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TP-6833 2/16

Section 2 Installation

Install and test the power cables.

Leave sufficient

slack in the power leads to reach all of the power

connecting lugs on the power switching device. Test the

power conductors before connecting them to the

transfer switch. Installing power cables in conduit, cable

troughs and ceiling-suspended hangers often requires

considerable force. Pulling cables can damage

insulation and stretch or break the conductor’s strands.
Test the cables after pulling them into position and

before

they are connected to verify that they are not

defective and that they were not damaged during

installation.

Install the cable spacers provided with 30--200 amp

switches as shown in Figure 2-22.

1. Cable spacers

127

Figure 2-22

Cable Spacers for 30--200 Amp Switches

Connect the cables.

Be careful when stripping

insulation from the cables; avoid nicking or ringing the

conductor. Clean cables with a wire brush to remove

surface oxides before connecting them to the terminals.

Apply joint compound to the connections of any

aluminum conductors.
Refer to the wiring diagram provided with the switch.
The connection points on the contactor are labeled

Normal, Emergency, and Load. Be sure to follow the

phase markings (A, B, C, and N). For single-phase

systems, connect to A and C.

Note:

Connect the source and load phases as

indicated by the markings and drawings to

prevent short circuits and to prevent phase-

sensitive load devices from malfunctioning or

operating in reverse.

Tighten the lugs.

Verify that all connections are

consistent with drawings before tightening the lugs.

Tighten all cable lug connections to the torque values

shown on the label on the switch. (See Figure 2-24 for a

typical rating/torque label.) Carefully wipe off any

excess joint compound after tightening the terminal

lugs.
For load connections to bus bars, use a compression

washer, flat washer, and a minimum grade 5 bolt and

torque the connections to the values in Figure 2-23.

Bolt Size, inches

Bolt Torque

ft. lb.

1/4

9.5

5/16

16.3

3/8

27.1

1/2

67.8

5/8

128.8

3/4

155

210.2

Figure 2-23

Tightening Torque for Bus Bars

USE COPPER OR ALUMINUM WIRE

FOR POWER TERMINALS

RECOMMENDED TIGHTENING

200 480 FUSE ANY CLASS J

TORQUE 600

IN--LBS

AMPS AT THE VOLTAGE SHOWN.

BREAKER/MFR/TYPE

DELIVERING NOT MORE THEN THE RMS SYMM

RATED FOR USE ON A CIRCUIT CAPABLE OF

ONLY OR BY FUSES THIS TRANSFER SWITCH IS

WITHOUT AN ADJUSTABLE SHORT--TIME RESPONSE

WHEN PROTECTED BY A CIRCUIT BREAKER

SWITCH RATING, 240V MAX.

TUNGSTEN LOAD DOES NOT EXCEED

% OF

NOT EXCEED THE SWITCH AMP RATING AND THE

LOAD AMPS AND AMPS OF OTHER LOADS DOES

ING EQPT, WHERE THE SUM OF MOTOR FULL--

DISCHARGE AND TUNGSTEN LAMPS, ELEC HEAT--

SUITABLE FOR CONTROL OF MOTORS, ELEC

RMS SYMM

VOLTS

MAX

X1000

AMPS

MAX

AMPS

42 480 GE SGL4,SGP4,TB4,

400

THLC4,TLB4

400

SKHA,SKL8,SKP8,TKL

SGLA,SGL6,SGP6,TB6

800

600

42 480 I--T--E CJD6,HHJD6,

400

CLD6,HHLD6,HHLXD6,HLD6,

HHJXD6,HJD6,SCJD6,SHJD6

600

400

CMD6,HMD6,HND6,MD6,MXD6,

SCLD6,SHLD6

800

600

SCMD6,SHMD6,SMD6,SND6

800

42 480 SQUARE D LC,LI

800

600

42 480 WESTH HKD,KDC,LCL,

400

HLD

TRI--PAC LA

600

400

TRI--PAC NB

800

100

35
22

600

480

ANY
ANY

PER NEC
PER NEC

483500--007

REV

USE 75



C MIN. CU/AL WIRE FOR POWER

CONNECTIONS. USE 60



C MIN. CU WIRE FOR

CONTROLS.

600

42 480 MERLIN GERIN

42 480 ABB S5

CJ600

400

600

800

007

1. Torque specification

Figure 2-24

Typical Rating/Torque Label

Содержание KCC

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

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

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

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

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

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

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

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

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

Страница 10: ...AC 1500 Non Automatic Non automatic controls are available on Models KCS and KCP only Voltage Frequency C 208 Volts 60 Hz K 440 Volts 60 Hz D 220 Volts 50 Hz M 480 Volts 60 Hz F 240 Volts 60 Hz N 600...

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 24: ...oor Figure 2 18 shows the locations of the connectors on the controller It is not necessary to open the cover to access the Ethernet Modbusr and input output connectors Opening the cover If necessary...

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

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

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

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

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

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

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

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

Страница 33: ...source and open the engine start contacts to the standby generator after the cooldown delay has elapsed 3 3 Preferred Source Toggle The preferred source toggle function alternates between the two gen...

Страница 34: ...set 1 to the normal side of ATS2 e Connect generator set 2 to the emergency side of ATS2 2 Three source systems require the following input output connections to control the engine start commandsfor...

Страница 35: ...FER BACK TO NORMAL AFTER THE UTILITY RETURNS WHEN THE UTIITY IS AVAILABLE THE BATTERY SUPPLY MODULE WILL PROVIDE POWER TO THE CONTROLLER ON ATS2 THE 3 SOURCE SYSTEM DISABLE INPUT AND OUTPUT WILL PREVE...

Страница 36: ...2 engine start ES connections See Figure 3 1 Figure 3 2 Input and Output Connections for Three Source Systems 3 6 ATS1 and ATS2 System Setup Use the System Setup Menu on each transfer switch to set th...

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

Страница 38: ...only TB2 A1 B1 GND1 3 6 1 4 A1 B1 GND1 Customer connections Input Output Cable shield Cable shield Figure 4 3 Modbus RS 485 Connections USB to RS 485 port converter RS 485 USB port Device USB port De...

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

Страница 40: ...MPAC Controller with Ethernet comm board IP xx xx xx 03 Figure 4 6 Remote Network Ethernet Connection MPAC Controller with Ethernet comm board IP xx xx xx 03 PC IP xx xx xx 02 Device Last device RS 4...

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

Страница 42: ...feet Outputs Outputs Available 6 Contact Type Form C SPDT Contact Voltage Rating 2 A 30 VDC 500 mA 125 VAC Connection Type Terminal Strip Wire Size 14 24 AWG Figure 4 11 Standard I O Module Specifica...

Страница 43: ...dule EBSM The external battery supply module kit allows connection to the generator set engine start battery ies or other batteries to provide 12 VDC power to the ATS controller The external battery s...

Страница 44: ...ection and Voltage Setting 1 Use 14 28 AWG wire to connect one or two batteries to terminal block TB13 A second battery can be connected but is not required Follow the marking on the board for the pos...

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

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

Страница 47: ...ctions GM89713 1 Input output terminal strip TB1 1 TB1 12 6 1 7 MLB Input 2 alternate connection 12 24 AWG wire 0 5 Nm 4 4 in lb MLB Input 1 MPAC Controller Circuit Board Figure 4 23 Forced Transfer t...

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

Страница 49: ...eater Connections 4 6 Other Accessories Refer to the following documentation for instructions to install connect and operate optional accessories D Transfer switch wiring diagrams D Installation instr...

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

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

Страница 52: ...he manufacturer s instructions to adjust the generator set The automatic transfer switch will only function with the rated system voltage and frequency specified on the nameplate 4 Use a phase rotatio...

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

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

Страница 55: ...s cu in cubic inch cw clockwise CWC city water cooled cyl cylinder D A digital to analog DAC digital to analog converter dB decibel dB A decibel A weighted DC direct current DCR direct current resista...

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

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

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

Страница 59: ......

Страница 60: ...r the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KOHLERPower com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 6...

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