Operation and

Installation
Automatic Transfer Switches

Models:
KCT, KCP
Power Switching Device:
Standard
Open-Transition 30 to 4000 Amps
Programmed-Transition 150 to 4000 Amps

Electrical Controls:
MPAC 1000t

TP-6126 8/02b
Product Identification Information

Product identification numbers determine service parts.

Record the product identification numbers in the spaces
below immediately after unpacking the products so that
the numbers are readily available for future reference.
Record field-installed kit numbers after installing the
kits.

Transfer Switch Identification Numbers

Record the product identification numbers from the
transfer switch nameplate.
Model Designation
Serial Number

Accessory Number Accessory Description

x:in:007:001
 Table of Contents

Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside front cover

Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
List of Related Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Section 1 Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Model Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Section 2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Receipt of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2.2 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2.3 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2.4 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4 Manual Operation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4.1 Manual Operation, 30--200 Amp Open-Transition Switches . . . . . . . . . . 5
2.4.2 Manual Operation, 225--4000 Amp Open-Transition Switches . . . . . . . 6
2.4.3 Manual Operation, Programmed-Transition Switches . . . . . . . . . . . . . . . 8
2.5 Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5.1 AC Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.5.2 Engine Start Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.5.3 Auxiliary Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.5.4 Controller Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Section 3 Setup and Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2 User Interface Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2.1 Pushbuttons and LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2.2 Controller Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.3 Controller Main Logic Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3.1 Main Logic Board DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.3.2 Main Logic Board Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.3.3 Communications Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.4 Programmed-Transition Interface Board (PTIB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.5 System Settings and Time Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.5.1 System Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.5.2 Time Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.6 Generator Set Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.7 Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.7.1 Manual Operation Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.7.2 Voltage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.7.3 Automatic Operation Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.8 Exerciser Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.9 Warranty Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Section 4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.2 Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.2.1 Automatic Operation, Open- and Programmed-Transition Switches . . . 27
4.2.2 System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2.3 Exerciser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

TP-6126 8/02 Table of Contents

Table of Contents, continued

4.2.4 Peak Shave/Area Protection Operation Sequence . . . . . . . . . . . . . . . . . 34

4.2.5 Pre- and Post-Transfer Load Control Sequence . . . . . . . . . . . . . . . . . . . 35
4.3 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.3.1 Service Required LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.3.2 Auxiliary Switch Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.3.3 Failure to Acquire Standby Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.3.4 Failure to Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.3.5 Phase Rotation Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.4 Controller Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Section 5 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.2 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.2.1 Weekly Generator Set Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.2.2 Monthly Automatic Control System Test . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.3 Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.3.1 General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.3.2 Other Inspections and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.4 Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Section 6 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.2 Setup Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.3 Control Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.3.1 Preferred Source Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.3.2 Supervised Transfer Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.4 In-Phase Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.5 Programmable Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.5.1 Programmable Input/Output (I/O) Modules . . . . . . . . . . . . . . . . . . . . . . . . 46
6.5.2 I/O Module Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.5.3 I/O Module Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.5.4 I/O Module Faults and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.6 Load Shed (Forced Transfer to OFF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.6.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.6.2 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.7 Security Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.8 Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.8.1 Battery Charger Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.8.2 Battery Charger Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.8.3 Battery Charger Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.8.4 Battery Charger Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-57
Appendix B Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-60

Table of Contents TP-6126 8/02

 Safety Precautions and Instructions

IMPORTANT SAFETY Safety decals affixed to the equipment Battery

INSTRUCTIONS. Electromechanical in prominent places alert the operator
equipment, including generator sets, or service technician to potential
transfer switches, switchgear, and hazards and explain how to act safely. WARNING
accessories, can cause bodily harm The decals are shown throughout this
and pose life-threatening danger when publication to improve operator
improperly installed, operated, or recognition. Replace missing or
maintained. To prevent accidents be damaged decals.
aware of potential dangers and act
safely. Read and follow all safety
precautions and instructions. SAVE
Accidental Starting Sulfuric acid in batteries.
Can cause severe injury or death.
THESE INSTRUCTIONS.
WARNING Wear protective goggles and
This manual has several types of safety clothing. Battery acid may cause
precautions and instructions: Danger, blindness and burn skin.
Warning, Caution, and Notice.

WARNING
DANGER Accidental starting.
Can cause severe injury or death.
Danger indicates the presence of a Disconnect the battery cables before
hazard that will cause severe working on the generator set.
personal injury, death, or substantial Remove the negative (--) lead first
property damage. when disconnecting the battery. Explosion.
Reconnect the negative (--) lead last Can cause severe injury or death.
when reconnecting the battery. Relays in the battery charger
WARNING cause arcs or sparks.

Disabling the generator set. Locate the battery in a well-ventilated

Warning indicates the presence of a area. Isolate the battery charger from
Accidental starting can cause
hazard that can cause severe explosive fumes.
severe injury or death. Before
personal injury, death, or substantial
working on the generator set or
property damage.
connected equipment, disable the
generator set as follows: (1) Move the
generator set master switch to the OFF
CAUTION
position. (2) Disconnect the power to
the battery charger. (3) Remove the
Caution indicates the presence of a battery cables, negative (--) lead first.
hazard that will or can cause minor Reconnect the negative (--) lead last
personal injury or property damage. when reconnecting the battery. Follow
these precautions to prevent starting of
NOTICE
the generator set by an automatic
Notice communicates installation, transfer switch, remote start/stop
operation, or maintenance information switch, or engine start command from a
that is safety related but not hazard remote computer.
related.

TP-6126 8/02 Safety Precautions and Instructions I

Battery electrolyte is a diluted Battery short circuits. Explosion
sulfuric acid. Battery acid can cause can cause severe injury or death.
DANGER
severe injury or death. Battery acid Short circuits can cause bodily injury
can cause blindness and burn skin. and/or equipment damage.
Always wear splashproof safety Disconnect the battery before
goggles, rubber gloves, and boots generator set installation or
when servicing the battery. Do not maintenance. Remove all jewelry Hazardous voltage.
open a sealed battery or mutilate the before servicing the equipment. Use Will cause severe injury or death.
battery case. If battery acid splashes in tools with insulated handles. Remove
Only authorized personnel should
the eyes or on the skin, immediately the negative (--) lead first when open the enclosure.
flush the affected area for 15 minutes disconnecting the battery. Reconnect
with large quantities of clean water. the negative (--) lead last when
Seek immediate medical aid in the case reconnecting the battery. Never WARNING
of eye contact. Never add acid to a connect the negative (--) battery cable
battery after placing the battery in to the positive (+) connection terminal
service, as this may result in hazardous of the starter solenoid. Do not test the
spattering of battery acid. battery condition by shorting the
terminals together.
Battery acid cleanup. Battery acid Hazardous voltage. Moving rotor.
can cause severe injury or death. Can cause severe injury or death.
Battery acid is electrically conductive
and corrosive. Add 500 g (1 lb.) of
Hazardous Voltage/ Operate the generator set only when
all guards and electrical enclosures
bicarbonate of soda (baking soda) to a Electrical Shock are in place.
container with 4 L (1 gal.) of water and
mix the neutralizing solution. Pour the DANGER Grounding electrical equipment.
neutralizing solution on the spilled
Hazardous voltage can cause
battery acid and continue to add the
severe injury or death. Electrocution
neutralizing solution to the spilled is possible whenever electricity is
battery acid until all evidence of a present. Open the main circuit
chemical reaction (foaming) has breakers of all power sources before
ceased. Flush the resulting liquid with Hazardous voltage.
Will cause severe injury or death. servicing the equipment. Configure the
water and dry the area. installation to electrically ground the
Disconnect all power sources before generator set, transfer switch, and
Battery gases. Explosion can cause
opening the enclosure. related equipment and electrical
severe injury or death. Battery gases
circuits to comply with applicable codes
can cause an explosion. Do not smoke and standards. Never contact
or permit flames or sparks to occur near DANGER electrical leads or appliances when
a battery at any time, particularly when standing in water or on wet ground
it is charging. Do not dispose of a because these conditions increase the
battery in a fire. To prevent burns and risk of electrocution.
sparks that could cause an explosion,
avoid touching the battery terminals
Hazardous voltage.
with tools or other metal objects.
Will cause severe injury or death.
Remove all jewelry before servicing the
equipment. Discharge static electricity Disconnect all power sources before
from your body before touching servicing. Install the barrier after
batteries by first touching a grounded adjustments, maintenance, or
metal surface away from the battery. To servicing.
avoid sparks, do not disturb the battery
charger connections while the battery
is charging. Always turn the battery
charger off before disconnecting the
battery connections. Ventilate the
compartments containing batteries to
prevent accumulation of explosive
gases.

II Safety Precautions and Instructions TP-6126 8/02

Installing the battery charger. Servicing the transfer switch. Testing live electrical circuits.
Hazardous voltage can cause Hazardous voltage can cause Hazardous voltage or current can
severe injury or death. An severe injury or death. Deenergize all cause severe injury or death. Have
ungrounded battery charger may power sources before servicing. Open trained and qualified personnel take
cause electrical shock. Connect the the main circuit breakers of all transfer diagnostic measurements of live
battery charger enclosure to the ground switch power sources and disable all circuits. Use adequately rated test
of a permanent wiring system. As an generator sets as follows: (1) Move all equipment with electrically insulated
alternative, install an equipment generator set master controller probes and follow the instructions of the
grounding conductor with circuit switches to the OFF position. (2) test equipment manufacturer when
conductors and connect it to the Disconnect power to all battery performing voltage tests. Observe the
equipment grounding terminal or the chargers. (3) Disconnect all battery following precautions when performing
lead on the battery charger. Install the cables, negative (--) leads first. voltage tests: (1) Remove all jewelry.
battery charger as prescribed in the Reconnect negative (--) leads last when (2) Stand on a dry, approved electrically
equipment manual. Install the battery reconnecting the battery cables after insulated mat. (3) Do not touch the
charger in compliance with local codes servicing. Follow these precautions to enclosure or components inside the
and ordinances. prevent the starting of generator sets enclosure. (4) Be prepared for the
by an automatic transfer switch, remote system to operate automatically.
Connecting the battery and the
start/stop switch, or engine start (600 volts and under)
battery charger. Hazardous voltage command from a remote computer.
can cause severe injury or death.
Before servicing any components
Reconnect the battery correctly, inside the enclosure: (1) Remove all Heavy Equipment
positive to positive and negative to jewelry. (2) Stand on a dry, approved
negative, to avoid electrical shock and
electrically insulated mat. (3) Test WARNING
damage to the battery charger and circuits with a voltmeter to verify that
battery(ies). Have a qualified
they are deenergized.
electrician install the battery(ies).
Servicing the transfer switch
Short circuits. Hazardous controls and accessories within the
voltage/current can cause severe
enclosure. Hazardous voltage can
injury or death. Short circuits can cause severe injury or death.
cause bodily injury and/or equipment Unbalanced weight.
Disconnect the transfer switch controls
damage. Do not contact electrical at the inline connector to deenergize Improper lifting can cause severe
connections with tools or jewelry while the circuit boards and logic circuitry but injury or death and equipment
making adjustments or repairs. damage.
allow the transfer switch to continue to
Remove all jewelry before servicing the supply power to the load. Disconnect Use adequate lifting capacity.
equipment.
all power sources to accessories that Never leave the transfer switch
Installing accessories to the are mounted within the enclosure but standing upright unless it is securely
transformer assembly. Hazardous are not wired through the controls and bolted in place or stabilized.
voltage can cause severe injury or deenergized by inline connector
death. To prevent electrical shock separation. Test circuits with a
disconnect the harness plug before voltmeter to verify that they are
installing accessories that will be deenergized before servicing.
connected to the transformer assembly
primary terminals on microprocessor
logic models. Terminals are at line
voltage.

Making line or auxiliary

connections. Hazardous voltage
can cause severe injury or death. To
prevent electrical shock deenergize the
normal power source before making
any line or auxiliary connections.

TP-6126 8/02 Safety Precautions and Instructions III

Moving Parts Notice NOTICE
Foreign material contamination.
NOTICE Cover the transfer switch during
WARNING installation to keep dirt, grit, metal drill
Hardware damage. The transfer
switch may use both American chips, and other debris out of the
Standard and metric hardware. Use components. Cover the solenoid
the correct size tools to prevent mechanism during installation. After
rounding of the bolt heads and nuts. installation, use the manual operating
Hazardous voltage. Moving rotor. handle to cycle the contactor to verify
Can cause severe injury or death. NOTICE that it operates freely. Do not use a
When replacing hardware, do not screwdriver to force the contactor
Operate the generator set only when mechanism.
all guards and electrical enclosures substitute with inferior grade
are in place. hardware. Screws and nuts are
available in different hardness ratings. NOTICE
To indicate hardness, American Electrostatic discharge damage.
WARNING Standard hardware uses a series of Electrostatic discharge (ESD)
markings, and metric hardware uses a damages electronic circuit boards.
numeric system. Check the markings Prevent electrostatic discharge
on the bolt heads and nuts for damage by wearing an approved
identification. grounding wrist strap when handling
electronic circuit boards or integrated
NOTICE circuits. An approved grounding wrist
Airborne particles. strap provides a high resistance (about
Improper operator handle usage.
Can cause severe injury or 1 megohm), not a direct short, to
Use the manual operator handle on the
blindness. ground.
transfer switch for maintenance
Wear protective goggles and clothing purposes only. Return the transfer
when using power tools, hand tools, switch to the normal position. Remove
or compressed air. the manual operator handle, if used,
and store it in the place provided on the
transfer switch when service is
completed.

IV Safety Precautions and Instructions TP-6126 8/02

 Introduction

This manual provides operation and installation List of Related Materials

instructions for Kohlerr Model KCT/KCP automatic
transfer switches with MPAC 1000t electrical controls. This manual includes operation and installation
t:in:002:001a information for standard open-transition and
programmed-transition transfer switches. Decode the
Information in this publication represents data available
transfer switch model number from the transfer switch
at the time of print. Kohler Co. reserves the right to
nameplate and verify that the it matches the model
change this literature and the products represented
shown on the front cover of this manual before
without notice and without any obligation or liability
proceeding with installation.
whatsoever.
Separate manuals cover service and parts information.
Read this manual and carefully follow all procedures
The following table lists the related literature part
and safety precautions to ensure proper equipment
numbers.
operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section at the
Literature Item Part Number
beginning of this manual. Keep this manual with the
equipment for future reference. Specification Sheet G11-80
Service Manual TP-6127
The equipment service requirements are very important Parts Catalog TP-6158
to safe and efficient operation. Inspect parts often and MPACt Setup Program Operation Manual TP-6135
perform required service at the prescribed intervals.
Obtain service from an authorized service
distributor/dealer to keep equipment in top condition.
x:in:002:002

TP-6126 8/02 Introduction i

Service Assistance

For professional advice on generator power China

requirements and conscientious service, please contact North China Regional Office, Beijing
your nearest Kohler distributor or dealer. Phone: (86) 10 6518 7950
(86) 10 6518 7951
D Consult the Yellow Pages under the heading (86) 10 6518 7952
Generators—Electric Fax: (86) 10 6518 7955

D Visit the Kohler Power Systems website at East China Regional Office, Shanghai
KohlerPowerSystems.com Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
D Look at the labels and stickers on your Kohler product India, Bangladesh, Sri Lanka
or review the appropriate literature or documents India Regional Office
included with the product Bangalore, India
Phone: (91) 80 3366208
D Call toll free in the US and Canada 1-800-544-2444 (91) 80 3366231
Fax: (91) 80 3315972
D Outside the US and Canada, call the nearest regional
office Japan, Korea
North Asia Regional Office
Africa, Europe, Middle East Tokyo, Japan
London Regional Office Phone: (813) 3440-4515
Langley, Slough, England Fax: (813) 3440-2727
Phone: (44) 1753-580-771
Latin America
Fax: (44) 1753-580-036
Latin America Regional Office
Asia Pacific Lakeland, Florida, USA
Power Systems Asia Pacific Regional Office Phone: (863) 619-7568
Singapore, Republic of Singapore Fax: (863) 701-7131
Phone: (65) 264-6422 X:in:008:001a

Fax: (65) 264-6455

ii Service Assistance TP-6126 8/02

 Section 1 Product Description

1.1 Purpose Normal Emergency

(Utility) (Generator)
An automatic transfer switch (ATS) transfers electrical Power Power
Generator
loads from a normal (preferred) source of electrical
power to an emergency (standby) source when the Start Generator
normal source falls outside the acceptable electrical Power Electrical
parameters. Switching Controls
Device
When the normal (preferred) source fails, the ATS Automatic Transfer Switch
signals the emergency (standby) source generator set
to start. When the emergency (standby) source reaches
acceptable levels and stabilizes, the ATS transfers the
load from the normal (preferred) source to the
emergency (standby) source. The ATS continuously
To Load TS-003
monitors the normal (preferred) source and transfers
the load back when the normal (preferred) source Figure 1-1 Typical ATS Block Diagram
returns and stabilizes. After transferring the load back to
the normal (preferred) source, the ATS removes the
generator start signal, allowing the generator set to shut
down.
3
1
Figure 1-1 shows a typical installation block diagram. 2

1.2 Nameplate
A nameplate attached to the controller cover on the
inside of the enclosure door includes a model
designation, a serial number, ratings, and other
information about the transfer switch. See Figure 1-2.

Copy the model designation, serial number, and

accessory information from the nameplate to the spaces
provided in the Product Identification Information
section inside the front cover of this manual for use when
requesting service or parts. Copy the model
designation into the spaces in Section 1.3 and use the GM21291
accompanying chart to interpret the model designation. 1. Model designation
2. Serial number
The serial number is also shown on a label inside the 3. Factory-installed accessory numbers
transfer switch enclosure.
Figure 1-2 Typical Transfer Switch Nameplate

TP-6126 8/02 Section 1 Product Description 1

1.3 Model Code
Record the transfer switch model designation in the boxes below. The transfer switch model designation defines
characteristics and ratings as explained in the accompanying chart.

Model Mechanism Transition Controls Voltage Poles Enclosure Current Rating Connections

r Model Designation Key

Kohlerr
SAMPLE MODEL DESIGNATION
This chart explains the Kohlerr transfer switch model designation system. The sample

KCT-AMTA-0225S
model designation shown is for a Model K automatic transfer switch that uses an
open-transition contactor with MPAC 1000t electrical controls rated at 480 volts/60 Hz,
3 poles, 4 wires, and solid neutral in a NEMA 1 enclosure with a current rating of
225 amperes. Not all possible combinations are available.

Model
K: Model K automatic transfer switch

Mechanism
C: Automatic
B: Bypass Isolation (See G11-81)
N: Non-automatic

Transition
T: Open-Transition
P: Programmed-Transition

Electrical Controls
A: MPAC 1000t (Microprocessor ATS Controls)

Voltage/Frequency
C: 208 Volts/60 Hz G: 380 Volts/50 Hz K: 440 Volts/60 Hz
D: 220 Volts/50 Hz H: 400 Volts/50 Hz M: 480 Volts/60 Hz
F: 240 Volts/60 Hz J: 416 Volts/50 Hz N: 600 Volts/60 Hz

Number of Poles/Wires
N: 2-pole, 3-wire, solid neutral W: 4-pole, 4-wire, overlapping neutral
T: 3-pole, 4-wire, solid neutral Z: 3-pole, 4-wire, integral solid neutral*
V: 4-pole, 4-wire, switched neutral

Enclosure
A: NEMA 1[ C: NEMA 3R] F: NEMA 4X]
B: NEMA 12] D: NEMA 4] G: Open unit
[ Standard on 30--4000 A models
] Available to order on 30--800 A models. For larger units, consult the factory.

Current Rating: Numbers indicate the current rating of the switch in amperes:
0030 0200 0600 1200 2600
0070 0225 0800 1600 3000
0104 0260 1000 2000 4000
0150 0400

Power Connections
S: Standard
F: Front bus (available on 1600 and 2000 A models only)

* Integral solid neutral is a solid neutral mounted on the contactor.

(Not available on all amperages.)

2 Section 1 Product Description TP-6126 8/02

 Section 2 Installation

2.1 Introduction 2.2.2 Lifting

Kohlerr transfer switches are shipped factory-wired, WARNING
factory-tested, and ready for installation. Have the
equipment installed only by trained and qualified
personnel, and verify that the installation complies with
applicable codes and standards. Switch installation
includes the following steps:

D Unpacking and inspecting the transfer switch upon Unbalanced weight.

receipt. Improper lifting can cause severe
injury or death and equipment
damage.
D Verifying that the transfer switch voltage and
frequency ratings match the voltages and Use adequate lifting capacity.
frequencies of the sources. Never leave the transfer switch
standing upright unless it is securely
D Mounting the transfer switch. bolted in place or stabilized.

D Checking the manual operation.

See Figure 2-1 through Figure 2-4 or the dimensional
D Wiring the normal power source (utility), emergency drawing for the weight of the transfer switch. Use a
power source (generator set), and load circuits. spreader bar to lift the transfer switch. Attach the bar
only to the enclosure’s mounting holes or lifting
D Wiring the generator set engine start connection. brackets; do not lift the unit any other way. Close and
latch the enclosure door before moving the unit.
D Connecting accessories, if provided.
Weight, kg (lb.)
D Connecting and initializing the electrical controls, as
required. Amps 2-Pole 3-Pole 4-Pole
30--200 28 (62) 30 (65) 31 (68)
D Checking voltages and operation. 225--400 52 (115) 56 (123) 59 (131)
600--800 220 (485) 231 (510) 238 (525)
Protect the switch against damage before and during
installation. 1000--1200 — 356 (785) 379 (835)
1600--2000 — 472 (1040) 494 (1090)
The functional tests in Section 3.7 are a necessary part 2600--3000 — 649 (1430) 679 (1495)
of the installation. Be sure to perform the functional
4000 — 1043 (2300) 1089 (2400)
tests, which include voltage checks and operation tests,
before putting the transfer switch into service. Figure 2-1 Weights, Open-Transition Models in
NEMA 1 Enclosures

2.2 Receipt of Unit Weight kg, (lb.)

Amps 2-Pole 3-Pole 4-Pole

2.2.1 Inspection 150--400 179 (395) 183 (403) 187 (413)

600--800 179 (395) 184 (405) 188 (415)
At the time of delivery, inspect the packaging and the 1000--1200 — 463 (1020) 485 (1070)
transfer switch for signs of shipping damage. Unpack
1600--2000 — 533 (1175) 556 (1225)
the transfer switch as soon as possible and inspect the
2600--3000 — 735 (1620) 765 (1685)
exterior and interior for shipping damage. If damage
and/or rough handling is evident, immediately file a 4000 — 1115 (2457) 1160 (2557)
damage claim with the transportation company. Figure 2-2 Weights, Programmed-Transition Models
in NEMA 1 Enclosures

TP-6126 8/02 Section 2 Installation 3

 Weight kg (lb.) For 600--800 amp transfer switches, remove the lag
screws that secure the transfer switch to the shipping
Amps 2-Pole 3-Pole 4-Pole
skid. For 1000--4000 amp transfer switches, open the
30--200 8 (17) 9 (20) 11 (23)
enclosure door to remove the lag screws that secure the
225--400 17 (37) 21 (45) 24 (53) transfer switch to the skid.
600--1200 68 (150) 78 (170) 90 (196)
1600--2000 — 190 (420) 213 (470)
2600--3000 — 213 (470) 243 (535)
2.3 Mechanical Installation
4000 — 545(1200) 590(1300) NOTICE
Figure 2-3 Weights, Open Units, Open-Transition Foreign material contamination. Cover the transfer switch
Models during installation to keep dirt, grit, metal drill chips, and other
debris out of the components. Cover the solenoid mechanism
Weight kg (lb.) during installation. After installation, use the manual operating
handle to cycle the contactor to verify that it operates freely.
Amps 2-Pole 3-Pole 4-Pole
Do not use a screwdriver to force the contactor mechanism.
150--400 21 (45) 24 (53) 28 (63)
600--1200 80 (175) 94 (205) 108 (235) NOTICE
1600--2000 — 252 (555) 274 (605) Hardware damage. The transfer switch may use both
American Standard and metric hardware. Use the correct size
2600--3000 — 300 (660) 329 (725)
tools to prevent rounding of the bolt heads and nuts.
4000 — 611(1347) 657(1447)

Figure 2-4 Weights, Open Units, Check the system voltage and frequency. Compare
Programmed-Transition Models the voltage and frequency shown on the transfer switch
nameplate to the source voltage and frequency. Do not
install the transfer switch if the system voltage and
2.2.3 Storage frequency are different from the nominal normal (utility)
Store the transfer switch in its protective packing until source voltage and frequency or the nominal
final installation. Protect the transfer switch at all times emergency source voltage and frequency shown on the
from moisture, construction grit, and metal chips. Avoid generator set nameplate.
storage in low-temperature and high-humidity areas
Plan the installation. Use the dimensions given on the
where moisture could condense on the unit. See
enclosure dimension (ADV) drawings. Select a
Figure 2-5 for acceptable storage temperatures.
mounting site that complies with local electrical code
restrictions for the enclosure type. Mount the transfer
Item Specification switch as close to the load and power sources as
Storage possible. Allow adequate space to fully open the
--40°C to 70°C (--40°F to 158°F)
Temperature enclosure and to service the switch. Provide cable
Operating bending space and clearance to live metal parts.
--20°C to 70°C (--4°F to 158°F)
Temperature
Humidity 5% to 95% noncondensing Prepare the foundation. Ensure that the supporting
Altitude 0 to 3050 m (10000 ft.) without derating
foundation for the enclosure is level and straight. For
bottom cable entry, if used, install conduit stubs in the
Figure 2-5 Environmental Specifications foundation. Refer to the enclosure dimension drawing
for the conduit stub locations. When pouring a concrete
2.2.4 Unpacking floor, use interlocking conduit spacer caps or a wood or
metal template to maintain proper conduit alignment.
Allow the equipment to warm to room temperature for at
least 24 hours before unpacking to prevent Install the ATS. For easy access during installation and
condensation on the electrical apparatus. Use care wiring, remove the front door of the enclosure. For
when unpacking to avoid damaging transfer switch 30--200 amp switches, support the door and remove the
components. Remove dirt and packing material that two screws at the bottom. Slide the door down until the
may have accumulated in the transfer switch or any of its top clears the enclosure. Open the door wide enough to
components. Do not use compressed air to clean the reach the controller wiring on the inside of the door.
switch. Cleaning with compressed air can cause debris Disconnect the cable plug that connects the front door
to lodge in the components and damage the switch. components to the internal components and disconnect
the grounding wire between the door and the enclosure.
Set the door out of the way to protect the controls.

4 Section 2 Installation TP-6126 8/02

For units with hinged doors, open the door and
disconnect the cable plug that connects the front door
components to the internal components. Disconnect
the grounding wire between the door and the enclosure.
Squeeze the release pins on each hinge together and
remove the door. See Figure 2-6. Set the door out of the
way to protect the controls.

Vertically mount 30- through 400-amp transfer switches

1
to a wall or other rigid vertical supporting structure. Use
the template on the shipping carton to locate the
mounting holes in the wall. Level the template before
marking and drilling the holes. Clearance holes through
the back of each enclosure are provided for mounting.
Use shims to plumb the enclosure. Verify that the door
hinges are vertical to avoid distortion of the enclosure or
door. 6126

1. Hinge release pins

Bolt 600- through 4000-amp automatic transfer
switches directly to floor mounting pads. Shim the Figure 2-6 Hinge
enclosure so that the enclosure is plumb.

2.4 Manual Operation Check 2.4.1 Manual Operation, 30--200 Amp

Open-Transition Switches
DANGER
The 30--200 amp open-transition models have an
attached manual operating handle. See Figure 2-7.

Manual Operation Test Procedure, 30--200 Amp

Hazardous voltage.
Transfer Switches
Will cause severe injury or death. 1. Turn the attached handle to manually operate the
Disconnect all power sources before transfer switch. It should operate smoothly without
opening the enclosure. any binding. If it does not, check for shipping
damage or construction debris.
Note: A manual operation handle is provided on the 2. Return the transfer switch to the Normal position.
transfer switch for maintenance purposes only. Do
not use the manual operation handle to transfer
the load with the power connected. 1

Use the manual operation handle to check the manual

operation before energizing the transfer switch. On
programmed-transition models, check the operation of
both the Normal and Emergency operators. Use the
following manual operation procedures to verify that the
contactor operates smoothly without binding.

Note: A contactor in normal and serviceable condition

operates smoothly without binding. Do not place 127a

the transfer switch into service if the contactor

does not operate smoothly; contact an 1. Handle
authorized distributor/dealer to service the
Figure 2-7 Manual Operation Handle, 30--200 Amp
contactor.
Open-Transition Switches

TP-6126 8/02 Section 2 Installation 5

2.4.2 Manual Operation, 225--4000 Amp
Open-Transition Switches
DANGER

Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.

The 225--4000 amp open-transition models use a

detachable manual operating handle. 1

NOTICE
Improper operator handle usage. Use the manual 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 the transfer switch when service is completed.
2
Manual Operation Test Procedure, 225--4000 Amp
Open-Transition Transfer Switches

1. Remove the maintenance handle from the clips on

the left side of the transfer switch frame. See
Figure 2-8.
1. Maintenance handle
2. 225--400 amp switches: See Figure 2-9. Insert 2. Storage clips
202

the maintenance handle into the hole in the shaft on

the left side of the operator. Figure 2-8 Manual Handle Storage, 600--1200 Amp
Switch Shown
600--1200 amp switches: See Figure 2-10.
Insert the maintenance handle into the hole in the
molded hub on the left side of the operator.

1600--2000 amp switches: See Figure 2-11.

Slide the hub onto the shaft and insert the
maintenance handle into the hole in the hub.

3000 and 4000 amp switches: See Figure 2-12.

Insert the maintenance handle into the hole in the
weight.

3. Move the maintenance handle up or down as

shown to manually operate the transfer switch. It
should operate smoothly without any binding. If it
does not, check for shipping damage or
construction debris.

4. Return the transfer switch to the Normal position.

5. Remove the maintenance handle and store it on the

frame in the clips provided.

6 Section 2 Installation TP-6126 8/02

 1 1

Turn counterclockwise
2 to Emergency.
Turn clockwise
to Normal.
127a
127a
1. Maintenance handle
1. Maintenance handle 2. Hub
2. Shaft
Figure 2-11 Manual Operation, 1600--3000 Amp
Figure 2-9 Manual Operation, 225--400 Amp Switches
Open-Transiton Switches and 150--400
Amp Programmed-Transition Switches
(one operator shown) 2

1 1

127a

1. Weight
1. Maintenance handle 202
2. Maintenance handle
2. Hub
Figure 2-12 Manual Operation, 4000 amp switches
Figure 2-10 Manual Operation, 600--1200 Amp
Switches

TP-6126 8/02 Section 2 Installation 7

2.4.3 Manual Operation,
Programmed-Transition Switches
Programmed-transition switches have two operators,
Normal and Emergency, on the left side of the contactor
assembly. Mechanical interlocks prevent closing both
operators at the same time. Refer to Figure 2-13 for
typical locations of the Normal and Emergency
operators.

Position indicators on the right side of the contactor

assembly show the positions of the operators. See
Figure 2-14.
Emergency Operator
Programmed-transition models use a detachable
(shown open)
manual operating handle. Refer to Figure 2-8 through
Figure 2-12.

DANGER

Hazardous voltage.
Will cause severe injury or death. Normal Operator
(shown closed)
Disconnect all power sources before
opening the enclosure.

NOTICE
Improper operator handle usage. Use the manual operator Figure 2-13 Programmed-Transition Switch Normal
handle on the transfer switch for maintenance purposes only. and Emergency Operators, 600--1200
Return the transfer switch to the normal position. Remove the Amp Model (shown in Normal position)
manual operator handle, if used, and store it in the place
provided on the transfer switch when service is completed.
1
Manual Operation Test Procedure, 150--4000 Amp
Programmed-Transition Transfer Switches

Check the operation of both operators by following the

instructions in Section 2.4.2 for both the Normal and
Emergency operators in the following sequence: 2

1. Starting with the contactor in the Normal position,

use the maintenance handle to move the Normal
operator from the closed to the open position. See
Figure 2-13 and Figure 2-14.
1. Emergency contact indicator: O is Open, C is closed
2. Move the Emergency operator from the open 2. Normal contact indicator
202
position to the closed position.
Figure 2-14 Contact Position Indicators (located on
3. Return the Emergency operator to the open the right side of the contactor assembly,
position and the Normal operator to the closed shown in Normal position)
position.

4. Remove the maintenance handle and store it in the

place provided on the switch.

8 Section 2 Installation TP-6126 8/02

2.5 Electrical Wiring DANGER
All internal electrical connections are factory-wired and
tested. Field installation includes connecting the
sources, loads, generator start circuit(s), and auxiliary
circuits, if used.
Hazardous voltage.
Note: Do not connect the wiring harness to the Will cause severe injury or death.
controller until instructed to do so in the voltage Disconnect all power sources before
check procedure, Section 3.7.2. opening the enclosure.

Refer to the wiring diagrams provided with the transfer

switch. Observe all applicable national, state, and local DANGER
electrical codes during installation.
Install DC, control, and communication system wiring
in metal conduit separate from AC power wiring.
Hazardous voltage.
It is not necessary to remove pole covers from the
Will cause severe injury or death.
transfer switch for cabling. If you do remove them,
reinstall them carefully. Disconnect all power sources before
servicing. Install the barrier after
adjustments, maintenance, or
WARNING servicing.

Making line or auxiliary connections. Hazardous voltage

can cause severe injury or death. To prevent electrical
shock deenergize the normal power source before making any
Accidental starting. line or auxiliary connections.
Can cause severe injury or death. Grounding electrical equipment. Hazardous voltage can
Disconnect the battery cables before cause severe injury or death. Electrocution is possible
working on the generator set. whenever electricity is present. Open the main circuit
Remove the negative (--) lead first breakers of all power sources before servicing the equipment.
when disconnecting the battery. Configure the installation to electrically ground the generator
Reconnect the negative (--) lead last set and related equipment and electrical circuits to comply with
when reconnecting the battery. applicable codes and standards. Never contact electrical
leads or appliances when standing in water or on wet ground
because these conditions increase the risk of electrocution.
Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on the
NOTICE
generator set or connected equipment, disable the generator
set as follows: (1) Move the generator set master switch to the Electrostatic discharge damage. Electrostatic discharge
OFF position. (2) Disconnect the power to the battery charger. (ESD) damages electronic circuit boards. Prevent
(3) Remove the battery cables, negative (--) lead first. electrostatic discharge damage by wearing an approved
Reconnect the negative (--) lead last when reconnecting the grounding wrist strap when handling electronic circuit boards
battery. Follow these precautions to prevent starting of the or integrated circuits. An approved grounding wrist strap
generator set by an automatic transfer switch, remote provides a high resistance (about 1 megohm), not a direct
start/stop switch, or engine start command from a remote short, to ground.
computer.

TP-6126 8/02 Section 2 Installation 9

2.5.1 AC Power Connections Test the cables after pulling them into position and
before they are connected to verify that they are not
Determine the cable size. Refer to the table in
defective and that they were not damaged during
Figure 2-15 to determine the cable size and number of
cables required for the transfer switch. Make sure the installation.
lugs provided are suitable for use with the cables being Install the cable spacers provided with 30--200 amp
installed. Watertight conduit hubs may be required for switches as shown in Figure 2-16. On 225--400 amp
outdoor use. switches, verify that the factory-installed insulator
backing piece shown in Figure 2-17 is in place behind
Note: Use only copper wire for 200 amp models.
the contactor.

UL-Listed Solderless Screw-Type Terminals

for External Power Connections
1
Normal, Emergency, and Load Terminals

Switch
Rating Maximum Number of Range of Wire Sizes,
(Amps) Cables per Pole Copper or Aluminum

30, 70, 104 1 #14 AWG to 2/0 AWG

150 1 #8 AWG to 3/0 AWG

1 ½ inch approximate
#8 AWG to 3/0 AWG
200 1
(use copper wire only)

1 #4 AWG to 600 MCM

225 400
225--400 1
2 #1/0 AWG to 250 MCM

600 3 #2 AWG to 600 MCM

800--1200 4 #1/0 AWG to 750 MCM

127
1600--2000 6 #1/0 AWG to 750 MCM
2600--3000 12 #1/0 AWG to 750 MCM
1. Cable spacers
4000 Bus Bar
Figure 2-16 Cable Spacers for 30--200 Amp Switches
Figure 2-15 Cable Sizes

NOTICE
Foreign material contamination. Cover the transfer switch 1
during installation to 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.

Drill the entry holes. Cover the transfer switch to

protect it from metal chips and construction grit. Then
drill entry holes for the conductors at the locations
shown on the enclosure drawings. Remove debris from
the enclosure with a vacuum cleaner. Do not use
compressed air to clean the switch because it can cause
debris to lodge in the components and cause damage.
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 127
power conductors before connecting them to the 1. Insulator backing piece
2. Contactor
transfer switch. Installing power cables in conduit, cable
troughs and ceiling-suspended hangers often requires Figure 2-17 Insulator for 225--400 Amp Switches
considerable force. Pulling cables can damage
insulation and stretch or break the conductor’s strands.

10 Section 2 Installation TP-6126 8/02

Connect the cables. Be careful when stripping
SUITABLE FOR CONTROL OF MOTORS, ELEC
insulation from the cables; avoid nicking or ringing the DISCHARGE AND TUNGSTEN LAMPS, ELEC HEAT--
ING EQPT, WHERE THE SUM OF MOTOR FULL--
conductor. Clean cables with a wire brush to remove LOAD AMPS AND AMPS OF OTHER LOADS DOES
NOT EXCEED THE SWITCH AMP RATING AND THE
TUNGSTEN LOAD DOES NOT EXCEED100% OF
surface oxides before connecting them to the terminals. SWITCH RATING, 240V MAX.
WHEN PROTECTED BY A CIRCUIT BREAKER
Apply joint compound to the connections of any WITHOUT AN ADJUSTABLE SHORT--TIME RESPONSE
ONLY OR BY FUSES THIS TRANSFER SWITCH IS
RATED FOR USE ON A CIRCUIT CAPABLE OF
aluminum conductors. DELIVERING NOT MORE THEN THE RMS SYMM
AMPS AT THE VOLTAGE SHOWN.
RMS SYMM
Refer to Figure 2-20, Interconnection Diagram, and the AMPS MAX
X1000 VOLTS BREAKER/MFR/TYPE
AMPS
MAX
35 480 ANY ANY ANY PER NEC
wiring diagram provided with the switch. A list of the 22 600 ANY ANY ANY PER NEC

42 480 GE SGL4,SGP4,TB4, 400

drawing numbers for the wiring diagrams and THLC4,TLB4 400
SGLA,SGL6,SGP6,TB6 600
schematics is given in Appendix B. SKHA,SKL8,SKP8,TKL 800

42 480 I--T--E CJD6,HHJD6, 400

HHJXD6,HJD6,SCJD6,SHJD6 400
The connection points on the contactor are labeled CLD6,HHLD6,HHLXD6,HLD6, 600
SCLD6,SHLD6 600
Normal, Emergency, and Load. Be sure to follow the CMD6,HMD6,HND6,MD6,MXD6, 800
SCMD6,SHMD6,SMD6,SND6 800
phase markings (A, B, C, and N). For single-phase 42 480 SQUARE D LC,LI 600
MH 800
systems, connect to A and C.
42 480 WESTH HKD,KDC,LCL, 400
TRI--PAC LA 400
HLD 600
Note: Connect the source and load phases as TRI--PAC NB 800

indicated by the markings and drawings to 42 480 ABB S5

S6
400
800
prevent short circuits and to prevent 42 480 MERLIN GERIN 600
CJ600
phase-sensitive load devices from
malfunctioning or operating in reverse.
On models equipped with the optional preferred source
switch, connect source N to the normal side and source
E to the emergency side of the contactor. 200 480 FUSE ANY CLASS J 600
USE 75 °C MIN. CU/AL WIRE FOR POWER
Verify that all connections are consistent with drawings CONNECTIONS. USE 60 °C MIN. CU WIRE FOR
CONTROLS.

before tightening the lugs. Tighten all cable lug

1 USE COPPER OR ALUMINUM WIRE
connections to the torque values shown on the label on FOR POWER TERMINALS
RECOMMENDED TIGHTENING 483500--007
the switch. (See Figure 2-19 for a typical rating/torque TORQUE 600 IN--LBS REV B

label.) Carefully wipe off any excess joint compound

after tightening the terminal lugs. 1. Torque specification 007

For load connections to bus bars, use a compression Figure 2-19 Typical Rating/Torque Label
washer, flat washer, and a minimum grade 5 bolt and
torque the connections to the values in Figure 2-18.

Bolt Torque
Bolt Size,
inches ft. lbs. Nm
1/4 7 9.5
5/16 12 16.3
3/8 20 27.1
1/2 50 67.8
5/8 95 128.8
3/4 155 210.2

Figure 2-18 Tightening torque for bus bars

TP-6126 8/02 Section 2 Installation 11

 ADV-6736

Figure 2-20 Interconnection Diagram

12 Section 2 Installation TP-6126 8/02

2.5.2 Engine Start Connection The generator engine start contacts are rated
2 amps @ 30 VDC/250 VAC.
WARNING

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.

Disabling the generator set. Accidental starting can

cause severe injury or death. Before working on the
generator set or connected equipment, disable the generator
set as follows: (1) Move the generator set master switch to the
OFF position. (2) Disconnect the power to the battery charger.
(3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the 6126

battery. Follow these precautions to prevent starting of the 1

generator set by an automatic transfer switch, remote
start/stop switch, or engine start command from a remote
computer.

Prevent the generator set from starting by moving the

generator set master switch to the OFF position; 14
disconnecting power to the generator engine start 15
battery charger, if installed; and disconnecting all
generator engine start battery cables, negative (--) leads
first. 16 (Do not use)
Connect the generator set remote starting circuit to the 1. Engine start contacts 14 and 15
engine start connections located on the transfer switch
contactor assembly. The engine start terminals are Figure 2-21 Engine Start Contacts, 30--200 Amp
labeled with a red decal. See Figure 2-21, Figure 2-22, Switches
and Figure 2-23 for the locations of the engine start
contacts. Refer to the generator set installation manual
for wire size specifications.

TP-6126 8/02 Section 2 Installation 13

 Not used
Not used
14
15
1

GM21298

4
2
27 26 25
24 23 22
21 20 19
18 17 16
15 14 13
12 11 10
9 8 7
6 5 4
2 1

GM21311

1. Typical terminal block location

2. Decal
3. Engine start contacts 1 and 2
1. Engine start contacts 14 and 15
4. Auxiliary contacts 4--27 (see the schematic diagram for
contacts closed on Normal or closed on Emergency)
Figure 2-22 Engine Start Contacts, 225--400 Amp
Open-Transition Models Figure 2-23 Engine Start and Auxiliary Contact
Terminal Block, Programmed-Transition
Models and 600--4000 Amp
Open-Transition Models

14 Section 2 Installation TP-6126 8/02

2.5.3 Auxiliary Contacts
Connect the auxiliary contacts to customer-supplied
alarms, remote indicators, or other devices. Auxiliary
contacts provide contacts that close when the transfer
switch is in the Normal position and contacts that close
when the transfer switch is in the Emergency position.
Each contact is rated 10 amps at 32 VDC or 250 VAC.
The table in Figure 2-24 lists the number of auxiliary
contacts provided with each transfer switch.

Figure 2-23, Figure 2-25, and Figure 2-26 show the

locations of the auxiliary contacts for different models. 1

Refer to the schematic diagram provided with the

transfer switch to identify which auxiliary contacts are
closed on Normal and which are closed on Emergency
for 600--4000 amp models. Follow the wire size and
tightening torque specifications shown on the decal on
the transfer switch.
6126
31 29
Auxiliary Position Indicating Contacts
(rated 10 amps @ 32 VDC/250 VAC)
Number of Contacts Closed on
Normal, Emergency 32 30
Switch Rating Open- Programmed-
(Amps) Transition Transition
13 11
30--104 2, 2 —

150--400 2, 2 2, 2

150--400 * — 6, 6 GM20601
12 10
600--800 2, 2 6, 6

1000--3000 8, 8 7, 7 1. Auxiliary contacts 10--13 and 29--32 (contacts shown with

contactor in Normal position)
4000 4, 4 4, 3

* Programmed-transition with switched neutral Figure 2-25 Auxiliary Contacts, 30--200 Amp
Open-Transition Models
Figure 2-24 Number of Auxiliary Contacts Available
on Each Switch

TP-6126 8/02 Section 2 Installation 15

 2.5.4 Controller Ground
Verify that the grounding wire is connected from the
controller’s lower left mounting stud to the enclosure.
This connection provides proper grounding that does
not rely upon the door hinges.

Note: Do not connect the controller harness to the

contactor until instructed to do so in the voltage
check procedure, Section 3.7.2. Disconnect the
power before connecting or disconnecting the
controller harness.

11 13

10 12

31 29

32 30

6126

1. Auxiliary contacts 10--13 and 29--32 (contacts shown with

contactor in Normal position)

Figure 2-26 Auxiliary Contacts, 225--400 Amp

Open-Transition Models

16 Section 2 Installation TP-6126 8/02

 Section 3 Setup and Test

3.1 Introduction voltage and frequency pickup and dropout, and other
system parameters. To view and change the system
This section explains the setup and test of the transfer settings, a personal computer running the
switch. Follow the instructions in this section after MPAC-1000t Setup Program is required. See
completing the physical installation described in the TP-6135, Software Operation Manual, for instructions to
previous section. use the Setup Program.

Note: Be sure to perform the functional tests explained

in Section 3.7 before putting the transfer switch 3.2 User Interface Panel
into operation.

The instructions in this section explain how to set up the 3.2.1 Pushbuttons and LED Indicators
system to operate using factory default settings. This The user interface panel is located on the transfer switch
section includes: door. Figure 3-1 shows the user interface pushbuttons
D User interface panel pushbuttons and LED indicators and LED indicators. The LEDs light steadily or flash to
D DIP switch functions and settings indicate different ATS conditions. The tables in
D Main logic board input and output connections and Figure 3-2 and Figure 3-3 describe the functions of the
default settings pushbuttons and LED indicators. Refer to the
appropriate section for more details about functions
D Communications connections
listed in Figure 3-3 and Figure 3-2; see the Table of
D Factory default settings for voltage, frequency, and Contents.
time delay functions
D Functional tests Figure 3-4 lists the fault conditions that cause the
D Exerciser setup Service Required LED to light or flash. Steady
D Warranty registration illumination indicates that maintenance is needed;
flashing indicates that service is required immediately.
The transfer switch is designed to be set up and
operated using the factory settings for time delays,

1. User interface panel location GM211077A

Figure 3-1 User Interface Panel

TP-6126 8/02 Section 3 Setup and Test 17

 LED Illumination
LED Indicator Color Steady Slow Flash Rapid Flash
Exercise Amber Unloaded exercise is Loaded exercise is When exercise button is pressed and
running. running. held, rapid flashing indicates the
exercise has been started and set.
Rapid flashing at any other time
indicates that the exerciser is inhibited
by the DIP switch setting.
Load Control Active Amber Pre/post-transfer load — —
control or peak shave
functions are operating.
Not in Auto Red — — ATS is not set for automatic
operation or a load shed (forced
transfer to OFF) sequence is
active.
Position N Red Contactor is in Normal — —
positon.
Position E Red Contactor is in Emergency — —
position.
Position Off/ Amber Contactor is in Off position — In-phase monitor is operating
In-Phase Sync (programmed-transition (open-transition models only).
models only).
Service Required Red Fault. Non-emergency is — Fault. Immediate maintenance is
maintenance required. required.
Source N Available Green Source N is available. — —
Source E Available Green Source E is available. — —
Test Red Unloaded test is running. Loaded test is running. —
Time Delay LED Bar Amber LEDs step down to indicate — —
time remaining in an active
time delay or exercise
period.
Figure 3-2 User Interface LED Indicators

Pushbutton Description 3.2.2 Controller Reset

Exercise Start and stop an exercise and set the The controller can be reset without disconnecting
exercise time.
power. Use the following procedure.
Lamp Test Test LEDs or reset the Service Required
LED.
Test Start and stop a test. Controller Reset Procedure
Time Delay End an active time delay. 1. Hold the Lamp Test button until the LEDs flash. Do
(Does not end the exercise active or
programmed-transition time delays.) not release the button.
Figure 3-3 User Interface Pushbuttons 2. Continue to hold the Lamp Test button in and press
the End Time Delay button. The LEDs will flash
Service Required when the controller resets.
LED Illumination Fault (See Section 4.3)
Flashing
g Auxiliary Switch Fault
Auxiliary Switch Open
Failure to Acquire Standby Source
Failure to Transfer
I/O Module Communications Lost
I/O Module Not Installed
I/O Module Not Found
Phase Rotation Fault
Remote Common Fault
Steady External Low Battery
Figure 3-4 Service Required LED

18 Section 3 Setup and Test TP-6126 8/02

3.3 Controller Main Logic Board 1 2

DANGER 3
11

Hazardous voltage. 4
Will cause severe injury or death.
5
Disconnect all power sources before
opening the enclosure. 6

NOTICE
10
Electrostatic discharge damage. Electrostatic discharge
(ESD) damages electronic circuit boards. Prevent
electrostatic discharge damage by wearing an approved
grounding wrist strap when handling electronic circuit boards
or integrated circuits. An approved grounding wrist strap
provides a high resistance (about 1 megohm), not a direct
short, to ground.

The controller’s main logic board is mounted in a plastic

housing on the inside of the transfer switch enclosure
door. It is not necessary to open the cover to access the
DIP switches or the PC connector on the circuit board.
9 7
8 GM21364
Figure 3-6 shows the locations the DIP switches and
connectors on the main logic board.

1 1. I/O board connection (P3)

2. User interface connections
3. DIP switches
4. Serial port for PC connection (P6)
2 5. Preferred source switch connection (P7)
6. Supervised transfer switch connection (P8)
7. Programmed-transition interface board (PTIB) connection
(factory connection) (P9)
8. Ground wire
9. Contactor harness connection
10. Serial number decal
11. Terminal strip (inputs, output, Modbus connections) (TB1)

Figure 3-6 Controller Board Component Locations

3
GM21079

1. Hinges
2. Access openings to DIP switches and PC connection
3. Latch

Figure 3-5 Controller Housing

TP-6126 8/02 Section 3 Setup and Test 19

3.3.1 Main Logic Board DIP Switch two live sources. When the output is activated, the
Settings contact opens for the programmed length of time before
transfer (default setting=3 seconds) to allow controlled
DIP switches on the main logic board control the test and disconnection of selected loads. The contact closes at
exercise functions. A maintenance DIP switch inhibits the time of transfer (default post-transfer time delay
transfer during ATS service. The factory settings for the setting=0). The contact is not activated if the controller
DIP switches are shown in Figure 3-8. detects no available source.

Before opening the transfer switch enclosure to check or See Section 4.2.5 for more information about the
change the DIP switch settings, open the circuit pre-transfer and post-transfer load control signal
breakers to disconnect the power to the transfer switch. operation sequence. The pre- and post-transfer time
delays can be adjusted using the optional setup
The DIP switches are located on the controller’s main program.
logic board on the inside of the enclosure door.
Figure 3-6 shows the locations of the switches on the Load Bank Control Output. Assigned to terminals
controller circuit board. A decal on the logic assembly TB1-3--TB1-5 (programmable). The load bank control
housing shows the DIP switch positions and settings output can be used to apply a load to the generator set
(see Figure 3-8). It is not necessary to remove the logic during the exercise. The load bank control output closes
assembly cover to see or adjust the DIP switches. or opens a contact that can be used to signal the load
Check the DIP switch settings and adjust if necessary bank controller to operate. If the Normal source is lost
for the application. during an exercise period, the load bank control output
is deactivated to remove the load bank and allow the
Note: Changing the position of the 1 week/2 week transfer of the building load to the emergency source.
exercise DIP switch after the exerciser has been
set does not change the time of the next Peak Shave/Area Protection Input. Assigned to
scheduled exercise. The new DIP switch setting terminals TB1-6 and TB1-7 (programmable input #1).
becomes effective after the next scheduled Starts the generator set and transfers to the standby
exercise. See Section 4.2.3 for more information source, ignoring the Time Delay Engine Start and
about the exerciser. Standby-to-Preferred time delays. The system
attempts to transfer to the preferred source when the
Close and lock the enclosure door before energizing the
input is removed. The peak shave command is
transfer switch.
overridden if the standby source fails.

3.3.2 Main Logic Board Inputs and TB1 Input/Output Factory Setting
Outputs Non-programmable output Pre-transfer load control
Programmable output Load bank control output
The controller main logic board’s inputs and outputs are
Programmable input #1 Peak shave/Area protection input
factory-assigned to the functions shown in Figure 3-7.
Programmable input #2 End time delay input
Pre-Transfer Load Control Output. Assigned to
Figure 3-7 Terminal Strip Input and Output Factory
terminals TB1-1 and TB1-2. The load control output Settings
operates only during the transfer sequence between

Figure 3-8 Logic Assembly Decal Showing DIP Switch Settings

20 Section 3 Setup and Test TP-6126 8/02

End Time Delay Input. Assigned to terminals TB1-8 (remote terminal unit) protocol for communication
and TB1-9 (programmable input #2). Allows a remote through this port.
signal to end an active time delay. The signal ends only
the time delay that is active at the time the signal is Connect the Modbus input and output to the terminals
applied. Repeated signals are required to end shown in Figure 3-9. Use #12--24 AWG twisted-pair
additional time delays. Does not end the wire; Belden cable #9841 or equivalent is
programmed-transition time delays or an exerciser run. recommended. Connect the shield to ground as shown
in Figure 3-9. Tighten the connections to 0.5 Nm
Other Inputs and Outputs. Other input and output (4.4 in. lbs.).
functions can be assigned to the programmable TB1
terminals. Refer to Section 6 for lists of available Note: Contact Kohler Co. for information about
programmable inputs and outputs. Use the Setup Modbusr communication protocol.
Program to change the input and output assignments if
necessary.

Connections. Connect input and output leads to the

controller terminal strip on the main logic board (MLB).
To gain access to the terminal strip, open the plastic
housing by pushing up on the latch on the bottom of the TRANSFER
cover and swinging the cover up and out. The cover is PRE-SIGNAL
10A@30VDC/250VAC
hinged at the top. Lift the cover off the hinges to remove
it completely, if necessary. Refer to the label on the
plastic housing or Figure 3-9 for the connections. Use PROGRAMMABLE
#12--24 AWG wire and tighten the connections to 0.5 OUTPUT
2A@30VDC/250VAC
Nm (4.4 in. lbs.).

The controller board terminal strip has two

PROGRAMMABLE
programmable inputs. Each input has a signal and a INPUT 1
return connection. Connect inputs to terminals 6 and 7
or 8 and 9 on terminal strip TB1. Record the connections
PROGRAMMABLE
on the label provided. Use the setup program to assign INPUT 2
the input functions if they are different from the default
assignments shown in Figure 3-7.

The main logic board has one programmable output, MODBUS RS485
B (+)
which is factory-assigned to the load bank control output
function. Connect to terminals 3 and 4 or 3 and 5 on A (--)
terminal strip TB1. Use the setup program to assign the
output function if it is different from the default
MODBUS RS485
assignment. B (+)

Note: Always replace the cover before energizing the A (--)

transfer switch controls.

3.3.3 Communications Connections GM22366

Customer connections
The controller has two communications connections.
Figure 3-9 Terminal Strip TB1 Connections
Serial Port. For connection to a personal computer to
run the Setup Program software. This is a non-isolated
RS-232 port with a connection speed of 57.6 kbps.

Modbusr r Network Interface (MNI). For connection to

building management systems, programmable logic
controls, etc. This is a non-isolated RS-485 port with
connection speeds of 9.6 kbps and 19.2 kbps. Use RTU

Modbusr is a registered trademark of Schneider Electric.

TP-6126 8/02 Section 3 Setup and Test 21

3.4 Programmed-Transition 3.5 System Settings and Time
Interface Board (PTIB) Delays
Programmed-transition model transfer switches use a The system can be operated using the factory settings
programmed-transition contactor and a listed in the following sections.
programmed-transition interface board (PTIB). The Use the Setup Program to change the controller time
PTIB is mounted on the inside of the enclosure door.
delays, pickup and dropout settings, inputs, outputs,
The PTIB is factory-wired and requires no additional and options if necessary.
wiring in the field. Verify that the PTIB wiring harness is
connected to the main logic board. See Figure 3-10 for 3.5.1 System Parameters
the PTIB connector location.
The system parameter factory settings are shown in
Figure 3-11. The controller voltage and frequency
sensing are factory-set to the default values shown in
1 Figure 3-12. The voltage and frequency debounce time
delays prevent nuisance transfers caused by brief
spikes and dips in the power supply.

System Parameter Factory Setting

Open or programmed transition Set to order
Single/three phase Set to order
Operating voltage Set to order
Operating frequency (50 or 60 Hz) Set to order
Phase rotation ABC
Commit to transfer (yes or no) No

2 Rated current Set to order

Operating mode:
Generator-toGenerator,
Utility-to-Generator
Utility-to-Generator, or
Utility-to-Utility
3 GM21079
In-phase monitor Disabled
1. Controller assembly (located inside the enclosure door) In-phase monitor transfer angle 0
2. PTIB connection
Transfer mode
3. PTIB Set to order
(automatic or non-automatic)*
* The transfer mode (automatic or non-automatic) cannot be
Figure 3-10 Programmed-Transition Interface Board
changed in the field.
(PTIB)
Figure 3-11 System Parameters

Voltage and Frequency Sensing

Parameter Default
Undervoltage pickup 90% of nominal
Undervoltage dropout 90% of pickup
Overvoltage dropout 110% of nominal
Overvoltage pickup 95% of dropout
Voltage debounce time 0.5 sec.
Underfrequency pickup 90% of nominal
Underfrequency dropout 99% of pickup
Overfrequency dropout 101% of pickup
Overfrequency pickup 110% of nominal
Frequency debounce time 3 sec.

Figure 3-12 Factory Settings, Voltage and Frequency

22 Section 3 Setup and Test TP-6126 8/02

3.5.2 Time Delays 3.7 Functional Test
The factory settings for the time delays are shown in The functional test includes three checks:
Figure 3-13.
D Manual Operation Test
The pre-transfer time delays operate only when both D Voltage Checks
sources are available. These delays allow time to D Automatic Operation Test
disconnect selected loads before transfer. The load
control LED on the user interface lights when the Note: Perform these checks in the order presented to
avoid damaging the ATS.
pre-transfer signal is active. The pre-transfer and
post-transfer time delays overlap the Read all instructions on the labels affixed to the
preferred-to-standby and standby-to-preferred transfer automatic transfer switch.
time delays.

Adjustable Time Delays 3.7.1 Manual Operation Test

Time Delay Default
If you have not already done so, test the contactor
Engine start 3 sec.
manual operation before proceeding to the voltage
Preferred to standby 1 sec.
check and electrical operation test.
Standby to preferred 15 min.
Off to standby (programmed-transition only) 1 sec. Note: Disable the generator set and disconnect the
Off to preferred (programmed-transition only) 1 sec. power by opening the circuit breakers or switches
Failure to acquire standby source 1 min. for both sources before manually operating the
Pretransfer to standby signal 3 sec. transfer switch.
Pretransfer to preferred signal 3 sec.
Post-transfer to standby signal 0 sec. Follow the instructions in Section 2.4 to check the
Post-transfer to preferred signal 0 sec. transfer switch manual operation.
Engine cooldown 0 min.
A contactor in normal and serviceable condition
In-phase monitor synch 30 sec.
transfers smoothly without binding when operated
Figure 3-13 Factory Settings, Time Delays manually. Do not place the transfer switch into service if
the contactor does not operate smoothly without
3.6 Generator Set Preparation binding; contact an authorized distributor/dealer to
service the contactor.
WARNING
Note: Do not reconnect the power sources at this time.
Proceed to the voltage check procedure
described in the following section.

Hazardous voltage. Moving rotor. 3.7.2 Voltage Check

Can cause severe injury or death.
The voltage, frequency, and phasing of the transfer
Operate the generator set only when
switch and the power sources must be the same to avoid
all guards and electrical enclosures
are in place. damage to loads and the transfer switch. Compare the
voltage and frequency ratings of the utility source,
transfer switch, and generator set, and verify that the
Disconnect all power sources to the transfer switch by
ratings are all the same.
opening upstream circuit breakers or switches to the
transfer switch. Use the voltage check procedure explained in this
section to verify that the voltages and phasing of all
Prepare the generator set for operation. Check the oil
power sources are compatible with the transfer switch
level, coolant level, fuel supply, batteries, and items
before connecting the power switching device and
specified by the generator set installation or operation
controller wire harnesses together.
checklist or manual.
Read and understand all instructions on installation
Move the generator set master switch to the OFF
drawings and labels on the switch. Note any optional
position; reconnect the generator engine start battery
accessories that have been furnished with the switch
cables, negative (--) leads last; and reconnect power to
and review their operation.
the generator engine start battery chargers, if installed.

TP-6126 8/02 Section 3 Setup and Test 23

Note: Source N is the source connected to the normal 6. Use a voltmeter to check the Source N (normal)
side of the contactor. Source E is the source phase-to-phase and phase-to-neutral (if
connected to the emergency side of the applicable) terminal voltages and frequency.
contactor.
a. If Source N is the utility and the measured input
The voltage check procedure requires the following does not match the voltage and frequency
equipment: shown on the transfer switch nameplate,
STOP! Do not proceed further in installation
D A digital voltmeter (DVM) with electrically insulated because the transfer switch is not designed for
probes capable of measuring the rated voltage and the application—call your distributor/dealer to
frequency order the correct transfer switch.

D A phase rotation meter b. If Source N is a generator set and the generator

set output voltage and frequency do not match
DANGER the nominal system voltage and frequency
shown on the transfer switch nameplate, follow
the 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.
Hazardous voltage.
Will cause severe injury or death. 7. Use a phase rotation meter to check the phase
Only authorized personnel should rotation at the Source N (normal) terminals.
open the enclosure. Rewire the transfer switch Source N terminals to
obtain the correct phase sequence if necessary.
Testing live electrical circuits. Hazardous voltage or
Note: The default setting for the phase rotation on
current can cause severe injury or death. Have trained and
qualified personnel take diagnostic measurements of live
the controller is ABC. If the application uses
circuits. Use adequately rated test equipment with electrically a phase rotation of CBA, use the Setup
insulated probes and follow the instructions of the test Program to change the phase rotation
equipment manufacturer when performing voltage tests. setting on the controller.
Observe the following precautions when performing voltage
8. If the source is a generator set, stop the generator
tests: (1) Remove all jewelry. (2) Stand on a dry, approved
electrically insulated mat. (3) Do not touch the enclosure or set by moving the master switch to the OFF
components inside the enclosure. (4) Be prepared for the position.
system to operate automatically. 9. Disconnect Source N by opening upstream circuit
(600 volts and under) breakers or switches.
10. Manually operate the transfer switch to position N.
Voltage Check Procedure
11. Repeat steps 4 through 8 for Source E. Then
Note: Perform voltage checks in the order given to proceed to step 17.
avoid damaging the transfer switch.
12. Disconnect both sources to the transfer switch by
1. Verify that the generator set master switch is in the opening the circuit breakers or switches.
OFF position and both power sources are
disconnected from the transfer switch. 13. Connect the power switching device and controller
wiring harnesses together at the inline disconnect
2. Disconnect the power switching device and plug.
controller wiring harnesses at the inline disconnect
plug, if they are connected. Note: Do not connect or disconnect the controller
wiring harness when the power is
3. Manually operate the transfer switch to position E. connected.
See Section 2.4.
14. Check the DIP switch settings. Verify that the
4. If Source N is a generator set, move the generator
TEST DIP switch is in the loaded position before
set master switch to the RUN position. The
proceeding with the next test.
generator set should start.
15. Close and lock the transfer switch enclosure door.
5. Close the Source N circuit breaker or switch.

24 Section 3 Setup and Test TP-6126 8/02

16. Reconnect both power sources by closing the Automatic Operation Test Procedure
circuit breakers or switches.
1. Check the controller LED indicators to verify that
17. Move the generator set master switch to the AUTO the Position N and Source N Available indicators
position. are lit.
Note: If the engine cooldown time delay setting is 2. Press the lamp test button and check that all
not set to zero (default setting), the controller LEDs illuminate.
generator set may start and run until the
Time Delay Engine Cooldown (TDEC) ends. 3. Verify that the generator set master switch is in the
AUTO position.
18. Proceed to the automatic operation test.
4. Press the TEST button on the controller to start the
3.7.3 Automatic Operation Test test. The TEST LED flashes to indicate that the
Check the transfer switch’s automatic control system ATS controller is set up to transfer the load during
immediately after the voltage check. The test sequence the test.
simulates a loss of the normal source, starts the 5. Verify that the generator set starts after the engine
generator set, and transfers the load to the emergency start delay times out. Check that the Source E
source, executing all time delays that are set up to Available LED lights.
operate during a loss of the normal source. When the
test is ended in step 7 of the procedure, the transfer 6. Verify that the switch transfers the load to Source E.
switch transfers the load back to the normal source and
a. Open-Transition Models: After the
removes the engine start signal, executing all
preferred-to-standby time delay, verify that the
appropriate programmed time delays. Position N LED goes out and the Position E
Refer to Section 4.2.2 for a description of the test LED lights, indicating that the switch has
sequence of operation. transferred the load to Source E.

Note: If the standby source fails during a test, the ATS b. Programmed-Transition Models: After the
will immediately attempt to transfer to the preferred-to-off time delay, verify that the
preferred source. Position N LED goes out and the Position OFF
LED lights. After the off-to-standby time delay,
Optional Switches. If the ATS is equipped with a check that the Position E LED lights, indicating
preferred source switch, check the switch position that the switch has transferred the load to
before proceeding with the automatic operation test. Source E.
The test procedure assumes that Source N is the
preferred source. 7. Push the Test button to end the test.

If the transfer switch is equipped with a supervised 8. Verify that the switch transfers the load back to
transfer switch, verify that it is set to the Auto position. Source N.

See Section 6 for more information about optional a. Open-Transition Models: After the
switches. standby-to-preferred time delay, verify that the
Position E LED goes out and the Position N
Note: Close and lock the enclosure door before starting LED lights, indicating that the switch has
the test procedure. transferred the load to Source N.

DANGER b. Programmed-Transition Models: After the

standby-to-off time delay, verify that the
Position E LED goes out and the Position OFF
LED lights. After the off-to-preferred time
delay, check that the Position N LED lights,
indicating that the switch has transferred the
Hazardous voltage.
load to Source N.
Will cause severe injury or death.
Only authorized personnel should
open the enclosure.

TP-6126 8/02 Section 3 Setup and Test 25

 Note: The generator set may have an engine The exerciser can be set without starting the generator
cooldown time delay that causes the set, if necessary. Use the following procedure.
generator set engine to run after the transfer
switch engine start signal is removed. Exerciser Setting Procedure
This completes the functional test. 1. Move the disable/enable exercise DIP switch to the
DISABLE position and close the enclosure door.
3.8 Exerciser Setup The Exercise LED flashes rapidly to indicate that
the exerciser is disabled.
The installer must activate the exerciser. Press and hold
the Exercise button for approximately 3 seconds until it 2. Press and hold the exercise button until the
flashes to activate the exerciser, start an exercise run, Exercise LED goes out for approximately 3
and set the time and date of the next exercise run. The seconds and then starts to flash again.
exercise time is set to the time that the button is pushed.
3. Move the disable/enable exercise DIP switch back
to the ENABLE position.
The default setting for the exerciser run duration is 30
minutes. The time delay LEDs show the time remaining 4. Close and lock the enclosure door.
in the exercise run. Press and hold the exercise button
again to end the exercise period early, if desired. 5. Verify that the EXERCISE LED is not flashing.

Note: Pressing the end time delay button does not end The exerciser time is set to the time that the button is
an exercise run. pushed. The exerciser will run in one or two weeks
according to the 1 week/2 week DIP switch position.
Set the exerciser period (every week or every 2 weeks)
and load condition by using DIP switches on the
controller circuit board. The factory settings for the
3.9 Warranty Registration
exerciser are shown in Figure 3-14. The transfer switch seller must complete a Startup
Notification Form and submit it to the manufacturer
Exerciser Parameter Factory Setting within 60 days of the initial startup date. A Startup
1 week/2 week exercise (DIP switch) 1 week Notification Form is included with generator sets and
Disable/enable exercise (DIP switch) Enable covers all equipment in the standby system. Standby
Load/no load exercise (DIP switch) No load systems not registered within 60 days of startup are
Run duration 30 minutes automatically registered using the manufacturer’s ship
Figure 3-14 Exerciser Factory Settings date as the startup date.

Use the Setup Program to change the exerciser run

duration, if desired. See Section 4.2.3 for more
information about the exerciser.

26 Section 3 Setup and Test TP-6126 8/02

 Section 4 Operation

4.1 Introduction alternate source. The system considers a phase lost if

its phase is 45 degrees from the rotation setting. The
This section contains descriptions and flowcharts for controller logs loss of phase events in the event history.
typical transfer switch operating sequences. This
section also describes faults and provides other Programmed-Transition Switches. Programmed
information related to the controller operation. transition switches provide an OFF position during
transfer between two sources. The adjustable time off
On systems not equipped with the preferred source period allows residual voltages in the load circuits to
selector switch, the preferred source is the source decay before connecting to the second source. During
connected to the Normal side of the power switching the off period, the ATS main contacts are open and
device. The source connected to the Emergency side of neither source powers the load.
the contactor is the standby source.
The off-to-standby and off-to-preferred time delays
control the length of the off period for
4.2 Sequence of Operation programmed-transition switches. The time delays are
factory-set to the defaults shown in Figure 3-13. The
4.2.1 Automatic Operation, Open- and time delays can be changed using the optional Setup
Programmed-Transition Switches Program.

Typical ATS operation in utility-to-generator set mode is The End Time Delay Button and Remote Bypass
divided into two sequences: command do not override the off-to-standby and
off-to-preferred time delays.
D Failure of the Normal (preferred) power source
and the resulting load transfer to the Emergency
(standby) source. Normal (preferred) power source fails

D Restoration of the preferred power source and the

resulting load transfer back to the preferred source. Time delay engine start

Events such as the failure of the generator set to start

can change the sequence of operation. Time delay preferred-to-standby

If the emergency source fails and the normal source is

not available, the transfer switch controller powers down Transfer to OFF position
(programmed-transition only)
until one of the sources returns.

Figure 4-1 Illustrates the transfer sequence when the Time delay off-to-standby
normal source fails, and Figure 4-2 illustrates the (programmed-transition only)
sequence when it returns. Figure 4-3 shows the
operation of the user interface LEDs during loss and Transfer to emergency (standby) source
restoration of the normal source.

Time Delays. Time delays before load transfer prevent Post-transfer load control (as programmed*)
nuisance transfers during brief power interruptions. The
voltage and frequency debounce time delays prevent * See the Setup Program Operation Manual.
nuisance transfers caused by brief spikes and dips in the
power supply. See Section 3.5 for the default settings Figure 4-1 ATS Sequence of Operation, Transfer to
for the time delays and debounce times. Emergency (standby source)

Loss of Phase. If the system detects a loss of phase in

the connected source, it attempts to transfer to an

TP-6126 8/02 Section 4 Operation 27

 Normal (preferred) power source returns

Pre-transfer load control (as programmed*)

Time delay standby-to-preferred

In-phase monitor (open-transition only,

as programmed*)

Transfer to OFF position

(programmed-transition only)

Time delay off-to-preferred

(programmed-transition only)

Transfer to normal (preferred) source

Post-transfer load control (as programmed*)

Time delay engine cooldown (TDEC)

(as programmed*)

Engine start signal removed

* See the Setup Program Operation Manual.

Figure 4-2 ATS Sequence of Operation, Return to

Normal (preferred source)
LED Indicators
N N OFF E E Load
Loss of Normal Source Available Position Position Available Position Control
Engine Start Time Delay
Preferred-to-Standby Time Delay X X
Post-transfer to Standby Load Control X X X
Standby-to-Preferred Time Delay X X X
Pre-transfer to Preferred Load Control X X X X
Off-to-Preferred Time Delay (programmed-transition X X X
only)
Post-transfer to Preferred Load Control X X X X
Engine Cooldown Time Delay (Default = 0) X X X
Figure 4-3 User Interface LED Indicators During Loss of Normal Source

28 Section 4 Operation TP-6126 8/02

4.2.2 System Test When the standby source is available and the time delay
preferred-to-standby expires, the ATS transfers the load
A system test simulates a preferred source failure and if the test DIP switch is set for a loaded test.
performs the transfer sequence. Press and release the
test button to start the test. Press and release the test When the test button is pressed again, the ATS transfers
button again to end the test. The test sequence does not the load back to the preferred source, if available, after
start if the ATS is in the standby position. the standby-to-preferred time delay. The ATS removes
the generator engine start signal after the related time
A test sequence can also be started or ended through delays expire. (The generator set may continue to run if
the setup software. See the Setup Program Operation the generator set controller provides an additional
manual. engine cooldown time delay.)
The Test LED flashes to indicate a loaded test or lights
steadily to indicate a test without load. Use the test DIP Test started
switch to select loaded or unloaded tests. See Section
3.3.1 for DIP switch locations and settings.
Time delay engine
Figure 4-4 and Figure 4-5 illustrate the following test start (TDES)
sequences. Figure 4-6 shows the operation of the user
interface LEDs during the test sequence.
Generator set engine start
Test without Load. The test without load sequence contacts close
starts the generator set but does not transfer the load.
The generator set continues to run until the test button is
Load bank control output
pushed again. activated (as programmed*)

Test with Load. The test with load sequence simulates

a preferred source failure and activates the pre- and Test ended
post-transfer load control sequences as programmed.
Refer to Section 4.2.5 for additional information about
pre-transfer time delays. Load bank control output
deactivated (as programmed*)
The test remains active until the test button is pushed
again or until a remote test signal is received. If the
standby source fails during a test cycle, the system Time delay engine cooldown (TDEC)
(as programmed)* (default = 0)
immediately transfers back to preferred.

The test sequence executes all time delays that are set
Generator set engine start
up to operate during a normal sequence of operation. signal removed
Press the End Time Delay button to shorten the time
delays while they are running, if desired. (The End Time * See the Setup Program Operation Manual.
Delay button does not end programmed-transition time
delays.) Figure 4-4 Test Without Load Sequence

At the start of the test, the ATS simulates a preferred

source failure and signals the generator set to start.

TP-6126 8/02 Section 4 Operation 29

 Test started A

Time delay engine start (TDES)

Test ended

Generator set engine start contacts close

Standby-to-preferred time delay

Pre-transfer load control (as programmed*)

Pre-transfer load control (as programmed*)

Preferred-to-standby time delay

In-phase monitor or transfer to off
(as programmed*)

In-phase monitor or transfer to off

(as programmed*)
Transfer to preferred source

Transfer to standby source

Post-transfer load control (as programmed*)

Post-transfer load control (as programmed*)

Time delay engine cooldown (TDEC)
(as programmed*) (default = 0)

A
Generator set engine start contacts open

* See the Setup Program Operation Manual.

Figure 4-5 Test with Load Sequence

N N OFF E E Load Test

System Test Available Position Position Available Position Control (flashing)
Engine Start Time Delay X X X
Preferred-to-Standby Time Delay X X X X
Pre-transfer to Standby Load Control X X X X X
Off-to-Standby Time Delay X X X X
(programmed-transition only)
Post-transfer to Standby Load Control X X X X X
Pre-transfer to Preferred Load Control X X X X X
Off-to-Preferred Time Delay X X X X
(programmed-transition only)
Post-transfer to Preferred Load Control X X X X X
Engine Cooldown Time Delay X X X X
(Default = 0)
Figure 4-6 User Interface LED Indicators During a Loaded Test

30 Section 4 Operation TP-6126 8/02

4.2.3 Exerciser Exercise Mode. The exerciser is factory-set to operate
in switch input mode, which uses the Exercise button on
Activate the exerciser after ATS installation by pressing the user interface to start, stop, and set the exerciser,
and holding the exercise button until the exercise LED and the 1 week/2 week DIP switch to determine the
flashes quickly. See Figure 3-1 for the location of the exercise schedule.
Exercise button and LED on the user interface panel.
Calendar modes with and without override are also
Press the Exercise button while the exercise is running available. The Setup Program software is required to
to end the exercise early, if desired. select and set up the exerciser calendar modes. See the
Setup Program Operation manual.
Figure 4-7 shows the exerciser factory default settings.
The exercise mode is set through the Setup Software. The calendar mode overrides the exercise button on the
All other settings in Figure 4-7 are set through DIP user interface. Pressing the exercise button when the
switches on the contoller’s main logic board. See exerciser is set for calendar mode will not start an
Section 3.3.1. exercise or set the exercise time.
Figure 4-8 describes the exercise LED operation. Calendar mode with override allows the starting and
setting of the exerciser by pressing the exercise button.
Exerciser Parameter Factory Setting Pressing the exercise button while in calendar mode
1 week/2 week exercise 1 week with override resets the exerciser to the switch input
Disable/enable exercise Enable mode.
Load/no load exercise No load
Run duration 30 minutes Exercise Schedule. The exercise repeats at the same
Exercise mode Switch Input time each week or every two weeks, depending on the
1 Week/2 Week DIP switch position. See Section 3.3
Figure 4-7 Exerciser Factory Settings
for the DIP switch location.
Exerciser LED Indicates Note: The exerciser clock is accurate to within 1 minute
Steady Illumination Unloaded exercise active. per month.
Slow Flash (1 Hz) Loaded exercise active
Rapid Flash (4 Hz) When exercise button is pressed and held, Pressing the exercise button starts the exercise and
rapid flashing indicates the exercise has sets the time for the next exercise according to the
been started and set. position of the 1 week/2 week DIP switch. Changing the
Rapid flashing at any other time indicates
that the exercise is inhibited by the DIP 1 week/2 week DIP switch position does not change the
switch setting. time of the next exercise because it has already been
Figure 4-8 Exerciser LED Indicator scheduled. The new DIP switch setting becomes
effective after the next scheduled exercise.
Loaded/Unloaded Exercise. A DIP switch on the
controller circuit board allows the selection of loaded or The system skips the exercise period if it is scheduled to
unloaded exercise runs. (See Section 3.3 for DIP switch start when the ATS is running under the following
locations.) Selecting unloaded exercise allows the ATS conditions:
to start and run the generator set without transfering the
D The ATS is running a test cycle initiated by the Test
building load.
button on the user interface.
The exercise LED flashes to indicate a loaded exercise. D The ATS is running on the standby source because
The exercise sequence starts the generator set engine the preferred source is not available.
immediately. and activates the pre-transfer load control
sequence. The in-phase monitor or D The ATS is running on the standby source because of
programmed-transition time delays operate if a peak shave/area protection command.
programmed. The post-transfer load control sequence
operates as programmed after the load is transferred. Exercise Duration. The default (factory) setting for the
See Figure 4-9 and Figure 4-10 for the exerciser run duration is 30 minutes. If the generator set fails
sequences of operation. Figure 4-11 shows the during an exercise period, the switch immediately
operation of the user interface LEDs during the exercise transfers back to the preferred source. Use the Setup
run. Refer to Section 4.2.5 for additional information Program to change the run duration, if desired.
about pre-transfer time delays.

TP-6126 8/02 Section 4 Operation 31

Load Bank Control. The load bank control output can
be used to apply a load to the generator set during the Exercise button pressed or scheduled
exercise. The load bank control output provides a exercise signaled to begin
contact closure that can be used to signal the load bank
controller to operate. If the Normal source is lost during Generator set engine start
an exercise period, the load bank control output contact
opens to remove the load bank and allow the transfer of
the building load to the emergency source. See Section Time delay preferred to standby
3.3.2 for the load bank control output connection.

Pre-transfer load control (as programmed*)

Exercise button pressed or scheduled
exercise signaled to begin
In-phase monitor or transfer to off (as programmed*)

Generator set engine start (immediate)

Transfer to standby source

Load bank control output

activated (as programmed*) Post-transfer load control (as programmed*)

Exercise time period ends or Exercise time period ends or

exercise button pressed exercise button pressed

Load bank control output Time Delay standby to preferred

deactivated (as programmed*)

Pre-transfer load control (as programmed*)

Time delay engine cooldown
(as programmed*)
In-phase monitor or transfer to off (as programmed*)

Generator set engine start signal removed

Transfer to preferred source
* See the Setup Program Operation Manual.

Figure 4-9 Exercise without Load Sequence Post-transfer load control (as programmed*)

Time delay engine cooldown (as programmed*)

Generator set engine start signal removed

* See the Setup Program Operation Manual.

Figure 4-10 Exercise with Load Sequence

32 Section 4 Operation TP-6126 8/02

 LED Indicators
N N OFF E E Load Exercise
Loaded Exercise Available Position Position Available Position Control (flashing)
Preferred-to-Standby Time Delay X X X X
Pre-Transfer to Standby Load Control X X X X X
Off-to-Standby Time Delay X X X X
(programmed-transition only)
In-Phase Synch (as programmed; X X X X
N/A for programmed-transition models.) (flashing)
Post-Transfer to Standby Load Control X X X X X
Pre-Transfer to Preferred Load Control X X X X X
Off-to-Preferred Time Delay X X X X
(programmed-transition only)
Post-Transfer to Preferred Load Control X X X X X
Engine Cooldown Time Delay X X X X
(Default = 0)
Figure 4-11 User Interface LED Indicators During a Loaded Exercise

TP-6126 8/02 Section 4 Operation 33

4.2.4 Peak Shave/Area Protection
Operation Sequence Peak Shave/Area Protection
signal received by controller
The peak shave input signals the transfer switch to start
the generator set and transfer to the standby source.
Immediate generator set engine start
The engine start (TDES) time delay is ignored.

When the peak shave input is removed, the system Pre-transfer load control (as programmed)
transfers back to preferred (if available) and removes
the generator engine start signal. The default setting
ignores the standby-to-preferred time delay when In-phase monitor or transfer to off (as programmed)
transferring back to preferred.

Note: The setup software can be set to bypass or Preferred to standby time delay
execute the standby-to-preferred time delay
during the peak shave sequence. See the Setup
Program Operation Manual. Transfer to standby source

See Figure 4-12 for the sequence of operation.

Post-transfer load control (as programmed)

Peak shave/area protection signal

removed

Pre-transfer load control

(as programmed)

In-phase monitor or transfer to off

(as programmed)

Standby to preferred time delay

(as programmed)[

Transfer to preferred source

Post-transfer load control (as programmed)

Time delay engine cooldown

(as programmed; default = 0)*

Generator set engine start signal removed

* See the Setup Program Operation Manual.

[ Default settings bypass this time delay

Figure 4-12 Peak Shave/Area Protection Sequence

34 Section 4 Operation TP-6126 8/02

4.2.5 Pre- and Post-Transfer Load The timelines in Figure 4-13 illustrate the pre-transfer
Control Sequence time delay sequence using the default settings. (The
default settings for the post-transfer signals are equal to
The pre-transfer and post-transfer load control time zero.) The default setting for the preferred-to-standby
delays operate during transfer between two live time delay is 1 second, and the default setting for the
sources, such as during a loaded test sequence or a pre-transfer time delay is three seconds. The time delay
loaded exercise. The load control LED lights when the before transfer is equal to the longer time delay, which is
pre- and post-transfer signals are active. 3 seconds. When transferring back to the preferred
source, the standby-to-preferred time delay is 15
The pre-transfer load control time delays overlap the minutes. The pre-transfer signal operates during the
preferred-to-standby and standby-to-preferred time final 3 seconds before transfer to the preferred source.
delays. The longer delay determines the time delay The total time delay before transfer back to preferred
before transfer. (using the default settings) is 15 minutes.

Pre-Transfer Load Control Signal, 3 Seconds

Preferred-to-Standby Time Delay, 1 second
Transfer to Standby

3 2 1 0
Time before Transfer, in Seconds

Standby-to-Preferred Time Delay, 15 minutes

Pre-Transfer Load Control Signal, 3 Seconds
Transfer to Preferred

15 minutes Time before Transfer 30

Figure 4-13 Pre-Transfer Time Delay Operation (default settings)

TP-6126 8/02 Section 4 Operation 35

4.3 Faults The fault clears when the system acquires a standby
source. Depress the Lamp Test button until the LEDs
flash to clear the Service Required LED.
4.3.1 Service Required LED
The following faults cause the Service Required LED to 4.3.4 Failure to Transfer
flash, indicating that immediate service is required:
If the unit fails to transfer on command, the controller
D Auxiliary switch fault
waits 1 second and then initiates another 200 msec
D Auxiliary switch open attempt to transfer. If the in-phase monitor is operating,
D Failure to acquire standby source the system waits 1 second and then begins monitoring
D Failure to transfer the source phases in preparation for transfer. When the
D Phase rotation fault sources are in phase, the system attempts to transfer.
D Input/output module faults (see Section 6.5.1) After three unsuccessful attempts to transfer, the
system stops attempting to transfer and generates a
Find and correct the cause of the fault before trying to fault. The Service Required LED illuminates.
reset the controller. The cause of the fault may be
shown by the other LEDs on the user interface; check The fault clears when the contactor transfers
the Source Available, Position, Load Control, Time successfully. Depress the Lamp Test button until the
Delay, Exercise, and Test LEDs to diagnose the cause of LEDs flash to clear the Service Required LED.
the faults. If the LEDs do not reveal the cause of the fault
condition, connect a PC to the controller and use the 4.3.5 Phase Rotation Faults
Setup Program to view the event history. The event
history lists fault conditions and transfers. See the A fault occurs if the phase rotation of an input channel
software operation manual for more information and does not match the system’s phase rotation direction
instructions. setting (ABC or CBA). The unit will not transfer to a
source if the source’s phase rotation does not match the
After correcting the fault condition, press the Lamp Test system setting. If the system detects a phase rotation
button for approximately 5 seconds until the LEDs flash fault in the connected source, it attempts to transfer to an
twice to clear the Service Required LED. alternate source that has the correct phase rotation.
The controller logs phase rotation faults in the event
4.3.2 Auxiliary Switch Faults history.

An Auxiliary Switch Fault occurs if the controller cannot If the system detects phase rotation faults on both
determine the contactor switch position. The Service sources, the Service Required LED lights. The system
Required LED flashes. does not transfer from the connected source.

The fault clears when the controller can detect the

switch position. Depress the Lamp Test button until the 4.4 Controller Power Supply
LEDs flash to clear the Service Required LED.
The controller is powered by the sources connected to
the transfer switch. The “dark time” is that period of time
4.3.3 Failure to Acquire Standby when neither source is available. During the dark time,
Source capacitors maintain the controller power for about 15
seconds. The capacitors require approximately one
A fault occurs if the unit attempts to start the generator hour to completely recharge after a power loss.
set but the standby source does not appear after the
Acquire Standby Source to Failure time delay. The The controller’s time, date, and all controller settings,
Service Required LED illuminates. Some conditions including time delays, system parameters, pickups and
that may cause this fault are failure of the generator set dropout settings, and input/output assignments, are
to start, no voltage output from the generator, or an error maintained by a controller battery during power
in sensing the voltage output from the generator set. outages.

36 Section 4 Operation TP-6126 8/02

 Section 5 Scheduled Maintenance

5.1 Introduction DANGER

Regular preventive maintenance ensures safe and
reliable operation and extends the life of the transfer
switch. Preventive maintenance includes periodic
testing, cleaning, inspection, and replacement of worn
or missing components. Section 5.4 contains a service Hazardous voltage.
Will cause severe injury or death.
schedule for recommended maintenance tasks.
Disconnect all power sources before
A local authorized distributor/dealer can provide opening the enclosure.
complete preventive maintenance and service to keep
the transfer switch in top condition. Unless otherwise
specified, have maintenance or service performed by an DANGER
authorized distributor/dealer in accordance with all
applicable codes and standards. See the Service
Assistance section in this manual for how to locate a
local distributor/dealer.
Hazardous voltage.
Keep records of all maintenance or service. Will cause severe injury or death.
Disconnect all power sources before
Replace all barriers and close and lock the enclosure servicing. Install the barrier after
door after maintenance or service and before reapplying adjustments, maintenance, or
power. servicing.

WARNING DANGER

Accidental starting. Hazardous voltage.

Can cause severe injury or death. Will cause severe injury or death.

Disconnect the battery cables before Only authorized personnel should

working on the generator set. open the enclosure.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last WARNING
when reconnecting the battery.

Disabling the generator set. Accidental starting can

cause severe injury or death. Before working on the
generator set or connected equipment, disable the generator Hazardous voltage. Moving rotor.
set as follows: (1) Move the generator set master switch to the Can cause severe injury or death.
OFF position. (2) Disconnect the power to the battery charger.
(3) Remove the battery cables, negative (--) lead first. Operate the generator set only when
Reconnect the negative (--) lead last when reconnecting the all guards and electrical enclosures
battery. Follow these precautions to prevent starting of the are in place.
generator set by an automatic transfer switch, remote
start/stop switch, or engine start command from a remote
computer.

TP-6126 8/02 Section 5 Scheduled Maintenance 37

Grounding the transfer switch. Hazardous voltage can reliability of the emergency power system. Press the
cause severe injury or death. Electrocution is possible Test button on the controller front panel to start and end
whenever electricity is present. Open main circuit breakers of the test. The Test LED flashes during a test with load or
all power sources before servicing equipment. Configure the lights steadily during a test without load. Use the DIP
installation to electrically ground the transfer switch and switch to set the system for a loaded test or use a load
related equipment and electrical circuits to comply with bank and the load bank control output to run loaded
applicable codes and standards. Never contact electrical
without transferring the building load. See Sections
leads or appliances when standing in water or on wet ground,
4.2.2 and 4.2.3 for more information about the exercise
as the chance of electrocution increases under such
and test functions.
conditions.

Servicing the transfer switch. Hazardous voltage can 5.2.2 Monthly Automatic Control
cause severe injury or death. Deenergize all power sources System Test
before servicing. Open the main circuit breakers of all transfer
switch power sources and disable all generator sets as Test the transfer switch’s automatic control system
follows: (1) Move all generator set master controller switches monthly. See Section 3.7.3 for the test procedure.
to the OFF position. (2) Disconnect power to all battery
chargers. (3) Disconnect all battery cables, negative (--) leads D Verify that the expected sequence of operations
first. Reconnect negative (--) leads last when reconnecting the occurs as the switch transfers the load to the
battery cables after servicing. Follow these precautions to emergency source when a preferred source failure
prevent the starting of generator sets by an automatic transfer occurs or is simulated.
switch, remote start/stop switch, or engine start command
from a remote computer. Before servicing any components D Observe the indicator LEDs included on the transfer
inside the enclosure: (1) Remove all jewelry. (2) Stand on a switch to check their operation.
dry, approved electrically insulated mat. (3) Test circuits with a
voltmeter to verify that they are deenergized. D Watch and listen for signs of excessive noise or
vibration during operation.
Short circuits. Hazardous voltage/current can cause
severe injury or death. Short circuits can cause bodily injury
D After the switch transfers the load to the standby
and/or equipment damage. Do not contact electrical
connections with tools or jewelry while making adjustments or
source, end the test and verify that the expected
repairs. Remove all jewelry before servicing the equipment. sequence of operations occurs as the transfer switch
retransfers to the preferred source and signals the
NOTICE generator set to shut down after a cooldown period.
When replacing hardware, do not substitute with inferior
grade hardware. Screws and nuts are available in different D On programmed-transition units, verify that the time
hardness ratings. To indicate hardness, American Standard delay in the OFF position functions during transfer to
hardware uses a series of markings, and metric hardware the standby source and transfer back to the preferred
uses a numeric system. Check the markings on the bolt heads source.
and nuts for identification.
5.3 Inspection and Service
NOTICE
Hardware damage. The transfer switch may use both Contact an authorized distributor/dealer to inspect and
American Standard and metric hardware. Use the correct size service the transfer switch annually and also when any
tools to prevent rounding of the bolt heads and nuts.
wear, damage, deterioration, or malfunction of the
NOTICE transfer switch or its components is evident or
Electrostatic discharge damage. Electrostatic discharge
suspected.
(ESD) damages electronic circuit boards. Prevent
electrostatic discharge damage by wearing an approved 5.3.1 General Inspection
grounding wrist strap when handling electronic circuit boards
External Inspection. Keep the transfer switch clean
or integrated circuits. An approved grounding wrist strap
provides a high resistance (about 1 megohm), not a direct
and in good condition by performing a weekly general
short, to ground. external inspection of the transfer switch for any
condition of vibration, leakage, excessive temperature,
contamination, or deterioration. Remove
5.2 Testing accumulations of dirt, dust, and other contaminants
from the transfer switch’s external components or
5.2.1 Weekly Generator Set Exercise enclosure with a vacuum cleaner or by wiping with a dry
Use the exerciser or a manual test to start and run the cloth or brush.
generator set under load once a week to maximize the

38 Section 5 Scheduled Maintenance TP-6126 8/02

Note: Do not use compressed air to clean the transfer D Wire or cable insulation deterioration, cuts, or
switch because it can cause debris to lodge in the abrasion
components and damage the switch.
D Signs of overheating or loose connections:
Tighten loose external hardware. Replace any worn, discoloration of metal, melted plastic, or a burning
missing, or broken external components with odor
manufacturer-recommended replacement parts.
Contact a local authorized distributor/dealer for specific D Other evidence of wear, damage, deterioration, or
part information and ordering. malfunction of the transfer switch or its components.

Internal Inspection. Disconnect all power sources, If the applicaton does not allow a power interruption for
open the transfer switch enclosure door, and inspect the time required for the internal inspection, have an
internal components monthly or when any condition authorized distributor/dealer perform the internal
noticed during an external inspection may have affected inspection.
internal components.
5.3.2 Other Inspections and Service
Contact an authorized distributor/dealer to inspect and Have an authorized distributor/dealer perform
service the transfer switch if any of the following scheduled maintenance, service, and other
conditions are found inside the transfer switch. maintenance that ensures the safe and reliable
operation of the transfer switch. See Section 5.4,
D Accumulations of dirt, dust, moisture, or other
Service Schedule, for the recommended maintenance
contaminants
items and service intervals.
D Signs of corrosion
Have an authorized distributor/dealer repair or replace
D Worn, missing, or broken components damaged or worn internal components with
manufacturer-recommended replacement parts.
D Loose hardware

TP-6126 8/02 Section 5 Scheduled Maintenance 39

5.4 Service Schedule
Follow the service schedule below for the recommended service intervals. Have all service performed by an
authorized distributor/dealer except for activities designated by an X, which may be performed by the switch operator.
Adjust,
See Visually Repair,
System Component or Procedure Section Inspect Check Replace Clean Test Frequency
ELECTRICAL SYSTEM
Check for signs of overheating or loose connections:
5.3.1 X X Y
discoloration of metal, melted plastic, or a burning odor
Check the contactor’s external operating mechanism D (clean
5.3.1 X Y
for cleanliness; clean and relubricate if dirty * and lube)
Inspect wiring insulation for deterioration, cuts, or
abrasion. Repair or replace deteriorated or damaged 5.3.1 X D D Y
wiring
Tighten control and power wiring connections to
2.5 D D Y
specifications
Check the transfer switch’s main power switching
contacts’ condition; clean or replace the main contacts 5.3.2 D D D Y
or replace the contactor assembly as necessary
CONTROL SYSTEM
Exercise the generator set under load 5.2.1
X W
4.2.3
Test the transfer switch’s automatic control system 5.2.2
X X M
3.7.3
Test all indicators (LEDs) and all remote control 3.2
systems for operation D D D D Y

GENERAL EQUIPMENT CONDITION

Inspect the outside of the transfer switch for any signs
of excessive vibration, leakage, high temperature, 5.3.1 X X M
contamination, or deterioration *
Check that all external hardware is in place, tightened,
5.3.1 X X X M
and not badly worn
Inspect the inside of transfer switch for any signs of
excessive vibration, leakage, high temperature, 5.3.2 D D D Y
contamination, or deterioration*
Check that all internal hardware is in place, tightened,
5.3.2 X D D Y
and not badly worn
* Service more frequently if the transfer switch is operated in dusty or dirty areas.
See Section: Read these sections carefully for additional information before attempting maintenance or service.
Visually Inspect: Examine these items visually.
Check: Requires physical contact with or movement of system components, or the use of nonvisual indications.
Adjust, Repair, Replace: Includes tightening hardware and lubricating the mechanism. May require replacement of components depending
upon the severity of the problem.
Clean: Remove accumulations of dirt and contaminants from external transfer switch’s components or enclosure with a vacuum cleaner or by
wiping with a dry cloth or brush. Do not use compressed air to clean the switch because it can cause debris to lodge in the components and cause
damage.
Test: May require tools, equipment, or training available only through an authorized distributor/dealer.
Symbols used in the chart:
X=The transfer switch operator can perform these tasks. Q=Quarterly
D=An authorized distributor/dealer must perform these tasks. S=Semiannually (every six months)
W=Weekly Y=Yearly (annually)
M=Monthly

40 Section 5 Scheduled Maintenance TP-6126 8/02

 Section 6 Accessories

6.1 Introduction
This section describes the installation and/or operation 1
of the following accessories:

D MPAC Setup Program

D Control Switches:

D Preferred source switch

D Supervised transfer switch

D In-phase monitor

D Programmable inputs and outputs:

D Main logic board terminal strip ADV-6698A

1. Preferred source switch and supervised transfer control switch
D Input/output modules location

D Load shed (Forced transfer to OFF) Figure 6-1 Control Switch Locations

D Security cover
6.3.1 Preferred Source Switch
D Battery charger The two-position, key-operated preferred source
selector switch allows selection of either power source
as the preferred source. The key can be removed with
6.2 Setup Program the switch in either position, locking the switch into the
The optional MPAC Setup Program allows you to use a selected position. The preferred source selection
personal computer to view and adjust system cannot be changed remotely through software or the
parameters, voltage and frequency pickup and dropout Modbusr connection. Figure 6-2 shows the preferred
settings, time delays, input and output functions, and source selector switch.
other system parameters. The software also includes a
time-stamped event log that is useful for system The transfer switch seeks and transfers to the preferred
diagnostics and troubleshooting. Refer to the Setup source whenever it is available. Source N is always the
Program Operation Manual for more information. source connected to the Normal side of the transfer
switch, and Source E is always connected to the
Emergency side. Generator engine start relays are
6.3 Control Switches assigned to the the source (Source N or Source E). The
engine start relays do not change when the preferred
Two control switches are available, the preferred source source switch position changes. This prevents the need
switch and the supervised transfer control switch. The to change the wiring of the engine start relay(s) when the
switches are mounted on the enclosure door. See preferred source changes.
Figure 6-1 for typical switch locations.

Note: Factory-installed switches are factory-wired and

require no additional wiring in the field.

TP-6126 8/02 Section 6 Accessories 41

 start output. Use the setup program to assign one of the
main logic board terminal strip or I/O module outputs to
Start Source N Generator, and connect the engine start
leads for the Source N generator set to the
corresponding terminals on the terminal strip or I/O
module terminals. See Sections 3.3.2 and 6.5.2. The
programmed engine start output remains tied to the
Source N generator set regardless of the position of the
preferred source switch.

The utility-utility mode is designed to use utility power for

both Source N and Source E. This mode does not use
the engine start outputs.

GM21287
Time Delays and Source Parameters. Engine start
relays and time delays, source voltage and frequency
Figure 6-2 Preferred Source Selector Switch trip points, and load shed time delays are assigned to
the source (N or E). They do not change assignment
Operating Modes. The transfer switch is factory-set for when the preferred source switch position is changed.
the generator set-to-utility mode of operation. This
mode uses one generator set, which is connected to the Note: Source N is always connected to the Normal side
Emergency side of the contactor (Source E), and one of the transfer switch, and Source E is always
engine start relay. The engine start relay connections connected to the Emergency side.
are located on the contactor on 30--400 amp units, and
on the customer-connection terminal block on larger Other time delays are assigned to the source function
units (see Section 2.5.2). The engine start contact is (preferred or standby). System parameters that are
assigned to the connected generator set and does not assigned to the function automatically change source
change assignment when the preferred source switch when the preferred source selection changes.
position is changed. In this mode, if the preferred source
Figure 6-3 shows which parameters are assigned to the
switch is set to Source E, then the system operates the
source and which are assigned to the function. The last
generator set indefinitely, transferring to utility power
two columns of the table show the effect of the preferred
only if the generator set fails.
source selector switch position on each parameter or
Use the setup program to change the mode to generator time delay.
set-generator set or utility-utility if necessary. The
generator set-generator set mode uses two generator
sets and requires the assignment of a second engine

42 Section 6 Accessories TP-6126 8/02

 Preferred Source Switch Position
Item Assignment N E
Source N generator engine start relay Source N N
Source E generator engine start relay Source E E
Source N engine start time delay Source N N
Source E engine start time delay Source E E
Source N engine cooldown time delay Source N N
Source E engine cooldown time delay Source E E
Source N voltage and frequency trip points Source N N
Source E voltage and frequency trip points Source E E
Source N load shed time delays Source N N
Source E load shed time delays Source E E
In-phase monitor synch Source E E
Preferred-to-standby time delay Function N to E E to N
Standby-to-preferred time delay Function E to N N to E
Failure to acquire standby source Function E N
Pretransfer to preferred signal Function N E
Pretransfer to standby signal Function E N
Post-transfer to preferred signal Function N E
Post-transfer to standby signal Function E N
Off-to-standby time delay (programmed-transition only) Function Off to E Off to N
Off-to-preferred time delay (programmed-transition only) Function Off to N Off to E
Figure 6-3 Preferred Source Selection Effect on System Parameters and Time Delays

TP-6126 8/02 Section 6 Accessories 43

6.3.2 Supervised Transfer Control cannot be converted in the field. The supervised
Switch transfer control switch cannot be removed from
non-automatic switches in the field.
The supervised transfer control switch
(AUTO/MANUAL/TRANSFER switch) is a Test and Peak Shave Operation. When the
three-position, key-operated switch that allows manual supervised transfer control switch on an automatic
control of load transfers. The switch has maintained system is in the MANUAL position, pressing the Test
AUTO and MANUAL positions and a momentary button or sending a peak shave command causes
TRANSFER position. The key can be removed in either transfer to the standby source. However, ending the test
the AUTO or MANUAL position. The key cannot be or removing the peak shave signal will not cause a
removed when the switch is in the TRANSFER position. transfer back to the preferred source. Move the
Figure 6-4 shows the switch. supervised transfer control switch to the TRANSFER
position to initiate transfer back to the preferred source.
The manual mode allows the system to run on the
standby source indefinitely, even if the preferred source Test and peak shave signals are ignored by
is available. In manual mode, the controller is inhibited non-automatic systems when the supervised transfer
from initiating a transfer sequence until the keyswitch is control switch is in the MANUAL position.
turned to the TRANSFER position.

It is not necessary to hold the switch in the TRANSFER

position during the transfer sequence. Turn the switch
to TRANSFER and release it to initiate transfer. The
transfer sequence will proceed after the switch returns
to the MANUAL position, executing all programmed
time delays and transferring the load to the other source
if it is available.

Automatic and Non-Automatic Transfer Switches.

The switch operation differs for automatic and
non-automatic switches. An automatic transfer switch
transfers automatically to an available source if the
connected source is lost. A non-automatic transfer
switch does not transfer automatically, even if the GM21286

connected source is lost. Figure 6-5 summarizes the

switch operation. Figure 6-4 Supervised Transfer Control Switch

Note: Transfer switches are built and UL-labeled as

automatic or non-automatic by the factory and

Switch
Position Operation, Automatic Switches Operation, Non-Automatic Switches
AUTO D Automatically transfers to the standby source, when available, if the preferred source is lost
D Transfers back to the preferred source when it becomes available
MANUAL D Automatically transfers to an available source if the D Enables the Not-in-Auto indicator
connected source is lost D Transfers only when the switch is manually moved
D Does not automatically transfer back to preferred to the TRANSFER position:
when both sources are available D Does not automatically transfer to an available
source when the connected source is lost
D Does not automatically transfer back to
preferred when both sources are available
TRANSFER D Can use to transfer when the switch is in the D Must use for all transfers when the switch is in the
MANUAL position and both sources are available MANUAL position
D Initiates transfer sequence to the other source, if D Initiates transfer sequence to the other source, if
available, including all programmed time delays available, including all programmed time delays
D Operates pre- and post-transfer load control time D Operates pre- and post-transfer load control time
delays if both sources are available delays if both sources are available
Figure 6-5 Supervised Transfer Control Switch Operation

44 Section 6 Accessories TP-6126 8/02

6.4 In-Phase Monitor 6.5 Programmable Inputs and
Transfer switches are shipped with the in-phase monitor Outputs
disabled. The factory settings are shown in Figure 6-6. Programmable inputs and outputs are available through
Use the Setup Program to enable the in-phase monitor the controller main logic board terminal strip and
and adjust the settings, if necessary. Refer to the Setup through optional input/output (I/O) modules.
Program Operation Manual. Programmable monitoring, control, and fault detection
outputs are available through the terminal strip on the
Note: The in-phase monitor is not available on
controller or through the programmable input/output
programmed transition switches.
(I/O) modules.
The in-phase monitor operates when both sources are
available, such as when transfering from the standby The main logic board inputs and outputs are
back to the preferred source. The in-phase monitor factory-assigned to the functions listed in Section 3.3.2.
assures that transfer occurs when the two sources are in The I/O modules are shipped with the input and output
phase. The phase angle measuring accuracy is ±5_. assignments undefined. The Setup Program is required
to change the main logic board terminal strip input and
The in-phase monitor does not operate when one output assignments and also to set up and assign inputs
source is lost. and outputs to the optional I/O modules. The table in
Figure 6-7 lists the available inputs. Figure 6-8 lists the
The OFF position LED on the user interface panel available programmable outputs.
flashes at 2 Hz when the in-phase monitor is operating.
Programmable Inputs
Synchronization Output. The synchronization output
Low External Battery Fault
provides a contact closure that can be used to signal
Peak Shave/Area Protection
some generator set controllers to synchronize the two
sources by adjusting the engine speed of a generator Inhibit Transfer
set equipped with a variable-speed governor. See the Remote Bypass Time Delay
generator set operation manual. The system activates Remote Test
the output after the synch output time delay. See Forced Transfer to OFF (programmed-transition models
Figure 6-6. only; requires load shed accessory)
Remote Common Fault
Parameter Factory setting Figure 6-7 Programmable Inputs
Enable/disable Disable
Phase angle, degrees 0
Synch output time delay, seconds 30
Figure 6-6 In-Phase Monitor Factory Settings

TP-6126 8/02 Section 6 Accessories 45

 Programmable Output Type 6.5.1 Programmable Input/Output (I/O)
Preferred Source Available Monitor Modules
Standby Source Available Monitor Programmable Input/Output (I/O) modules provide two
Contactor in Preferred Position Monitor inputs and six outputs, numbered 1--6, for controller
Contactor in Standby Position Monitor communications. Up to four modules can be connected
Contactor in OFF position Monitor to the controller.
Contactor in Source N Position Monitor
The I/O modules are mounted on a DIN rail and covered
Contactor in Source E Position Monitor
by a protective cover. See Figure 6-9. Figure 6-10 and
Not in Auto Monitor Figure 6-11 show typical I/O module locations.
Load Control Active Monitor
Exerciser Active Monitor
Low Battery on Standby Source Monitor
Test Active Monitor
Peak Shave Active Monitor
Non-Emergency Transfer Monitor
Load Bank Control Control
Start Source N Generator Control
Start Source E Generator Control
Load Shed Disconnect 0--8 Control 1
Synchronization Output Command Control
Common Alarm Fault
Undervoltage Source N Fault
2
Overvoltage Source N Fault
Loss of Phase Source N Fault
Phase Rotation Error Source N Fault
Overfrequency Source N Fault 3
Underfrequency Source N Fault
Undervoltage Source E Fault
Overvoltage Source E Fault 4
Loss of Phase Source E Fault
Phase Rotation Error Source E Fault
Overfrequency Source E Fault
Underfrequency Source E Fault GM21360

Failure to Transfer Fault

Figure 6-9 Input/Output Modules and Harness
Auxiliary Switch Fault Fault (cover is shown transparent to show
Auxiliary Switch Open Fault detail)
Failure to Acquire Standby Source Fault
I/O Module Lost Fault
I/O Module Not Found Fault
I/O Module Not Installed Fault
Modbusr-Controlled Relay Driver Control
Output #1
Modbusr-Controlled Relay Driver Control
Output #2
Modbusr-Controlled Relay Driver Control
Output #3
Modbusr-Controlled Relay Driver Control
Output #4
Figure 6-8 Available Programmable Outputs

46 Section 6 Accessories TP-6126 8/02

 1 6.5.2 I/O Module Connection
Optional input/output (I/O) modules are connected to
the controller by a factory-installed harness.
Figure 6-12 shows the controller connection.

The input and output ratings are shown in Figure 6-13.

Figure 6-14 shows an I/O module with its input and
output terminal blocks and address DIP switches.

Each I/O Module requires a unique address.

Factory-installed I/O module addresses are set at the
factory.

1
2

GM21360

1. I/O modules

Figure 6-10 Typical I/O Module Locations (welded

enclosures)

1 1

GM21079-A
1. I/O module harness GM21341
2. Transfer switch controller

Figure 6-12 I/O Circuit Board Module Harness

Connection to Transfer Switch Controller

I/O Module Item Rating

Side View Front View Input 16 mA@12 VDC
gm21360b Output 2 A@250 VAC
1. I/O module locations (typ.)
Figure 6-13 I/O Module Ratings
Figure 6-11 Typical I/O Module Locations (framework
enclosures)

TP-6126 8/02 Section 6 Accessories 47

 1 6.5.3 I/O Module Address
Each I/O Module requires a unique address.

P1
2
Factory-installed I/O module addresses are set at the

6
DIAGNOSTIC
factory.

LED1

----OPEN----

1 2 3
SW1
To check the I/O module addresses, compare the DIP

RDO1
4
RDO4

switch settings with Figure 6-16, starting with the

module connected to the controller harness.
RDO2
RDO5

3 Figure 6-14 shows the address DIP switch location on

the I/O module. Push down the end of the DIP switch
RDO3
RDO6

near the OPEN label to open the switch, or push down

TB1
INPUT
DIGITAL
IN1--
IN2--
the other end to close it. See Figure 6-17.
TB2
RELAY OUTPUT

IN2+
IN1+

6
Address DIP Switches
1

I/O Module
P2 1 2 3
Number
gm21115a 1 Closed Closed Closed
1. Controller harness connection 2 Closed Closed Open
2. Address DIP switches
3. Input connections
3 Closed Open Closed
4. Output connections 4 Closed Open Open
Figure 6-16 I/O Module Address DIP Switches
Figure 6-14 I/O Module Input and Output
Connections

I/O Module Connection Procedure 1 2 3

1. Disconnect power to the transfer switch before
connecting to the I/O modules.

2. Remove the I/O module cover and connect devices OPEN 1

to the I/O module input terminals on terminal block
6126
TB1 or output terminals on terminal block TB2. See
1. Push this side down to open.
Figure 6-14 for the terminla block locations. The
output connections on the I/O module are labelled Figure 6-17 I/O Module Address DIP Switches
RDO (relay driver output) 1 through 6. Use wire
sizes within the specifications in Figure 6-15 for the
input and output connections. 6.5.4 I/O Module Faults and Diagnostics
3. Tighten the connections to 0.5 Nm (4.4 in. lb.). When power is applied to the system, the controller
attempts to initiate communication with each connected
4. Record the connections on the label on the cover I/O board. The following faults may occur on powerup if
and replace the cover. the I/O modules are not correctly installed, addressed,
or configured in the setup software. Check the LED on
5. Use the Setup Program to set up the I/O board each I/O module for diagnostic information in the case of
communications and to define the I/O board inputs a fault.
and outputs. Refer to the Setup Program
Operation Manual for instructions. Diagnostic LED. Each I/O module has a diagnostic
LED that lights or flashes to indicate the I/O board status
Number Wire Size Tightening as described in the table in Figure 6-18.
Component of Wires Range Torque

Controller terminal 1 #12--24 AWG

I/O Module Not Found. If the system does not detect
strip I/O terminals 0.5 Nm an I/O module at an expected address, the Service
(4.4
(4 4 in.
in lb.)
lb ) Required LED flashes and the software logs the
I/O board terminals 1 #14--26 AWG
message, “I/O Module Not Found”. Check that the
Figure 6-15 Input and Output Connection number of I/O modules installed matches the number
Specifications expected by the setup program. Check that the I/O

48 Section 6 Accessories TP-6126 8/02

modules are connected and the address DIP switches position. The load shed (forced transfer to off)
are set correctly. Check the diagnostic LED to verify that accessory is available only for programmed-transition
the module is receiving power and communicating with transfer switches.
the controller.
When the forced transfer to off input is activated (contact
I/O Module Not Installed. If the software detects an I/O closed), the contactor moves from Source E to the OFF
module that is connected but not expected by the setup position immediately, ignoring all time delays. If the
program, the Service Required LED flashes and the normal source is available when the input is activated,
software logs the message, “I/O Module Not Installed.” the ATS transfers to the Off position and then to Source
The system ignores the board if it does not find the setup N, executing all programmed time delays. If Source N is
definition. Check that the number of I/O modules not available, the ATS remains in the Off position until
expected in the Setup Program matches the number of the input is deactivated. When the input is deactivated,
modules installed on the transfer switch. Check that the the ATS transfers back to Source N, if available,
I/O module address DIP switches are set correctly. executing all programmed time delays. If Source N is
Check the diagnostic LED. not available, the ATS transfers to Source E.

I/O Module Communications Lost. If communication The load shed (forced transfer to off) function only sheds
to an I/O module that was previously installed and loads connected to Source E. The preferred source
working is lost, the Service Required LED flashes and selector switch position (if equipped) does not affect this
the software logs the message “I/O Module function.
Communications Lost.” Check the I/O module
connections and diagnostic LED.
6.6.2 Connection
Diagnostic On transfer switches with the factory-installed load shed
I/O board Status LED accessory, the forced transfer to off input is assigned to
Unpowered Off main logic board terminal strip programmable input #2
Operating correctly On, Steady (terminals 8 and 9). Connect the forced transfer to off
Power but no communication with Quick Flash signal from the generator set controller or other
control board (2 Hz) customer device to terminals 8 and 9 following the
No defined program at I/O module Slow Flash instructions in Section 3.3.2. Use #12--24 AWG wire
address (0.5 Hz) and tighten the terminals to 0.5 Nm (4.4 in. lb.).
Figure 6-18 I/O Module Diagnostic LED

6.7 Security Cover

6.6 Load Shed (Forced Transfer to
The gasketed, hinged security cover prevents
OFF) unauthorized access to the transfer switch controls and
protects the user interface from harsh environmental
6.6.1 Description conditions. Use a customer-supplied padlock to lock the
cover.
The load shed (forced transfer to off) accessory allows
the removal of non-critical loads from the Source E The cover is available with or without a window for
generator set. The accessory requires an external NEMA 1 enclosures. NEMA 3R enclosures include a
signal (contact closure) to initiate transfer to the Off windowless cover as standard equipment.

TP-6126 8/02 Section 6 Accessories 49

6.8 Battery Charger Battery electrolyte is a diluted sulfuric acid. Battery acid
can cause severe injury or death. Battery acid can cause
The GM22502 is a 3-stage electronic battery charger blindness and burn skin. Always wear splashproof safety
designed for 12 or 24 VDC systems. It is designed to be goggles, rubber gloves, and boots when servicing the battery.
used for lead acid batteries (flooded cell or AGM types) Do not open a sealed battery or mutilate the battery case. If
and gel cell batteries. The sealed and potted design is battery acid splashes in the eyes or on the skin, immediately
rainproof, lightweight, silent, and completely automatic. flush the affected area for 15 minutes with large quantities of
clean water. Seek immediate medical aid in the case of eye
The charger contains internal, self-resetting
contact. Never add acid to a battery after placing the battery in
short-circuit protection for the outputs and fuses for
service, as this may result in hazardous spattering of battery
reversed-polarity protection.
acid.
The battery charger produces 12 VDC at 6 Amps or Battery acid cleanup. Battery acid can cause severe
24 VDC at 3 Amps. Red and green LEDs indicate that injury or death. Battery acid is electrically conductive and
the unit is recharging or maintaining the battery. corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking
soda) to a container with 4 L (1 gal.) of water and mix the
Figure 6-19 shows the battery charger. Refer to the neutralizing solution. Pour the neutralizing solution on the
transfer switch dimension drawing for the location of the spilled battery acid and continue to add the neutralizing
battery charger. solution to the spilled battery acid until all evidence of a
chemical reaction (foaming) has ceased. Flush the resulting
liquid with water and dry the area.
WARNING
Battery gases. Explosion can cause severe injury or
death. Battery gases can cause an explosion. Do not smoke
or permit flames or sparks to occur near a battery at any time,
particularly when it is charging. Do not dispose of a battery in a
fire. To prevent burns and sparks that could cause an
explosion, avoid touching the battery terminals with tools or
Sulfuric acid in batteries. other metal objects. Remove all jewelry before servicing the
Can cause severe injury or death. equipment. Discharge static electricity from your body before
Wear protective goggles and touching batteries by first touching a grounded metal surface
clothing. Battery acid may cause away from the battery. To avoid sparks, do not disturb the
blindness and burn skin. battery charger connections while the battery is charging.
Always turn the battery charger off before disconnecting the
battery connections. Ventilate the compartments containing
WARNING batteries to prevent accumulation of explosive gases.

Battery short circuits. Explosion can cause severe injury

or death. Short circuits can cause bodily injury and/or
equipment damage. Disconnect the battery before generator
set installation or maintenance. Remove all jewelry before
Explosion. servicing the equipment. Use tools with insulated handles.
Can cause severe injury or death. Remove the negative (--) lead first when disconnecting the
Relays in the battery charger battery. Reconnect the negative (--) lead last when
cause arcs or sparks. reconnecting the battery. Never connect the negative (--)
battery cable to the positive (+) connection terminal of the
Locate the battery in a well-ventilated
starter solenoid. Do not test the battery condition by shorting
area. Isolate the battery charger from
the terminals together.
explosive fumes.

50 Section 6 Accessories TP-6126 8/02

 63.5
47.6 REF FUSE HOLDER (2) 234.4
AGC--10 10A 9.5 215.9
33.3
REF
12.7

FASTBLOW FUSE RED LIGHT

REF GREEN LIGHT

7.1 (4)
REF
34.9
+
REF
47.6

95.3 REF

165.1
--
REF

114.3
44.5

+
REF
47.6

25.4

--

#10--32 TERMINALS TYP. (4)

6” LEAD LENGTH REF

(CHARGER BODY TO INSERTION END OF CONNECTOR)

GM22502-A

Figure 6-19 Battery Charger

6.8.1 Battery Charger Connection

The battery charger is powered by the load side of the
transfer switch contactor through a factory-installed
wiring harness with a 9-pin inline connector. Verify that
the power to the ATS is disconnected before connecting
or disconnecting the 9-pin connector to the battery TERMINAL
charger. INSERTION
END
Ring terminals for battery charger connections are
included with the battery charger. CONNECTOR PIN--OUT
PIN WIRE FUNCTION
The installing technician must supply the cable with 1 1 NEUTRAL INPUT
2 2 208 VAC INPUT
terminals between the battery charger and the battery.
3 -- --
Figure 6-21 provides details regarding cable length and 4 3 240 VAC INPUT
gauge. Using red cable for battery positive (+) and black 5 -- --

cable for battery negative (--) is strongly recommended. 6 4 480 VAC INPUT
7 6 EARTH GROUND
8 -- --
Use the following procedure to connect the battery 9 5 600 VAC INPUT
GM22502
charger.
Figure 6-20 Battery Charger Power Connection

TP-6126 8/02 Section 6 Accessories 51

Battery Charger Connection Procedure 7. Determine whether the generator set electrical
system uses 12 or 24 volts. This information is
DANGER shown on the generator set nameplate.

8. Connect the jumpers as shown in Figure 6-22 for

a12-volt system or Figure 6-23 for a 24-volt
system, reconnecting the jumper lead for 24-volt
systems as shown. Place the jumper lead terminal
Hazardous voltage. between the two flat washers on the battery
Will cause severe injury or death.
charger terminal.
Disconnect all power sources before
opening the enclosure. Note: Battery chargers are configured for 12-volt
systems at the factory. For 24-volt systems,
Connecting the battery and the battery charger. reconnect the jumper lead as shown in
Hazardous voltage can cause severe injury or death. Figure 6-23 and discard the second jumper
Reconnect the battery correctly, positive to positive and lead.
negative to negative, to avoid electrical shock and damage to
the battery charger and battery(ies). Have a qualified 9. Connect the battery cables as shown in
electrician install the battery(ies). Figure 6-22 for 12 VDC systems or Figure 6-23 for
24 VDC systems.
1. Verify that power to the ATS is disconnected
(switches or circuit breakers to the ATS are open). Note: The positive (POS, P, +) battery post usually
has a larger diameter than the negative
2. Verify that the inline connector to the charger is (NEG, N, --) post.
disconnected.
a. Connect the red POSITIVE terminal of the
3. Clean the battery terminals and check the battery battery charger to the positive post of the
according to the battery manufacturer’s battery.
instructions.
b. Connect the black NEGATIVE terminal of the
4. Determine the length of cable needed to connect battery charger to the negative post of the
the battery to the battery charger and refer to battery.
Figure 6-21 for the required wire size. The
distances shown are the one-way distances from 10. Slide the boots over the battery charger posts.
the charger to the battery.
11. Connect the in-line connectors on the battery
Note: Use the recommended wire size to prevent charger power cord.
overcharging the battery. Route AC and DC
wiring in separate conduits.

5. Remove the boots and ring terminals from the

battery charger posts.

Maximum Battery Charger Eyelet Terminal

Distance Wire Size Terminal Size Part No.

4.5 m (15 ft.) 12 AWG

No 10
No. X 283 11
X-283-11
7.5 m (25 ft.) 10 AWG

Figure 6-21 Battery Cable and Terminal

Specifications

6. Slide a red boot onto the red cable and a black boot
onto the black cable. Attach ring terminals and use
a crimping tool to crimp the ring terminals tightly.

52 Section 6 Accessories TP-6126 8/02

 Battery Charger Disconnection Procedure

DANGER

Hazardous voltage.
+ -- + -- Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.

1. Before opening the transfer switch enclosure,

disconnect power to the transfer switch by opening
6126 switches or circuit breakers to the transfer switch.

Figure 6-22 12-Volt Battery Charger Connections 2. Disconnect the AC power cord at the in-line
connector.

3. Remove the black (NEGATIVE) wire from the the

battery terminal first.

4. Remove the red (POSITIVE) wire from the battery

terminal.

+ -- + --

6126

Figure 6-23 24-Volt Battery Charger Connections

12. Connect the charger to the battery according to the

generator set or battery manufacturer’s
instructions, watching the polarity (+/--) of the
connections.

13. Close the enclosure door and reconnect power to

the transfer switch after the charger connections
are complete.

14. Use a voltmeter to check the voltage at the battery

and compare the readings to Figure 6-25 or
Figure 6-26 to verify charger operation.

TP-6126 8/02 Section 6 Accessories 53

6.8.2 Battery Charger Operation indicator operation. Figure 6-25 and Figure 6-26 show
the 3-stage charging charging method for 12 VDC and
Red and green LEDs on the charger indicate the charge 24 VDC configurations.
rate. Refer to Figure 6-24 for a description of the LED
LED Indicators
Red Green Operating Condition
On Off The battery is discharged and the charger is recharging at the BULK rate (stage 1). This charging
rate is 6 Amps at 12V or 3 Amps at 24V. The measured voltage (with the charger on) is 11.8 to 14
Volts in 12VDC mode or 23.6 to 28VDC 24VDC mode.
If the red LED stays on for more than 24 hours, refer to Problem 1 in the troubleshooting section in
this manual.
On On The charger is charging at an ABSORPTION rate of between 1.5 and 5 Amps (stage 2). This
mode of charging gradually “tops off” your battery, and reduces harmful sulfating. While both LED’s
are on, the voltage measured (with the charger on) should be approx. 14.0 to 14.5VDC in 12VDC
mode or 28.0 to 29.0 in 24VDC mode.
If both LED’s stay on longer than 24 hours, refer to Problem 2 in the troubleshooting section in this
manual.
Off On The charer is charging at a FLOAT or MAINTENANCE rate of less than 1.5 Amps, (stage 3). The
battery is now 90% charged and ready for use. This ”float” charging current will gradually decrease
to as low as 0.1 Amps as the battery reaches 100% charge. The float rate maintains the battery at
full charge without overcharging.
If the green LED stays on when your battery is known to be low, refer to Problem 3 in the
troubleshooting section in this manual.
Figure 6-24 Charger Operation

15
Output Voltage To Battery -- VDC

14

13

12 Bulk Absorption Float

(Red LED On) (Red/Green LEDs On) (Green LED On)

11
6 5.5 5 4.5 4 3.5 3 2.5 2 1.5 1 0.5 0.1
DC Amps

gi267712

Figure 6-25 Charging Method, 12 VDC, 6 A Configuration

54 Section 6 Accessories TP-6126 8/02

 30

Output Voltage To Battery -- VDC

28

26

24

Bulk Absorption Float

22 (Red LED On) (Red/Green LEDs On) (Green LED On)

20
3 2.5 2 1.5 1 0.5 0.1
DC Amps
gi267712

Figure 6-26 Charging Method, 24 VDC 3 A Configuration

6.8.3 Battery Charger Troubleshooting

Problem Cause Solution
Red LED stays on for One or more defective or damaged Load test the battery and replace if necessary.
more than 24 hours. cells.
Charger has reduced its output voltage Remove the source of the overload or short.
below the normal level due to a DC Disconnect the charger’s black (NEGATIVE) ring
overload or a DC short. terminal from the battery. Reapply AC power and the
green LED only should now light.
On-board DC systems are drawing Turn off excessive DC equipment while charging.
more current than the charger can
replace.
The red and green LEDs On-board DC systems are drawing Turn off excessive DC equipment while charging.
y on for more than 24
stay between 1.5 – 5A.
hours. One or more defective or damaged Load test the battery and replace if necessary.
cells.
Extremely low AC voltage at the battery Apply a higher AC voltage source or reduce the length
charger. of the power cord.
Green LED stays on Open DC output fuse. Replace the DC output fuse with a Bussmann
y is
when the battery AGC--10.
known to be low. Faulty or contaminated terminal Clean and tighten or repair all terminal connections.
connections.
One or more defective or damaged Load test the battery and replace if necessary.
cells.
Neither of the LEDs turn No AC power available at the charger. Connect AC power or reset the AC breaker on the
p
on when the AC power is main panel.
applied. Component failure. Return charger to the Service Department.
Figure 6-27 Battery Charger Troubleshooting

TP-6126 8/02 Section 6 Accessories 55

6.8.4 Battery Charger Specifications
Figure 6-28 lists the battery charger specifications.
Output
Charging 12 Volts DC (min.) at 6 Amps
24 Volts DC (min.) at 3 Amps
Maintaining 13.30 Volts DC at 0.1 Amps
Input
Rated AC Voltage 208 VAC, AC connector pin 2
240 VAC, AC connector pin 4
480 VAC, AC connector pin 6
600VAC, AC connector pin 9
Current Draw @ 50/ 60 Hz, 0.7 Amps Maximum
Maximum Recommended Battery Size
Recharging 150 Amp--Hours
Maintenance only 300 Amp--Hours
Physical Dimensions
Height 3.5 in. (8.9 cm.)
Width 6.4 in. (16.3 cm.)
Depth 2.1 in. (5.3 cm.)
Weight 3.5 lb. (1.6 kg)
Figure 6-28 Battery Charger Specifications

56 Section 6 Accessories TP-6126 8/02

 Appendix A Abbreviations

The following list contains abbreviations that may appear in this publication.
A, amp ampere cont. continued
ABDC after bottom dead center CPVC chlorinated polyvinyl chloride
AC alternating current crit. critical
A/D analog to digital CRT cathode ray tube
ADC analog to digital converter CSA Canadian Standards Association
adj. adjust, adjustment CT current transformer
ADV advertising dimensional drawing Cu copper
AHWT anticipatory high water temperature cu. in. cubic inch
AISI American Iron and Steel Institute cw. clockwise
ALOP anticipatory low oil pressure CWC city water-cooled
alt. alternator cyl. cylinder
Al aluminum D/A digital to analog
ANSI American National Standards Institute DAC digital to analog converter
(formerly American Standards Association, ASA) dB decibel
AO anticipatory only dBA decibel (A weighted)
API American Petroleum Institute DC direct current
approx. approximate, approximately DCR direct current resistance
AR as required, as requested deg., ° degree
AS as supplied, as stated, as suggested dept. department
ASE American Society of Engineers dia. diameter
ASME American Society of Mechanical Engineers DI/EO dual inlet/end outlet
assy. assembly DIN Deutsches Institut fur Normung e. V.
ASTM American Society for Testing Materials (also Deutsche Industrie Normenausschuss)
ATDC after top dead center DIP dual inline package
ATS automatic transfer switch DPDT double-pole, double-throw
auto. automatic DPST double-pole, single-throw
aux. auxiliary DS disconnect switch
A/V audiovisual DVR digital voltage regulator
avg. average E, emer. emergency (power source)
AVR automatic voltage regulator EDI electronic data interchange
AWG American Wire Gauge EFR emergency frequency relay
AWM appliance wiring material e.g. for example (exempli gratia)
bat. battery EG electronic governor
BBDC before bottom dead center EGSA Electrical Generating Systems Association
BC battery charger, battery charging EIA Electronic Industries Association
BCA battery charging alternator EI/EO end inlet/end outlet
BCI Battery Council International EMI electromagnetic interference
BDC before dead center emiss. emission
BHP brake horsepower eng. engine
blk. black (paint color), block (engine) EPA Environmental Protection Agency
blk. htr. block heater EPS emergency power system
BMEP brake mean effective pressure ER emergency relay
bps bits per second ES engineering special, engineered special
br. brass ESD electrostatic discharge
BTDC before top dead center est. estimated
Btu British thermal unit E-Stop emergency stop
Btu/min. British thermal units per minute etc. et cetera (and so forth)
C Celsius, centigrade exh. exhaust
cal. calorie ext. external
CARB California Air Resources Board F Fahrenheit, female
CB circuit breaker fglass. fiberglass
cc cubic centimeter FHM flat head machine (screw)
CCA cold cranking amps fl. oz. fluid ounce
ccw. counterclockwise flex. flexible
CEC Canadian Electrical Code freq. frequency
cfh cubic feet per hour FS full scale
cfm cubic feet per minute ft. foot, feet
CG center of gravity ft. lbs. foot pounds (torque)
CID cubic inch displacement ft./min. feet per minute
CL centerline g gram
cm centimeter ga. gauge (meters, wire size)
CMOS complementary metal oxide substrate (semiconductor) gal. gallon
cogen. cogeneration gen. generator
COM communications (port) genset generator set
conn. connection GFI ground fault interrupter

TP-6126 8/02 Appendix A-57

GND, ground Lph liters per hour
gov. governor Lpm liters per minute
gph gallons per hour LOP low oil pressure
gpm gallons per minute LP liquefied petroleum
gr. grade, gross LPG liquefied petroleum gas
GRD equipment ground LS left side
gr. wt. gross weight Lwa sound power level, A weighted
HxWxD height by width by depth LWL low water level
HC hex cap LWT low water temperature
HCHT high cylinder head temperature m meter, milli (1/1000)
HD heavy duty M mega (106 when used with SI units), male
HET high exhaust temperature m3 cubic meter
hex hexagon m3/min. cubic meters per minute
Hg mercury (element) mA milliampere
HH hex head man. manual
HHC hex head cap max. maximum
HP horsepower MB megabyte (220 bytes)
hr. hour MCM one thousand circular mils
HS heat shrink MCCB molded-case circuit breaker
hsg. housing meggar megohmmeter
HVAC heating, ventilation, and air conditioning MHz megahertz
HWT high water temperature mi. mile
Hz hertz (cycles per second) mil one one-thousandth of an inch
IC integrated circuit min. minimum, minute
ID inside diameter, identification misc. miscellaneous
IEC International Electrotechnical Commission MJ megajoule
IEEE Institute of Electrical and Electronics Engineers mJ millijoule
IMS improved motor starting mm millimeter
in. inch mOhm, mW
milliohm
in. H2O inches of water
MOhm, MW
in. Hg inches of mercury megohm
in. lbs. inch pounds MOV metal oxide varistor
Inc. incorporated MPa megapascal
ind. industrial mpg miles per gallon
int. internal mph miles per hour
int./ext. internal/external MS military standard
I/O input/output m/sec. meters per second
IP iron pipe MTBF mean time between failure
ISO International Organization for Standardization MTBO mean time between overhauls
J joule mtg. mounting
JIS Japanese Industry Standard MW megawatt
k kilo (1000) mW milliwatt
K kelvin mF microfarad
kA kiloampere N, norm. normal (power source)
KB kilobyte (210 bytes) NA not available, not applicable
kg kilogram nat. gas natural gas
kg/cm2 kilograms per square centimeter NBS National Bureau of Standards
kgm kilogram-meter NC normally closed
kg/m3 kilograms per cubic meter NEC National Electrical Code
kHz kilohertz NEMA National Electrical Manufacturers Association
kJ kilojoule NFPA National Fire Protection Association
km kilometer Nm newton meter
kOhm, kW kilo-ohm NO normally open
kPa kilopascal no., nos. number, numbers
kph kilometers per hour NPS National Pipe, Straight
kV kilovolt NPSC National Pipe, Straight-coupling
kVA kilovolt ampere NPT National Standard taper pipe thread per general use
kVAR kilovolt ampere reactive NPTF National Pipe, Taper-Fine
kW kilowatt NR not required, normal relay
kWh kilowatt-hour ns nanosecond
kWm kilowatt mechanical OC overcrank
L liter OD outside diameter
LAN local area network OEM original equipment manufacturer
LxWxH length by width by height OF overfrequency
lb. pound, pounds opt. option, optional
lbm/ft3 pounds mass per cubic feet OS oversize, overspeed
LCB line circuit breaker OSHA Occupational Safety and Health Administration
LCD liquid crystal display OV overvoltage
ld. shd. load shed oz. ounce
LED light emitting diode

A-58 Appendix TP-6126 8/02

p., pp. page, pages SPDT single--pole, double--throw
PC personal computer SPST single--pole, single--throw
PCB printed circuit board spec, specs
pF picofarad specification(s)
PF power factor sq. square
ph., Æ phase sq. cm square centimeter
PHC Phillips head crimptite (screw) sq. in. square inch
PHH Phillips hex head (screw) SS stainless steel
PHM pan head machine (screw) std. standard
PLC programmable logic control stl. steel
PMG permanent-magnet generator tach. tachometer
pot potentiometer, potential TD time delay
TDC top dead center
ppm parts per million
PROM programmable read-only memory TDEC time delay engine cooldown
psi pounds per square inch TDEN time delay emergency to normal
pt. pint TDES time delay engine start
PTC positive temperature coefficient TDNE time delay normal to emergency
PTO power takeoff TDOE time delay off to emergency
PVC polyvinyl chloride TDON time delay off to normal
qt. quart temp. temperature
qty. quantity term. terminal
R replacement (emergency) power source TIF telephone influence factor
rad. radiator, radius TIR total indicator reading
RAM random access memory tol. tolerance
turbo. turbocharger
RDO relay driver output
ref. reference typ. typical (same in multiple locations)
rem. remote UF underfrequency
RFI radio frequency interference UHF ultrahigh frequency
RH round head UL Underwriter’s Laboratories, Inc.
RHM round head machine (screw) UNC unified coarse thread (was NC)
rly. relay UNF unified fine thread (was NF)
rms root mean square univ. universal
rnd. round US undersize, underspeed
ROM read only memory UV ultraviolet, undervoltage
rot. rotate, rotating V volt
rpm revolutions per minute VAC volts alternating current
VAR voltampere reactive
RS right side
RTV room temperature vulcanization VDC volts direct current
SAE Society of Automotive Engineers VFD vacuum fluorescent display
scfm standard cubic feet per minute VGA video graphics adapter
SCR silicon controlled rectifier VHF very high frequency
s, sec. second W watt
SI Systeme international d’unites, International System of WCR withstand and closing rating
Units w/ with
SI/EO side in/end out w/o without
sil. silencer wt. weight
SN serial number xfmr transformer

TP-6126 8/02 Appendix A-59

 Appendix B Specifications

Withstand and Closing Ratings, Open- and Programmed-Transition Models

Maximum current in RMS symmetrical amperes when coordinated with customer-supplied fuses or circuit breakers.

Withstand and Closing Current Ratings in RMS Symmetrical Amperes*

Any Circuit Breaker Current-Limiting Fuses

Specific
S ifi Ci
Circuit
it
Switch Breaker
Rating, Cycles @ kAmps @ kAmps @ Max. kAmps @ Volts, Fuse Size,
Amps 60 Hz 480 VAC 600 VAC 480 VAC kAmps Max. Amps Type
30[ 1.5 10 10 N/A 100 60
RK1
RK1,
70[
104[ 15
1.5 10 10 22 480 200 J
150[ 200
150w 3 35 22 42 450 J
10 22
200[ 1.5 N/A 200 240 200 J
(240 VAC max.) (240 VAC max.)
225
260 3 35 22 42 480 600 J
400
600
800 3 50 50
65 1600
1000 18 ** 36 36
1200 200
600
1600] L
3000
2000] 3 100 100
N/A
3000 30 ** 65 65 4000
4000 480 6000
* All values are available symmetrical RMS amperes and tested in accordance with the withstand and close-on requirements of UL 1008.
200 amp switches are limited to 240 VAC max., copper wire only. Application requirements may permit higher withstand ratings for certain size
switches. Contact Kohler Co. for assistance.
[ Open-transition models only
w Programmed-transition models only
] Optional front-connected service limited to 85,000 amps for specific and any breaker ratings.
** Withstand rating only. This testing is not defined in UL 1008.

A-60 Appendix TP-6126 8/02

 Ratings with Specific Manufacturers’ Circuit Breakers
Open- and Programmed-Transition Models
The following charts list power switching device withstand and closing ratings (WCR) in RMS symmetrical amperes for specific
manufacturers’ circuit breakers. Circuit breakers are supplied by the customer.

Switch Molded-Case Circuit Breakers

Rating, WCR, kA Voltage, Max. Size,
Amps RMS Max. Manufacturer Type Amps
FH 80
Square
q D FC, FI 100
KA, KC, KH, KI, LA, LH 250
TB1 100
GE TEL, THED, THLC1, THLC2 150
TFL 225
CED6, ED6, HED4, HED6 125
ITE CFD6 150
70* 22 480
FD6, FXD6, HFD6 250
FCL, Tri-Pac FB 100
FD, FDC, HFD 150
Cutler-Hammer
HJD, JD, JDB, JDC 250
HKD, KD, KDB, KDC, LCL, Tri-Pac LA 400
S1 125
ABB
S3 150
Merlin Gerin CE104, CE106 100
FC, FI 100
Square D
KA, KC, KH, KI, LA, LH 250
TB1 100
GE TEL, THED, THLC1, THLC2 150
TFL 225
CED6, ED6, HED4, HED6 125
ITE CFD6 150
FD6, FXD6, HFD6 250
104* 22 480
FCL, Tri-Pac FB 100
FD, FDC, HFD 150
Cutler-Hammer
HJD, JD, JDB, JDC 250
HKD, KD, KDB, KDC, LCL, Tri-Pac LA 400
S1 125
ABB
S3 150
CE104, CE106 100
Merlin Gerin
CF250 250
TEL, THED, THLC1 150
TFL, THFK, THLC2 225
GE
SFL, SFP, TFJ, TFK 250
SGL4, SGP4, TLB4 400
CFD6, FD6, FXD6, HFD6 250
ITE CJD6, HHJD6, HHJXD6, HJD6, JD6, JXD6, SCJD6, SHJD6,
400
SJD6
KA, KC, KH, KI 250
150* 22 480 Square
q D LC, LI 300
LA, LH 400
FD, FDC, HFD 150
Cutler-Hammer HJD, JD, JDB, JDC 250
LCL, Tri-Pac LA, HKD, KD, KDB, KDC 400
ABB S3 150
CF250 250
Merlin Gerin
CJ400 400
* Open-transition models only
[ Programmed-transition models only

TP-6126 8/02 Appendix A-61

Ratings with Specific Manufacturers’ Circuit Breakers, continued

Switch Molded-Case Circuit Breakers

Rating, WCR, kA Voltage, Max. Size,
Amps RMS Max. Manufacturer Type Amps
TEL, THED, THLC1, 150
TFL, THLC2 225
GE SFL, SFLA, SFP 250
SGL4, SGP4, TB4, THLC4, TLB4 400
SGLA, SGL6, SGP6, TB6 600
CFD6, HFD6 250
ITE CJD6, HHJD6, HHJXD6, HJD6, SCJD6, SHJD6 400
CLD6, HHLD6, HHLXD6, HLD6, SHLD6 600
150[
50[ 42 480 KC, KI 250
Square D
LC, LI 400
HJD, JDC 250
LCL, Tri-Pac LA, HKD, KDC 400
Cutler-Hammer
HLD 600
Tri-Pac NB 800
ABB S3 150
CF250 250
Merlin Gerin
CJ400 400
TFL, THFK, THLC2 225
GE SFL, SFP, TFJ, TFK 250
SGL4, SGP4, TLB4 400
CFD6, FD6, FXD6, HFD6 250
ITE CJD6, HHJD6, HHJXD6, HJD6, JD6, JXD6, SCJD6, SHJD6,
400
SJD6
200*
200 22 240 KA, KC, KH, KI 250
Square
q D LC, LI 300
LA, LH 400
HJD, JD, JDB, JDC 250
Cutler-Hammer
LCL, Tri-Pac LA, HKD, KD, KDB, KDC 400
CF250 250
Merlin Gerin
CJ400 400
TFL, THLC2 225
SFL, SFLA, SFP 250
GE SGL4, SGP4, TB4, THLC4, TLB4 400
SGLA, SGL6, SGP6, TB6 600
SKHA, SKLB, SKP8, TKL 800
CFD6, FD6, FXD6, HFD6 250
CJD6, HHJD6, HHJXD6, HJD6, JD6, JXD6, SCJD6, SHJD6,
400
SJD6
ITE
CLD6, HHLD6, HHLXD6, HLD6, SCLD6, SHLD6 600
CMD6, HMD6, HND6, MD6, MXD6, SCMD6, SHMD6, SMD6,
800
SND6
225 42 480
260 KC, KI 250
Square
q D LC, LI 600
MH 800
HJD, JDC 250
HKD, KDC, LCL, Tri-Pac LA 400
Cutler-Hammer
HLD 600
Tri-Pac NB 800
S5 400
ABB
S6 600
CF250 250
Merlin Gerin
CJ400 400
* Open-transition models only
[ Programmed-transition models only

A-62 Appendix TP-6126 8/02

Ratings with Specific Manufacturers’ Circuit Breakers, continued

Switch Molded-Case Circuit Breakers

Rating, WCR, kA Voltage, Max. Size,
Amps RMS Max. Manufacturer Type Amps
SGL4, SGP4, TB4, THLC4, TLB4 400
GE SGLA, SGL6, SGP6, TB6 600
SKHA, SKL8, SKP8, TKL 800
CJD6, HHJD6, HHJXD6, HJD6, SCJD6, SHJD6 400
CLD6, HHJD6, HHLXD6, HLD6, SCLD6, SHLD6 600
ITE
CMD6, HMD6, HND6, MD6, MXD6, SCMD6, SHMD6, SMD6,
800
SND6
400 42 480 LC, LI 600
Square D
MH 800
HKD, KDC, LCL, Tri-Pac LA 400
Cutler-Hammer HLD 600
Tri-Pac NB 800
S5 400
ABB
S6 800
Merlin Gerin CJ600 600
TB8 800
GE
Microversatrip TKL 1200
CLD6, HHLD6, HHLDX6, HLD6, SCLD6, SHLD6 600
CMD6, HMD6, SCMD6, SHMD6 800
480 ITE
CND6, HND6, SCND6, SHND6 1200
65 CPD6 1600
600 MH Series 2 1000
800 Square D
SE (LS Trip), SEH (LS Trip) 2500
1000
1200 Tri-Pac NB 800
600 Cutler-Hammer Tri-Pac PB 1600
RDC 2500
S6 800
ABB
S7 1200
42 480
CJ600 600
Merlin Gerin
CK1200 1200
* Open-transition models only
[ Programmed-transition models only

Environmental Specifications

Environmental Specifications
Operating
--20°C to 70°C (--4°F to 158°F)
Temperature

Storage
--40°C to 70°C (--40°F to 158°F)
Temperature

Humidity 5% to 95% noncondensing

Altitude 0 to 3050 m (10000 ft.) without derating

TP-6126 8/02 Appendix A-63

Codes and Standards
The ATS meets or exceeds the requirements of the D EN61000-4-5 Surge Immunity Class 4
following specifications: (voltage sensing and programmable inputs only)

D Underwriters Laboratories UL 508, Standard for D EN61000-4-4 Fast Transient Immunity

Industrial Control Equipment Severity Level 4

D Underwriters Laboratories UL 1008, Standard for D IEC Specifications for EMI/EMC Immunity:
Automatic Transfer Switches
D CISPR 11, Radiated Emissions
D Underwriters Laboratories Inc., listed to Canadian
Safety Standards (cUL) D IEC 1000-4-2, Electrostatic Discharge

D NFPA 70, National Electrical Code D IEC 1000-4-3, Radiated Electromagnetic Fields

D NFPA 99, Essential Electrical Systems for Health D IEC 1000-4-4, Electrical Fast Transients (Bursts)
Care Facilities
D IEC 1000-4-5, Surge Voltage
D NFPA 110, Emergency and Standby Power Systems
D IEC 1000-4-6, Conducted RF Disturbances
D IEEE Standard 446, IEEE Recommended Practice
D IEC 1000-4-8, Magnetic Fields
for Emergency and Standby Power Systems for
Commercial and Industrial Applications D IEC 1000-4-11, Voltage Variations and
D NEMA Standard IC10--1993 (formerly ICS2--447),
Interruptions
AC Automatic Transfer Switches

Diagrams and Drawings

Dimension Drawing
Model Schematic Wiring Diagram Enclosure Drawing Number
30--200A, Open-Transition NEMA 1 ADV-6698
GM20611 GM20601
NEMA 12, 4, 4X ADV-6699
225--400A, Open-Transition NEMA 1 ADV-6700
GM20611 GM20615
NEMA 12, 4, 4X ADV-6701
600--800A, Open-Transition NEMA 1 ADV-6702
GM20612 GM20602
NEMA 12, 4, 4X ADV-6702
1000--1200A, Open-Transition GM20612 GM20602 NEMA 1 ADV-6663
1600--2000A, Open-Transition NEMA 1 ADV-6664
GM20613 GM20604 NEMA 1
ADV-6684
Front-Connected
2500--3000A, Open-Transition GM20611 GM20605 NEMA 1 ADV-6665
4000A, Open-Transition GM20611 GM20605 NEMA 1 ADV-6666
150--400A, Programmed Transition GM20616 GM20606 NEMA 1 ADV-6704
600--800A, Programmed Transition NEMA 1 ADV-6702
GM20617 GM20607
NEMA 12, 4, 4X ADV-6703
1000--1200A, Programmed Transition GM20619 GM20609 NEMA 1 ADV-6663
1600--2000A, Programmed Transition NEMA 1 ADV-6664
GM20619 GM20609 NEMA 1
ADV-6684
Front-Connected
2500--3000A, Programmed Transition GM20616 GM20610 NEMA 1 ADV-6665
4000A, Programmed Transition GM20616 GM20610 NEMA 1 ADV-6666

A-64 Appendix TP-6126 8/02

 KOHLER CO. Kohler, 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
KohlerPowerSystems.com
Kohler Power Systems
Asia Pacific Headquarters
TP-6126 8/02b 7 Jurong Pier Road
Singapore 619159
E 2002 by Kohler Co. All rights reserved. Phone (65)264-6422, Fax (65)264-6455