Kohler KCP MPAC 1000 Operation And Installation Download Page 1

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Automatic Transfer Switches

Operation and

Installation

Models:

KCT, KCP

Power Switching Device:

Standard

Open-Transition 30 to 4000 Amps

Programmed-Transition 150 to 4000 Amps

Electrical Controls:

MPAC 1000

TP-6126 8/02b

Summary of Contents for KCP MPAC 1000

Page 1: ...Transfer Switches Operation and Installation Models KCT KCP Power Switching Device Standard Open Transition 30 to 4000 Amps Programmed Transition 150 to 4000 Amps Electrical Controls MPAC 1000t TP 61...

Page 2: ...ately 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 Re...

Page 3: ...10 2 5 2 Engine Start Connection 13 2 5 3 Auxiliary Contacts 15 2 5 4 Controller Ground 16 Section 3 Setup and Test 17 3 1 Introduction 17 3 2 User Interface Panel 17 3 2 1 Pushbuttons and LED Indica...

Page 4: ...on 38 5 3 2 Other Inspections and Service 39 5 4 Service Schedule 40 Section 6 Accessories 41 6 1 Introduction 41 6 2 Setup Program 41 6 3 Control Switches 41 6 3 1 Preferred Source Switch 41 6 3 2 Su...

Page 5: ...otential hazards and explain how to act safely The decals are shown throughout this publication to improve operator recognition Replace missing or damaged decals Accidental Starting Accidental startin...

Page 6: ...charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulati...

Page 7: ...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...

Page 8: ...uts for identification NOTICE Improper operator handle usage Use the manual operator handle on the transfer switch for maintenance purposes only Return the transfer switch to the normal position Remov...

Page 9: ...t for future reference The equipment service requirements are very important to safe and efficient operation Inspect parts often and perform required service at the prescribed intervals Obtain service...

Page 10: ...nal office Africa Europe Middle East London Regional Office Langley Slough England Phone 44 1753 580 771 Fax 44 1753 580 036 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic...

Page 11: ...et to shut down Figure 1 1 shows a typical installation block diagram 1 2 Nameplate A nameplate attached to the controller cover on the inside of the enclosure door includes a model designation a seri...

Page 12: ...00 1200 1600 2000 2600 3000 4000 KCT AMTA 0225S SAMPLE MODEL DESIGNATION Mechanism C Automatic B Bypass Isolation See G11 81 N Non automatic Transition T Open Transition P Programmed Transition Power...

Page 13: ...livery inspect the packaging and the transfer switch for signs of shipping damage Unpack the transfer switch as soon as possible and inspect the exterior and interior for shipping damage If damage and...

Page 14: ...rill chips and other debris out of the components Cover the solenoid mechanism duringinstallation Afterinstallation usethemanualoperating handle to cycle the contactor to verify that it operates freel...

Page 15: ...ote A manual operation handle is provided on the transfer switch for maintenance purposes only Do not use the manual operation handle to transfer the load with the power connected Use the manual opera...

Page 16: ...switch frame See Figure 2 8 2 225 400 amp switches See Figure 2 9 Insert the maintenance handle into the hole in the shaft on the left side of the operator 600 1200 amp switches See Figure 2 10 Insert...

Page 17: ...ed Transition Switches one operator shown 202 2 1 1 Maintenance handle 2 Hub 1 Figure 2 10 Manual Operation 600 1200 Amp Switches 1 127a 1 Maintenance handle 2 Hub Turn counterclockwise to Emergency T...

Page 18: ...t in the place provided on the transfer switch when service is completed Manual Operation Test Procedure 150 4000 Amp Programmed Transition Transfer Switches Check the operation of both operators by f...

Page 19: ...when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer...

Page 20: ...o not use a screwdriver to force the contactor mechanism Drill the entry holes Cover the transfer switch to protect it from metal chips and construction grit Then drill entry holes for the conductors...

Page 21: ...se a compression washer flat washer and a minimum grade 5 bolt and torque the connections to the values in Figure 2 18 Bolt Size Bolt Torque Bolt Size inches ft lbs Nm 1 4 7 9 5 5 16 12 16 3 3 8 20 27...

Page 22: ...TP 6126 8 02 12 Section 2 Installation ADV 6736 Figure 2 20 Interconnection Diagram...

Page 23: ...vent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer Prevent the generator set from starting by moving the generat...

Page 24: ...al block location 2 Decal 3 Engine start contacts 1 and 2 4 Auxiliary contacts 4 27 see the schematic diagram for contacts closed on Normal or closed on Emergency GM21298 GM21311 4 3 1 2 4 5 6 7 8 9 1...

Page 25: ...iagram provided with the transfer switch to identify which auxiliary contacts are closed on Normal and which are closed on Emergency for 600 4000 amp models Follow the wire size and tightening torque...

Page 26: ...5 4 Controller Ground Verify that the grounding wire is connected from the controller s lower left mounting stud to the enclosure This connection provides proper grounding that does not rely upon the...

Page 27: ...d operated using the factory settings for time delays voltage and frequency pickup and dropout and other system parameters To view and change the system settings a personal computer running the MPAC 1...

Page 28: ...Source E is available Test Red Unloaded test is running Loaded test is running Time Delay LED Bar Amber LEDs step down to indicate time remaining in an active time delay or exercise period Figure 3 2...

Page 29: ...side of the transfer switch enclosure door It is not necessary to open the cover to access the DIP switches or the PC connector on the circuit board Figure 3 6 shows the locations the DIP switches and...

Page 30: ...two live sources When the output is activated the contact opens for the programmed length of time before transfer default setting 3 seconds to allow controlled disconnection of selected loads The con...

Page 31: ...etup program to assign the input functions if they are different from the default assignments shown in Figure 3 7 The main logic board has one programmable output which is factory assigned to the load...

Page 32: ...e factory set to the default values shown in Figure 3 12 The voltage and frequency debounce time delays prevent nuisance transfers caused by brief spikes and dips in the power supply System Parameter...

Page 33: ...ery chargers if installed 3 7 Functional Test The functional test includes three checks D Manual Operation Test D Voltage Checks D Automatic Operation Test Note Perform these checks in the order prese...

Page 34: ...to check the Source N normal phase to phase and phase to neutral if applicable terminal voltages and frequency a If Source N is the utility and the measured input does not match the voltage and frequ...

Page 35: ...age Will cause severe injury or death Only authorized personnel should open the enclosure DANGER Automatic Operation Test Procedure 1 Check the controller LED indicators to verify that the Position N...

Page 36: ...No load Run duration 30 minutes Figure 3 14 Exerciser Factory Settings Use the Setup Program to change the exerciser run duration if desired See Section 4 2 3 for more information about the exerciser...

Page 37: ...ent nuisance transfers during brief power interruptions The voltage and frequency debounce time delays prevent nuisance transfers caused by brief spikes and dips in the power supply See Section 3 5 fo...

Page 38: ...In phase monitor open transition only as programmed Figure 4 2 ATS Sequence of Operation Return to Normal preferred source LED Indicators Loss of Normal Source N Available N Position OFF Position E Av...

Page 39: ...e test button is pushed again or until a remote test signal is received If the standby source fails during a test cycle the system immediately transfers back to preferred The test sequence executes al...

Page 40: ...cts open In phase monitor or transfer to off as programmed A A Test ended See the Setup Program Operation Manual Figure 4 5 Test with Load Sequence System Test N Available N Position OFF Position E Av...

Page 41: ...ing the exercise run Refer to Section 4 2 5 for additional information about pre transfer time delays Exercise Mode The exerciser is factory set to operate in switch input mode which uses the Exercise...

Page 42: ...e time period ends or exercise button pressed Load bank control output activated as programmed Load bank control output deactivated as programmed See the Setup Program Operation Manual Figure 4 9 Exer...

Page 43: ...dby Time Delay programmed transition only X X X X In Phase Synch as programmed N A for programmed transition models X X flashing X X Post Transfer to Standby Load Control X X X X X Pre Transfer to Pre...

Page 44: ...ram Operation Manual See Figure 4 12 for the sequence of operation Post transfer load control as programmed Transfer to standby source Immediate generator set engine start Pre transfer load control as...

Page 45: ...o The default setting for the preferred to standby time delay is 1 second and the default setting for the pre transfer time delay is three seconds The time delay before transfer is equal to the longer...

Page 46: ...enerator set The fault clears when the system acquires a standby source Depress the Lamp Test button until the LEDs flash to clear the Service Required LED 4 3 4 Failure to Transfer If the unit fails...

Page 47: ...erator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery WARNING Disabling the generator set Accidental starting can caus...

Page 48: ...ircuit 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 provi...

Page 49: ...umulations 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 ov...

Page 50: ...of excessive vibration leakage high temperature contamination or deterioration 5 3 1 X X M Check that all external hardware is in place tightened and not badly worn 5 3 1 X X X M Inspect the inside o...

Page 51: ...ed on the enclosure door See Figure 6 1 for typical switch locations Note Factory installed switches are factory wired and require no additional wiring in the field 1 ADV 6698A 1 Preferred source swit...

Page 52: ...ip or I O module outputs to Start Source N Generator and connect the engine start leads for the Source N generator set to the corresponding terminals on the terminal strip or I O module terminals See...

Page 53: ...oad shed time delays Source N N Source E load shed time delays Source E E In phase monitor synch Source E E Preferred to standby time delay Function N to E E to N Standby to preferred time delay Funct...

Page 54: ...ervised transfer control switch on an automatic system is in the MANUAL position pressing the Test button or sending a peak shave command causes transfer to the standby source However ending the test...

Page 55: ...em activates the output after the synch output time delay See Figure 6 6 Parameter Factory setting Enable disable Disable Phase angle degrees 0 Synch output time delay seconds 30 Figure 6 6 In Phase M...

Page 56: ...age Source E Fault Overvoltage Source E Fault Loss of Phase Source E Fault Phase Rotation Error Source E Fault Overfrequency Source E Fault Underfrequency Source E Fault Failure to Transfer Fault Auxi...

Page 57: ...harness Figure 6 12 shows the controller connection The input and output ratings are shown in Figure 6 13 Figure 6 14 shows an I O module with its input and output terminal blocks and address DIP swi...

Page 58: ...ule Address Each I O Module requires a unique address Factory installed I O module addresses are set at the factory To check the I O module addresses compare the DIP switch settings with Figure 6 16 s...

Page 59: ...position The load shed forced transfer to off accessory is available only for programmed transition transfer switches When the forced transfer to off input is activated contact closed the contactor mo...

Page 60: ...attery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 lb of bicarbonate of soda baking soda to a container with 4 L 1 gal...

Page 61: ...r to the ATS is disconnected before connecting or disconnecting the 9 pin connector to the battery charger Ring terminals for battery charger connections are included with the battery charger The inst...

Page 62: ...harger Terminal Size Eyelet Terminal Part No 4 5 m 15 ft 12 AWG No 10 X 283 11 7 5 m 25 ft 10 AWG No 10 X 283 11 Figure 6 21 Battery Cable and Terminal Specifications 6 Slide a red boot onto the red c...

Page 63: ...oltmeter to check the voltage at the battery and compare the readings to Figure 6 25 or Figure 6 26 to verify charger operation Battery Charger Disconnection Procedure Hazardous voltage Will cause sev...

Page 64: ...ng gradually tops off your battery and reduces harmful sulfating While both LED s are on the voltage measured with the charger on should be approx 14 0 to 14 5VDC in 12VDC mode or 28 0 to 29 0 in 24VD...

Page 65: ...place Turn off excessive DC equipment while charging The red and green LEDs stay on for more than 24 On board DC systems are drawing between 1 5 5A Turn off excessive DC equipment while charging y hou...

Page 66: ...DC at 0 1 Amps Input Rated AC Voltage 208 VAC AC connector pin 2 240 VAC AC connector pin 4 480 VAC AC connector pin 6 600VAC AC connector pin 9 Current Draw 50 60 Hz 0 7 Amps Maximum Maximum Recomme...

Page 67: ...rclockwise CEC Canadian Electrical Code cfh cubic feet per hour cfm cubic feet per minute CG center of gravity CID cubic inch displacement CL centerline cm centimeter CMOS complementary metal oxide su...

Page 68: ...aker LCD liquid crystal display ld shd load shed LED light emitting diode Lph liters per hour Lpm liters per minute LOP low oil pressure LP liquefied petroleum LPG liquefied petroleum gas LS left side...

Page 69: ...second SI Systeme international d unites International System of Units SI EO side in end out sil silencer SN serial number SPDT single pole double throw SPST single pole single throw spec specs speci...

Page 70: ...22 42 450 J 200 1 5 10 240 VAC max N A 22 240 VAC max 200 240 200 J 225 225 260 3 35 22 42 480 600 J 260 400 3 35 22 42 480 600 J 400 600 800 3 50 50 65 1600 800 1000 1200 3 18 50 36 36 65 200 600 16...

Page 71: ...HKD KD KDB KDC LCL Tri Pac LA 400 ABB S1 125 ABB S3 150 Merlin Gerin CE104 CE106 100 Square D FC FI 100 Square D KA KC KH KI LA LH 250 TB1 100 GE TEL THED THLC1 THLC2 150 TFL 225 CED6 ED6 HED4 HED6 12...

Page 72: ...400 CFD6 FD6 FXD6 HFD6 250 ITE CJD6 HHJD6 HHJXD6 HJD6 JD6 JXD6 SCJD6 SHJD6 SJD6 400 200 22 240 KA KC KH KI 250 200 22 240 Square D LC LI 300 q LA LH 400 Cutler Hammer HJD JD JDB JDC 250 Cutler Hammer...

Page 73: ...ABB S5 400 ABB S6 800 Merlin Gerin CJ600 600 GE TB8 800 GE Microversatrip TKL 1200 CLD6 HHLD6 HHLDX6 HLD6 SCLD6 SHLD6 600 480 ITE CMD6 HMD6 SCMD6 SHMD6 800 480 ITE CND6 HND6 SCND6 SHND6 1200 65 CPD6 1...

Page 74: ...EC 1000 4 5 Surge Voltage D IEC 1000 4 6 Conducted RF Disturbances D IEC 1000 4 8 Magnetic Fields D IEC 1000 4 11 Voltage Variations and Interruptions Diagrams and Drawings Dimension Drawing Model Sch...

Page 75: ......

Page 76: ...Wisconsin 53044 Phone 920 565 3381 Fax 920 459 1646 For the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KohlerPowerSystems com Kohler Power Systems Asia Pacific Headquarters...

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