Kohler KCC Operation And Installation Download Page 2

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Product Identification Information

Product identification numbers determine service parts.

Record the product identification numbers in the spaces

below immediately after unpacking the products so that

the numbers are readily available for future reference.

Record field-installed kit numbers after installing the

kits.

Transfer Switch Identification Numbers

Record the product identification numbers from the

transfer switch nameplate.

Model Designation
Serial Number

Accessories

Alarm Board

Battery Module

Controller Disconnect Switch

Current Monitoring

Digital Meter

Heater

I/O Module, Standard (max. 4) qty:

I/O Module, High Power (max. 4) qty:

Load Shed

Line-Neutral Monitoring

Seismic Certification

Supervised Transfer Switch

Surge Protection Device (SPD)

Controller Identification

Record the controller description from the generator set

operation manual, spec sheet, or sales invoice.

Controller Description

Summary of Contents for KCC

Page 1: ...Models KCS KCP KCC 30 to 4000 Amperes TP 6833 2 16a Operation and Installation Automatic Transfer Switches...

Page 2: ...Numbers Record the product identification numbers from the transfer switch nameplate Model Designation Serial Number Accessories Alarm Board Battery Module Controller Disconnect Switch Current Monitor...

Page 3: ...t Procedure 1600 4000 Amp Programmed Transition Transfer Switches 20 2 7 Manual Operation Model KCC Closed Transition Switches 21 2 7 1 Manual Operation Test Procedure 150 1200 Amp Model KCC 21 2 7 2...

Page 4: ...ccessory Module Mounting 41 4 3 2 Input Output I O Modules 42 4 3 3 External Battery Supply Module EBSM 43 4 3 4 Alarm Module 44 4 4 Load Shed Forced Transfer to OFF 46 4 5 Heater 48 4 6 Other Accesso...

Page 5: ...ve lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a rem...

Page 6: ...Generator Set Controllers Testing live electrical circuits Hazardous voltage or current can cause severe injury or death Have trained and qualified personnel take diagnostic measurements of live circ...

Page 7: ...injury Read and follow the Safety Precautions and Instructions section at the beginning of this manual Keep this manual with the equipment for future reference The equipment service requirements are v...

Page 8: ...ope Middle East Africa EMEA Kohler Power Systems Netherlands B V Kristallaan 1 4761 ZC Zevenbergen The Netherlands Phone 31 168 331630 Fax 31 168 331631 Asia Pacific Power Systems Asia Pacific Regiona...

Page 9: ...l preferred source the ATS removes the generator start signal allowing the generator set to shut down Figure 1 2 shows a typical installation block diagram Figure 1 1 Automatic Transfer Switch Figure...

Page 10: ...AC 1500 Non Automatic Non automatic controls are available on Models KCS and KCP only 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...

Page 11: ...utting the transfer switch into service 2 2 Receipt of Unit 2 2 1 Inspection At the time of delivery inspect the packaging and the transfer switch for signs of shipping damage Unpack the transfer swit...

Page 12: ...rce voltage and frequency Do not install the transfer switch if the system voltage and frequency are different from the nominal normal utility source voltage and frequency or the nominal emergency sou...

Page 13: ...n accordance with ACI 355 2 04 and documented in a report by a reputable testing agency for example the Evaluation Service Report issued by the International Code Council 7 Wide washers must be instal...

Page 14: ...smoothly without binding Do not place the transfer switch into service if the contactor does not operate smoothly contact an authorized distributor dealer to service the contactor 2 5 1 Manual Operati...

Page 15: ...sfer switch to the Normal position 6 Remove the maintenance handle and store it on the frame in the clips provided Note Verify that the maintenance handle has been removed before proceeding 202 1 Main...

Page 16: ...e hub until the spring is fully compressed 4 Move the maintenance handle as shown to manually operate the transfer switch It should operate smoothly without anybinding Ifit doesnot check for shipping...

Page 17: ...onnect power to all battery chargers 3 Disconnect all battery cables negative leads first Reconnect negative leads last when reconnecting the battery cables after servicing Follow these precautions to...

Page 18: ...to the open position and the Normal operator to the closed position 5 Remove the maintenance handle and store it in the place provided on the switch 1 Emergency contact indicator 2 Normal contact ind...

Page 19: ...closed Up Load Disconnected E N Up E O upper contacts open N O lower contacts open Down Emergency E N Down E C upper contacts closed N O lower contacts open Down Note If Normal and Emergency connectio...

Page 20: ...rmal source contacts 5 Grasp the handle firmly with both hands and rotate down a Rotate counterclockwise to open the contacts b Rotate clockwise to close the contacts 6 Repeat steps 4 and 5 on the oth...

Page 21: ...d Use the manual operation handle to check the manual operation before energizing the transfer switch Check the operation of both the Normal and Emergency operators A contactor in normal and serviceab...

Page 22: ...TOR shown open NORMAL OPERATOR shown closed Insert the maintenance handle into the hub 800 1200 Amps 150 600 Amps Handle storage location Figure 2 15 Transfer Switch Manual Operation 150 1200 Amp Mode...

Page 23: ...5 Grasp the handle firmly with both hands and rotate down a Rotate counterclockwise to open the contacts b Rotate clockwise to close the contacts 6 Repeat steps 4 and 5 on the other transfer switch 7...

Page 24: ...oor Figure 2 18 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 25: ...VDC 500 mA 120 VAC I O terminals wire size 12 24 AWG Figure 2 19 Main Board I O Specifications 6866 Input 1A Input 1B Input 2A Input 2B Output 1 NC Output 1 C Output 1 NO Output 2 NC Output 2 C Outpu...

Page 26: ...ed electrically insulated mat 3 Test circuits with a voltmeter to verify that they are deenergized Hazardous voltage Will cause severe injury or death Disconnect all power sources before opening the e...

Page 27: ...all cable lug connections to the torque values shown on the label on the switch See Figure 2 24 for a typical rating torque label Carefully wipe off any excess joint compound after tightening the term...

Page 28: ...e time delay Compare your equipment to Figure 2 26 and Figure 2 29 to identify the relay used on your transfer switch GM89661 Figure 2 25 Typical Relay Connections see the schematic diagram for your t...

Page 29: ...me Some examples are shown in Figure 2 32 1 Time select pushbuttons 2 Relay timing LED 3 Range selection switch Note See Figure 2 26 for relay location on the field connection assembly 3 IMG_0732 1 2...

Page 30: ...prevent the starting of the generator set by the remote start stop switch Prevent the generator set from starting by pressing the OFF button on the generator controller disconnecting power to the gene...

Page 31: ...odel and size amps See Figure 2 35 through Figure 2 37 for contact locations Follow the wire size and tightening torque specifications shown on the decal on the transfer switch Auxiliary Position Indi...

Page 32: ...Terminal Block 230 4000 Amp Transfer Switches GM89645 Figure 2 37 Typical Auxiliary Contact Connection 230 4000 Amp Transfer Switches see Figure 2 36 and schematic diagram 2 10 Communication and Acce...

Page 33: ...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 34: ...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 35: ...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 36: ...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 37: ...fore servicing Turn off the main circuit breakers of all transfer switch power sources and disable all generator sets as follows 1 Press the generator set off reset button to shut down the generator s...

Page 38: ...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 39: ...y The Ethernet communication board allows the transfer switch to be connected to a building s Ethernet network to communicate with personal computers connected to the same subnet Note For an ethernet...

Page 40: ...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 41: ...ller This bus incorporates a standard serial communication interface for passing data back and forth between the main logic board and the assemblies on the expansion bus The module mounting kit holds...

Page 42: ...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 43: ...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 44: ...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 45: ...orn sounds anytime a fault event happens in the system The horn continues to sound unless the alarm silence button is pressed When the fault is cleared the alarm silence is ended and reset for the nex...

Page 46: ...ote computer Before servicing any components inside the enclosure 1 Remove all jewelry 2 Stand on a dry approved electrically insulated mat 3 Test circuits with a voltmeter to verify that they are dee...

Page 47: ...ctions 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 Figure 4 23 Forced Transfer t...

Page 48: ...tand on a dry approved electrically insulated mat 3 Test circuits with a voltmeter to verify that they are deenergized An anti condensation heater kit is available The strip heater is controlled by a...

Page 49: ...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 50: ...TP 6833 2 16 50 Section 4 Communication and Accessory Connections Notes...

Page 51: ...rs smoothly without binding when operated manually Do not place the transfer switch into service if the contactor does not operate smoothly without binding contact an authorized distributor dealer to...

Page 52: ...he 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 rotatio...

Page 53: ...ped with the Decision Makerr MPAC 750 controller may also use the optional programmable exerciser Refer to the instructions provided with the exerciser to schedule additional loaded or unloaded exerci...

Page 54: ...TP 6833 2 16 54 Section 5 Functional Tests and Setup Notes...

Page 55: ...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 56: ...hillipsr head Crimptiter screw PHH Phillipsr hex head screw PHM pan head machine screw PLC programmable logic control PMG permanent magnet generator pot potentiometer potential ppm parts per million P...

Page 57: ...TP 6833 2 16 57 Notes...

Page 58: ...TP 6833 2 16 58 Notes...

Page 59: ......

Page 60: ...r 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 6...

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