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TP-6461 1/08

57

Section 4 Controller Test and Replacement

4.2

Controller Circuit Boards and
Connectors

2

GM21079

1

GM46733

6

8

10

13

3

4

14

7

9

18

5

15

1. Hinges
2. Latch
3. Transfer switch harness connection P1
4. RS-485 Modbus connections TB2
5. User interface LCD display connection P17
6. Accessory module assembly connection P16
7. User interface connection P14
8. DIP switches SW1
9. Ethernet connector P13

10. USB port P12

11. LED1 (ON = 12VDC)

12. Relays
13. Programmed-transition interface board (PTIB) connection P2

(factory connection)

14. Ground wire
15. Current sensing kit connection P3 (optional)
16. Ribbon cable connection
17. Controller backup battery
18. Logic board input and output connections TB1

17

Logic
Board

Power
Board

12

11

With Cover

Cover Removed

16

Figure 4-5

Controller

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55
56
57
58
59
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Summary of Contents for KGP

Page 1: ...Automatic Transfer Switches Models KSS KSP KGS KGP Power Switching Device Standard and Bypass Isolation 30 to 4000 Amperes Electrical Controls MPACt 1500 TP 6461 1 08 Service ...

Page 2: ......

Page 3: ...ing 23 2 1 Initial Checks 23 2 2 Controller Backup Battery 24 2 3 View Event History 24 2 4 System Settings 26 2 4 1 Controller Source Settings 26 2 4 2 Voltage and Frequency Pickup and Dropout Settings 26 2 5 Time Delays 27 2 6 Common Alarms 28 2 7 Warnings and Faults 29 2 7 1 Fault Reset 30 2 7 2 Module Status Change 30 2 7 3 Module Status Conflict 31 2 8 Events and Faults 32 2 9 Controller Trou...

Page 4: ...ler Backup Battery 59 4 3 3 Powering the Controller Directly Service Kit GM52407 59 4 4 Sequence of Operation 60 4 4 1 Controller Powerup Reset Sequence of Operation 60 4 4 2 Preferred Source Loss and Return 60 4 5 System Test 61 4 5 1 Unloaded System Test 61 4 5 2 Loaded System Test 61 4 5 3 Auto Loaded System Test 61 4 5 4 Test Procedure 61 4 5 5 Test Sequence of Operation 64 4 6 Exercise 66 4 6...

Page 5: ...ement 100 400 Amps 104 7 2 4 Closing Coil Replacement 100 400 Amps 105 7 2 5 Select Coil Replacement 100 400 Amps 105 7 2 6 Trip Coil Replacement 100 400 Amps 106 7 2 7 Arc Chute Replacement 100 400 Amps 108 7 3 Component Replacement 600 Amp Models 108 7 3 1 Closing Coil Replacement 600 Amp Models 108 7 3 2 Shaft Adjustment 600 Amp Models 109 7 3 3 Auxiliary Switch Replacement 600 Amp Models 109 7...

Page 6: ...TP 6461 1 08 6 Notes ...

Page 7: ...rove operator recognition Replace missing or damaged decals Accidental Starting Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator 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 cause severe inj...

Page 8: ...er switch Hazardous voltage can cause severeinjuryordeath Deenergizeall power sources before servicing Turn off the main circuit breakers of all transfer switch power sources and disable all generator sets as follows 1 Move all generator set master controllerswitches totheOFFposition 2 Disconnect power to all battery chargers 3 Disconnect all battery cables negative leads first Reconnectnegative l...

Page 9: ...keep dirt grit metal drill chips and other debris out of the components Cover the solenoid mechanism during installation After installation use the manual operating handle to cycle the contactor to verify that it operates freely Do not use a screwdriver to force the contactor mechanism NOTICE Electrostatic discharge damage Electrostatic discharge ESD damages electronic circuit boards Prevent elect...

Page 10: ...TP 6461 1 08 10 Safety Precautions and Instructions Notes ...

Page 11: ... Instructions 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 parts often and perform required service at the prescribed intervals Obtain service from an authorized service distributor dealer to keep equipment in top condition List of Related Materials Figu...

Page 12: ...Headquarters Europe Middle East Africa EMEA Kohler Power Systems 3 rue de Brennus 93200 Saint Denis France Phone 33 1 49 178300 Fax 33 1 49 178301 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 6264 6422 Fax 65 6264 6455 China North China Regional Office Beijing Phone 86 10 6518 7950 86 10 6518 7951 86 10 6518 7952 Fax 86 10 6518 7955 East China Re...

Page 13: ...equipment disable the generator set as follows 1 Move the generator set master switch to the OFFposition 2 Disconnectthepowertothebatterycharger 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 generator set by an automatic transfer switch remote start stop switch or engine start comma...

Page 14: ...ransfer switch controls and accessories within the enclosure Hazardous voltage can cause severe injury or death Disconnect the transfer switch controlsattheinlineconnectortodeenergizethecircuitboards and logic circuitry but allow the transfer switch to continue to supply power to the load Disconnect all power sources to accessories that are mounted within the enclosure but are not wired through th...

Page 15: ...ed replacement parts Contact a local authorized distributor dealer for part information and part ordering Tighten loose internal hardware Terminal Tightening Loose connections on the power circuits can lead to overheating or explosion Tighten all lugs to the torque values shown on the label on the switch Tighten engine start input output and auxiliary connections to the torque indicated on the dec...

Page 16: ...mize the reliability of the emergency power system See the transfer switch operation and installation manual for additional information about the exerciser 1 3 2 Monthly Automatic Operation Test Test the transfer switch s automatic control system monthly See Section 4 5 4 or the transfer switch operation and installation manual for the test procedure Verify that the expected sequence of operations...

Page 17: ...ssible from current carrying conductors and the meter leads as short direct and at right angles to current carrying conductors as possible This minimizes the effect of induced voltages transformer effect in the vicinity of the current carrying conductors 3 Use an ammeter to measure the current flow through the circuit 4 Calculate the contact resistance using the following formula R V I Where V mea...

Page 18: ...m the controller at connector P1 2 Use a hi pot tester or meggar to check the insulation resistance phase to phase and phase to neutral and phase to ground if neutral and ground are isolated For a hi pot tester the maximum potential is 500 VAC and the maximum test time is 1 second 3 Verify that the measured insulation resistance exceeds 1 24 megohms MΩ 4 If the hi pot tester indicates wire insulat...

Page 19: ...side of the transfer switch for any signs of excessive vibration leakage high temperature contamination or deterioration 1 2 1 X X M Check that all external hardware is in place tightened and not badly worn 1 2 1 X X X M Inspect the inside of the transfer switch for any signs of vibration leakage noise high temperature 1 2 2 X M vibration leakage noise high temperature contamination or deteriorati...

Page 20: ...ooting Review the event history and or save it to a file before resetting it See Section 2 3 1 6 3 Reset Default Parameters Check the system voltage and frequecy before selecting Reset Default Parameters Resetting to the default parameters will reset all parameters including the system voltage and frequency to a factory default setting The default system voltage and frequency settings may not be a...

Page 21: ...Test Password Yes No B Save Back Disable Test Password Yes No B Save Back File Maintenance B Back Delete Files Filename B Del Back Force History Save Save Back Press the up arrow to toggle yes or no Note Resetting to the default parameters will reset all parameters including the system voltage and frequency to a factory default setting The transfer switch will not operate correctly if the system v...

Page 22: ...TP 6461 1 08 22 Section 1 Scheduled Maintenance Notes ...

Page 23: ...e transfer switch and connected equipment Refer to the wiring diagrams provided with the switch or the Wiring Diagram Manual when troubleshooting the transfer switch and controller Hazardous voltage Will cause severe injury or death Disconnect all power sources before opening the enclosure DANGER Hazardous voltage Will cause severe injury or death Only authorized personnel should open the enclosur...

Page 24: ...tch Password disable DIP switch closed Manual Option Switch Supervised transfer switch changed position New Module New I O alarm or battery supply module detected Contactor in Off Transfer switch moved to the OFF position programmed transition models only Contactor in Src N Transfer switch moved to the Source N position Contactor in Src E Transfer switch moved to the Source E position Low Battery ...

Page 25: ... above the over voltage dropout setting Under Voltage L1 L2 Source voltage across L1 and L2 is below the undervoltage dropout setting Under Voltage L2 L3 Source voltage across L2 and L3 is below the undervoltage dropout setting Under Voltage L3 L1 Source voltage across L3 and L1 is below the undervoltage dropout setting Voltage Imbalance Source voltage imbalance detected Save History To File Event...

Page 26: ... single or three 4 5 6 Figure 2 3 Typical Transfer Switch Nameplate Use the procedure in Section 3 3 2 to measure the source voltage frequency and phase rotation and compare the measured values to the controller settings Follow the instructions in the transfer switch Operation and Installation manual to change the controller settings if they do not match the measured source parameters 2 4 2 Voltag...

Page 27: ...tory settings and adjustment ranges for the adjustable time delays Observe the controller s display to identify which time delay is executing at any given time Initiate a test and observe as each programmed time delay executes Compare the operation to the test sequence illustrated in the flowcharts in Figure 4 8 or Figure 4 9 Adjustable Time Delays Time Delay Default Adjustment Range Emergency sou...

Page 28: ...onal Alarm Module If any of the conditions included in the Critical Service Required or Non Critical Service Required function occurs the alarm horn will sound The message on the ATS display will identify which condition for example Fail to Acquire Standby triggered the alarm and caused the horn to sound Functions that can be Assigned to Common Alarms Aux Switch Fault Src E Over Freq Aux Switch Op...

Page 29: ...ching Warning status The two sources did not come into phase within the Fail to Synchronize time delay NOTE If the sources do become in phase the warning is automatically cleared and normal ATS operation continues Battery Backup Low Warning The ATS backup battery voltage is low Replace the battery on the main logic board See Section 4 3 2 External Battery Low Warning The voltage of the battery con...

Page 30: ...odule type s 3 Navigate to the Set Input Outputs Set Aux I O screen to check that the controller has recognized the connected modules See Figure 2 14 See the transfer switch Operation Installation Manual for instructions to assign programmable inputs and outputs to I O modules or assign functions to the audible alarm for an Alarm Module Module Status Change Norm V Emer V Reset View Set Test Reset ...

Page 31: ...14 2 7 3 Module Status Conflict The message Module Status Conflict appears if one type of module is replaced with another type of module that has the same address Follow the procedure below to resolve the conflict Procedure to Clear a Module Status Conflict 1 Disconnect power to the transfer switch 2 Disconnect the module 3 Close the enclosure door and reconnect power to the ATS The display will s...

Page 32: ...4 Source connections Check for loose connections Check wiring W D Overvoltage Undervoltage Voltage settings Check that the system voltage setting matches the actual source voltage 3 3 2 2 4 Check the over undervoltage pickup and dropout settings 2 4 2 4 2 Check that the voltage debounce setting is long enough to prevent nuisance faults caused by brief voltage dips or spikes 2 4 Source availability...

Page 33: ... rotation settings and compare to actual values 3 3 2 2 4 Check for loose source connections Check the labels on the switch for tightening torques 1 2 2 Check for open switch or circuit breaker to the source Check ATS calibration 4 9 Failure to Acquire Preferred Open circuit breaker Check and close ATS source and generator set circuit breakers ATS does not recognize the source Check source voltage...

Page 34: ... 2 7 2 Communication to an installed I O module has been lost Check I O module connections 2 7 2 Real time clock failure on logic board If the procedures in Section 2 7 2 fail to clear the error message replace the controller s logic board 2 7 2 4 14 Module Status Conflict One type of module was replaced with another type of module that has the same address Follow the procedure in Section 2 7 3 to...

Page 35: ...n of all LEDs Replace the controller if one or more LEDs do not light If no LEDs light troubleshoot power and connections to the controller 4 1 3 Source settings do not match actual source parameters Check settings 2 4 Incorrect ATS meter calibration Check calibration 4 9 Position LED not lit Position microswitch malfunction Check the operation of the position microswitches 4 10 Transfer switch in...

Page 36: ...TP 6461 1 08 36 Section 2 Controller Troubleshooting Notes ...

Page 37: ...ction numbers in the last column refer to other sections of this manual TOC refers to the Table of Contents in this manual see the table of contents for service procedures for your transfer switch Also see the controller troubleshooting table in Section 2 9 Always follow the safety precautions at the beginning of this manual when troubleshooting and servicing the transfer switch Problem Possible C...

Page 38: ...ime delay setting Check generator set controller engine cooldown setting if applicable Generator O M Engine start connection closed Check wiring and connections ATS O I M W D Check that the 40 pin ribbon cable connector between the logic and power boards on the ATS controller is connected 4 2 Figure 4 5 Test the engine start contact operation 4 7 Generator set master switch not in AUTO Move the ge...

Page 39: ...the time delay settings 2 5 Maintenance DIP switch enabled Check DIP switch setting 4 8 Connected source available Check the Source Available LEDs 4 1 Preferred source selection set to emergency and emergency source is available Check the preferred source selection and the Source Available LEDs Supervised transfer control switch optional in manual position Check the position of the supervised tran...

Page 40: ...tact operation See the Table of Contents for control contact test procedures for your model transfer switch TOC Faulty connections Check leads and harnesses for loose connections broken leads or incorrect connections W D Wrong voltage Check system voltage controller system voltage and over undervoltage pickup and dropout settings and controller meter calibration 2 4 Chattering noise when attemptin...

Page 41: ...gital voltmeter DVM with electrically insulated probes capable of measuring the rated voltage and frequency D A phase rotation meter Hazardous voltage Will cause severe injury or death Only authorized personnel should open the enclosure DANGER Testing live electrical circuits Hazardous voltage or current can cause severe injury or death Have trained and qualified personnel take diagnostic measurem...

Page 42: ...t breakers or switches 10 Manually operate the transfer switch to position N 11 Repeat steps 4 through 8 for Source E Then proceed to step 12 12 Disconnect both sources to the transfer switch by opening the circuit breakers or switches 13 Connect the power switching device and controller wiring harnesses together at the inline disconnect plug Note Do not connect or disconnect the controller wiring...

Page 43: ...de current flows from the positive terminal of the meter to the negative terminal in the same direction as the diode arrow low resistance 2 Reverse biased diode current flows from the positive terminal of the meter to the negative terminal in the opposite direction of the diode arrow high resistance Typical rectifier diode arrangement COIL Low Ω High Ω Figure 3 2 Testing Diodes 3 6 Solenoid Tests ...

Page 44: ...25 amp model KSS standard transition switches control contacts SCN and SCE control the amount of time that power is applied to the solenoid coil The contacts open before the operating mechanism reaches Top Dead Center TDC Inertia carries the mechanism through TDC and a spring in the solenoid assembly moves the mechanism into the Source E or standby position Model KSP programmed transition models s...

Page 45: ...vailable The controller is calling for transfer to Source N The coil is energized and the transfer switch will transfer to Source N Source E position Source E available The solenoid coil is not energized Source N position Source N lost The coil is energized if Source E is available The transfer switch is ready to transfer to Source E Source N position Source N available The solenoid coil is not en...

Page 46: ... The controller is calling for transfer to Source N The coil is energized and the transfer switch will transfer to Source N Source E position Source E available The solenoid coil is not energized Source N position Source N lost The coil is energized if Source E is available The transfer switch is ready to transfer to Source E Source N position Source N available The solenoid coil is not energized ...

Page 47: ...AC BTS2 SC AC SI BT2 AT2 ATS2 TC AC SI BTS1 ATS1 AT1 BT1 EA ER1 NR1 EC BX ATS1 AND ATS2 Closed in Normal Open in OFF ER is pulsed for 250 ms to energize trip coil TC Source N position Source N is lost Emergency available Normal to OFF 6226 OFF to Emergency ER1 is pulsed for 250 ms to energize select coil SC SC picks up LS which energizes closing coil CC BX Closed in OFF Open in Emergency Figure 3 ...

Page 48: ...C AC SI AX LS BX A1 B1 AC AC BTS2 SC AC SI BT2 AT2 ATS2 TC AC SI BTS1 ATS1 AT1 BT1 NC NR1 NA Emergency to OFF NR1 is pulsed for 250 ms to energize trip coil TC BTS1 and BTS2 Closed in Emergency Open in OFF OFF to Normal NR is pulsed for 250 ms to energize closing coil CC AX is closed in OFF Figure 3 7 Model KSP Programmed Transition Switches Transfer from Emergency to Normal ...

Page 49: ...olenoid Operation Diagrams Model KGS Open Transition Bypass Isolation Switches GM46246 Central voltage C V triggers SCR RN to activate coil CN Central voltage C V triggers SCR RE to activate coil CE SCR RN SCR RE SCR RN SCR RE Normal to Emergency Emergency to Normal ...

Page 50: ...TP 6461 1 08 50 Section 3 Transfer Switch Troubleshooting 3 6 7 Solenoid Operation Diagrams 150 400 Amp Model KGP Programmed Transition Bypass Isolation Switches GM46248 Off to Emergency Normal to Off ...

Page 51: ...P 6461 1 08 51 Section 3 Transfer Switch Troubleshooting Solenoid Operation Diagrams 150 400 Amp Model KGP Programmed Transition Bypass Isolation Switches continued GM46248 Off to Normal Emergency to Off ...

Page 52: ...sfer Switch Troubleshooting 3 6 8 Solenoid Operation Diagrams 600 3000 Amp Model KGP Programmed Transition Bypass Isolation Switches GM46249 SCR RN SCR REO SCR RE SCR RNO SCR RN SCR REO SCR RE SCR RNO Off to Emergency Normal to Off ...

Page 53: ...er Switch Troubleshooting Solenoid Operation Diagrams 600 3000 Amp Model KGP Programmed Transition Bypass Isolation Switches Continued GM46249 SCR RN SCR REO SCR RE SCR RNO SCR RN SCR REO SCR RE SCR RNO Off to Normal Emergency to Off ...

Page 54: ...TP 6461 1 08 54 Section 3 Transfer Switch Troubleshooting Notes ...

Page 55: ...Hz D Current amps D Source setup information D Time and date D Time and date of next scheduled exercise The display also identifies the pushbutton functions which can change from screen to screen 4 1 2 LED Indicators LEDs on the user interface indicate contactor position source availability faults and other conditions Figure 4 2 describes the functions of the LED indicators See Section 2 7 for mor...

Page 56: ...are shown above each button in the last line of the display and can change from screen to screen The pushbutton functions are defined in Figure 4 4 B Y Down arrow closed Step down to the next screen or scroll through a list Up arrow closed Step back to the previous screen Right arrow closed Move to the next submenu Up arrow open Increases the selected numerical value Down arrow open Decreases the ...

Page 57: ... Accessory module assembly connection P16 7 User interface connection P14 8 DIP switches SW1 9 Ethernet connector P13 10 USB port P12 11 LED1 ON 12VDC 12 Relays 13 Programmed transition interface board PTIB connection P2 factory connection 14 Ground wire 15 Current sensing kit connection P3 optional 16 Ribbon cable connection 17 Controller backup battery 18 Logic board input and output connections...

Page 58: ...h is equipped with an EBSM disconnect the I O module assembly at connector P16 on the controller to remove the external battery supply Then check LED1 with the Normal or Emergency source available D If LED1 lights but the controller display is dark check the ribbon cable connections between the controller s power board and logic board and from the logic board to the display D If LED1 does not ligh...

Page 59: ...ble A Low Backup Battery message on the screen indicates that this battery needs to be replaced See Figure 4 5 for the battery location Note Do not use a standard AA battery the voltage is not correct and the specifications are not adequate for this equipment Obtain replacement battery GM47057 from the manufacturer Note Do not use a metal tool to remove or install the battery When installing the b...

Page 60: ...fers to preferred the engine cooldown time delay runs and then the engine start contacts open If the available source is the preferred source and the contactor was already in the preferred position the engine start contacts open immediately bypassing the engine cooldown time delay 4 4 2 Preferred Source Loss and Return Following is an explanation of the sequence of operation for MPACt 1500 ATS Con...

Page 61: ...ociated time delays Since the loaded test transfer will be between two live sources the in phase monitor will be activated if it is enabled If the preferred source is lost during a loaded test with the contactor in the standby position the test will continue to be active even on restoration of preferred If the standby source is lost and the preferred source is available the test will be terminated...

Page 62: ...the Source E Available LED lights 7 Verify that the switch transfers the load to Source E a Open Transition Models After the preferred to standby time delay verify that the Position N LED goes out and the Position E LED lights indicating that the switch has transferred the load to Source E b Programmed Transition Models After the preferred to off time delay verify that the Position N LED goes out ...

Page 63: ...the Start button to initiate the displayed type of test sequence Test Sequence Screens Press the End Test button during the test run to end the test and return to normal operation An Auto Load test will end automatically after the set time During a test sequence press the End Delay button to end the current time delay if desired Press Main to step to the main screen then Test to return to the test...

Page 64: ... Source is available 1 Test function is de activated 2 Load control contacts open 3 Contactor immediately transfers to preferred 4 Immediate failure to acquire standby alarm 5 Post transfer load control sequences and time delay engine cooldown time out 6 Load control contacts close 7 Engine start contacts open Test Function is Deactivated Loaded 1 Time delay standby to preferred and pre transfer l...

Page 65: ...o off as programmed Standby to preferred time delay and pre transfer load control as programmed Load control contacts close Transfer to preferred source and post transfer load control as programmed Load control contacts open Test started Time delay engine cooldown TDEC as programmed default 0 Generator set engine start contacts open In phase monitor or transfer to off as programmed Test ended See ...

Page 66: ... 4 The load bank control is activated Exerciser Accessory is de activated Unloaded 1 The load bank control is de activated 2 Time delay engine cooldown times out 3 The generator is signaled to stop Exerciser Accessory is activated Loaded 1 Exerciser timer begins 2 The generator is signaled to start 3 The generator starts and the standby source becomes available 4 Time delay preferred to standby an...

Page 67: ...s programmed Post transfer load control as programmed Transfer to standby source Generator set engine starts and the standby source becomes available Load control contacts open In phase monitor or transfer to off as programmed Time Delay standby to preferred and Pre transfer load control time delays as programmed Post transfer load control and engine cooldown time delays as programmed Transfer to ...

Page 68: ...severe injury or death Have trained and qualified personnel take diagnostic measurements of live circuits Use adequately rated test equipment with electrically insulated probes and follow the instructions of the test equipment manufacturer when performing voltage tests Observe the following precautions when performing voltage tests 1 Remove all jewelry 2 Stand on a dry approved electrically insula...

Page 69: ...ord Disable Closing the password disable DIP switch SW1 1 disables the setup password and resets it to the factory defaults When the switch is closed system setup and programming is allowed without the need to enter a password Note Disable the setup password only during service unless the transfer switch is installed in a secure location Closing and then reopening DIP switch SW1 1 resets the passw...

Page 70: ... to operate automatically 600 volts and under The transfer switch controls are calibrated at the factory and should not require recalibration in the field However if recalibration is necessary measure the source voltages as instructed in Section 3 3 2 record the measured values and use the Setup Screen Calibration to enter the measured values See Figure 4 15 The current sensing accessory is requir...

Page 71: ...ector P1 for Source E and pins 10 and 14 for Source N 4 11 Programmed Transition Interface Board The programmed transition interface board PTIB contains two replaceable 10 amp relays K1 NR1 and K2 ER1 See Figure 4 16 Refer to the operation sequence diagrams in Section 3 6 2 and to the schematic diagram provided with the transfer switch to troubleshoot the relays 2 tp6158 1 Programmed Transition In...

Page 72: ...5 for instructions to run a test Loading Settings when Controller is Replaced If the controller needs to be replaced the configuration file from the old controller if available can be loaded onto the new controller for quick setup Note Operation problems can be caused by incorrect controller settings Do not load the old configuration file onto the new controller unless you are certain that all the...

Page 73: ...igure 4 19 USB Access Screens 4 13 Controller Application Program The manufacturer occasionally releases new versions of the controller application code The new code can be downloaded from the Tech Tools section of the Kohlernet website www Kohlernet com and loaded onto the controller through the USB port Program Loader software is not required for loading code onto the 1500 controller To downlod ...

Page 74: ...settings Do not load the old configuration file onto the new controller unless you are certain that all the settings in the file are correct If the configuration settings file is not available use the controller user interface to check and adjust the system settings for the application Refer to the Transfer Switch Operation and Installation Manual for instructions 4 14 2 Circuit Board and Electron...

Page 75: ...cing 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 deenergized Controller Replacement Procedure 1 Move the generator set master switch to the OFF position 2 Disconnect the generator set engine starting battery negative lead first 3 Disconnect power to the transfer switch by open...

Page 76: ...oved c Set the new power board and insulating cover in place Install the mounting screws making sure to reinstall the ground lead and the P1 connector with mounting bracket Note Be sure to reinstall the insulating cover for the power board See Figure 4 20 d Reconnect the ribbon cable between the boards e Proceed to step 18 1 GM46733 1 Insulator power board 2 Logic board 3 Carrier 4 Power board 5 G...

Page 77: ...roller user interface to check and adjust the system settings for the application Refer to the Transfer Switch Operation and Installation Manual for setup instructions Note Contactor and ATS serial numbers can only be entered through Modbus using Monitor III or a customer supplied Modbus driver and the distributor level password Check settings and verify operation 30 Check the system settings and ...

Page 78: ...TP 6461 1 08 78 Section 4 Controller Test and Replacement Notes ...

Page 79: ...el Refer to Figure 5 1 and Figure 5 2 for the following procedure 1 Arc chute retaining screws 2 Arc chute 3 Arc chute pad 4 Machine screws 566866 1 2 3 8 7 4 5 6 5 Stationary contact assembly 6 Transfer switch panel 7 Lug terminal 8 Hex head cap screw Figure 5 1 Stationary Contact 800 1200 Amp Removing Contact Assemblies 800 1200 Amp Models 1 Remove the machine screws and flat washers that secure...

Page 80: ... the machine screws to 13 6 Nm 10 ft lb 4 Using the new hardware supplied with the contact assemblies kit secure the new movable contact assembly with the bus stud bolt compression washer and clamp bracket 5 Torque the bus stud bolt to 31 2 Nm 23 ft lb 6 Install the pivot pin and secure with the retaining ring 7 Connect the actuator arms to the contact posts and secure with the two retaining rings...

Page 81: ...tch assemblies 18 Reinstall and secure the blue plastic cover 19 Close cabinet door 20 Reconnect the normal power source and the emergency power source If a generator set is the emergency power source connect the negative battery cable to the starting battery and place the generator set master switch in its original position 21 Test the switch for proper operation 5 2 2 1600 2000 Amp Models Removi...

Page 82: ... Close the contacts fully 9 Rock the arcing contact from toe to heel and verify that there is a 0 0762 mm 0 003 in minimum gap at the arcing contacts The feeler gauge must enter 1 59 mm 1 16 in past the edge of the silver 10 The spring gap dimension must be 1 59 mm 1 16 in less than prespring gap measured in step 7 If the contacts are not within specs reject the contact assembly 11 Check that the ...

Page 83: ...e plastic switch cover 2 Remove the cover 3 Remove the screws that secure the arc chute 4 Remove the arc chute and arc chute pad 5 Manually place the movable contact assembly that will be removed in the open position 6 Remove the two retaining rings and slide the actuator arms from the contact posts 7 Remove the twelve 1 4 20 socket head cap screws from the load bus assembly and lift out the ancho...

Page 84: ...Connect the actuator arms to the contact posts and secure with two retaining rings 6 Close the contacts slowly until the arcing contacts touch The main contacts should have a 6 35 mm 1 4 in minimum gap If they do not adjust the arc finger adjustment nut as required If the contacts cannot be brought within specifications reject the contact assembly 7 Measure and record the prespring gap 8 Close the...

Page 85: ...o the corresponding terminals of the replacement switch assembly 5 Install the new auxiliary switch assembly with the two mounting screws 6 Manually operate the transfer switch to make sure that the new auxiliary switch trips Listen for an audible click when the switch trips 7 Check the following on the new auxiliary switch a SN SNO and SE SEO pairs are adjusted to have the same over travel b The ...

Page 86: ...TP 6461 1 08 86 Section 5 Component Replacement Model KGS KGP Notes ...

Page 87: ... Deenergize all power sources before servicing Turn off the main circuit breakers of all transfer switch power sources 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 Reconnect negative leads last when reconnecting the battery cables afte...

Page 88: ...te the location of the fast on connectors to the microswitch terminals See Figure 6 1 Figure 6 1 Microswitches 6 Disconnect the fast on connectors 7 Remove the holding screws 8 Remove the suspect microswitch Note For SN SE assemblies that have four microswitches you must remove the end plate to access the microswitches See Figure 6 2 9 Install the new microswitch Note For SN SE assemblies that hav...

Page 89: ...enerator set engine starting battery ies negative lead first Note On systems with multiple transfer switches connected to a single generator set disconnect all power sources to the generator set before proceeding 2 Disconnect power to the transfer switch 3 Open the transfer switch enclosure 4 Verify zero volts across each phase Note A3 A4 microswitches can still be energized with customer power Th...

Page 90: ...ncy power to the transfer switch 3 Open the enclosure 4 Check for zero volts on the normal and emergency power lugs 5 Remove the tie wraps securing the harness 6 Disconnect the power panel harness from the controller harness Note The replacement power panel is shipped with a factory wired power panel harness 7 Disconnect the engine start leads from the ATS engine start terminals 8 Disconnect the e...

Page 91: ... 4 5 4 Note Do not leave the transfer switch in the Test mode 6 4 Arc Chute Replacement Required tools and equipment Basic electricians hand tools Arc chute Arc chute Required protective equipment Rubber insulating gloves class 0 Safety glasses Electrical hazard safety shoes Arc Chute Replacement Procedure 1 Prevent all connected generator sets from starting a Place the generator set master switch...

Page 92: ... 4 5 4 Note Do not leave the transfer switch in the Test mode Figure 6 9 Manual Operation Handle Inserted 6 5 Limit Switch Assembly Replacement Required tools and equipment Basic electricians hand tools Multimeter digital or analog Limit switch Limit switch Required protective equipment Rubber insulating gloves class 0 Safety glasses Electrical hazard safety shoes Procedure 1 Prevent all connected...

Page 93: ...n connections to the microswitch terminals as noted in step 5 Figure 6 11 Microswitch Insulator with Label Figure 6 12 Microswitch 12 Clean the inside of the ATS 13 Close and lock the enclosure 14 Connect power to the ATS 15 Enable the generator set startup a Check that the generator set master switch is in the OFF position b Reconnect the generator set engine starting batter ies negative lead las...

Page 94: ...ower 4 Verify zero volts across each phase 5 Remove DC fast on connections from the rectifier terminals See Figure 6 14 Figure 6 14 Rectifier Connections DC solenoid leads shown disconnected 6 Check the coil resistance See Figure 6 15 Note If the resistance reading is infinite or shorted replace the coil Figure 6 15 Checking Coil Resistance Rectifier Check and Replacement 7 Remove the AC fast on c...

Page 95: ...ng loaded parts can cause severe personal injury or property damage The spring in thesolenoid assemblyexerts substantialforce onthe coil Hold the coil assembly securely when removing the screws 12 Remove tie wraps as necessary Note Do not cut the insulation on the wiring 13 Remove the front bolt of the coil securing the strap See Figure 6 17 14 Loosen the rear bolt of the coil securing the strap 1...

Page 96: ...eck that the generator set master switch is in the OFF position b Reconnect the generator set engine starting batter ies negative lead last c Reconnect the battery charger if equipped 27 Move the generator set master switch to the AUTO position 28 Test the transfer switch operation by performing the Automatic Operation Test Procedure described in Section 4 5 4 Note Do not leave the transfer switch...

Page 97: ...ion 3 5 for rectifier test instructions If the rectifier is bad replace it If the rectifier is good proceed to step 9 8 Replace the rectifier Orient the new rectifier so that the red dot is in the upper right corner when the contactor is mounted in the enclosure 9 Connect AC fast on connections to AC terminals Figure 6 21 Checking Rectifier Diode Operation Solenoid Replacement Spring loaded parts ...

Page 98: ...d assembly with the attached linkage away from the contactor Note The sealed solenoid coil assembly contains the coil and the plunger Do not attempt to remove the plunger from the coil assembly 16 Remove the clip that secures the plunger to the linkage and remove the linkage from the coil assembly 17 Use the clip to attach the linkage to the new coil assembly 18 Place the new solenoid assembly int...

Page 99: ...Install any required tie wraps See Figure 6 23 23 Close the ATS enclosure 24 Reconnect power to the ATS 25 Enable the generator set startup a Check that the generator set master switch is in the OFF position b Reconnect the generator set engine starting batter ies negative lead last c Reconnect the battery charger if equipped 26 Move the generator set master switch to the AUTO position 27 Test the...

Page 100: ...TP 6461 1 08 100 Section 6 Component Replacement Model KSS Switches Notes ...

Page 101: ...switch power sources 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 Reconnect negative leads last when reconnecting the battery cables after servicing Follow these precautions to prevent the starting of generator sets by an automatic tra...

Page 102: ...e 7 4 Separating Units 100 and 200 Amp 6226 1 Loosen four M6 bolts 1 Figure 7 5 Separating Units 400 Amp 6226 Figure 7 6 Mechanical Unit 7 2 2 Reassembly 100 400 Amps Reassemble the mechanical unit and the current carrying unit 1 Assemble the current carrying unit and the mechanical unit Make sure that the shaft from the mechanical unit goes through both main shaft levers See Figure 7 7 On 400 amp...

Page 103: ...evers if removed aligning the square indentation with the end of the square shaft See Figure 7 9 and Figure 7 10 4 Reinstall the auxiliary switches if removed The 100 and 200 amp models use one bolt and one alignment pin per switch See Figure 7 9 Larger models use two bolts per switch See Figure 7 10 1 6226 1 Auxiliary switch levers 2 Auxiliary switches 2 Figure 7 9 100 and 200 Amp Models 6226 1 A...

Page 104: ...s at three terminals See Figure 7 12 Note Hold the terminals while loosening the screws to avoid damage 3 Note the connections for reconnection later and disconnect the control switch leads at eight locations See Figure 7 13 4 Remove the bolt and replace the printed circuit board See Figure 7 11 5 Reconnect all leads as noted during step 1 6226 1 Coil leads 2 Bolt 1 2 Figure 7 11 Circuit Board Con...

Page 105: ... See Figure 7 15 and Figure 7 16 5 Loosen the M12 nut and replace the closing coil See Figure 7 16 6226 1 M12 nut 1 Figure 7 16 Closing Coil with Frame 100 400 Amp Models 6 Reinstall movable steel shaft To adjust the shaft a Turn the large round shaft in clockwise until mechanism just latches when operated with the manual handle If turned too far it won t latch b Back the shaft out counterclockwis...

Page 106: ...19 Select Coil Assembly 4 Replace the select coil See Figure 7 20 6226 1 Select coil 1 Figure 7 20 Select Coil 7 2 6 Trip Coil Replacement 100 400 Amps Note Remove the select coil first for easier access to the trip coil See Section 7 2 5 1 Locate the trip coil See Figure 7 21 6226 1 Trip coil 1 Figure 7 21 Trip Coil Location 2 Note the connections and disconnect the trip coil leads from the print...

Page 107: ...es when servicing spring loaded parts Hold parts securely during disassembly WARNING 4 The trip shaft is spring loaded Hold the shaft securely while removing the trip shaft bolt See Figure 7 24 Remove the M4 bolt with ring trip shaft spring and L shaped bracket See Figure 7 25 Keep the parts for reassembly later 5 Loosen three bolts shown in Figure 7 26 remove the side plate and replace the trip c...

Page 108: ... shown in Figure 7 27 and replace the required arc chute Reinstall the retainer clips 6226 1 Arc chute retainer clips 1 Figure 7 27 Arc Chutes 7 3 Component Replacement 600 Amp Models 7 3 1 Closing Coil Replacement 600 Amp Models 1 Remove the M4 bolts and the M6 bolt Remove the cover from the mechanical unit See Figure 7 28 2 Note the connections shown in Figure 7 29 and disconnect the closing coi...

Page 109: ...gure 7 30 d Reconnect four leads shown in Figure 7 29 5 Adjust the movable steel shaft as described in the following procedure 7 3 2 Shaft Adjustment 600 Amp Models Note It is not necessary to remove the movable steel shaft when replacing the closing coil 1 Turn the large round shaft in clockwise until the mechanism just latches when operated with the manual handle If turned too far it won t latch...

Page 110: ...s 1 2 3 Figure 7 32 Circuit Board Connections 6226 1 Trip coil M4 bolts 2 Control switch 3 Insulator 1 2 3 Figure 7 33 Trip Coil Replacement 600 Amp Models 2 Remove two M4 bolts and replace the trip coil Retain the small spring for the trip coil lever See Figure 7 33 and Figure 7 34 3 Connect the trip coil leads to the printed circuit board and control switch as noted during disassembly Tighten co...

Page 111: ...ft and spring see Figure 7 36 2 Select coil 3 Select coil M4 bolts 3 1 2 Figure 7 35 Select Coil Replacement 600 Amp Models 1 6226 1 Spring Figure 7 36 Spring Location 7 3 6 Printed Circuit Board Replacement 600 Amp Models Note The individual rectifiers are not replaceable Replace the entire printed circuit board in the case of rectifier failure 1 Note the connections and disconnect all leads to t...

Page 112: ...me apart if the parts are not clamped as shown before the nuts or retainers are removed 3 Loosen the M6 nuts or remove the retainers See Figure 7 39 4 Remove the upper rod shown in Figure 7 39 tp6226 1 Remove this rod 2 Fixture 3 M6 nuts or retainers 2 3 1 Figure 7 39 Fixture or Clamp 600 Amp Models 5 Replace the arc chutes 6 Replace the rod 7 Reinstall and tighten the M6 nuts or install new retai...

Page 113: ...riter s Laboratories CUL Canadian Underwriter s Laboratories 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 resistance deg degree dept department DFMEA Design Failure Mode and Effects Analysis dia diameter DI EO dual inlet end outlet DIN Deutsches Institut...

Page 114: ...oversize overspeed OSHA Occupational Safety and Health Administration OV overvoltage oz ounce p pp page pages PC personal computer PCB printed circuit board pF picofarad 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 potentiometer potential ppm parts per million P...

Page 115: ...iser Active D Source Voltages D Time Remaining in exercise run D End Exercise Button View Event History D Event Description D Date and Time of event View Maintenance Records D Total Min Not Preferred D Reset Min Not Preferred D Total Min in Standby D Reset Min in Standby D Total Min Operation D Reset Min Operation D Total Transfers D Reset Transfers D Total Fail Transfer D Reset Fail Transfer D To...

Page 116: ... d Aux I O Module d Module Type and Address d Module Status d Input Function Descriptions d Output Function Descriptions View Common Alarms D Alarm Group 1 and 2 D Alarm Description D Audible Yes or No D Common Yes or No View Communications Setup D Modbus Server TCP Enabled Disabled D Modbus Server Port 1 and 2 Enable Disabled D Modbus Address Port 1 and 2 D Baud Rate Port 1 and 2 9600 19200 57600...

Page 117: ... Alarms Yes No Set System D Source Type Utility Generator Generator Generator Utility Utility Utility Generator Generator 3 source system D Transition Type Standard Programmed D Rated Current Amps D 3 Source Engine Start Mode d Mode1 Mode2 d Preferred Source Toggle Enable Disable D Transfer Commit Commit No Commit D Remote Test Loading Loaded Unloaded D Peak Shave TD Bypass Enable Disable Set Comm...

Page 118: ...e Loads on high power distribution circuits are nearly immune to noise D General Purpose Power Distribution Circuits to medium power loads such as lighting offices light duty equipment and small motors such as fans and pumps can emit transient medium levels of broad spectrum noise Some electronic equipment such as computers emits constant levels of broad spectrum noise in addition to transient bro...

Page 119: ...op of nut 3 Below top of nut Figure 1 Acceptable Bolt Lengths Steps for common hardware application 1 Determine entry hole type round or slotted 2 Determine exit hole type fixed female thread weld nut round or slotted For round and slotted exit holes determine if hardware is greater than 1 2 inch in diameter or 1 2 inch in diameter or less Hardware that is greater than 1 2 inch in diameter takes a...

Page 120: ...214 0 895 Metric Fasteners Torque Specifications Measured in Nm ft lb Assembled into Cast Iron or Steel Assembled into Aluminum Size mm Grade 5 8 Grade 8 8 Grade 10 9 Aluminum Grade 5 8 or 8 8 M6 x 1 00 6 2 4 6 9 5 7 13 6 10 M8 x 1 25 15 0 11 23 0 17 33 0 24 M8 x 1 00 16 0 11 24 0 18 34 0 25 M10 x 1 50 30 0 22 45 0 34 65 0 48 M10 x 1 25 31 0 23 47 0 35 68 0 50 M12 x 1 75 53 0 39 80 0 59 115 0 85 M...

Page 121: ...nal External Tooth Lock Hardness Grades American Standard Grade 2 Grade 5 Grade 8 Grade 8 9 Hex Socket Head Metric Number stamped on hardware 5 8 shown 5 8 Allent head screw is a trademark of Holo Krome Co Phillipsr screw is a registered trademark of Phillips Screw Company Sample Dimensions 1 4 20 x 1 Major Thread Diameter In Fractional Inches Or Screw Number Size Length In Inches Screws and Bolts...

Page 122: ...24 2 7 16 14 x 1 00 X 6024 8 7 16 14 x 1 25 X 6024 3 7 16 14 x 1 50 X 6024 4 7 16 14 x 2 00 X 6024 11 7 16 14 x 2 75 X 6024 12 7 16 14 x 6 50 X 129 15 1 2 13 x 75 X 129 17 1 2 13 x 1 00 X 129 18 1 2 13 x 1 25 X 129 19 1 2 13 x 1 50 X 129 20 1 2 13 x 1 75 X 129 21 1 2 13 x 2 00 X 129 22 1 2 13 x 2 25 X 129 23 1 2 13 x 2 50 X 129 24 1 2 13 x 2 75 X 129 25 1 2 13 x 3 00 X 129 27 1 2 13 x 3 50 X 129 2...

Page 123: ...3 00 x 160 M931 24200 60 M24 3 00 x 200 Hex Head Bolts Full Thread M933 04006 60 M4 0 70 x 6 M933 05030 60 M5 0 80 x 30 M933 05035 60 M5 0 80 x 35 M933 05050 60 M5 0 80 x 50 M933 06010 60 M6 1 00 x 10 M933 06012 60 M6 1 00 x 12 M933 06014 60 M6 1 00 x 14 M933 06016 60 M6 1 00 x 16 M933 06020 60 M6 1 00 x 20 M933 06025 60 M6 1 00 x 25 M933 06030 60 M6 1 00 x 30 M933 06040 60 M6 1 00 x 40 M933 06050...

Page 124: ...M12 1 75 Spiralock M982 12 80 M12 1 75 Elastic Stop M982 14 60 M14 2 00 Elastic Stop M6923 16 80 M16 2 00 Spiralock M982 16 80 M16 2 00 Elastic Stop M934 18 80 M18 2 5 Standard M982 18 60 M18 2 50 Elastic Stop M934 20 80 M20 2 50 Standard M982 20 80 M20 2 50 Elastic Stop M934 22 60 M22 2 50 Standard M934 24 80 M24 3 00 Standard M982 24 60 M24 3 00 Elastic Stop M934 30 80 M30 3 50 Standard Washers ...

Page 125: ......

Page 126: ...er 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 KohlerPower com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65 6264 6455 ...

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