Kohler KBC Operation And Installation Download Page 4

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Table of Contents, continued

TP-6835 9/17

Table of Contents

4.3

Accessory Modules

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4.3.1

Accessory Module Mounting

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

4.3.2

Input/Output (I/O) Modules

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

4.3.3

External Battery Supply Module (EBSM)

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

4.3.4

Alarm Module

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

4.4

Load Shed (Forced Transfer to OFF)

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

4.5

Heater

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4.6

Other Accessories

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Section 5 Functional Tests and Setup

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5.1

Introduction

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

5.2

Manual Operation Test

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

5.3

Voltage Check

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5.4

Lamp Test

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5.5

Automatic Operation Test

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5.6

System Setup

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5.7

Exerciser Setup

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

5.8

User Interface Cover

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5.9

Startup Notification

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Section 6 Scheduled Maintenance

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Section 7 Bypass, Isolation, and Manual Transfer

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7.1

Introduction

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7.1.1

Bypassing the Transfer Switch

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7.1.2

Isolating the Transfer Switch

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7.2

150--600 Amp Models

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7.2.1

Bypassing the ATS, 150--600 Amp Models

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7.2.2

Isolating the Transfer Switch, 150--600 Amp Models

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7.2.3

Return to Service, 150--600 Amp Models

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7.2.4

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

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7.2.5

Manual Load Transfer, 150--600 Amp Models

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7.3

800--1200 Amp Models

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7.3.1

Bypassing the ATS, 800--1200 Amp Models

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7.3.2

Isolating the ATS, 800--1200 Amp Models

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7.3.3

Return to Service, 800--1200 Amp Models

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7.3.4

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

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7.3.5

Manual Load Transfer, 800--1200 Amp Models

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7.4

1600--4000 Amp Models

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7.4.1

Bypassing the Transfer Switch, 1600--4000 Amp Models

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7.4.2

Isolating the Transfer Switch, 1600--4000 Amp Models

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7.4.3

Removing the Transfer Switch, 1600--4000 Amp Models

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7.4.4

Return to Operation, 1600--4000 Amp Models

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7.4.5

Manual Load Transfer, 1600--4000 Amp Models

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Appendix A Abbreviations

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Summary of Contents for KBC

Page 1: ...Automatic Transfer and Bypass Isolation Switches Models KBS KBP KBC 150 to 4000 Amperes TP 6835 9 17c Operation and Installation...

Page 2: ...the product identification numbers from the transfer switch nameplate Model Designation Serial Number Accessories Alarm Board Battery Module California OSHPD Approval Controller Disconnect Switch Curr...

Page 3: ...t and Output Connections 19 2 6 2 Harness Connection 19 2 6 3 Controller Ground 19 2 7 Electrical Wiring 20 2 7 1 Source and Load Connections 20 2 7 2 Extended Transfer Time Relay Model KBC only 22 2...

Page 4: ...the Transfer Switch 51 7 2 150 600 Amp Models 52 7 2 1 Bypassing the ATS 150 600 Amp Models 52 7 2 2 Isolating the Transfer Switch 150 600 Amp Models 55 7 2 3 Return to Service 150 600 Amp Models 57...

Page 5: ...the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the gen...

Page 6: ...fer switch power sources and disable all generator sets as follows 1 Press the generator set off reset button to shut down the generator set 2 Disconnect power to all battery chargers 3 Disconnect all...

Page 7: ...ctions section at the beginning of this manual Keep this manual with the equipment for future reference The equipment service requirements are very important to safe and efficient operation Inspect pa...

Page 8: ...call the nearest regional office Headquarters Europe Middle East Africa EMEA Kohler Power Systems Netherlands B V Kristallaan 1 4761 ZC Zevenbergen The Netherlands Phone 31 168 331630 Fax 31 168 33163...

Page 9: ...he bypass connection provides a direct connection to either the Normal or Emergency source bypassing the transfer switch to provide power to the load during transfer switch service Isolation removes t...

Page 10: ...utomatic Voltage Frequency C 208 Volts 60 Hz K 440 Volts 60 Hz D 220 Volts 50 Hz M 480 Volts 60 Hz F 240 Volts 60 Hz N 600 Volts 60 Hz G 380 Volts 50 Hz P 380 Volts 60 Hz H 400 Volts 50 Hz R 220 Volts...

Page 11: ...for circuit protection and use as a disconnect device The functional tests in Section 5 are a necessary part of the installation Be sure to perform the functional tests which include voltage checks a...

Page 12: ...t and packing material that may have accumulated in the transfer switch or any of its components Note Do not use compressed air to clean the transfer switch Cleaning with compressed air can cause debr...

Page 13: ...locations with very high ambient temperatures installation in a shaded area or a location with the enclosure door facing away from direct sunlight is recommended Prepare the foundation Ensure that the...

Page 14: ...d rated to resist seismic loading in accordance with ACI 355 2 04 and documented in a report by a reputable testing agency for example the Evaluation Service Report issued by the International Code Co...

Page 15: ...l operator handle on the transfer switch for maintenance purposes only Return the transfer switch to the normal position Remove the manual operator handle if used and store it in the place provided on...

Page 16: ...7 Slide the hub onto the shaft and insert the maintenance handle into the hole in the hub 4 Move the maintenance handle up or down as shown to manually operate the transfer switch It should operate sm...

Page 17: ...tacts c Starting with the contactor in the NORMAL position use the maintenance handle to move the Normal operator from the CLOSED to the OPEN position d Move the Emergency operator from the OPEN posit...

Page 18: ...oor Figure 2 10 shows the locations of the connectors on the controller It is not necessary to open the cover to access the Ethernet Modbusr and input output connectors Opening the cover If necessary...

Page 19: ...cations 6866 Input 1A Input 1B Input 2A Input 2B Output 1 NC Output 1 C Output 1 NO Output 2 NC Output 2 C Output 2 NO TB1 NC normally closed NO normally open C common 12 6 1 7 Figure 2 12 Input and O...

Page 20: ...osure 1 Remove all jewelry 2 Stand on a dry approved electrically insulated mat 3 Test circuits with a voltmeter to verify that they are deenergized Hazardous voltage Will cause severe injury or death...

Page 21: ...a typical rating torque label Carefully wipe off any excess joint compound after tightening the terminal lugs Bus connections For bus connections use SAE grade 5 hardware to connect the bus to the te...

Page 22: ...set the time delay Compare your equipment to Figure 2 17 and Figure 2 20 to identify the relay used on your transfer switch GM89661 Figure 2 16 Typical Relay Connections see the schematic diagram for...

Page 23: ...time Some examples are shown in Figure 2 23 1 Time select pushbuttons 2 Relay timing LED 3 Range selection switch Note See Figure 2 17 for relay location on the field connection assembly 3 IMG_0732 1...

Page 24: ...ury or death To prevent electrical shock deenergize the normal power source before making any line or auxiliary connections Prevent the generator set from starting by pressing the OFF button on the ge...

Page 25: ...l block is mounted on the upper right side inside the enclosure on most models See Figure 2 24 Figure 2 26 shows typical auxiliary contact connections Refer to the schematic drawing provided with the...

Page 26: ...TP 6835 9 17 26 Section 2 Installation Notes...

Page 27: ...source and open the engine start contacts to the standby generator after the cooldown delay has elapsed 3 3 Preferred Source Toggle The preferred source toggle function alternates between the two gen...

Page 28: ...r set 1 to the normal side of ATS2 e Connect generator set 2 to the emergency side of ATS2 2 Three source systems require the following input output connections to control the engine start commandsfor...

Page 29: ...FER BACK TO NORMAL AFTER THE UTILITY RETURNS WHEN THE UTIITY IS AVAILABLE THE BATTERY SUPPLY MODULE WILL PROVIDE POWER TO THE CONTROLLER ON ATS2 THE 3 SOURCE SYSTEM DISABLE INPUT AND OUTPUT WILL PREVE...

Page 30: ...2 engine start ES connections See Figure 3 1 Figure 3 2 Input and Output Connections for Three Source Systems 3 6 ATS1 and ATS2 System Setup Use the System Setup Menu on each transfer switch to set th...

Page 31: ...t breakers of all transfer switch power sources and disable all generator sets as follows 1 Press the generator set off reset button to shut down the generator set 2 Disconnect power to all battery ch...

Page 32: ...only TB2 A1 B1 GND1 3 6 1 4 A1 B1 GND1 Customer connections Input Output Cable shield Cable shield Figure 4 3 Modbus RS 485 Connections USB to RS 485 port converter RS 485 USB port Device USB port De...

Page 33: ...ion board allows the transfer switch to be connected to a building s Ethernet network to communicate with personal computers connected to the same subnet Note For an ethernet connection obtain an IP a...

Page 34: ...MPAC Controller with Ethernet comm board IP xx xx xx 03 Figure 4 6 Remote Network Ethernet Connection MPAC Controller with Ethernet comm board IP xx xx xx 03 PC IP xx xx xx 02 Device Last device RS 4...

Page 35: ...ic board and the assemblies on the expansion bus The module mounting kit holds up to five optional modules The total current draw of all modules must not exceed 300 mA See Figure 4 8 Add the current d...

Page 36: ...feet Outputs Outputs Available 6 Contact Type Form C SPDT Contact Voltage Rating 2 A 30 VDC 500 mA 125 VAC Connection Type Terminal Strip Wire Size 14 24 AWG Figure 4 11 Standard I O Module Specifica...

Page 37: ...dule EBSM The external battery supply module kit allows connection to the generator set engine start battery ies or other batteries to provide 12 VDC power to the ATS controller The external battery s...

Page 38: ...ection and Voltage Setting 1 Use 14 28 AWG wire to connect one or two batteries to terminal block TB13 A second battery can be connected but is not required Follow the marking on the board for the pos...

Page 39: ...arm Setup The alarm board is equipped with a 90 dB audible alarm The audible alarm can be set to sound under selected fault conditions Use the Common Alarms Setup menu to assign functions to the audib...

Page 40: ...Press the generator set off reset button to shut down the generator set 2 Disconnect power to all battery chargers 3 Disconnect all battery cables negative leads first Reconnect negative leads last w...

Page 41: ...d Shed Accessory for identification GM89713 1 Input output terminal strip TB1 1 TB1 12 6 1 7 MLB Input 2 alternate connection 12 24 AWG wire 0 5 Nm 4 4 in lb MLB Input 1 MPAC Controller Circuit Board...

Page 42: ...omputer Before servicing any components inside the enclosure 1 Remove all jewelry 2 Stand on a dry approved electrically insulated mat 3 Test circuits with a voltmeter to verify that they are deenergi...

Page 43: ...eater Connections 4 6 Other Accessories Refer to the following documentation for instructions to install connect and operate optional accessories D Transfer switch wiring diagrams D Installation instr...

Page 44: ...TP 6835 9 17 44 Section 4 Communication and Accessory Connections Notes...

Page 45: ...r 5 3 Voltage Check The voltage frequency and phasing of the transfer switch and the power sources mustbe the same to avoid damage to loads and the transfer switch Compare the voltage and frequency ra...

Page 46: ...manufacturer s instructions to adjust the generator set The automatic transfer switch will only function with the rated system voltage and frequency specified on the nameplate 4 Use a phase rotation...

Page 47: ...he exerciser to start and run the generator set at least once a week See the controller Operation Manual for instructions 5 8 User Interface Cover The gasket sealed hinged user interface cover prevent...

Page 48: ...TP 6835 9 17 48 Section 5 Functional Tests and Setup Notes...

Page 49: ...and service must comply with all applicable codes and standards See the Service Assistance section in this manual for how to locate a local distributor dealer The transfer switch Operation Manual cont...

Page 50: ...TP 6835 9 17 50 Section 6 Scheduled Maintenance Notes...

Page 51: ...cator Interlocks prevent bypassing to the wrong source do not force the bypass handle Figure 7 1 Bypass to Normal Figure 7 2 Bypass to Emergency The bypass handle positions are labeled Normal and Emer...

Page 52: ...st be in the CONN connected position Check the position window indicator See Figure 7 6 D The TS Connected light must be on See Figure 7 7 and Figure 7 8 Note You can only bypass to the same source th...

Page 53: ...Transfer Switch Position Bypass Switch can be in either Normal Open or Normal Emergency Open or Emergency Figure 7 10 Allowable Bypass Switch Position Procedure to Bypass to Normal Source connect load...

Page 54: ...low window indicator See Figure 7 13 and Figure 7 14 The red Bypassed to Emergency light will come on and the amber Not In Automatic light will flash The automatic transfer switch can nowbe putin TEST...

Page 55: ...until window shows TEST See Figure 7 15 and Figure 7 16 The TS Test amber light should come on Figure 7 16 The ATS can be tested now without load interruption Note In the TEST position the transfer sw...

Page 56: ...n models Hazardous voltage will cause severe injury or death Bypass and isolate the transfer switch before removing it from the enclosure The bypass isolation switch is energized Do not touch the isol...

Page 57: ...w to return the automatic transfer switch ATS to service after inspection and maintenance Observe the bypass switch position indicator and lights 1 Use the two handles to roll the transfer switch into...

Page 58: ...h Connected To light is on Normal or Emergency on the door This is the position of the transfer switch If it is not in the same position as the bypass handle change the position of the transfer switch...

Page 59: ...igure 7 28 Note You can only bypass to the same source that is connected to the ATS A solenoid interlock prevents incorrect operation 1 Observe which bypass switch position indicator is yellow NORMAL...

Page 60: ...er Switch Connected To Normal light is off Turn the handle counterclockwise Turn the bypass handle counterclockwise until the bypass switch position shows OPEN green window indicator See Figure 7 26 T...

Page 61: ...Figure 7 31 D The TS Connected light must be on See Figure 7 30 and Figure 7 32 Window indicator shows green when the ATS is not bypassed Window indicator shows yellow when ATS is bypassed to Emergen...

Page 62: ...mal Open or Normal Emergency Open or Emergency Figure 7 34 Allowable Bypass Switch Position Procedure to Bypass to Normal Source connect load to normal source The Transfer Switch Connected To Normal l...

Page 63: ...ENCY yellow window indicator See Figure 7 37 and Figure 7 38 The red Bypassed to Emergency light will come on and the amber Not In Automatic light will flash The automatic transfer switch can nowbe pu...

Page 64: ...Note In the TEST position the transfer switch solenoid operator circuit is energized through secondary disconnects Position window CONN TEST ISOLATE Counterclockwise draws out the transfer switch Fig...

Page 65: ...fingers or the control circuit terminals Note The transfer switch weighs 59 90 kg 130 200 lb depending upon the number of poles 4 Open the lower enclosure door Pull out both left and right side rails...

Page 66: ...Isolation Handle Turned to TEST 3 Observe which bypass switch position window indicator is yellow NORMAL or EMERGENCY at the bypass switch handle This indicates the source connected to the load Note A...

Page 67: ...e bypassswitch handle to the OPEN position The bypass handle must be in the CLOSED position yellow indicator on NORMAL or EMERGENCY and the isolation handle must be in the CONN position window See Fig...

Page 68: ...position To Open the Bypass when Connected to the Emergency Source The Transfer Switch Connected To Emergency light is on The Transfer Switch Connected To Normal light is off Turn the handle countercl...

Page 69: ...is bypassed to the Emergency source or Source E The NORMAL or Source N CLOSED indicator is yellow when the ATS is bypassed to the Normal Source or Source N Figure 7 52 Bypass Handle and Position Indi...

Page 70: ...interruption Note In the TEST position the power switching device solenoid operator circuit is energized through secondary disconnects CONN TEST ISOLATE Unfold crank Position window Turning the handl...

Page 71: ...e transfer switch weights are shown in Figure 7 58 Use an overhead crane or other lifting equipment capable of handling this weight to move the transfer switch Size Amps Weight kg lbs 1600 3000 160 20...

Page 72: ...n and Manual Transfer 136e 1 Handles 2 Locking pin with clevis pin 3 Support leg fold down and lock adjust length to touch floor 4 Rail support carriage 1 2 4 2 3 3 Figure 7 60 4000 Amp Transfer Switc...

Page 73: ...tion window Do not leave the handle in an intermediate position E B L N A Turn crank clockwise until window shows TEST ATS Bypass Switch Figure 7 61 Moving from ISOLATE to TEST Position 6 Observe whic...

Page 74: ...e not in these positions go back to Section 7 4 4 Return To Operation 2 Observe which bypass switch position indicator is yellow NORMAL or EMERGENCY at the bypass switch handle This indicates the sour...

Page 75: ...indicator turns green showing that the bypass contacts are open See Figure 7 65 The Not in Auto light should be off E L N ATS Bypass Switch Pull out bypass handle and turn it counter clockwise Figure...

Page 76: ...TP 6835 9 17 76 Section 7 Bypass Isolation and Manual Transfer Notes...

Page 77: ...s cu in cubic inch cw clockwise CWC city water cooled cyl cylinder D A digital to analog DAC digital to analog converter dB decibel dB A decibel A weighted DC direct current DCR direct current resista...

Page 78: ...arad PF power factor ph phase PHC Phillipsr head Crimptiter screw PHH Phillipsr hex head screw PHM pan head machine screw PLC programmable logic control PMG permanent magnet generator pot potentiomete...

Page 79: ......

Page 80: ...the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KOHLERPower com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65...

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