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Table of Contents

TP-6835 9/17

Table of Contents 3

Safety Precautions and Instructions

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Introduction

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List of Related Materials

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Service Assistance

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Section 1 Product Description

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1.1

Purpose

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1.2

Nameplate

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1.3

Model Designation

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Section 2 Installation

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2.1

Introduction

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2.2

Receipt of Unit

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2.2.1

Inspection

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2.2.2

Lifting

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2.2.3

Storage

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2.2.4

Unpacking

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2.3

Installation

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2.4

IBC Seismic Certification or California OSHPD Approval

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2.5

Manual Operation Check

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2.5.1

Manual Operation, 150--4000 Amp Standard-Transition Model KBS

. .

2.5.2

Manual Operation, 150--4000 Amp Programmed- and Closed-

Transition Models KBP and KBC

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2.6

Controller Connections

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2.6.1

Controller Input and Output Connections

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2.6.2

Harness Connection

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2.6.3

Controller Ground

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2.7

Electrical Wiring

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2.7.1

Source and Load Connections

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2.7.2

Extended Transfer Time Relay (Model KBC only)

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2.7.3

Engine Start Connection

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2.7.4

Auxiliary Contacts

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2.8

Communication and Accessory Connections

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2.9

Functional Tests

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Section 3 Three-Source Systems

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3.1

Three-Source Systems

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3.2

Three Source Engine Start Mode

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3.2.1

Mode 1

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3.2.2

Mode 2

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3.3

Preferred Source Toggle

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3.4

Three Source System Test and Exercise

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3.4.1

Unloaded Test

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3.4.2

Loaded Test

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3.4.3

Unloaded Exercise

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3.4.4

Loaded Exercise

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3.5

Three-Source System Connection

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3.6

ATS1 and ATS2 System Setup

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Section 4 Communication and Accessory Connections

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4.1

Introduction

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4.2

Communication Connections

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4.2.1

USB Port SiteTech Connection

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4.2.2

Modbus Connection

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4.2.3

Ethernet Connection

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Содержание KBC

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 79: ......

Страница 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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