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

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Kohler ZCS Operation And Installation

Specifications and Main Features

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