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TP-5660 11/98

ii Introduction

Service Assistance

Service Information

For sales, service, or other information about a Kohler
Generator Division product, contact a local authorized
distributor or dealer first.

To locate a local authorized distributor or dealer

D

Look on the product or the information included with
the product

D

Consult the Yellow Pages under the heading
Generators— Electric

D

Visit the Kohler Generator Division Web site at
www.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,
write the product identification numbers in the spaces
below. Record the identification numbers immediately
after unpacking the products so that the numbers are
readily available for future reference.

Record the

field-installed kit numbers after installing the kit.

Transfer Switch Identification Numbers

Record the product identification numbers from the

transfer switch nameplate.
Part Number
Serial Number

Accessory Number

Accessory Description

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6
7
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Содержание ZCS series

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

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

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

Страница 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...

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

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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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