Kohler ZCS series Operation And Installation Download Page 1

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Automatic Transfer Switches

Models:

ZCS

Contactors:

40 to 3000 Amperes

TP-5660 11/98

Operation and

Installation

Summary of Contents for ZCS series

Page 1: ...Automatic Transfer Switches Models ZCS Contactors 40 to 3000 Amperes TP 5660 11 98 Operation and Installation...

Page 2: ...15 3 1 1 Description 15 3 1 2 Adjustment 15 3 2 Other Accessories 16 Section 4 Scheduled Maintenance 17 4 1 Inspection and Service 18 4 1 1 General Inspection 19 4 1 2 Other Inspections and Service 19...

Page 3: ...arting Can cause severe injury or death Disconnect battery cables before working on generator set Remove negative lead first when disconnecting battery Reconnect negative lead last when reconnecting b...

Page 4: ...wer sources before servicing Install barrier after adjustments maintenance or service under 600 Volt WARNING Hazardous voltage Will cause severe injury or death Disconnect power sources before servici...

Page 5: ...uipment Servicing the transfer switch Hazardous voltage can cause severe injury or death Deenergize all power sources before servicing Open main circuit breakers of all power sources to the transfer s...

Page 6: ...l operator handle provided on the transfer switch for maintenance purposes only Return the transfer switch to the normal position Remove manual operator handle if used and store it on the transfer swi...

Page 7: ...power switching device matches that what is shown on the front cover of this manual before proceeding with operation or installation A separate operation and installation manual that covers informatio...

Page 8: ...ww kohlergenerators com D Call 1 800 544 2444 inside the U S A and Canada or 920 565 3381 outside the U S A and Canada Product Identification To ensure the supply of correct parts and information writ...

Page 9: ...nects the inner panel to the power switching device Controls and indicators on the transfer switch are determined by the logic controller and installed accessories For details see the operation and in...

Page 10: ...4 to interpret the part number Copy the part number factory installed accessory numbers and serial number from the nameplate into the spaces provided in the Service Assistance section in this manual...

Page 11: ...s 60 hertz 3 phase 3 pole and 4 wires in a NEMA Type 1 enclosure with a contactor rating of 1000 amperes SAMPLE PART NUMBER Classification of Power Switch Z Power Switch Type of Power Switch C Contact...

Page 12: ...ent protective device Figure 1 6 and Figure 1 7 provides WCR when coordinated with specific manufacturer s circuit breakers or fuse types Figure 1 6 has ratings for 480 V maximum and apply to both UL...

Page 13: ...6 SHLD6 HHJD6 HHLD6 600 200 000 J RK5 RK1 600 400 50 000 ITE MD6 MXD6 SMD6 CMD6 SCMD6 HMD6 HMXD6 SHMD6 800 200 000 RK1 600 Square D IL 400 Square D MH ME SE 600 Westinghouse HKD KDC LCL LA TRI PAC 400...

Page 14: ...E CJD6 SCJD6 SHP SHK CED6 CFD6 400 150 000 J RK5 RK1 600 ITE CLD6 SCLD6 HLD6 SHLD6 600 Westinghouse HKD KDC LA TRI PAC 400 Westinghouse NB TRI PAC 800 GE TB8 TKL TP THP TC THC TKH TBC8 L J RK5 600 50...

Page 15: ...tch Size Normal Emergency and Load Terminals Size amps Cables per Pole Range of Wire Sizes Size amps Cables per Pole Range of Wire Sizes 40 1 14 AWG to 2 AWG 800 4 2 AWG to 600 MCM 80 100 1 14 AWG to...

Page 16: ...TP 5660 11 98 8 Specifications Notes...

Page 17: ...m circuit breakers or switches to the transfer switch 3 Open the enclosure and check that the wire harnesses for the power switching device and the controller are plugged together at the inline discon...

Page 18: ...the emergency power source After signalling the generator to start the controller monitors the emergency power source When the controller determines that the emergency generator power source is accep...

Page 19: ...efore servicing Install barrier after adjustments maintenance or service under 600 Volt WARNING Hazardous voltage Will cause severe injury or death Disconnect power sources before servicing Install ba...

Page 20: ...binding Both normal and emergency sources are disconnected from the load in the middle off position 7 Locate the mid position manual release handle on the left side of the switch See Figure 2 1 8 Pull...

Page 21: ...ually connect the load to the normal source and move it down to disconnect The switch should operate smoothly in both directions without binding 6 Attach the manual operator handle to the emergency sw...

Page 22: ...ion Standard Switch 600 3000 Amps 5 Attach the manual operating handle to the switch lever 6 Move the handle up to the normal position to connect the load to the normal source or down to the emergency...

Page 23: ...he emergency to normal power transfer Each relay has a separate adjustment To make the adjustment proceed as follows Accidental starting Can cause severe injury or death Disconnect battery cables befo...

Page 24: ...ransfer switch enclosure door 4 Locate the appropriate relay on the interface circuit board See Figure 3 1 5 Insert a screwdriver into the slot of the adjustment screw which is visible through the cov...

Page 25: ...ace all barriers and close and lock the enclosure door after maintenance or service and before reapplying power Accidental starting Can cause severe injury or death Disconnect battery cables before wo...

Page 26: ...hargers 3 Disconnect all battery cables negative leads first Reconnect negative leads last when reconnecting battery cables after servicing Follow these precautions to prevent starting of generator se...

Page 27: ...ernal inspection is unacceptable in the application have an internal inspection performed by an authorized service center 4 1 2 Other Inspections and Service Have an authorized service center perform...

Page 28: ...itch s automatic control system 4 2 2 L X X M Test all indicators incandescent lamps and LEDs and all remote control systems for operation L D D D R D Y GENERAL EQUIPMENT CONDITION Inspect the outside...

Page 29: ...n ADV 5976B C 40 260 Amp Programmed Transition ADV 5976C A 400 Amp Programmed Transition ADV 5976D B 600 Amp Programmed Transition ADV 5976E A 600 1200 Amp Programmed Transition ADV 5976F B 1600 2000...

Page 30: ...TP 5660 11 98 22 Diagrams and Drawings Notes...

Page 31: ...TP 5660 11 98 Diagrams and Drawings 23 Enclosure Dimensions Drawing 40 260 Amp NEMA Type 1 and Type 3R ADV 6180...

Page 32: ...24 Diagrams and Drawings TP 5660 11 98 Enclosure Dimensions Drawing 400 Amp NEMA Type 1 and Type 3R ADV 5934 C...

Page 33: ...TP 5660 11 98 Diagrams and Drawings 25 Enclosure Dimensions Drawing 600 1200 Amp NEMA Type 1 and Type 3R ADV 5936A F...

Page 34: ...26 Diagrams and Drawings TP 5660 11 98 Enclosure Dimensions Drawing 600 1200 Amp NEMA Type 12 ADV 5936B B...

Page 35: ...TP 5660 11 98 Diagrams and Drawings 27 Enclosure Dimensions Drawing 1600 2000 Amp NEMA Type 1 ADV 5941 E...

Page 36: ...28 Diagrams and Drawings TP 5660 11 98 Enclosure Dimensions Drawing 1600 2000 Amp NEMA Type 3R E33 and S340 Logic ADV 5990 A...

Page 37: ...TP 5660 11 98 Diagrams and Drawings 29 Enclosure Dimensions Drawing 1600 2000 Amp NEMA Type 3R M340 Logic ADV 5989 A...

Page 38: ...30 Diagrams and Drawings TP 5660 11 98 Enclosure Dimensions Drawing 2500 3000 Amp NEMA Type 1 ADV 6242 B...

Page 39: ...TP 5660 11 98 Diagrams and Drawings 31 Enclosure Dimensions Drawing 2500 3000 Amp NEMA Type 3R E33 and S340 Logic ADV 6241 A...

Page 40: ...32 Diagrams and Drawings TP 5660 11 98 Enclosure Dimensions Drawing 2500 3000 Amp NEMA Type 3R M340 Logic ADV 6240 A...

Page 41: ...CE P1 36 P1 35 77 76 NA EB EC NB NC NTS NTS NTS SOURCE FROM EMERGENCY EA EB EC EN LA LB LC LN NN TO LOAD 77 76 NA NB NC T2 T3 EA 76 77 NA NC T1 ET1 EB EC NA EC EB EA T2 T3 T6 T7 P1 22 P1 23 P1 24 P1 8...

Page 42: ...NN TO LOAD 77 76 NA NB NC T2 T3 EA 76 77 NA NC T1 ET1 EB EC NA EC EB EA T2 T3 T6 T7 P1 22 P1 23 P1 24 P1 8 P1 9 R NB NC NORMAL SWITCH EMERGENCY SWITCH NC NT1 P2 9 P2 11 P2 10 P2 6 P2 3 P2 12 SN 1 SE 1...

Page 43: ...SFER SWITCH PANEL TERMINAL BLOCK SECONDARY OF TRANSFORMER TERMINAL BLOCK PRIMARY OF TRANSFORMER COMPONENT CONNECTION TERMINAL TRANSFER SWITCH POWER TERMINALS 2 SN 1 SEO 1 SNO 1 SNO 2 SEO 2 SE 1 NO 15...

Page 44: ...OSITION EMERGENCY J J JA K3 K5 K4 ES4 ES3 POWER SUPPLY 12VDC TO 24VAC P3 9 12 11 10 9 8 7 6 5 4 3 2 1 TB1 JP4 JP3 JP2 P3 3 P3 1 P3 2 NB NC P15 9 P15 8 P15 7 P15 4 P15 3 K3 K1 K2 K5 12 11 9 W W G TB2 8...

Page 45: ...TP 5660 11 98 Diagrams and Drawings 37 Schematic Diagram S340 Logic 600 1200 Amp 321096 C...

Page 46: ...38 Scheduled Maintenance TP 5660 11 98 Schematic Diagram S340 Logic 1600 3000 Amp 321097 A...

Page 47: ...TP 5660 11 98 Diagrams and Drawings 39 Schematic Diagram S340 Logic 120 VAC 40 260 Amp with Programmed Transition 346311...

Page 48: ...40 Scheduled Maintenance TP 5660 11 98 Schematic Diagram S340 Logic 208 VAC 40 260 Amp with Programmed Transition 353185...

Page 49: ...TP 5660 11 98 Diagrams and Drawings 41 Schematic Diagram S340 Logic 240 and 480 VAC 40 260 Amp with Programmed Transition 353184...

Page 50: ...42 Scheduled Maintenance TP 5660 11 98 Schematic Diagram S340 Logic 380 and 416 VAC 40 260 Amp with Programmed Transition 353183...

Page 51: ...TP 5660 11 98 Diagrams and Drawings 43 Schematic Diagram S340 Logic 600 VAC 40 260 Amp with Programmed Transition 353182...

Page 52: ...44 Scheduled Maintenance TP 5660 11 98 Schematic Diagram S340 Logic 400 Amp with Programmed Transition 321098 B...

Page 53: ...TP 5660 11 98 Diagrams and Drawings 45 Schematic Diagram S340 Logic 600 3000 Amp with Programmed Transition 321099 B...

Page 54: ...46 Diagrams and Drawings TP 5660 11 98 Schematic Diagram M340 Logic 600 1200 Amp 321287 C...

Page 55: ...TP 5660 11 98 Diagrams and Drawings 47 Schematic Diagram M340 Logic 1600 3000 Amp 321301 B...

Page 56: ...48 Diagrams and Drawings TP 5660 11 98 Schematic Diagram M340 Logic 120 VAC 40 260 Amp with Programmed Transition 346312...

Page 57: ...TP 5660 11 98 Diagrams and Drawings 49 Schematic Diagram M340 Logic 208 VAC 40 260 Amp with Programmed Transition 353174...

Page 58: ...50 Diagrams and Drawings TP 5660 11 98 Schematic Diagram M340 Logic 240 and 480 VAC 40 260 Amp with Programmed Transition 353175...

Page 59: ...TP 5660 11 98 Diagrams and Drawings 51 Schematic Diagram M340 Logic 380 and 416 VAC 40 260 Amp with Programmed Transition 353176...

Page 60: ...52 Diagrams and Drawings TP 5660 11 98 Schematic Diagram M340 Logic 600 VAC 40 260 Amp with Programmed Transition 353177...

Page 61: ...TP 5660 11 98 Diagrams and Drawings 53 Schematic Diagram M340 Logic 400 Amp with Programmed Transition 321300 B...

Page 62: ...54 Diagrams and Drawings TP 5660 11 98 Schematic Diagram M340 Logic 600 3000 Amp with Programmed Transition 321286 A...

Page 63: ...matic transfer switch for signs of shipping damage If damage and or rough handling is evident file a damage claim immediately with the transportation company and promptly notify the distributor or dea...

Page 64: ...When mounting these units plumb the enclosure to ensure that the door hinges are vertical to avoid any distortion of the enclosure or door Place washers behind the mounting bracket key holes to shim...

Page 65: ...esent Open main circuit breakers of all power sources before servicing equipment Configure the installation to electrically ground the transfer switch and related equipment and electrical circuits to...

Page 66: ...tch components for protection from metal chips and construction grit Remove any debris from the enclosure with a vacuum cleaner Do not use compressed air to clean the switch because it can cause debri...

Page 67: ...e generator engine start battery charger if installed and disconnecting all generator engine start battery cables negative leads first Connect the generator set remote starting circuit to the generato...

Page 68: ...connected 3 Move the generator set master switch to the OFF position to inhibit generator set starting 4 Manually transfer the load to the emergency source See Section 2 3 5 Reapply the normal source...

Page 69: ...EC if equipped NOTE When initially applying power to the transfer switch the engine start contacts remain closed signalling the generator to run until the ATS s Time Delay Engine Cooldown TDEC if equi...

Page 70: ...TP 5660 11 98 62 Installation Notes...

Page 71: ...O International Standards Organization J joule joules JIS Japanese Industry Standard kg kilogram kilograms kg cm2 kilograms per square centimeter kgm kilogram meter s kJ kilojoules btu cal km kilomete...

Page 72: ...565 3381 Web site www kohlergenerators com Fax 920 459 1646 U S A Sales Fax 920 459 1614 International For the nearest sales and service outlet in U S A and Canada Phone 1 800 544 2444 KohlerrPower S...

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