Kohler ZCS Operation And Installation

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Operation and

Installation

Automatic Transfer Switches

Models:

ZCS

Contactors:

40 to 3000 Amperes

TP-5660 11/98

Table of Contents

Safety Precautions and Instructions I. . . . . . . . .

Introduction i. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

List of Related Materials i. . ..... . . . . . . . . . . . . . .

Service Assistance ii. . . . . . . . . . . . . . . . . . . . . . . . .

Service Information ii. . . . . . . . . . . . . . . . . . . . . . . . . .

Product Indentification ii. . . . . . . . . . . . . . . . . . . . . . .

Section 1. Specifications 1. . . . . . . . . . . . . . . . . . .

1.1 Purpose 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 Nameplate 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 Part Number Model Code 3. . . . . . . . . . . . . . . . . . . .

1.5 Standard Features 4. . . . . . . . . . . . . . . . . . . . . . . . . .

1.6 Ratings 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7 Application Data 7.. . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2. Operation 9. . . . . . . . . . . . . . . . . . . . . . .

2.1 Startup 9.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Automatic Operation 9. . . . . . . . . . . . . . . . . . . . . . . . .

2.2.1 Failure of Normal Power 10. . . . . . . . . . . . . .

2.2.2 Restoration of Normal Power 10. . . . . . . . . .

2.3 Manual Operation 11. . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.1 Programmed Transition Switch,

40--260 Amps 12.. . . . . . . . . . . . . . . . . . . . . .

2.3.2 Programmed Transition Switch,

400--3000 Amps 13.. . . . . . . . . . . . . . . . . . . .

2.3.3 Standard Switch, 800--3000 Amps 14. . . . . .

Section 3. Accessories 15. . . . . . . . . . . . . . . . . . . . .

3.1 Programmed Transition 15. . . . . . . . . . . . . . . . . . . . . .

3.1.1 Description 15.. . . . . . . . . . . . . . . . . . . . . . . . .

3.1.2 Adjustment 15. . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Other Accessories 16.. . . . . . . . . . . . . . . . . . . . . . . . .

Section 4. Scheduled Maintenance 17. . . . . . . . . .

4.1 Inspection and Service 18.. . . . . . . . . . . . . . . . . . . . . .

4.1.1 General Inspection 19. . . . . . . . . . . . . . . . . . .

4.1.2 Other Inspections and Service 19. . . . . . . . .

4.2 Testing 19.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.1 Weekly Generator Set Exercise 19. . . . . . . .

4.2.2 Monthly Automatic Control System

Test 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Service Schedule 20. . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 5. Diagrams and Drawings 21. . . . . . . . . .

Section 6. Installation 55. . . . . . . . . . . . . . . . . . . . . .

6.1 Upon Receipt of Unit 55. . . . . . . . . . . . . . . . . . . . . . . .

6.1.1 Inspection 55. . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.2 Lifting 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.3 Unpacking 56. . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.4 Storage 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Mechanical Installation 56. . . . . . . . . . . . . . . . . . . . . . .

6.3 Check Manual Operation 56.. . . . . . . . . . . . . . . . . . . .

6.4 Electrical Wiring 56.. . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4.1 AC Power Connections 58. . . . . . . . . . . . . . .

6.4.2 Generator Start Connection 59. . . . . . . . . . .

6.4.3 Accessory and Controller Connections 59. .

6.5 Prepare the Generator Set for Operation 59. . . . . . .

6.6 Functional Tests 60.. . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6.1 Voltage Check 60. . . . . . . . . . . . . . . . . . . . . . .

6.6.2 Automatic Operation Test 61. . . . . . . . . . . . .

6.7 Controller Setup 61. . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.8 Ensure Warranty Registration 61. . . . . . . . . . . . . . . . .

Appendix A. Glossary of Abbreviations A-1. . . . . .

TP-5660 11/98 Table of Contents

Safety Precautions and Instructions

A transfer switch, like any other electromechanical device, can pose potential dangers to life and limb if improperly maintained or operated. The best way to prevent accidents is to be aware of potential dangers and act safely. Please read and follow the safety precautions and instructions below to prevent harm to yourself and others. This manual contains several types of safety precautions and instructionswhich are explained below. SAVE THESE INSTRUCTIONS.

DANGER

Danger indicates the presence of a hazard that will cause severe personal injury, death, or substantial property damage.

WARNING

Warning indicates the presence of a hazard that can cause severe personal injury, death, or substantial property damage.

CAUTION

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

Accidental Starting

W ARNING

Accidental starting. Can cause severe injury or death.

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

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

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

Battery

W ARNING

Sulfuric acid in batteries. Can cause severe injury or death.

Use protective goggles and clothes. Battery acid can cause permanent damage to eyes, burn skin, and eat holes in clothing.

Battery acid. Sulfuric acid in batteries can cause severe injury or death. Sulfuric acid in battery can

cause permanent damage to eyes, burn skin, and eat holes in clothing. Always wear splash-proof safety goggles when working near the battery. Ifbattery acidis splashed in the eyes or on skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service,as this mayresult in hazardous spattering of battery acid.

NOTICE

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

Safety decals affixed to the transfer switch in prominent places advise the operator or service technician of potentialhazards andhow toact safely. The decals are reproduced here to improve operator recognition. Replace missing or damaged decals.

TP-5660 11/98 Safety Precautions and Instructions I

W ARNING

Hazardous Voltage/ Electrical Shock

W ARNING

Explosion. Can cause severe injury or death. Relays in battery charger cause arcs or sparks.

Locate battery in a well-ventilated area. Isolate battery charger from explosive fumes.

Battery gases. Explosion can cause severe injury or death. Battery

gases can cause an explosion. Do not smokeor permit flameor spark tooccur near a battery at any time, particularly when it is charging. Avoid touching terminals with tools, etc., to prevent burns and sparks that could cause an explosion. Remove wristwatch, rings, and any other jewelry before handling battery. Never connect negative (--) battery cable to positive (+) connection terminal of starter solenoid. Donot test battery condition by shorting terminals together. Sparks could ignite battery gases or fuel vapors. Ventilate any compartment containing batteries to prevent accumulation of explosive gases. To avoid sparks, do not disturb battery charger connections while batteryis charging. Alwaysturnbattery charger off before disconnecting battery connections. Remove negative (--) lead first when disconnecting battery. Reconnect negative (--) lead last when reconnecting battery.

Hazardous voltage. Can cause severe injury or death.

Disconnect all power sources before opening enclosure.

(under 600 Volt)

DANGER

Hazardous voltage. Will cause severe injury or death.

Disconnect all power sources before opening enclosure.

(600 Volt and above)

W ARNING

Hazardous voltage. Can cause severe injury or death.

Disconnect power sources before servicing. Install barrier after adjustments, maintenance, or service.

(under 600 Volt)

DANGER

Hazardous voltage. Can cause severe injury or death.

Operate generator set only with all guards and electrical enclosures in place.

Grounding the transfer switch. Hazardous voltage can cause severe injury or death. Electrocution

is possible whenever electricity is present. Open main circuit breakers of all power sources before servicing equipment. Configure the installation to electrically ground the transfer switch and related equipment and electrical circuits to comply with applicable codes and standards. Never contact electrical leads or appliances when standing in water or on wet ground, as the chance of electrocution increases under such conditions.

Installing battery charger. Hazardous voltage can cause severe injury or death. Electrical

shock may occur if battery charger is not electrically grounded. Connect battery charger enclosure to ground of a permanent wiring system. As an alternative, install an equipment grounding conductor with circuit conductors and connect to equipment grounding terminal or lead on battery charger. Perform battery charger installation as prescribed in equipment manual. Install battery charger in compliance with local codes and ordinances.

Movingrotor.

Hazardous voltage. Will cause severe injury or death.

Disconnect power sources before servicing. Install barrier after adjustments, maintenance, or servicing.

(600 Volt and above)

Connecting battery and battery charger. Hazardous voltage can cause severe injury or death.

Reconnect battery correctly to avoid electrical shock and damage to battery charger and battery(ies). Have a qualified electrician install battery(ies).

TP-5660 11/98II Safety Precautions and Instructions

Installing accessories to transformer assembly. Hazardous voltage can cause severe injury or death. To prevent the possibility of

electrical shock, disconnect harness plug before installing any accessories involving connection to transformer assembly primary terminals 76, 77, 78, and 79. Terminals are at line voltage!

(Models with E33+, S340, S340+, 340, R340, or R33 controls only.)

Installing accessories to transformer assembly. Hazardous voltage can cause severe injury or death. To prevent the possibility of

electrical shock, disconnect harness plug before installing any accessories which will be connected to transformer assembly primary terminals on microprocessor logic models. Terminals are at line voltage!

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

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

Servicing transfer switch controls and accessories within the enclosure. Hazardous voltage can cause severe injury or death.

Disconnect transfer switch controls at the inline connector to deenergize the circuit boards and logic circuitry but allow the transfer switch to continue to supply power to the load. Disconnect all power sources to any accessories mountedwithin the enclosure butwhich are not wired through the controls and deenergized by inline connector separation. Test circuits with a voltmeter to verify that they are unpowered before servicing.

Heavy Equipment

W ARNING

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

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

Short circuits. Hazardous voltage/current can 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 wristwatch, rings, and jewelry before servicing equipment.

Servicing the transfer switch. Hazardous voltage can cause severeinjuryor death. Deenergizeall

power sources before servicing. Open main circuit breakers of all power sources to the transfer switch 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. Reconnectnegative(--)leadslastwhen reconnecting battery cables after servicing. Follow these precautions to prevent starting of generator sets by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.

TP-5660 11/98 Safety Precautions and Instructions III

Moving Parts

W ARNING

Hazardous voltage. Can cause severe injury or death.

Operate generator set only with all guards and electrical enclosures in place.

Movingrotor.

Notice

NOTICE

Hardware damage! Transfer switch

may use both American Standard and metric hardware. Use the correct size tools to prevent rounding of bolt heads and nuts.

NOTICE

When replacing hardware, do not substitute with inferior grade hardware. Screws and nuts are

available in different hardness ratings. American Standard hardware uses a seriesofmarkingsand metric hardware uses a numeric system to indicate hardness. Check markings on bolt head and nuts for identification.

NOTICE

Improper operator handle usage!

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

NOTICE

Foreign material contamination!

Cover transfer switch during installation to keep dirt, grit, metal drill chips, etc., out of components. Cover solenoid mechanism during installation. After installation, use manual operating handle to position contactor to ensure that it operates freely. Do not use a screwdriver to force contactor mechanism.

NOTICE

Electrostatic discharge damage!

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

TP-5660 11/98IV Safety Precautions and Instructions

Introduction

This manual provides operation and installation instructions for Kohler Model ZCS automatic transfer switchesthatusea40-to3000-amperecontactor asthe power switching device.

All information in this publication represents data availableattimeofprint. KohlerCo.reservestherightto change this literature and the products represented without incurring obligation.

Read through 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 equipment for future reference.

Equipment service requirements are minimal but are veryimportantto safeand efficientoperation;therefore, inspect parts often and perform required service at the prescribed intervals. An authorized service distributor or dealer (authorized service center) should perform required service to keep equipment in top condition.

List of Related Materials

This manual covers operation and installation information for the transfer switch’s power switching device. Decode the transfer switch part number model codefrom the transfer switch nameplateand verifythat the transfer switch’s power switching device matches that what is shown on the front cover of this manual before proceeding with operation or installation.

a separate manual. The following table lists the available electrical controls and the related operation and installation manual part numbers.

Operation/

Installation

Electrical Controls

E33+ (Solid State) TP-5662 S340+ (Solid State) TP-5663 M340+ (Microprocessor) TP-5664

Manual

Separate manuals cover service and parts information for transfer switch power switching devices and electricalcontrols. Thefollowingtableliststheavailable manuals and the related manual part numbers.

Service/Parts

Power Switching Device

ZCS/ZCB (Contactor) TP-5668

Electrical Controls

E33+ (Solid State) TP-5670 S340+ (Solid State) TP-5671 M340+ (Microprocessor) TP-5672

Manual

Service/Parts

Manual

Transfer switches with microprocessor electrical controls and communication accessories can be monitoredand controlledwith a personalcomputer and software. Thefollowingtableliststheavailablemanuals and part numbers.

A separate operation and installation manual that covers information specific to the transfer switch’s electricalcontrols(logiccontroller)completesoperation and installation instructions for the transfer switch.

Three types of electrical controls are available on the

Communications Item

Remote Monitoring and Control Communications (Monitor) Software

Communications Kits TT-847

Operation/

Installation

Manual

TP-5823

ModelZCS transfer switch, and each typeis coveredin

TP-5660 11/98 Introduction i

Service Assistance

TransferSwitchIdentificationNumbers

Service Information

For sales, service, or other information about a Kohler Generator Division product, contact a local authorized distributor or dealer first.

To locate a local authorized distributor or dealer D Look on the product or the information includedwith

the product

D Consult the Yellow Pages under the heading

Generators—Electric

D Visit the Kohler Generator Division Web site at

www.kohlergenerators.com

D Call1-800-544-2444(insidetheU.S.A.andCanada)

or 920-565-3381 (outside the U.S.A. and Canada)

Product Identification

To ensure the supply of correct parts and information, write the product identification numbers in the spaces below. Record the identification numbers immediately after unpacking the products so that the numbers are readily available for future reference. Record the field-installed kit numbers after installing the kit.

Record the product identification numbers from the transfer switch nameplate.

Part Number Serial Number

Accessory Number Accessory Description

TP-5660 11/98ii Introduction

Section 1. Specifications

1.1 Purpose

An automatic transfer switch (ATS) transfers critical electrical loads from a normal (preferred) source of electrical power to an emergency (standby) source when the normal source fails to maintain minimum voltage and/or frequency levels.

Upon normal source failure, the ATS signals the generator set to start. When the emergency source reaches a minimum voltage and/or frequency level, the ATS transfers the load from the normal source to the emergency source. The ATS continuously senses the normalsource and transfers the load backto the normal sourcewhenthe normalsourcereturns. Aftertransferof theloadback tothenormal source,theATSremovesthe generator set start signal, allowing the generator set to shut down.

1.2 Components

A typical transfer switch consists of functional units mounted in an enclosure with a hinged front door. See Figure 1-1. The power switching device connects the load to the normal or emergency sources of power. An inner panel mounted on theinside of the enclosure door containsthe electrical controls (logic controller) circuitry that monitors power sources, controls the power switching device, and signals the generator to start when needed. Enclosure door-mounted controls and indicators allow the operator to control the transfer switch operation mode and obtain system status information. A wire harness with inline connectors to facilitate component replacement and door removal connects the inner panel to the power switching device.

Controls and indicators on the transfer switch are determined by the logic controller and installed accessories. For details see the operation and installation manual for the logic controller specified by the part number model code on the transfer switch nameplate. See Sections 1.3 and 1.4 to determine the logic controller on the transfer switch. See List of Related Materials in the Introduction section in this manual.

1. Power switching device

2. Enclosure

3. Enclosure door

4. Inner panel electrical controls (logic controller)

5. Controls and indicators (mounted on enclosure door)

6. Neutral lug

TS-001

Figure 1-1. Typical Transfer Switch Components

The power switching device transfers power from the normal or emergency power source to the load. See Figure 1-2. The controller electrically actuates the power switching device to select a power source, and theswitch mechanically latches inthe selected position. The switch also includes a provision for manual mechanical operation in emergency nonpowered conditions. Within the switch are two sets of multipole contacts. One set of contacts selects power from the normal source and the other set selects power from the emergency source. The two sets of contacts are mechanically interlocked within the switch, ensuring that only one set of contacts is closed simultaneously. Mechanical interlocking ensures load servicing without cross-coupling of the power sources.

Normal (Utility)

Power Switching Device

Power

Automatic Transfer Switch

To Load

Emergency (Generator) Power

Interface

Generator

Start Generator

Logic

Controller

TS-002

Figure 1-2. Typical Transfer Switch Block Diagram

TP-5660 11/98 Specifications 1

1.3 Nameplate

A nameplate providing characteristic and rating information that affects operation, installation, and servicing is attached to the inside of the transfer switch enclosure door. See Figure 1-3.

Copy the part number into the blank spaces provided in Figure 1-4 and then use Figure 1-4 to interpret the part number.

Copy the part number, factory-installed accessory numbers,and serialnumber fromthe nameplateinto the spaces provided in the Service Assistance section in this manual for use when requesting service or parts.

AUTOMATICTRANSFER SWITCH

PARTNO.

SERIAL NO. VOLTS PHASE HERTZ

1. Location for part number used to identify type of ATS.

2. Location for factory-installed accessory numbers.

3. Location for the ATSserial number.

AMPS WIRES POLES

TS-003

Figure 1-3. Typical Transfer Switch Nameplate

TP-5660 11/982 Specifications

1.4 Part Number Model Code

Use the diagram below to record and interpret the transfer switch part number model code.

Record the transfer switch part number in the boxes below. The transfer switch part number defines characteristics and ratings as explained in the accompanying chart.

Type of Switch Type of Logic Voltage& Frequency

Number of

Poles

Number of

Wires

Type of

Enclosure Amperage Rating Code

Kohler Part Number Key

This chart explains the Kohler transfer switch part numbering code system. The sample part number shown is for a standard contactor power switch with M340+ logic rated at 600 volts, 60 hertz, 3-phase, 3-pole, and 4 wires in a NEMA Type 1 enclosure with a contactor rating of 1000 amperes.

Classification of Power Switch

Z: Power Switch

Type of Power Switch

C: Contactor

Type of Switch

S: Standard

Type of Electrical Controls (Logic Controller)

1: S340+ 2: E33+ 3: S340+ with Programmed Transition 4: E33+ with Programmed Transition 5: M340+ 6: M340+ with Programmed Transition

Voltage Code

60: 600 Volt, 60 Hz 66: 480 Volt, 60 Hz 62: 120 Volt, 60 Hz 68: 208 Volt, 60 Hz 63: 220 Volt, 50 Hz 71: 380 Volt, 50/60 Hz 64: 240 Volt, 60 Hz

SAMPLE PART NUMBER

ZCS-560341-1000

Number of Poles

2: 2 Pole, 1 Phase 3: 3 Pole, 3 Phase

Number of Wires

3: 3 Wire 4: 4 Wire

Enclosure

0 = Open 1 = NEMA Type 1 2 = NEMA Type 12 3 = NEMA Type 3R

Amperes

Numbers Indicate Ampere Rating of Switch

4: 3 Pole, 1 Phase 6: 4 Pole, Fully Rated

Figure 1-4. Transfer Switch Model Designations

TP-5660 11/98 Specifications 3

1.5 Standard Features

UL100

Max.FuseSiz

SwitchRatin

Max.FuseSiz

The standard features listed here are for the ZCS contactor power switching device. Refer to the logic controller operation and installation manual for controller specifications. See List of Related Materials in the Introduction section in this manual.

D Provided as a complete automatic transfer switch

D Two-pole, three-pole and four-pole D Four-pole—fully rated D Can be operated manually when unpowered D Twonormallyopen (N.O.) and two normallyclosed

(N.C.) main shaft auxiliary contacts

D Withstand and closing current ratings as shown

below. with E33+ (solid state logic), S340+ (solid state logic), or M340+ (microprocessor logic) controller

1.6 Ratings

in various enclosures

D Meets UL and CSA standards D Voltage ratings up to 600 vac D Amperage ratings for Programmed Transition

Switches from 40 to 3000 amperes

D Amperage ratings for Standard Switches from

600 to 3000 amperes

D Switching device electrically and mechanically

interlocked

Withstand and Closing Current Ratings per UL 1008 and CSA *

When Used With Any Current-limiting Fuse

Maximum Current (amps) Maximum Current (amps)

(amps)

Programmed Transition Models:

40 50 200,000 150,000 22,000 18,000

80 100 200,000 150,000 22,000 18,000 100 125 200,000 150,000 22,000 18,000 150 200 200,000 150,000 30,000 25,000 225 300 200,000 150,000 30,000 25,000 260 350 200,000 150,000 30,000 25,000 400 600 200,000 150,000 35,000 30,000

Standard and Programmed Transition Models:

600 750 200,000 150,000 50,000 42,000 800 1000 200,000 150,000 50,000 42,000

1000 1250 200,000 150,000 50,000 42,000 1200 1500 200,000 150,000 50,000 42,000 1600 2500 200,000 150,000 100,000 85,000 2000 2500 200,000 150,000 100,000 85,000 2500 4000 200,000 150,000 100,000 85,000 3000 4000 200,000 150,000 100,000 85,000

* UL1008 listed at 480 vac and CSA listed at 600 vac.

(amps)

@ 480 VAC @ 600 VAC @ 480 VAC @ 600 VAC

The following tables provide information on contactor withstand and closing current ratings (WCR). Figure 1-5 provides WCR when used with any current-limiting fuse or any overcurrent protective device. Figure 1-6 and Figure 1-7 provides WCR when coordinated with specific manufacturer’s circuit breakers or fuse types. Figure 1-6 has ratings for 480 V maximum and apply to both UL and CSA listings. Figure 1-7 has ratings for 600 V maximum and apply to a CSA listing only.

When Used With Any Overcurrent

Protective Device (3 cycles)

Figure 1-5. Withstand and Closing Current Ratings

TP-5660 11/984 Specifications

Switch

40,80,J,RK5

40,80

22,000Any,150AmperesMaximum150200,000J,RK5,

200

150

and26

RK1

MerlinGerin

40050,000IT

200,000RK1600

SquareD

RK1

MerlinGerin

800,1000,

and

120

85,000ITE

200,000L3000120

SquareD

Rating (amps)

WCR, RMS

Symmetrical

Amperes

Molded-case Circuit Breakers Fuses

Manufacturer Type or Class

Maximum

Size

(amps)

WCR, RMS

Symmetrical

Amperes

Type or

Class

Maximum

Size

(amps)

and 100

ABB JHB

GE TB4, TJL, TLB4, THLC4

Merlin Gerin CJ400L, CK400H

225,

400 50,000 ITE

600 65,000

800,

1600 and 2000

2500 and 3000

42,000

100,000 Any, 4000 Ampere Maximum 4000 200,000 L 2500

100,000 Any, 4000 Ampere Maximum 4000 200,000 L 4000

ITE

Square D IL

Westinghouse

ITE

Square D NC, SE

Westinghouse NB TRI-PAC, DSL206

GE TP, THP, TC, THC 1600

Westinghouse PC, PCC, PB TRI-PAC 1600

CJD6, SCJD6, HJD6, SHJD6

HKD, KDC, LCL, LA TRI-PAC

TB4, TLB4, THLC4 400 TB6, TJL 600 TB8, TKH, TKL, TP, THP,

TC, THC CJ400L, CK400H 400 CK800H 600 CJD6, SCJD6, HJD6,

SHJD6 CLD6, SCLD6, HLD6,

SHLD6, HHJD6, HHLD6 MD6, MXD6, SMD6,

CMD6, SCMD6, HMD6, HMXD6, SHMD6

IL 400 MH, ME, SE 600 HKD, KDC, LCL,

LA TRI-PAC HLD, LDC 600 HMC, NB TRI-PAC 800 TB8, TKL, TP, THP, TC,

THC CMD6, SCMD6, HMD6,

HMXD6, SHMD6

CK 1000L 1200 CM 1600 1600 CND6, SCND6 1200 CPD6 1600 NC, NE 1200 PH, PE, SE 1600

400 200,000

800

400

600

800

400

800 200,000

200,000

RK1

J, RK5,

RK1

J, RK5,

L, J, RK5,

400

600

750

Figure 1-6. Withstand and Closing Current Ratings (WCR) With Coordinated Circuit Breakers or Fuses,

480 V Maximum, UL and CSA Listings

TP-5660 11/98 Specifications 5

Switch

40,80,J,RK5

40,80

18,000Any,150AmperesMaximum150150,000J,RK5,

200

150

and26

400

RK1

400

MerlinGerin

J,RK5

ITE

Westinghous

60050,000

800150,00

750

60050,000

800150,000RK175

1000,

65,00

150,000L3000and

ITE

SquareD

Rating (amps)

WCR, RMS

Symmetrical

Amperes

Molded-case Circuit Breakers Fuses

Manufacturer Type or Class

Maximum

Size

(amps)

WCR, RMS

Symmetrical

Amperes

Type or

Class

Maximum

Size

(amps)

and 100

225,

400 42,000

800, and

1200

1600 and 2000

2500 and 3000

35,000

85,000 Any, 4000 Ampere Maximum 4000 150,000 L 2500

85,000 Any, 4000 Ampere Maximum 4000 150,000 L 4000

ABB JHB, MHB 400

TB4, SGH4, TJJ 400 TB6, SGH6 600

Merlin Gerin

ITE CJ, SKM

Westinghouse

ITE CP, CN

Square D SE, SES, SEH, MA, MH

Westinghouse NB TRI-PAC, DSL206

Merlin Gerin

Westinghouse PC, PCC, PB TRI-PAC 1600

CK400H, CK400L, CK400N, CK400NN

HKD, KDC, HLD, LA TRI-PAC

SGL4, SGP4 400 SGL6, SGP6 600 CJ400L, SK400N,

SK400H SK800N 600 CJD6, SCJD6, SHP,

SHK, CED6, CFD6 CLD6, SCLD6, HLD6,

SHLD6 HKD, KDC, LA TRI-PAC 400 NB TRI-PAC 800 TB8, TKL, TP, THP, TC,

THC, TKH, TBC8

TKMA, THKMA, TPMM, THMM, TPSS, TJS, TJSS, TKS, THKS, THKSS, THSS

MP16H1, MP16H2, MC16H1

CND6 1200 CPD6, HPD6, HRD6 1600 NC 1200 PHF, PCF 1600

400

400 600

1600

150,000

RK1

J, RK5,

RK1

L, J, RK5,

400

600

Figure 1-7. Withstand and Closing Current Ratings (WCR) With Coordinated Circuit Breakers or Fuses,

600 V Maximum, CSA Listings

TP-5660 11/986 Specifications

1.7 Application Data

Siz

See Figure 1-8 for application data including the range of wire sizes for the transfer switch’s power terminals.

AL/CU UL-listed Solderless Screw-type Terminals for External Power Connections

Switch

(amps)

40 1 #14 AWG to #2 AWG 800 4 #2 AWG to 600 MCM

80--100 1 #14 AWG to 1/0 AWG 1000 4 #2 AWG to 600 MCM

150 1 #8 AWG to 3/0 AWG 1200 4 #2 AWG to 600 MCM 225 1 #6 AWG to 250 MCM 1600 Bus Bar Connection 260 1 #6 AWG to 350 MCM 2000 Bus Bar Connection 400 1 #4 AWG to 600 MCM 2500 Bus Bar Connection 600 2 #2 AWG to 600 MCM 3000 Bus Bar Connection

Normal, Emergency, and Load Terminals

Cables per Pole Range of Wire Sizes

Figure 1-8. Application Data

Switch

(amps)

Normal, Emergency, and Load Terminals

Cables per Pole Range of Wire Sizes

TP-5660 11/98 Specifications 7

Notes

TP-5660 11/988 Specifications

Section 2. Operation

W ARNING

Hazardous voltage. Can cause severe injury or death.

Disconnect all power sources before opening enclosure.

(under 600 Volt)

DANGER

Hazardous voltage. Will cause severe injury or death.

Disconnect all power sources before opening enclosure.

(600 Volt and above)

Have preventive maintenance performed on the transferswitch at regularintervals afterinstallation. See Section 4 for preventive maintenance.

Contact an authorized service center to inspect and service the transfer switch when any wear, damage, deterioration, or malfunction of the transfer switch or its components is evident or suspected; DO NOT

ENERGIZE THE SWITCH.

2.1 Startup

Use this section when power sources have been disconnected to the transfer switch for an extended period after maintenance or service of the standby system, NOT FOR INITIAL STARTUP.

For initial startup, follow the instructions in the installation section of the operation and installation manual for the logic controller and Section 6—Installation in this manual.

Follow the following steps to power up the transfer switch and prepare it for automatic operation.

Powerup Procedure

1. Move the generator set master switch to the OFF position to prevent the generator set from starting.

2. Ensure that BOTH the normal and emergency power sources are disconnected by opening upstream circuit breakers or switches to the transfer switch.

3. Open the enclosure and check that the wire harnesses for the power switching device and the controller are plugged together at the inline disconnect plugP1. See thedrawings in Section 5 to locate the disconnect plug on the contactor.

4. Follow the manual operation procedure to prepare the transfer switch for automatic operation. See Section 2.3.

5. Close and lock the transfer switch enclosure door.

6. Prepare the generator set that provides standby power for operation. Check the oil level, coolant level, fuel supply, batteries, and items specified by the generator set installation or operation checklist or manual.

7. Move the generator set masterswitch to the AUTO position. The generator set should start.

8. When loads can be safely energized, reapply power sources to the transfer switch by closing circuit breakers or switches.

NOTE

Wheninitially applyingpower tothetransfer switch, the engine start contacts remain closed signalling the generator to run until the ATS’s Time Delay Engine Cooldown (TDEC), if equipped, ends.

9. Perform an automatic operation test. See the logic controller operation and installation manual.

Refer to the logic controller operation and installation manual for other startup and setup procedures.

2.2 Automatic Operation

The logic controller installed in the unit provides automatic operation. Refer to the logic controller operation and installation manual for automatic operation details and procedures. See List of Related Materials in the Introduction section in this manual.

TP-5660 11/98 Operation 9

The transfer switch logic controller circuitry, programming, or accessories determine when a power source is acceptable, has failed, or has been restored and operates accordingly. Failure of a power source occurswhen the the voltage and/or frequency on oneor more phases fall below preset limits. A power source is acceptable when the voltage and/or frequency on all monitored phases rise above preset levels. A power source is restored when it becomes acceptable after failing. Typical ATS operation is divided into two sequences.

D Failure of the normal power source and the

resulting transfer to the emergency source or Emergency.

D Restorationof the normalpower sourceandthe

resulting transfer back to the normal source or Normal.

The following sections briefly explain these sequences of operation. Installed controller accessories can change the sequence of operation. See the logic controller operation and installation manual for specifications on time delays, voltage and frequency limits, control adjustments, and accessory information.

2.2.2 Restoration of Normal Power

After normal power source restoration, the controller starts a time delay called Time Delay Emergency to Normal(TDEN). Ifthe normal power source fails before TDEN ends, the time delay resets. TDEN ensures normal power source stabilization before load reconnection.

When the controller determines that the normal power source has maintained an acceptable level and TDEN ends, the controller signals the power switching device to reconnect the load to the normal source.

Afterload transferthe switchmechanically latchesin the normal position and the controller starts a time delay called Time Delay Engine Cooldown (TDEC), if equipped. TDECallowsthe engineand generatorto run unloadedand cooldownbefore shutdown. WhenTDEC expires the controller signals the generator set to shut down.

The generator set controller may allow the generator to run for an additional cooldown period after the transfer switch signals a shutdown. Consult the generator set operation manual for more information.

2.2.1 Failure of Normal Power

When the normal power source fails, the controller starts a time delay called Time Delay Engine Start (TDES). TDES prevents unnecessary generator startup during short normal power interruptions. If the normalpower source is restoredbefore TDES ends, the controller resets the time delay. If the normal power failure persists and TDES ends, the controller issues a signal to start the standby (emergency) generator to produce the emergency power source.

After signalling the generator to start, the controller monitors the emergency power source. When the controller determines that the emergency (generator) power source is acceptable it starts a time delay called Time Delay Normal to Emergency (TDNE). TDNE allows emergency power source stabilization before loadconnection and prevents nuisance transfersduring short power interruptions. When TDNE ends the controller signals the transfer switch toconnect the load to the emergency source.

Afterload transferthe switchmechanically latchesin the emergency position, supplying emergency source power to the load until normal power source restoration and stabilization.

TP-5660 11/9810 Operation

2.3 Manual Operation

To test or troubleshoot the transfer switch, or when the controller fails in an emergency situation, manually operatethe power switching deviceas described below.

W ARNING

Accidental starting. Can cause severe injury or death.

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

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

generator set or connected equipment, disable the generator set as follows: 1) Move the generator set master switch to the OFF position. 2) Disconnect power to the battery charger.

3) Remove battery cables, negative (--)lead first. Reconnect negative(--)lead last whenreconnecting battery. Follow these precautions to prevent starting of generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.

W ARNING

Hazardous voltage. Can cause severe injury or death.

Disconnect all power sources before opening enclosure.

(under 600 Volt)

DANGER

Hazardous voltage. Can cause severe injury or death.

Disconnect power sources before servicing. Install barrier after adjustments, maintenance, or service.

(under 600 Volt)

DANGER

Hazardous voltage. Will cause severe injury or death.

Disconnect power sources before servicing. Install barrier after adjustments, maintenance, or servicing.

(600 Volt and above)

Servicing the transfer switch. Hazardous voltage can cause severe injury or death. Deenergizeall powersources

before servicing. Open main circuit breakers of all power sourcesto the transferswitch and disable all generatorsets 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 battery cables after servicing. Follow these precautions to prevent starting of generator sets by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.

NOTICE

Improper operator handle usage! Use the manual operator

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

Hazardous voltage. Will cause severe injury or death.

Disconnect all power sources before opening enclosure.

(600 Volt and above)

A contactor in normal and serviceable condition transfers smoothly without binding when operated manually. Do notplace the transfer switchinto service if the contactor does not manually operate smoothly without binding; contact an authorized service center to

NOTE

service the contactor.

TP-5660 11/98 Operation 11

2.3.1 Programmed Transition Switch, 40--260 Amps

Manual Operation Procedure

1. Prevent the generator set, which provides the emergency power source to the transfer switch, from starting by moving the generator set master switch to the OFF position; disconnecting power to the generator engine start battery charger, if installed; and disconnecting all generator engine start batteries, negative (--) leads first.

2. Disconnect BOTH the normal and emergency power sources by opening upstream circuit breakers or switches to the transfer switch.

3. Open the transfer switch enclosure door.

4. Set the disconnect switch (DS) to the INHIBIT position to preventthe controller fromenergizing the solenoid(s). See Figure 2-1.

5. Attach the manual operating handle to the switch lever.

6. If the handleis notin the middle(off) position,move thehandle upor downtobring itinto themiddle(off) position. The switch should operate smoothly without binding. Both normal and emergency sources are disconnected from the load in the middle (off) position.

7. Locate the mid-position manual release handle on the left side of the switch. See Figure 2-1.

8. Pull and hold the mid-position manual release handle to the left. This releases the mechanism that allows manual switching to the normal or emergency source from the off position. Move the handle up to the normal position to manually connect the load to the normal source or down to the emergency position to manually connect the load to the emergency source. The switch should operate smoothly in both directions without binding.

9. Manually connect the load to the normal source for automatic operation.

1. Mid-position manual release handle

2. Switch lever, middle (off) position shown

3. Disconnect switch, INHIBIT position shown

4. Manual operating handle, typical

NORMAL

LOCK

EMERGENCY

AUTO INHIBIT

Figure 2-1. Manual Operation, Programmed

Transition Switch 40--260Amps

5660201

10. Remove and return the manual operator handle to the holder provided.

11. Move the disconnect switch (DS) to the AUTO position for automatic operation.

12. Close and lock the transfer switch enclosure door.

13. Reconnect power supplies to the transfer switch.

NOTE

Wheninitially applyingpower tothetransfer switch, the engine start contacts remain closed signalling the generator to run until the ATS’s Time Delay Engine Cooldown (TDEC), if equipped, ends.

14. Reconnect generator engine start battery cables, negative (--) leads last; reconnect power to the generator engine start battery charger, if installed; and move the generator set master switch to the AUTO (automatic) position. The generator may start and run for a while (see NOTE above).

TP-5660 11/9812 Operation

2.3.2 Programmed Transition Switch, 400--3000 Amps

Manual Operation Procedure

2. Disconnect BOTH the normal and emergency power sources by opening upstream circuit breakers or switches to the transfer switch.

3. Open the transfer switch enclosure door.

4. Set the disconnect switch (DS) to the INHIBIT position to preventthe controller fromenergizing the solenoid(s). See Figure 2-2.

NORMAL

LOCK

5. Attach the manual operator handle to the normal switchleverand moveit uptothe normalposition to manually connect the load to the normal source andmove itdown todisconnect. Theswitchshould operate smoothly in both directions without binding.

6. Attach the manual operator handle to the emergency switch lever. Move the handle down to the emergency position to manually connect the load to the emergency source and move it up to disconnect. Theswitchshould operatesmoothly in both directions without binding.

NOTE

A mechanical interlock prevents simultaneous emergency and normal source connection to the load. Both sources can be manually disconnected from the load simultaneously.

7. Manually connect the load to the normal source for automatic operation.

8. Remove and return the manual operator handle to the holder provided.

9. Move the disconnect switch (DS) to the AUTO position for automatic operation.

10. Close and lock the transfer switch enclosure door.

11. Reconnect power supplies to the transfer switch.

LOCK

1. Normal switch lever, normal source shown connected to load

2. Emergency switch lever, emergency source shown disconnected from load

3. Disconnect switch, INHIBIT position shown

4. Manual operating handle, typical

LOCK

EMERGENCY

AUTO

INHIBIT

5660202

Figure 2-2. Manual Operation, Programmed

Transition Switch 400--3000Amps

NOTE

Wheninitially applyingpower tothetransfer switch, the engine start contacts remain closed signalling the generator to run until the ATS’s Time Delay Engine Cooldown (TDEC), if equipped, ends.

12. Reconnect generator engine start battery cables, negative (--) leads last; reconnect power to the generator engine start battery charger, if installed; and move the generator set master switch to the AUTO (automatic) position. The generator may start and run for a while (see NOTE above).

TP-5660 11/98 Operation 13

2.3.3 Standard Switch, 800--3000 Amps

Manual Operation Procedure

5. Attach the manual operating handle to the switch lever.

6. Move the handle up to the normal position to connect the load to the normal source or down to the emergency position to connect the load to the emergency source. Switch should operate smoothly between both positions without binding.

7. Manually connect the load to the normal source for automatic operation.

2. Disconnect BOTH the normal and emergency power sources by opening upstream circuit breakers or switches to the transfer switch.

3. Open the transfer switch enclosure door.

4. Set the disconnect switch (DS) to the INHIBIT position to preventthe controller fromenergizing the solenoid(s). See Figure 2-3.

NORMAL

LOCK

EMERGENCY

8. Remove and return the manual operator handle to the holder provided.

9. Move the disconnect switch (DS) to the AUTO position for automatic operation.

10. Close and lock the transfer switch enclosure door.

11. Reconnect power supplies to the transfer switch.

NOTE

Wheninitially applyingpower tothetransfer switch, the engine start contacts remain closed signalling the generator to run until the ATS’s Time Delay Engine Cooldown (TDEC), if equipped, ends.

AUTO INHIBIT

1. Switch lever, normal source shown connected to load

2. Disconnect switch, INHIBIT position shown

3. Manual operating handle, typical

5660203

Figure 2-3. Manual Operation, Standard Switch

600--3000 Amps

TP-5660 11/9814 Operation

Section 3. Accessories

3.1 Programmed Transition

NOTE

ATSs using microprocessor logic control do not use this section. The programmed transition function takes place within the microprocessor and no time relays are required. See TP-5664, operation and installation manual for the M340+ controller, for operational details. Relays K3 and K4 on the interface board are replaced with a standard form C relay.

3.1.1 Description

The Programmed Transition accessory consists of two timing relays that plug into an interface circuit board. See Figure 3-1. If these relays are present, power transfers from normal to emergency or emergency to normalin threesteps: (1)the switch orcircuit breakerfor the previously connected power source opens, (2) a delay period, adjustable from 2 to 40 seconds, allows any residual voltage in the load circuit to decay, and (3) the switch or circuit breaker for the new power source closes.

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

generator set or connected equipment, disable the generator set as follows: 1) Move the generator set master switch to the OFF position. 2) Disconnect power to the battery charger.

W ARNING

Hazardous voltage. Can cause severe injury or death.

Disconnect all power sources before opening enclosure.

(under 600 Volt)

DANGER

3.1.2 Adjustment

Two separate timing relays are used. One relay, K4 (TDOE), produces the time delay for the normal to emergencypower transfer.The other relay,K3(TDON), produces the time delay for the emergency to normal power transfer. Each relay has a separate adjustment. To make the adjustment, proceed as follows.

W ARNING

Accidental starting. Can cause severe injury or death.

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

Hazardous voltage. Will cause severe injury or death.

Disconnect all power sources before opening enclosure.

(600 Volt and above)

W ARNING

Hazardous voltage. Can cause severe injury or death.

Disconnect power sources before servicing. Install barrier after adjustments, maintenance, or service.

(under 600 Volt)

TP-5660 11/98 Accessories 15

DANGER

Hazardous voltage. Will cause severe injury or death.

NOTE

Wheninitially applyingpower tothetransfer switch, the engine start contacts remain closed signalling the generator to run until the ATS’s Time Delay Engine Cooldown (TDEC), if equipped, ends.

Disconnect power sources before servicing. Install barrier after adjustments, maintenance, or servicing.

(600 Volt and above)

Servicing the transfer switch. Hazardous voltage can cause severe injury or death. Deenergizeall powersources

Time Delay Off Adjustment Procedure

2. Disconnect BOTH the normal and emergency power sources by opening upstream circuit breakers or switches to the transfer switch.

3. Open the transfer switch enclosure door.

8. Reconnect generator engine start battery cables, negative (--) leads last; reconnect power to the generator engine start battery charger, if installed; and move the generator set master switch to the AUTO (automatic) position. The generator may start and run for a while (see NOTE above).

9. Perform an automatic operation test to verify time delays. See the logic controller operation and installation manual. See List of Related Materials in the Introduction section in this manual.

1. K3 (TDON)

2. K4 (TDOE)

A-320687

Figure 3-1. Interface Circuit Board with

Time Delay Off Relays

4. Locate the appropriaterelay on the interfacecircuit board. See Figure 3-1.

5. Insert a screwdriver into the slot of the adjustment screw, which is visible through the cover of the relay, and turn the adjustment screw to the desired time delay period. Turnclockwise to increase time, counterclockwise to decrease time.

6. Close and lock the transfer switch enclosure door.

7. Reconnect power supplies to the transfer switch.

3.2 Other Accessories

With the exception of the Time Delay Off accessory, all other accessories for this automatic transfer switch are controller accessories. For controller accessory information and procedures, refer to the appropriate logic controller operation and installation manual. See List of Related Materials in the Introduction section in this manual.

TP-5660 11/9816 Accessories

Section 4. Scheduled Maintenance

Scheduled 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.

A local authorized distributor or dealer (authorized service center) can provide complete preventive maintenance and services tokeep the transfer switch in top condition. Contact a local distributor or dealer for additional information. See the Service Assistance sectionin thismanual forhow to locatea localdistributor or dealer.

Read this entire section carefully before attempting any maintenance or service. Unless otherwise specified, have maintenance or service performed by an authorized service center that has trained and qualified personnel who follow all applicable codes and standards.

Keep records of all maintenance or service. Replace all barriers and close and lock the enclosure

dooraftermaintenance orservice andbeforereapplying power.

W ARNING

Accidental starting. Can cause severe injury or death.

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

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

generator set or connected equipment, disable the generator set as follows: 1) Move the generator set master switch to the OFF position. 2) Disconnect power to the battery charger.

W ARNING

Hazardous voltage. Can cause severe injury or death.

Disconnect all power sources before opening enclosure.

(under 600 Volt)

DANGER

Hazardous voltage. Will cause severe injury or death.

Disconnect all power sources before opening enclosure.

(600 Volt and above)

TP-5660 11/98 Scheduled Maintenance 17

W ARNING

Hazardous voltage. Can cause severe injury or death.

Disconnect power sources before servicing. Install barrier after adjustments, maintenance, or service.

(under 600 Volt)

DANGER

Hazardous voltage. Will cause severe injury or death.

Disconnect power sources before servicing. Install barrier after adjustments, maintenance, or servicing.

(600 Volt and above)

W ARNING

Servicing the transfer switch. Hazardous voltage can cause severe injury or death. Deenergizeall powersources

Servicingtransfer switch controlsand accessories within the enclosure. Hazardous voltage can cause severe injury or death. Disconnect transfer switch controls at the

inline connector to deenergize the circuit boards and logic circuitry but allow the transfer switch to continue to supply power to the load. Disconnect all power sources to any accessories mounted within the enclosure but which are not wired through the controls and deenergized by inline connector separation. Test circuits with a voltmeter to verify that they are unpowered before servicing.

NOTICE

When replacing hardware, do not substitute with inferior grade hardware. Screws and nuts are available in different

hardness ratings. American Standard hardware uses a series of markings and metric hardware uses a numeric system to indicate hardness. Check markings on bolt head and nuts for identification.

Hazardous voltage. Can cause severe injury or death.

Operate generator set only with all guards and electrical enclosures in place.

Grounding the transfer switch. Hazardous voltage can cause severe injury or death. Electrocution is possible

whenever electricity is present. Open main circuit breakers of all power sources before servicing equipment. Configure the installation to electrically ground the transfer switch and related equipment and electrical circuits to comply with applicable codes and standards. Never contact electrical leads or appliances when standing in water or on wet ground, as the chance of electrocution increases under such conditions.

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

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

Movingrotor.

NOTICE

Hardware damage! Transferswitch may use both American

Standard and metric hardware. Use the correct size tools to prevent rounding of bolt heads and nuts.

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.

4.1 Inspection and Service

Contact an authorized service center to inspect and service the transfer switch when any wear, damage, deterioration, or malfunction of the transfer switch or its components is evident or suspected.

TP-5660 11/9818 Scheduled Maintenance

4.1.1 General Inspection

External Inspection Keep the transfer switch clean

and in good condition by performing a weekly general external inspection of the transfer switch for any condition of vibration, leakage, noise, temperature, contamination, or deterioration. Remove accumulations of dirt, dust, and other contaminants from the transfer switch’s external components or enclosure with a vacuum cleaner or by wiping with adry cloth or brush. Do not use compressed air to clean the

switch because it can cause debris to lodge in the components and cause damage. Replace any worn,

missing, or broken external components with manufacturer-recommended replacement parts. Contact a local authorized service center for specific part information and part ordering. Tighten loose external hardware.

Internal Inspection Disconnect all power sources, open the transfer switch enclosure door, and inspect internal components monthly or when any condition noticedduring an externalinspection may haveaffected internal components.

Contact an authorized service center to inspect and service the transfer switch if any of the following conditions are found inside the transfer switch.

D Accumulations of dirt, dust, moisture, or other

contaminants

D Signs of corrosion D Worn, missing, or broken components D Loose hardware D Wire or cable insulation deterioration, cuts, or

abrasion

D Signs of overheating or loose connections:

discoloration of metal, melted plastic, or a burning odor

D Other evidence of wear, damage, deterioration, or

malfunction of the transfer switch or its components.

4.1.2 Other Inspections and Service

Have an authorized service center perform scheduled maintenance, service, and other maintenance that ensures the safe and reliable operation of the transfer switch including annual inspection and testing. See Section 4.3—Service Schedule for the recommended maintenance items and service intervals.

Have an authorized service center repair or replace components inside the transfer switch enclosure with manufacturer-recommended replacement parts.

4.2 Testing

4.2.1 Weekly Generator Set Exercise

Use a plant exerciser or manual test to start and run the generatorset under a load oncea week to maximizethe reliabilityof theemergency powersystem. See thelogic controller operation and installation manual for the procedure to exercise the generator set. See List of Related Materials in the Introduction section in this manual.

4.2.2 Monthly Automatic Control System Test

Test the transfer switch’s automatic control system monthly. See the logic controller operation and installationmanual forthe testprocedure. Verifythat the expected sequence of operations occurs as the switch transfers the load to the emergency source when a normal source failure occurs or is simulated. Observe the indicators (incandescent lamps and LEDs) included on the transfer switch to check their operation. When the switch transfers the load to the emergency source (after a time delay in the off position on programmed transition units), end the test and verify that the expectedsequence of operations occursas the transfer switchretransfers tothe availablenormalsource (aftera time delay in the off position on programmed transition units) and signals the generator set to shut down after a cooldown period.

If the power interruption required to perform an internal inspection is unacceptable in the application, have an internal inspection performed by an authorized service center.

TP-5660 11/98 Scheduled Maintenance 19

4.3 Service Schedule

D,R

abrasionandrepairorreplacewiringtoregainthe

D,R

vibration,leakage,noise,temperature,contamination

Follow the service schedule below for the recommended service intervals. Have all service performed by an authorized service center except for activities limited to the items designated by an X.

System Component or Procedure

See

Section

Visually

Inspect

Check Change Clean Test

Frequency

ELECTRICAL SYSTEM

Check for signs of overheating or loose connections: discoloration of metal, melted plastic, or a burning odor

Check the contactor’s external operating mechanism for cleanliness and clean and relubricate if dirty *

Check wiring insulation for deterioration, cuts, or properties of the original wiring

Check the transfer switch’s main power switching mechanisms’ mechanical operation and integrity

Tighten control and power wiring connections to specifications

Check the transfer switch’s main power switching contacts’ condition and clean or replace the main contacts or replace the contactor assembly as necessary

Perform a thermal scan or millivolt drop test to check for high contact resistances on power circuits. Tighten connections, clean main contacts, adjust or replace main contacts or contactor assembly to eliminate high contact resistances

Test wire and cable insulation for electrical breakdown 4.1.2 D Every 3 Years Check calibration of voltage-sensing circuitry and

setpoints, and recalibrate circuitry as necessary

4.1.1 X X M

4.1.1 X

4.1.2 D D

4.1.2 D D D Y

4.1.2, 6.4, L D D Y

4.1.2 D D, R D Y

4.1.2 D D, R D D Y

4.1.2 D D Every 5 Years

D, R

(lubricant)

(wiring)

D M

CONTROL SYSTEM

Exercise the generator set under load 4.2.1, L X W Test the transfer switch’s automatic control system 4.2.2, L X X M Test all indicators (incandescent lamps and LEDs) and

all remote control systems for operation

L D D D, R D Y

GENERAL EQUIPMENT CONDITION

Inspect the outside of the transfer switch for any condition of vibration, leakage, noise, temperature, contamination, or deterioration to keep the transfer switch clean and in good condition *

Check that all external hardware is in place, tightened, and not badly worn

Inspect the inside of transfer switch for any condition of or deterioration to keep the inside of the transfer switch

clean, dry, and in good condition * Check that all internal hardware is in place, tightened,

and not badly worn

* Service more frequently if operated in dusty or dirty areas.

See Section Read these sections carefully for additional information before attempting maintenance or service. Visually Inspect Examine these items visually. Check Requires physical contact with or movement of system components, or the use of nonvisual indications. Change May require replacement of components depending upon the severity of the problem. Clean Removeaccumulationsofdirtandcontaminantsfromexternaltransferswitch’scomponentsorenclosurewithavacuum

cleaner or by wiping with a dry cloth or brush. Do not use compressed air to clean the switch because it can cause debris to lodge in the components and cause damage.

Test May require tools, equipment, or training available only through an authorized service center. L See the transfer switch logic controller operation and installation manual for more information. D Have service performed by an authorized service center. X Operator action. R May require replacement of components.

4.1.1 X X W

4.1.1 X X R W

4.1.1 X X D M

4.1.2 D D D Y

4.1.2 X D M W=Weekly

M=Monthly Q=Quarterly S=SixMonths Y=Yearly

TP-5660 11/9820 Scheduled Maintenance

Section 5. Diagrams and Drawings

Diagram or Drawing Drawing Number Page Enclosure Dimensions Drawings

40--260 Amp, NEMA Type 1 and Type 3R ADV-6180- 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

400 Amp, NEMA Type 1 and Type 3R ADV-5934-C 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

600--1200 Amp, NEMA Type 1 and 3R ADV-5936A-F 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

600--1200 Amp, NEMA Type 12 ADV-5936B-B 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1600--2000 Amp, NEMA Type 1 ADV-5941-E 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1600--2000 Amp, NEMA Type 3R, E33+ and S340+ Logic ADV-5990-A 28. . . . . . . . . . . . . . . . . . .

1600--2000 Amp, NEMA Type 3R, M340+ Logic ADV-5989-A 29. . . . . . . . . . . . . . . . . . . . . . . . . . . .

2500--3000 Amp, NEMA Type 1 ADV-6242-B 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2500--3000 Amp, NEMA Type 3R, E33+ and S340+ Logic ADV-6241-A 31. . . . . . . . . . . . . . . . . . .

2500--3000 Amp, NEMA Type 3R, M340+ Logic ADV-6240-A 32. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Open Units Dimensions Drawings*

600--3000 Amp, M340+ Logic and Inner Panel Mounting ADV-5975A-B *. . . . . . . . . . . . . . . . . . . . .

600--3000 Amp, E33+ and S340+ Logic and Inner Panel Mounting ADV-5975B-B *. . . . . . . . . . . .

600 Amp ADV-5975C-A *. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

800--1200 Amp ADV-5975D-A *. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1600--2000 Amp ADV-5975E-B *. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2500--3000 Amp ADV-5975F-B *. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40--3000 Amp, M340+ Logic and Inner Panel Mtg., Prog. Transition ADV-5976A-C *. . . . . . . . . . .

40--3000 Amp, E33+ and S340+ Logic and Inner Panel Mtg., Prog. Transition ADV-5976B-C *. .

40--260 Amp, Programmed Transition ADV-5976C-A *. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

400 Amp, Programmed Transition ADV-5976D-B *. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

600 Amp, Programmed Transition ADV-5976E-A *.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

600--1200 Amp, Programmed Transition ADV-5976F-B *. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1600--2000 Amp, Programmed Transition ADV-5976G-B *. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2500--3000 Amp, Programmed Transition ADV-5976H-B *. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Schematic Diagrams, E33+ Logic

600--1200 Amp 321283-C 33.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1600--3000 Amp 321296-B 34.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

400 Amp with Programmed Transition 321295-C 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

600--3000 Amp with Programmed Transition 321285-B 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Schematic Diagrams, S340+ Logic

600--1200 Amp 321096-C 37.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1600--3000 Amp 321097-A 38.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40--260 Amp with Programmed Transition

120 VAC 346311- 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

208 VAC 353185- 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

240 and 480 VAC 353184- 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

380 and 416 VAC 353183- 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

600 VAC 353182- 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

400 Amp with Programmed Transition 321098-B 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

600--3000 Amp with Programmed Transition 321099-B 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Schematic Diagrams, M340+ Logic

600--1200 Amp 321287-C 46.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1600--3000 Amp 321301-B 47.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40--260 Amp with Programmed Transition

120 VAC 346312- 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

208 VAC 353174- 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

240 and 480 VAC 353175- 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

380 and 416 VAC 353176- 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

600 VAC 353177- 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

400 Amp with Programmed Transition 321300-B 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

600--3000 Amp with Programmed Transition 321286-A 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

* Contact your local distributor or dealer for a copy of these drawings. They are not included in this manual.

TP-5660 11/98 Diagrams and Drawings 21

Notes

TP-5660 11/9822 Diagrams and Drawings

ADV-6180-

Enclosure Dimensions Drawing, 40--260 Amp, NEMA Type 1 and Type 3R

TP-5660 11/98 Diagrams and Drawings 23

ADV-5934-C

Enclosure Dimensions Drawing, 400 Amp, NEMA Type 1 and Type 3R

24 Diagrams and Drawings TP-5660 11/98

ADV-5936A-F

Enclosure Dimensions Drawing, 600--1200 Amp, NEMA Type 1 and Type 3R

TP-5660 11/98 Diagrams and Drawings 25

ADV-5936B-B

Enclosure Dimensions Drawing, 600--1200 Amp, NEMA Type 12

26 Diagrams and Drawings TP-5660 11/98

ADV-5941-E

Enclosure Dimensions Drawing, 1600--2000 Amp, NEMA Type 1

TP-5660 11/98 Diagrams and Drawings 27

ADV-5990-A

Enclosure Dimensions Drawing, 1600--2000 Amp, NEMA Type 3R, E33+ and S340+ Logic

28 Diagrams and Drawings TP-5660 11/98

ADV-5989-A

Enclosure Dimensions Drawing, 1600--2000 Amp, NEMA Type 3R, M340+ Logic

TP-5660 11/98 Diagrams and Drawings 29

ADV-6242-B

Enclosure Dimensions Drawing, 2500--3000 Amp, NEMA Type 1

30 Diagrams and Drawings TP-5660 11/98

ADV-6241-A

Enclosure Dimensions Drawing, 2500--3000 Amp, NEMA Type 3R, E33+ and S340+ Logic

TP-5660 11/98 Diagrams and Drawings 31

ADV-6240-A

Enclosure Dimensions Drawing, 2500--3000 Amp, NEMA Type 3R, M340+ Logic

32 Diagrams and Drawings TP-5660 11/98

MECHANISM

P1--34

TB6

P3--2P3--1 P3--3

P15--1 P15--2 NA NB

P15--4

P15--7

AB1

AB2

P3--4 P3--7 P3--8

FOR 3

NORMAL

SENSING

TRANSFORMER

CONNECTION

SEE ABOVE

OPTION DA--26

AT INNER PANEL

P15--3

OPTION

NT3NT2

DA--26

3 NORMAL

SENSING

P15--8

P15--9

BC2

BC1

P3--9

P3--1 P3--2 P3--3 P3--4 P3--7 P3--8 P3--9

REMOVE JUMPER ”JA” TO INSTALLTEST SWITCH, ENABLING TESTING OF N/AC VOLTAGESENSING CIRCUIT FROM DOOR.

FROM NORMAL

SOURCE

P1--36P1--35

76 77

P1--23

P1--24

8180797877767574

P1--22

P2--9 P2--11

P2--1P2--4P2--7

SENSING

CIRCUIT

+12V

1 2 3 4 5 6 7 8 9 10 11 12

TB1

JA J J

TEST

NB NC

T2 T3

24VAC

12VDC

POWER SUPPLY

NCNBNA

NT1

TO LOAD

2 2

NTS ETS

NTS

76 77

CN1

K5K3

ES3

P1--30

P1--25

P8--10

209

4 7

ES4

P1--12 P1--11

P1--6

P8--11

REMOTE

ENGINE START

SN--2

206

TB2

P1--18

P8--9

P1--13

P4--1

P9--1

CN1 CE1

2 1

52 53

10 4 5 6 3 2 1 7 8

K5 K2

NORMAL

POSITION

LOGIC

P4--2

P9--2

CN CE

SN--1

10 11

NORMAL

SWITCH

POSITION

NORMAL

P8--15

EMERGENCY

W W

P4--3

P9--3

LNNN

SWITCH

POSITION

SOURCESOURCE

AVAILABLEAVAILABLE

6762

1110

P1--3

P1--14

J1J2

EMERGENCY

POSITION

P4--4

P9--4

ETS

306

ERNR

693996

SE--1

T6T2

91112

N/CA

VOLT R17 NORMAL C--AVOLTAGE SENSING

N/AB

VOLT R34 NORMALA--BVOLTAGE SENSING

N/BC

LOGIC

VOLT R37 NORMAL B--CVOLTAGESENSING

NOTE: JP1, JP2, JP3, JP4 JUMPER REMOVED FOR VOLTAGE SENSING ABOVE 240 VAC

P8--4

P8--2P1--7

330

LOGIC BOARD

JP2

JP3

JP4

CE1

307

P8--1

E FREQ.

R42 EMERGENCY FREQUENCY

AND VOLTAGE SENSING.

JP1

ENGINE

START

R29

P1--10

ECNC

EC EB EA

P2--12

E VOLT

LED1

EMERGENCY

VOLTAGE

P1--9

P1--8

EBEC

ET1

T6 T7

T7T6

P2--10

24VAC

12VDC

POWER SUPPLY

NOTE: JP5 JUMPER REMOVED

P2--3

SENSING

CIRCUIT

NORMAL SOURCE AVAILABLE

EMERGENCY SOURCE

AVAILABLE

SENSING.

FOR 3

FROM EMERGENCY SOURCE

P2--6

JP5

SN--1

SN--2

SE--1

NC NO NC NO NC

X X

LEGEND

EMERGENCY TRANSFER OPERATOR (TRANSFER TO EMERGENCY)

CE1 TRANSFER COIL CONTROL RELAY (TO EMERGENCY)

NORMALTRANSFER OPERATOR (TRANSFER TO NORMAL)

TRANSFER COIL CONTROL RELAY (TO NORMAL)

CN1

DS DISCONNECT SWITCH ER

EMERGENCY RELAY

EMERGENCY TRANSFORMER

ETS EMERGENCY CONTACTOR POWER CONTACTS

JUMPER K1 EMERGENCY SOURCE AVAILABLE RELAY K2 NORMALSOURCE AVAILABLERELAY K3 EMERGENCYPOSITION RELAY

K4 ENGINE START RELAY

K5 NORMALPOSITION RELAY

LED

LIGHT EMITTING DIODE

NORMAL CONTACTORAUX. SWITCHN

NORMAL RELAY NT

NORMALTRANSFORMER

NTS

NORMAL CONTACTOR POWER CONTACTS

LIMITSWITCH (EMERGENCY)SE SN LIMITS SWITCH (NORMAL)

T SENSING TRANSFORMER

COMPONENT CONNECTION

###

CONNECTION NODE #

LEAD

P#--#

PLUG/SOCKET CONNECTOR

A4--1

TERMINAL BLOCK ON TRANSFER SWITCH

TERMINAL BLOCK ON LOGIC BOARD

TERMINAL BLOCK PRIMARY OF TRANSFORMER

TERMINAL BLOCK SECONDARYOF TRANSFORMER

INDICATORLAMP

W -- WHITE R -- RED G -- GREEN

NOTES:

1.ATS SHOWN IN NORMAL POSITION WITH NORMAL POWER PRESENT

NEUTRAL CONTACTS NTS & ETS PRESENT

ON 4 POLE UNITS ONLY.

OPTIONAL NEUTRAL BUS

EMERG.NORMAL

AUXILIARYCONTACTS

15A, 240VAC

A4--1

A4--1A4--1

A4--2

A4--2 A4--2

A3--1 A3--1

A3--1

A3--2

A3--2A3--2

321283-C

Schematic Diagram, E33+ Logic, 600--1200 Amp

TP-5660 11/98 Diagrams and Drawings 33

MECHANISM

P1--34

TO LOAD

2 2

NTS ETS

FROM NORMAL

SOURCE

P1--36P1--35

76 77

AT INNER PANEL

TB6

8180797877767574

P1--22

P1--23

P1--24

NB NC

CN1 CE1

6 4

209R

209

206R

NCNBNA

NTS

76 77

206

P1--18

-- --

LNNN

ETS

306

307R

P1--3

306R

P1--10

P1--9

307

EC EB EA

FROM EMERGENCY SOURCE

EMERG.NORMAL

SN--1

P1--8

EBEC

SN--2

SE--1

SE--2

NC NO NC NO NC NO NC

X X

AUXILIARYCONTACTS

15A, 240VAC

A4--1

A4--2

A4--2 A4--2

A3--1

A3--1 A3--1

A3--2

A4--1A4--1

A3--2A3--2

P3--2P3--1 P3--3

P15--1 P15--2 NA NB

P15--4

P15--7

AB1

AB2

P3--4 P3--7 P3--8

FOR 3

NORMAL

SENSING

TRANSFORMER

CONNECTION

SEE ABOVE

OPTION DA--26

P15--3

OPTION

NT3NT2

DA--26

3 NORMAL

SENSING

P15--8

P15--9

BC2

BC1

P3--9

P3--1 P3--2 P3--3 P3--4 P3--7 P3--8 P3--9

REMOVE JUMPER ”JA” TO INSTALLTEST SWITCH, ENABLING TESTING OF N/AC VOLTAGESENSING CIRCUIT FROM DOOR.

NT1

T2 T3

P2--9 P2--11

P2--1P2--4P2--7

24VAC

12VDC

POWER SUPPLY

SENSING

CIRCUIT

+12V

1 2 3 4 5 6 7 8 9 10 11 12

TB1

JA J J

TEST

ET1

T6 T7

T7T6

N/CA VOLT

N/AB VOLT

N/BC VOLT

330

P8--4

P8--2P1--7

JP2

JP3

JP4

LOGIC BOARD

P8--1

VOLT

FREQ.

R29

R42 EMERGENCY FREQUENCY

AND VOLTAGE SENSING.

JP1

ENGINE

EMERGENCY

START

VOLTAGE

P2--12

LED1

24VAC 12VDC

POWER SUPPLY

P2--10

NOTE: JP5 JUMPER REMOVED

FOR 3

P2--6

P2--3

SENSING

CIRCUIT

NORMAL SOURCE AVAILABLE

EMERGENCY SOURCE AVAILABLE

SENSING.

JP5

P8--9

P8--15

P1--12 P1--11

4 7

P8--11

SN--2

NO NC

P8--10

K5K3

ES3

ES4

P1--30

P1--25

P1--6

REMOTE ENGINE START

SN--1

TB2

P1--13

10 4 5 6 3 2 1 7 8

K5 K2

NORMAL

POSITION

LOGIC

P4--1

P4--2

P9--2

P9--1

10 11

CCN CCE

2 1

NORMAL

EMERGENCY

SWITCH

POSITION

52 53

EMERGENCY

NORMAL

SOURCESOURCE

AVAILABLEAVAILABLE

W W

P4--3

P9--3

SWITCH

6762

J1J2

EMERGENCY

P4--4

P9--4

1110

P1--14

POSITION

LOGIC

ERNR

693996

SE--1

T6T2

91112

R17 NORMAL C--AVOLTAGE SENSING

R34 NORMALA--BVOLTAGE SENSING

R37 NORMAL B--CVOLTAGESENSING

NOTE: JP1, JP2, JP3, JP4 JUMPER REMOVED FOR VOLTAGE SENSING ABOVE 240 VAC

LEGEND

EMERGENCY TRANSFER OPERATOR (TRANSFER TO EMERGENCY)

CCE TRANSFER COIL CONTROL RELAY (TO EMERGENCY)

NORMALTRANSFER OPERATOR (TRANSFER TO NORMAL)

TRANSFER COIL CONTROL RELAY (TO NORMAL)

CCN

DS DISCONNECT SWITCH ER

EMERGENCY RELAY

EMERGENCY TRANSFORMER

ETS EMERGENCY CONTACTOR POWER CONTACTS

JUMPER K1 EMERGENCY SOURCE AVAILABLE RELAY K2 NORMALSOURCE AVAILABLERELAY K3 EMERGENCYPOSITION RELAY

K4 ENGINE START RELAY

K5 NORMALPOSITION RELAY

LED

LIGHT EMITTING DIODE

NORMAL CONTACTORAUX. SWITCHN

NORMAL RELAY NT

NORMALTRANSFORMER

NTS

NORMAL CONTACTOR POWER CONTACTS

LIMITSWITCH (EMERGENCY)SE SN LIMITS SWITCH (NORMAL)

T SENSING TRANSFORMER

COMPONENT CONNECTION

###

CONNECTION NODE #

LEAD

P#--#

PLUG/SOCKET CONNECTOR

A4--1

TERMINAL BLOCK ON TRANSFER SWITCH

TERMINAL BLOCK ON LOGIC BOARD

TERMINAL BLOCK PRIMARY OF TRANSFORMER

TERMINAL BLOCK SECONDARYOF TRANSFORMER

INDICATORLAMP

W -- WHITE R -- RED G -- GREEN

NOTES:

1.ATS SHOWN IN NORMAL POSITION WITH NORMAL POWER PRESENT

NEUTRAL CONTACTS NTS & ETS PRESENT

ON 4 POLE UNITS ONLY.

OPTIONAL NEUTRAL BUS

321296-B

Schematic Diagram, E33+ Logic, 1600--3000 Amp

34 Diagrams and Drawings TP-5660 11/98

MECHANISM

P1--34

AT INNER PANEL

TB6

P3--2P3--1 P3--3

P15--1 P15--2

NA NB

P15--4

P15--7

AB1

AB2

P3--4 P3--7 P3--8

FOR 3 NORMAL SENSING

TRANSFORMER

CONNECTION

SEE ABOVE

OPTION DA--26

FROM NORMAL

76 77

P15--3

OPTION

NT3NT2

DA--26

3 NORMAL

SENSING

P15--8

P15--9

BC2

BC1

P3--9

P3--1 P3--2 P3--3 P3--4 P3--7 P3--8 P3--9

REMOVE JUMPER ”JA” TO INSTALLTEST SWITCH, ENABLING TESTING OF N/AC VOLTAGESENSING CIRCUIT FROM DOOR.

SOURCE

P1--36P1--35

TO LOAD

2 2

NTS ETS

REMOTE ENGINE START

P1--6

P1--15

NTS

76 77

TB2

SN--1

SEO--1

P4--1

P9--1

P1--18

P1--33

P1--17

P1--5

P8--9

P1--13

2 1

P1--26

52 53

10 4 5 6 3 2 1 7 8

K5 K2

NORMAL

POSITION

LOGIC

P4--2

P9--2

206NC

209

406

309

10 11

P1--22

P1--23

P1--24

CN1

6 4

TDON

B A

SN--2

NC NO

CN1

5 3

CEO

6 4

CE0

P8--12

P8--11

SEO--2

3 4

8180797877767574

T3T7

TO T3

TO T7

T2 T3

P2--1P2--4P2--7

24VAC

12VDC

POWER SUPPLY

SENSING

CIRCUIT

+12V

1 2 3 4 5 6 7 8 9 10 11 12

TB1

JA J J

TEST

NB NC

NT1

P2--11P2--9

NCNBNA

TO TB6--81

P8--10

P4--7

P1--1

P9--7 P1--4P8--7

T2 40 50

K5K3

ES3

ES4

P1--12

P1--11

P1--30

P1--25

SCN

201

SCEO

502

P8--15

CN1 CE1

CEO

12 1 2

NORMAL

EMERGENCY

SWITCH

POSITION

EMERGENCY

NORMAL

W W

P4--3

P9--3

LNNN

RTN

-401R

RTE

-500R

NR ER

CNO

SWITCH

POSITION

SOURCESOURCE

AVAILABLEAVAILABLE

6762

J1J2

EMERGENCY

P4--4

P9--4

1110

209

400R

217

501R

307

P1--14

P1--28

POSITION

LOGIC

ETS

CN/0

SCNO

CE/0

SCE

P8--4

SE--1

P1--7

SNO--1

P1--27

P1--21

T6T2

91112

N/CA

VOLT R17 NORMAL C--AVOLTAGE SENSING

N/AB

VOLT R34 NORMALA--BVOLTAGE SENSING

N/BC

VOLT R37 NORMAL B--CVOLTAGESENSING

NOTE: JP1, JP2, JP3, JP4 JUMPER REMOVED FOR VOLTAGE SENSING ABOVE 240 VAC

P1--2

P1--3

TDOETDON

P8--3

P8--2

SNO--2

P8--6 P9--6

TDOE

B A

LOGIC BOARD

JP2

JP3

JP4

506

309

306

P1--16

E FREQ.

R42 EMERGENCY FREQUENCY

AND VOLTAGE SENSING.

JP1

ENGINE

START

CNO

3 5

CNO

4 6

CE1

3 5

CE1

P4--6

R29

P8--1

P1--10

E VOLT

EMERGENCY

EBEC

EC EB EA

T6 T7

P2--12

POWER SUPPLY

LED1

VOLTAGE

P1--8P1--9

ET1

TB6--80

T7T6

P2--3

24VAC

12VDC

SENSING

CIRCUIT

NORMAL SOURCE

AVAILABLE EMERGENCY SOURCE

AVAILABLE

NOTE: JP5 JUMPER REMOVED

SENSING.

FOR 3

FROM EMERGENCY SOURCE

OFF

SE--1

SE--2

SN--1

SN--2

SCN

C NO

SCEO

CE1 COILCONTROL EMERGENCY RELAY

CEO COILCONTROL EMERGENCYRELAY(TRANSFEROPERATOR)

CN1 COILCONTROLNORMAL RELAY

CN/0

COIL CONTROL NORMAL RELAY (TRANSFER OPERATOR)

CE TRANSFER OPERATOR (CLOSE TO EMERGENCY)

CE/0 TRANSFER OPERATOR(OPEN FROM EMERGENCY)

TRANSFER OPERATOR(CLOSETO NORMAL)

CN0

TRANSFER OPERATOR(OPEN FROM NORMAL) DISCONNECTSWITCH

EFR EMERGENCY FREQUENCY RELAY

ER EMERGENCY RELAY

LED LIGHT EMITTING DIODE

NORMALRELAYNR

NR1 NORMALRELAY #1

BRIDGE RECTIFIER (EMERGENCYTRANSFER OPERATOR)RE

REO BRIDGERECTIFIER (EMERGENCY TRANSFER OPERATOR)

RN BRIDGE RECTIFIER (NORMALTRANSFER OPERATOR)

RNO BRIDGERECTIFIER (NORMAL TRANSFER OPERATOR)

SE, SEO

LIMIT SWITCH (EMERGENCY)

SN, SNO

LIMIT SWITCH (NORMAL)

TDES

TIME DELAY ENGINE START RELAY

TDOE

TIME DELAY ON EMERGENCYRELAY

TDON

TIME DELAY ON NORMALRELAY JUMPER

P2--6P2--10

JP5

NORMAL EMERG.

NC NO

NC NO NC

NO NC NC

NOC NC

NOTES:

1.ATS SHOWN IN NORMAL POSITION WITH NORMAL POWER PRESENT

NEUTRAL CONTACTS NTS & ETS PRESENT

ON 4 POLE UNITS ONLY.

OPTIONAL NEUTRAL BUS

AUXILIARYCONTACTS

15A, 240VAC

A4--1

A4--2

A4--2 A4--2

A3--1

A3--1 A3--1

A3--2

SE0--1

SE0--2

SNO--1

SNO--2

SCNO

SCE

LEGEND

NC NO

C NO

NC NOC NC

COMPONENT CONNECTION TERMINAL

###

LEAD

P#--#

PLUG/SOCKET CONNECTOR LOGIC BOARD DIP CONNECTOR

CONNECTION NODE

TERMINAL BLOCK ON TRANSFER SWITCH PANEL

A4--1

TRANSFER SWITCH POWER TERMINALS

TERMINAL BLOCK PRIMARY OF TRANSFORMER TERMINAL BLOCK SECONDARYOF TRANSFORMER

INDICATORLAMP

G -- GREEN R -- RED W -- WHITE

X X

XXX

OFF

A4--1A4--1

A3--2A3--2

EMERG.NORMAL

321295-C

Schematic Diagram, E33+ Logic, 400 Amp with Programmed Transition

TP-5660 11/98 Diagrams and Drawings 35

MECHANISM

P1--34

INNER

PANEL

TB6

P15--2P15--1 NBNA

NT2 NT3

P15--8

P15--7

P15--4

BC2

AB2

AB1

P3--8P3--7P3--4

P3--1 P3--2

FOR 3 NORMAL SENSING

TRANSFORMER

CONNECTION

SEE ABOVE

OPTION DA--26

P3--3 P3--4 P3--7 P3--8 P3--9

FROM NORMAL

SOURCE

P1--36P1--35

76 77

P3--3P3--1 P3--2

P15--3

OPTION

DA--26

3 NORMAL

SENSING

P15--9

BC1

P3--9

P2--7 P2--4

REMOVE JUMPER ”JA” TO INSTALLTEST SWITCH, ENABLING TESTING OF N/AC VOLTAGESENSING CIRCUIT FROM DOOR.

SENSING

CIRCUIT

TB1

8180797877767574

P2--1

T3T7

TO T7

P1--22

TO T3

TEST

P1--23

T2 T3

24VAC

12VDC POWER SUPPLY +12V

P1--24

NB NC

NT1

P2--11P2--9

JJJA

TO LOAD

2 2

NTS ETS

NTS

76 77

LNNN

206R

CCN

P1--18

206

-208R

209

307

406R

CCEO

406

6 4

NCNBNA

TO TB6--81

P8--10

T2 40 50

P4--7

K3 K5

ES3

P1--1

P9--7 P1--4P8--7

ES4

121110987654321

P1--12 P1--11

P1--30

P1--25

REO

209R

P1--6

P8--12

P8--11

P1--15

SEO--2

TDON

AB B A

REMOTE

ENGINE START

SN--2

209

CEO

P1--13

P1--26

NORMAL

POSITION

P4--2

P9--2

CCN

2 1

CCEO

2 1

NORMAL

SWITCH

POSITION

52 53

NORMAL

W W

K2K5

LOGIC

P8--15

P4--3

P9--3

P8--9

SN--1

SEO--1

TB2

12 11 9

P4--1

P9--1

1110

NR ER

CCE

1 2

CCNO

1 2

EMERGENCY

SWITCH

POSITION

EMERGENCY

SOURCESOURCE

AVAILABLEAVAILABLE

6762

J1J2

10 11

2 8

307

P1--14

P1--28

EMERGENCY

POSITION

P4--4

P9--4

ETS

306R

307R

506R

RNO

308R

CNO

P8--4

SE--1

P1--7

SNO--1

P1--27

P1--21

T6T2

8712365410

N/CA VOLT

R17

NORMAL C--AVOLTAGE SENSING

N/AB

VOLT R34 NORMALA--BVOLTAGE SENSING

N/BC

LOGIC

VOLT R37 NORMAL B--CVOLTAGESENSING

NOTE: JP1, JP2, JP3, JP4 JUMPER REMOVED FOR VOLTAGE SENSING ABOVE 240 VAC

P1--3

P8--6 P9--6

306

P1--2P1--17

506

TDOETDON

P8--3

P8--2

SNO--2

TDOE

LOGIC BOARD

JP2

JP3

JP4

FROM EMERGENCY SOURCE

P1--10

P1--9

EMERG.NORMAL

OFF

LEGEND

P#--#

A4--1

POWER PRESENT

NEUTRAL CONTACTS NTS & ETS PRESENT ON 4 POLE UNITS ONLY.

OPTIONAL NEUTRAL BUS

AUXILIARYCONTACTS

15A, 240VAC

A4--1

A4--1 A4--1

A3--2 A3--2

###

EA T7

A4--2

A3--1

A3--2

COMPONENT CONNECTION TERMINAL

LEAD

PLUG/SOCKET CONNECTOR LOGIC BOARD DIP CONNECTOR

CONNECTION NODE TERMINAL BLOCK ON TRANSFER SWITCH PANEL

TRANSFER SWITCH POWER TERMINALS TERMINAL BLOCK PRIMARY OF TRANSFORMER TERMINAL BLOCK SECONDARYOF TRANSFORMER

INDICATORLAMP G -- GREEN R -- RED W -- WHITE

CCE

CCNO

P8--1

P1--16

P4--6

FREQ.

JP1

ENGINE

START

R29

VOLT

EMERGENCY

R42 EMERGENCY FREQUENCY

AND VOLTAGE SENSING.

EBEC

EC EB EA

T6 T7

P2--12

POWER SUPPLY

LED1

VOLTAGE

P1--8

ET1

TB6--80

T7T6

P2--3

P2--10

24VAC 12VDC

SENSING

CIRCUIT

NORMAL SOURCE

AVAILABLE EMERGENCY SOURCE

AVAILABLE

NOTE: JP5 JUMPER REMOVED

SENSING.

FOR 3

SN--1

SN--2

SE--1

SE0--1

SE0--2

SNO--1

SNO--2

CCE COIL CONTROL EMERGENCY RELAY

CCEO COIL CONTROLEMERGENCY RELAY(TRANSFER OPERATOR)

CCN COILCONTROLNORMAL RELAY

CCN0

COIL CONTROL NORMAL RELAY (TRANSFER OPERATOR)

CE TRANSFER OPERATOR (CLOSE TO EMERGENCY)

CE0 TRANSFER OPERATOR (OPEN FROM EMERGENCY)

TRANSFER OPERATOR(CLOSETO NORMAL)

CN0

TRANSFER OPERATOR(OPEN FROM NORMAL) DISCONNECTSWITCH

EFR EMERGENCY FREQUENCY RELAY

ER EMERGENCY RELAY

LED LIGHT EMITTING DIODE

NORMALRELAYNR

NR1 NORMALRELAY #1

BRIDGE RECTIFIER (EMERGENCYTRANSFER OPERATOR)RE

REO BRIDGERECTIFIER (EMERGENCY TRANSFER OPERATOR)

RN BRIDGE RECTIFIER (NORMALTRANSFER OPERATOR)

RNO BRIDGERECTIFIER (NORMAL TRANSFER OPERATOR)

SE, SEO

LIMIT SWITCH (EMERGENCY)

SN, SNO

LIMIT SWITCH (NORMAL)

TDES

TIME DELAY ENGINE START RELAY

TDOE

TIME DELAY ON EMERGENCYRELAY

TDON

TIME DELAY ON NORMALRELAY JUMPER

P2--6

NC NO

NOTES:

1.ATS SHOWN IN NORMAL POSITION WITH NORMAL

JP5

Schematic Diagram, E33+ Logic, 600--3000 Amp with Programmed Transition

A4--2A4--2

A3--1A3--1

321285-B

36 Diagrams and Drawings TP-5660 11/98

321096-C

Schematic Diagram, S340+ Logic, 600--1200 Amp

TP-5660 11/98 Diagrams and Drawings 37

Schematic Diagram, S340+ Logic, 1600--3000 Amp

321097-A

38 Scheduled Maintenance

TP-5660 11/98

346311-

Schematic Diagram, S340+ Logic, 120 VAC, 40--260 Amp with Programmed Transition

TP-5660 11/98 Diagrams and Drawings 39

Schematic Diagram, S340+ Logic, 208 VAC, 40--260 Amp with Programmed Transition

353185-

40 Scheduled Maintenance

TP-5660 11/98

353184-

Schematic Diagram, S340+ Logic, 240 and 480 VAC, 40--260 Amp with Programmed Transition

TP-5660 11/98 Diagrams and Drawings 41

Schematic Diagram, S340+ Logic, 380 and 416 VAC, 40--260, Amp with Programmed Transition

353183-

42 Scheduled Maintenance

TP-5660 11/98

353182-

Schematic Diagram, S340+ Logic, 600 VAC, 40--260 Amp with Programmed Transition

TP-5660 11/98 Diagrams and Drawings 43

Schematic Diagram, S340+ Logic, 400 Amp with Programmed Transition

321098-B

44 Scheduled Maintenance

TP-5660 11/98

321099-B

Schematic Diagram, S340+ Logic, 600--3000 Amp with Programmed Transition

TP-5660 11/98 Diagrams and Drawings 45

321287-C

Schematic Diagram, M340+ Logic 600--1200 Amp

46 Diagrams and Drawings TP-5660 11/98

321301-B

Schematic Diagram, M340+ Logic, 1600--3000 Amp

TP-5660 11/98 Diagrams and Drawings 47

346312-

Schematic Diagram, M340+ Logic, 120 VAC, 40--260 Amp with Programmed Transition

48 Diagrams and Drawings TP-5660 11/98

353174-

Schematic Diagram, M340+ Logic, 208 VAC, 40--260 Amp with Programmed Transition

TP-5660 11/98 Diagrams and Drawings 49

353175-

Schematic Diagram, M340+ Logic, 240 and 480 VAC, 40--260 Amp with Programmed Transition

50 Diagrams and Drawings TP-5660 11/98

353176-

Schematic Diagram, M340+ Logic, 380 and 416 VAC, 40--260 Amp with Programmed Transition

TP-5660 11/98 Diagrams and Drawings 51

353177-

Schematic Diagram, M340+ Logic, 600 VAC, 40--260 Amp with Programmed Transition

52 Diagrams and Drawings TP-5660 11/98

321300-B

Schematic Diagram, M340+ Logic, 400 Amp with Programmed Transition

TP-5660 11/98 Diagrams and Drawings 53

321286-A

Schematic Diagram, M340+ Logic, 600--3000 Amp with Programmed Transition

54 Diagrams and Drawings TP-5660 11/98

Section 6. Installation

Kohler automatic transfer switches are shipped factory wired and tested, ready for installation. Installation of the switch consists of the following.

D Unpackingand inspecting thetransfer switch upon

receipt.

D Protecting the switch against damage before and

during installation.

D Wiring of normal source (utility), emergency

source (generator), and load circuits.

D Wiring of control connections such as generator

start signals and accessories.

D Checking voltages and functions. D Connecting and initializing the controller.

Follow this installation section first when installing the transfer switch. Refer to the logic controller operation and installation manual packed with the transfer switch for details on electrical controls and accessories. See Sections 1.3 and 1.4 for nameplate and model number informationto identify typeof logic controller. See List of Related Materials in the Introduction section in this manual.

6.1 Upon Receipt of Unit

6.1.1 Inspection

At time of delivery,inspect the automatic transfer switch for signs of shipping damage. If damage and/or rough handling is evident, file a damage claim immediately with the transportationcompany and promptly notify the distributor or dealer.

6.1.2 Lifting W ARNING

See Figure 6-1 for the approximate weight of each transfer switch covered in this manual. Use a spreader bar for lifting. Attach the bar only to the enclosure’s mounting holes or lifting brackets; do not lift the unit at anyotherpoints. Replace,close,andlock theenclosure door before moving or mounting the unit.

Transfer Switch

Rating (amps)

100

150

225

260

400 Any 524 (238)

600

800

1000

1200

1600

2000

2500

3000

Number of

Poles

2, 3

2,3

2, 3

4 3

Approximate

Weight lb. (kg)

237 (108)

242 (110)

237 (108)

242 (110)

237 (108)

242 (110) 242 (110)

247 (112) 242 (110)

247 (112)

638 (290) 658 (298)

678 (308) 761 (345)

975 (442)

1100 (499)

975 (442)

1100 (499) 1155 (524)

1295 (587)

1155 (524)

1295 (587)

Figure 6-1. Approximate Transfer Switch Weight

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

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

TP-5660 11/98 Installation 55

6.1.3 Unpacking

Unpack the transfer switch immediately after receipt and inspect for shipping damage. Failureto perform an immediate inspection impedes recovery of losses causedby shippingdamage. Use carewhenunpacking to avoid damaging any of the transfer switch components. Remove all dirt and packing material that mayhaveaccumulatedin thetransferswitch oranyof its components.

If the equipment has been stored at cold temperatures, allow equipment to warm to room temperature for 24 hours (minimum) before unpacking to prevent condensation on the electrical apparatus from surrounding moist air.

such as a wall. When mounting these units either way, plumb the enclosure to ensure that the door hinges are vertical to avoid any distortion of the enclosure or door. For floor mounting, bolt the mounting feet to the floor and shim the mounting feet as needed to plumb the enclosure. Keyholeslots for wallmounting areprovided intherearpanelof theenclosure. Placewashersbehind themounting bracket key holes to shim the enclosureto a plumb condition.

Bolt the 600- through 3000-ampere automatic transfer switches directly to floor mounting pads. When mountingone of these units, level themounting pads so that the doorhinges are plumb when the unit is installed to avoid distorting the enclosure or door.

6.1.4 Storage

Store the transfer switch in its protective packing until ready for final installation. Protect the automatic transfer switch at all times from excessive moisture, construction grit, and metal chips. Avoid storage in low temperature and high humidity areas where condensation could occur on the unit.

6.2 Mechanical Installation

Check the System Voltage and Frequency Do not

install a transfer switch if the system voltage and frequency shown on the transfer switch nameplate are differentfrom the nominal normal(utility)source voltage and frequency and the nominal emergency source voltage and frequency shown on the generator set nameplate.

To plan theinstallation,use the dimensions given on the enclosure dimension drawings in Section 5. Select the

mounting site to comply 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 open the enclosure door fully and to service the switch.

6.3 Check Manual Operation

Follow a procedure in Section 2.3 to manually operate thecontactor but stopbefore reapplyingpower sources. Verify that the contactor operates smoothly without binding and prepare it for automatic operation. If the contactor does not operate smoothly without binding, STOP! Call an authorized service center to service the contactor before proceeding!

6.4 Electrical Wiring

All internal electrical connections are prewired. The onlywiringnecessary wheninstallingthetransferswitch is to connect the unit to external devices.

Observe all applicable national, state, and local electr ical codes during installation.

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

See Section 5 for schematic diagrams and enclosure drawings.

W ARNING

Vertically mount the 40- through 260-ampere transfer switches covered in this manual to a wall or other rigid vertical supporting structure. Keyhole slots for mounting purposes are provided in the mounting brackets on the top and bottom of each unit. When mounting these units, plumb the enclosure to ensure thatthe doorhingesare verticalto avoidanydistortionof the enclosure or door. Place washers behind the mounting bracket key holes to shim the enclosure to a plumb condition.

Floor mount or attach the 400-ampere transfer switch covered in this manual to a rigid supporting structure

Accidental starting. Can cause severe injury or death.

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

TP-5660 11/9856 Installation

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

generator set or connected equipment, disable the generator set as follows: 1) Movethe generator set master switch to the OFF position. 2) Disconnect power to the battery charger.

3) Remove battery cables, negative (--)lead first. Reconnect

negative(--) l ead lastwhenreconnecting battery. Follow these precautions to prevent starting of generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.

W ARNING

Hazardous voltage. Can cause severe injury or death.

Disconnect all power sources before opening enclosure.

(under 600 Volt)

DANGER

Hazardous voltage. Will cause severe injury or death.

Disconnect all power sources before opening enclosure.

(600 Volt and above)

W ARNING

DANGER

Hazardous voltage. Will cause severe injury or death.

Disconnect power sources before servicing. Install barrier after adjustments, maintenance, or servicing.

(600 Volt and above)

Grounding the transfer switch. Hazardous voltage can cause severe injury or death. Electrocution is possible

wheneverelectricity is present. Open main circuit breakers of all power sources before servicing equipment. Configure the installation to electrically ground the transfer switch and related equipment and electrical circuits to comply with applicable codes and standards. Never contact electrical leads or appliances when standing in water or on wet ground, as the chance of electrocution increases under such conditions.

Installing battery charger. Hazardous voltage can cause severe injury or death. Electrical shock may occur if battery

charger is not electrically grounded. Connect battery charger enclosure to ground of a permanent wiring system. As an alternative, install an equipment grounding conductor with circuit conductors and connect to equipment grounding terminal or lead on battery charger. Perform battery charger installation as prescribed in equipment manual. Installbattery charger in compliance with local codes and ordinances.

Connecting battery and battery charger. Hazardous voltage c an cause severe injury or death. Reconnect

battery correctly to avoid electrical shock and damage to battery charger and battery(ies). Have a qualified electrician install battery(ies).

Installing accessories to transformer assembly.

Hazardous voltage. Can cause severe injury or death.

Disconnect power sources before servicing. Install barrier after adjustments, maintenance, or service.

(under 600 Volt)

TP-5660 11/98 Installation 57

Hazardous voltage can cause severe injury or death. To prevent the possibility of electrical shock, disconnect harness plug before installing any accessories involving connection to transformer assembly primary terminals 76, 77, 78, and 79. Terminals are at line voltage! (Models with E33+, S340,

S340+, 340, R340, or R33 controls only.)

Installing accessories to transformer assembly. Hazardous voltage can cause severe injury or death. To

prevent the possibility of electrical shock, disconnect harness plugbefore installing any accessories which will be connected to transformer assembly primaryterminals on microprocessor logic models. Terminals are at line voltage!

Making line or auxiliary connections. Hazardous voltage can cause severe injury or death. Toprevent the possibility

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

NOTICE

Hardware damage! Transferswitch may use both American

Standard and metric hardware. Use the correct size tools to prevent rounding of bolt heads and nuts.

NOTICE

Electrostatic discharge damage! Electrostatic discharge

short, to ground.

compressedairtocleanthe switchbecauseitcancause debris to lodge in the components and cause damage.

Use watertight conduit hubs approved for outdoor use for installing the transfer switch outdoors.

Before connecting wiring cables to terminal lugs, remove surface oxides from cables by cleaning with a wire brush. If using aluminum conductors, apply a joint compound to cables. After tightening terminal lugs, carefully wipe off excess joint compound.

Connection points for the normal power, emergency power, and load are clearly marked on the contactor assembly and are also shown on the drawings in Section4. Be suretoheed thephase markings (A,B,C, and N).

NOTE

Connect source and load phases as indicated by the markings and drawings. Improper connections may cause short circuits or cause phase-sensitive load devices to malfunction or operate in reverse.

NOTE

For easy access during installation wiring, remove the front door of the enclosure. Disconnect the cable plug that connects the front door components to the internal components and then lift the door off its hinge pins.

6.4.1 AC Power Connections

All conductors should enter the enclosure at the locations shown on the drawings. When drilling entry holes for any conductors, cover the transfer switch components for protection from metal chips and construction grit. Remove any debris from the enclosure with a vacuum cleaner. Do not use

NOTE

When making power connections to the power switching device, leave sufficient slack in the power leads to reach all of the power connecting lugs on the power switching device.

NOTE

The power source leads must be phased A-B-C for option DD-34-Z (phase sequence and loss monitoring) to function correctly. If the power source phase sequence is not A-B-C and option DD-34-Z is enabled the controller consider the source to have failed.

Connectthe normal, emergencyand load conductors to the clearly marked terminals on the transfer switch. Verify that all connections are consistent with drawings before tightening the lugs. Tighten all cable lug connections to the torque values shown in Figure 6-2.

TP-5660 11/9858 Installation

SocketSiz

Torque

SocketSiz

Bol

Across Flat

1/8 45 4 5.1 5/32 100 8 11.3 3/16 120 10 13.6 7/32 150 12 17.0

1/4 200 17 22.6 5/16 275 23 31.1

3/8 375 31 42.3

1/2 500 42 56.5 9/16 600 50 67.8

in. lbs. ft. lbs. Nm

Figure 6-2. Tightening Torque for Lugs

In cases where the normal, emergency, and load connections are made to a rear connected bus bar,use a compression washer, flat washer, and a minimum grade 5 bolt and torque to the values in Figure 6-3.

Torque Bolt (Grade 5)

Size

1/4-20 72 6 8.1

5/16-18 132 11 14.9

3/8-16 300 25 33.9 1/2-13 720 60 81.4

in. lbs. ft. lbs. Nm

Figure 6-3. Tightening Torque for Bus Bars

6.4.2 Generator Start Connection W ARNING

position; disconnecting power to the generator engine start battery charger, if installed; and disconnecting all generatorenginestart batterycables, negative(--)leads first.

Connect the generator set remote starting circuit to the generator start signal connections located on terminals 3and 4 of the transferswitch contactor assembly. Ared decal identifies the location of the terminal block. See the enclosure dimension drawings in Section 5. The transfer switch controller provides a contact closure through the wiring harness to these terminals to signal the generator set to start.

6.4.3 Accessory and Controller Connections

Complete any external connections for accessories. See Section the transfer switch logic controller operation and installation manual. See Sections 1.3 and1.4 fornameplate and model number informationto identify type of logic controller. See List of Related Materialsin the Introduction section in this manual. See the logic controller operation and installation manual for additional control connection information. Connect the powerswitching device and controller wiring harnesses together at the inline disconnect plug after performing the voltage check procedure to complete installation.

6.5 Prepare the Generator Set for

Operation

Accidental starting. Can cause severe injury or death.

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

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

generator set or connected equipment, disable the generator set as follows: 1) Movethe generator set master switch to the OFF position. 2) Disconnect power to the battery charger.

3) Remove battery cables, negative (--)lead first. Reconnect negative(--) l ead lastwhenreconnecting battery. Follow these precautions to prevent starting of generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.

Prevent the generator set that provides the emergency power source to the transfer switch from starting by moving the generator set master switch to the OFF

W ARNING

Hazardous voltage. Can cause severe injury or death.

Operate generator set only with all guards and electrical enclosures in place.

Disconnect all power sources to the transfer switch by opening upstream circuit breakers or switches to the transfer switch.

Prepare the generator set that provides the emergency powersourcetothetransferswitchforoperation. Check the oil level, coolant level, fuel supply, batteries, and items specified by the generator set installation or operation checklist or manual.

Move the generator set master switch to the OFF position; reconnect generator engine start battery

Movingrotor.

TP-5660 11/98 Installation 59

cables, negative (--) leads last; and reconnect power to the generator engine start battery chargers, if installed.

6.6 Functional Tests

3. Move the generator set master switch to the OFF position to inhibit generator set starting.

4. Manually transfer the load to the emergency source. See Section 2.3.

6.6.1 Voltage Check

Perform a voltage check to verify that the voltages and phasing of all power sources are compatible with the transferswitch beforeenergizing the load orconnecting the power switching device and controller wire harnesses together.

Thenominalvoltage andfrequencyof thenormal(utility) source, transfer switch nameplate, and generator set output and nameplate should all be the same to avoid damage to loads and the transfer switch.

W ARNING

Hazardous voltage. Can cause severe injury or death.

Operate generator set only with all guards and electrical enclosures in place.

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

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

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

V oltage Check Procedure

Perform voltage checks in the order given to avoid damaging the transfer switch.

1. Disconnect all power sources before opening the transfer switch enclosure by opening upstream circuit breakers or switches to the transfer switch.

Movingrotor.

NOTE

5. Reapply the normal source by closing circuit breakers or switches.

6. Use an accurate voltmeter to check the normal source phase-to-phase and phase-to-neutral terminal voltages. Use accurate test equipment to check the phase rotation at the normal source terminals. If the nominal normal source voltage or frequency is not what is shown on the transfer switch nameplate, STOP! Do not proceed further in installation because the transfer switch is not designed for the application—call a local service center to order the correct transfer switch. Rewire the transfer switch normal source terminals to obtain a phase sequence of A-B-C if required on transfer switches with microprocessor controls (see NOTE.)

NOTE

Thepower sourceleads must be phased A-B-Cfor option DD-34-Z (phase sequence and loss monitoring) to function correctly on microprocessor-based controls. If the power source phase sequence is not A-B-C and option DD-34-Z is enabled the controller considers the source to have failed.

7. Disconnect the normal power source by opening upstream circuit breakers or switches to the transfer switch.

8. Manually transfer the load to the normal source. See Section 2.3.

9. Reapply the emergency source by closing circuit breakers or switches.

10. Move the generator set master switch to the RUN position. The generator set should start.

11. Use anaccuratevoltmeterto checktheemergency source phase-to-phase and phase-to-neutral terminal voltages. Use accurate test equipment to check the phase rotation at the emergency-source terminals. Rewire the transfer switch emergency source terminals if the emergency source phase rotation is not the same as the normal source.

2. Disconnect the power switching device and the logic controller wire harnesses at the inline disconnect plug if they are connected.

TP-5660 11/9860 Installation

12. Follow the generator set manufacturer’s instructions to adjust the generator output voltage and frequency to match the nominal system voltage and frequency shown on the transfer switch nameplate if they are different. The automatictransferswitch willoperatecorrectly only to the rated system voltage and frequency specified on the nameplate.

13. Move the generatorset master switch to the AUTO position.

14. Disconnect the emergency power source by opening upstream circuit breakers or switches to the transfer switch.

15. Connect the power switching device and controller wiring harnesses together at the inline disconnect plug.

16. Close and lock the transfer switch enclosure door.

17. Reconnect power sources by closing circuit breakers or switches. The transfer switch may signal the generator set to run for TDEC, if equipped.

6.6.2 Automatic Operation Test

Test thetransfer switch’sautomatic controlsystem. See the logic controller operation and installation manual for the test procedure.

6.7 Controller Setup

See the logic controller operation and installation manual for controller startup and setup procedures.

6.8 Ensure Warranty Registration

The transfer switch seller must complete a Startup Notification Form and submit it to the manufacturer within 60 days of the initial startup date. A Startup Notification Form is included with generator sets and covers all equipment in the standby system. Standby systems not registeredwithin 60 days of the initial date are automatically registered using the manufacturer’s ship date as the startup date.

NOTE

Wheninitially applyingpowertothe transferswitch, the engine start contacts remain closed signalling the generator to run until the ATS’s Time Delay Engine Cooldown (TDEC), if equipped, ends.

Installation of the transfer switch’s power switching device is complete. Close and lock the enclosure door.

TP-5660 11/98 Installation 61

Notes

TP-5660 11/9862 Installation

Appendix A. Glossary of Abbreviations

Abbreviations are used throughout this manual. Normally in the text they will appear in complete form with the abbreviation following in parenthesis the first time they are used. After that they will appear in the abbreviated form. The commonly used abbreviations are shown below.

AC alternating current AISI American Iron and Steel Institute Amp ampere Amps amperes ANSI American National Standard

Institute API American Petroleum Institute approx. approximate, approximately A/R as required, as requested A/S as supplied, as stated,

as suggested ASA American Standards Association ASME American Society of Mechanical

Engineers assy. assembly ASTM American Society for Testing

Materials ATDC after top dead center aux. auxiliary AWG American Wire Gauge AWM appliance wiring material BBDC before bottom dead center BDC before dead center BHP brake horsepower bmep brake m ean effective pressure Btu British thermal unit °C Celsius degree cc cubic centimeter CCA cold cranking Amps. CEC Canadian Electrical Code cfh cubic feet per hour cfm cubic feet per minute CID cubic inch displacement cm centimeter, centimeters cmm cubic meters per minute co. company cont’d. continued CSA Canadian Standards Association CT current transformer cu. in. cubicinch, cubic inches cyl. cylinder dB decibel dBA decibels (A weighted) DC direct current DCR direct current resistance deg. degree dept. department dia. diameter e.g. example given EIA Electronic Industries Association EMI electromagnetic interference EPA Environmental Protection

Agency etc. et cetera (and so forth) ext. external °F Fahrenheit degree fl. oz. fluid ounce, fluid ounces FM frequency modulation ft. foot, feet ft. lbs. foot pound, foot pounds ga. gauge(meters, wire size)

gal./ gals.gallon, gallons gph gallons per hour gpm gallons per minute gr. grade gnd. ground HCHT high cyli nder head temperature HET high exhaust (or engine)

temperature Hg mercury (element) H2O water HP horsepower hr, hrs hour Hz hertz (cycles per second) ID inside diameter IEEE Institute of Electrical and

Electronic Engineers in. inch(es) inc. incorporated in. lbs. inch pounds int. internal int.-ext. internal-external ISO International Standards

Organization J joule, joules JIS Japanese Industry Standard kg kilogram, kilograms kg/cm2kilograms per square centimeter kgm kilogram meter(s) kJ kilojoules (btu cal) km kilometer, kilometers kPa kiloPascal, kiloPascals kph kilometers per hour kV kilovolt kVA kilovolt amperes kW kilowatt, kilowatts kWH kilowatt hour L liter, liters LxWxH length x width x height LED(s) light emitting diode lb., lbs. pound, pounds L/hr. liter per hour, liters per hour L/min. liter(s) per minutes LOP low oil pressure LP liquefied petroleum m meter, meters

m max. maximum MCM one t housand circular mils. meggar megohmmeter MHz megahertz mi. mile, miles mil one one-thousandth of an inch min. minimum mJ millijoule, millijoules MJ mega joule, mega joules mm millimeter, millimeters m3/min cubic meters per minute MPa m egaPascal mW milliwatt, milliwatts MW megawatt, megawatts N/A not available or not applicable

cubic meter, cubic meters

NBS National Bureau of Standards N.C. normally closed NEC National Electrical Code NEMA National Electrical

Manufacturers Association

NFPA National Fire Protection

Association Nm Newton meter, Newton meters no., nos number, numbers NPT National Standard taper pipe

thread per general use N/R not required OC overcrank OD outside diameter OEM original equipment manufacturer OS overspeed, oversize O/S oversize OSHA Occupational Safety and Health

Act OV overvoltage oz. ounce, ounces PF power factor PMG permanent magnet generator pot. potentiometer ppm parts per million psi pounds per square inch pt., pts. pint, pints PVC polyvinyl chloride qt., qts. quart, quarts qty. quantity ref. reference RFI radio frequency interference r.h.m. round-head machine (screw) rms root mean square RPM revolutions per minute RTV room temperature vulcanization SAE Society of Automotive Engineers SCR silicon-controlled rectifier sec. second, seconds spec. specs, specification sq. square sq. cm square centimeters sq. in. square inch, square inches tach tachometer TDC top dead center tech. pub.technical publications temp. temperature TIF telephone i nfluence factor TP, TPs technical publications turbo turbocharger UHF ultrahigh frequency UNC Unified coarse thread (was NC) UNF Unified fine thread (was NF) UL Underwriter’s Laboratories, Inc. U/S undersize U.S.A. United States of America V volt, volts vac volts alternating current vdc volts direct current VHF very high frequency W watt, watts

Appendix A-1TP-5660 11/98

TP-5660 11/98

KOHLER CO. Kohler, Wisconsin 53044 Phone 920-565-3381, Web site www.kohlergenerators.com Fax 920-459-1646 (U.S.A. Sales), Fax 920-459-1614 (International) For the nearest sales and service outlet in U.S.A. and Canada Phone 1-800-544-2444

Kohlerr Power Syst ems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65)264-6422, Fax (65)264-6455

Kohler ZCS Operation And Installation

Specifications and Main Features

Frequently Asked Questions

User Manual