1/24

Service reconnect procedure when Normal source is NOT available

2. Manually reset the utility-side circuit breaker by moving the breaker handle to fully OFF and then ON.

3. Reset the fault on the generator set controller. See the generator controller Operation Manual for instructions to reset the fault and prepare the generator set for operation. Then place the generator set controller in AUTO.

WARNING

The generator set will start when the controller is placed in AUTO.

4. Reset any faults on the ATS controller. See the Decision-Maker® MPAC 1500 Operation Manual for instructions, if necessary.

5. Verify that the ATS controller display shows emergency source available and ATS in emergency position.

Page 83

7.3 Controller Disconnect Switch Operation

WARNING

Accidental starting. Can cause severe injury or death.

DANGER

Hazardous voltage. Will cause severe injury or death.

Only authorized personnel should open the enclosure.

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.

The optional controller disconnect switch allows disconnection of the power to the controller during maintenance and service. See Figure 69.

Note: On service entrance models, power is always present on the utility side of the ATS. The service disconnect procedure removes power from the load, but utility power is still present at the transfer switch lugs whenever the utility source is available.

Note:

Disconnecting power to the controls will cause the ATS to send an engine start signal to the generator set. Disable the generator set before using the controller disconnect switch to disconnect power to the ATS controls.

Operation Instructions

The switch has two positions, auto (I) and disconnect (0).

1. Disable the generator set to prevent starting. Refer to the generator set documentation for specific instructions, if necessary.

2. Move the controller disconnect switch to the 0 position to disconnect power to the ATS controller.

3. After maintenance or service, move the controller disconnect switch to the I position to reconnect power.

4. Follow the instructions in the generator set documentation to reenable the generator set.

TP-7280 1/24 83

Page 84

84 TP-7280 1/24

Figure 69 Controller Disconnect Switch

I = Connect

0 = Disconnect

Page 85

TP-7280 1/24 85

Appendix A. Abbreviations

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

A, amp

ampere

CID

cubic inch displacement

FHM

flat head machine (screw)

ABDC

after bottom dead center

centerline

fl. oz.

fluid ounce

alternating current

centimeter

flex.

flexible

A/D

analog to digital

CMOS

complementary metal oxide

freq.

frequency

ADC

advanced digital control;

substrate (semiconductor)

full scale

analog to digital converter

com

communications (port)

ft.

foot, feet

adj.

adjust, adjustment

coml

commercial

ft. lb.

foot pounds (torque)

ADV

advertising dimensional

Coml/Re

Commercial/Recreational

ft./min.

feet per minute

amp-hour

conn.

connection

ftp

file transfer protocol

AHWT

anticipatory high water

cont.

continued

gram

temperature

CPVC

chlorinated polyvinyl chloride

ga.

gauge (meters, wire size)

AISI

American Iron and Steel

crit.

critical

gal.

gallon

ALOP

anticipatory low oil pressure

CSA

Canadian Standards Association

gen.

generator

alt.

alternator

current transformer

genset

generator set

aluminum

copper

GFI

ground fault interrupter

ANSI

American National Standards

cUL

Canadian Underwriter’s

GND,

ground

Institute (formerly American

Laboratories

gov.

governor

Standards Association, ASA)

CUL

Canadian Underwriter’s

gph

gallons per hour

anticipatory only

Laboratories

gpm

gallons per minute

APDC

Air Pollution Control District

cu. in.

cubic inch

gr.

grade, gross

API

American Petroleum Institute

cw.

clockwise

GRD

equipment ground

approx.

approximate, approximately

CWC

city water-cooled

gr. wt.

gross weight

APU

Auxiliary Power Unit

cyl.

cylinder

H x W x D

height by width by depth

AQMD

Air Quality Management

D/A

digital to analog

hex cap

as required, as requested

DAC

digital to analog converter

HCHT

high cylinder head

as supplied, as stated, as

decibel

heavy duty

suggested

dB(A)

decibel (A weighted)

HET

high exhaust temp., high

ASE

American Society of Engineers

direct current

temp.

ASME

American Society of

DCR

direct current resistance

hex

hexagon

Engineers

deg., °

degree

mercury (element)

assy.

assembly

dept.

department

hex head

ASTM

American Society for Testing

dia.

diameter

HHC

hex head cap

Materials

DIN

Deutsches Institut fur Normung

horsepower

ATDC

after top dead center

e. V. (also Deutsche Industrie

hr.

hour

ATS

automatic transfer switch

Normenausschuss)

heat shrink

auto.

automatic

DIP

dual inline package

hsg.

housing

aux.

auxiliary

DPDT

double-pole, double-throw

HVAC

heating, ventilation, and air

avg.

average

DPST

double-pole, single-throw

conditioning

AVR

automatic voltage regulator

DVR

digital voltage regulator

HWT

high water temperature

AWG

American Wire Gauge

E, emer.

emergency (power source)

hertz (cycles per second)

AWM

appliance wiring material

EBSM

external battery supply module

IBC

International Building Code

bat.

battery

ECM

electronic control module,

integrated circuit

BBDC

before bottom dead center

engine control module

inside diameter, identification

battery charger, battery

E2PROM

EEPROM

IEC

International Electrotechnical

BCA

battery charging alternator

electrically-erasable

Commission

BCI

Battery Council International

programmable read-only

IEEE

Institute of Electrical and

BDC

before dead center

memory

Electronics Engineers

BHP

brake horsepower

EDI

electronic data interchange

IMS

mproved motor starting

blk.

black (paint color), block

EFR

emergency frequency relay

in.

inch

(engine)

e.g.

for example (exempli gratia)

in. H2O

inches of water

blk. htr.

block heater

electronic governor

in. Hg

inches of mercury

BMEP

brake mean effective pressure

EGSA

Electrical Generating Systems

in. lb.

inch pounds

bps

bits per second

Association

Inc.

incorporated

br.

brass

EIA

Electronic Industries Association

ind.

industrial

BTDC

before top dead center

EI/EO

end inlet/end outlet

int.

internal

Btu

British thermal unit

EMI

electromagnetic interference

int./ext.

internal/external

Btu/min.

British thermal units per minute

emiss.

emission

I/O

input/output

Celsius, centigrade

eng.

engine

internet protocol

cal.

calorie

EPA

Environmental Protection

ISO

International Organization for

CAN

controller area network

Agency

Standardization

CARB

California Air Resources Board

EPS

emergency power system

joule

CAT5

Category 5 (network cable)

emergency relay

JIS

Japanese Industry Standard

circuit breaker

ERMS

energy reduction maintenance setting

kilo (1000)

crank cycle

engineering special, engineered

kelvin

cubic centimeter

special, engine start

kiloampere

CCA

cold cranking amps

ESD

electrostatic discharge

kilobyte (210 bytes)

ccw.

counterclockwise

est.

estimated

KBus

Kohler communication

CEC

Canadian Electrical Code

E-Stop

emergency stop

kilogram

cert.

certificate, certification,

etc.

et cetera (and so forth)

kg/cm2

kilograms per square

cfh

cubic feet per hour

exh.

exhaust

kgm

kilogram-meter

cfm

cubic feet per minute

ext.

external

kg/m3

kilograms per cubic meter

center of gravity

Fahrenheit, female

kHz

kilohertz

Page 86

86 TP-7280 1/24

kilojoule

NPSC

National Pipe, Straight-coupling

SPDT

single-pole, double-throw

kilometer

NPT

National Standard taper pipe

SPST

single-pole, single-throw

kOhm,

kilo-ohm

thread per general use

spec

specification

kPa

kilopascal

NPTF

National Pipe, Taper-Fine

specs

specification(s)

kph

kilometers per hour

not required, normal relay

sq.

square

kilovolt

nanosecond

sq. cm

square centimeter

kVA

kilovolt ampere

overcrank

sq. in.

square inch

kVAR

kilovolt ampere reactive

outside diameter

SMS

short message service

kilowatt

OEM

original equipment manufacturer

stainless steel

kWh

kilowatt-hour

overfrequency

std.

standard

kWm

kilowatt mechanical

opt.

option, optional

stl.

steel

kWth

kilowatt-thermal

oversize, overspeed

tach.

tachometer

liter

OSHA

Occupational Safety and Health

terminal block

LAN

local area network

Administration

TCP

transmission control protocol

L x W x

length by width by height

overvoltage

time delay

lb.

pound, pounds

oz.

ounce

TDC

top dead center

lbm/ft3

pounds mass per cubic feet

p., pp.

page, pages

TDEC

time delay engine cooldown

LCB

line circuit breaker

personal computer

TDEN

time delay emergency to

LCD

liquid crystal display

PCB

printed circuit board

TDES

time delay engine start

LED

light emitting diode

pF pic

picofarad

TDNE

time delay normal to

Lph

liters per hour

power factor

TDOE

time delay off to emergency

Lpm

liters per minute

ph., Ø

phase

TDON

time delay off to normal

LOP

low oil pressure

PHC

Phillips® head Crimptite®

temp.

temperature

liquefied petroleum

(screw)

term.

terminal

LPG

liquefied petroleum gas

PHH

Phillips® hex head (screw)

THD

total harmonic distortion

left side

PHM

pan head machine (screw)

TIF

telephone influence factor

Lwa

sound power level, A weighted

PLC

programmable logic control

tol.

tolerance

LWL

low water level

PMG

permanent magnet generator

turbo.

turbocharger

LWT

low water temperature

pot

potentiometer, potential

typ.

typical (same in multiple

meter, milli (1/1000)

ppm

parts per million

locations)

mega (106 when used with SI

PROM

programmable read-only

underfrequency

units), male

memory

UHF

ultrahigh frequency

cubic meter

psi

pounds per square inch

UIF

user interface

m3/hr.

cubic meters per hour

psig

pounds per square inch gauge

Underwriter’s Laboratories,

m3/min.

cubic meters per minute

pt.

pint

UNC

unified coarse thread (was

milliampere

PTC

positive temperature coefficient

UNF

unified fine thread (was NF)

man.

manual

PTO

power takeoff

univ.

universal

max.

maximum

PVC

polyvinyl chloride

URL

uniform resource locator (web

megabyte (220 bytes)

qt.

quart, quarts

address)

MCCB

molded-case circuit breaker

qty.

quantity

undersize, underspeed

MCM

one thousand circular mils

replacement (emergency) power

ultraviolet, undervoltage

meggar

megohmmeter

source

volt

MHz

megahertz

rad.

radiator, radius

VAC

volts alternating current

mi.

mile

RAM

random access memory

VAR

voltampere reactive

mil

one one-thousandth of an inch

RBUS

RS-485 proprietary

VDC

volts direct current

min.

minimum, minute

communications

VFD

vacuum fluorescent display

misc.

miscellaneous

RDO

relay driver output

VGA

video graphics adapter

megajoule

ref.

reference

VHF

very high frequency

millijoule

rem.

remote

watt

millimeter

Res/Com

Residential/Commercial

WCR

withstand and closing rating

mOhm,m

milliohm

RFI

radio frequency interference

with

MOhm,M

megaohm

round head

write only

MOV

metal oxide varistor

RHM

round head machine (screw)

w/o

without

MPa

megapascal

rly.

relay

wt.

weight

mpg

miles per gallon

rms

root mean square

xfmr

transformer

mph

miles per hour

rnd.

round

military standard

read only

millisecond

ROM

read only memory

m/sec.

meters per second

rot.

rotate, rotating

mtg.

mounting

rpm

revolutions per minute

MTU

Motoren-und Turbinen-Union

right side

megawatt

RTDs

Resistance Temperature

milliwatt

Detectors

µF

microfarad

RTU

remote terminal unit

N, norm.

Normal (power source)

RTV

room temperature vulcanization

not available, not applicable

read/write

nat. gas

natural gas

SAE

Society of Automotive Engineers

NBS

National Bureau of Standards

s, sec.

second

normally closed

read/write

NEC

National Electrical Code

SAE

Society of Automotive Engineers

NEMA

National Electrical

Systeme international d’unites,

Manufacturers Association

International System of Units

NFPA

National Fire Protection

SI/EO

side in/end out

Association

sil.

silencer

newton meter

SMTP

simple mail transfer protocol SN

normally open

SI/EO

side in/end out

no., nos.

number, numbers

SNMP

simple network management

NPS

National Pipe, Straight

protocol

Page 87

Page 88

TP-7280 1/24

Original Instructions (English)

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