TP 7191
TP 7191
TP 7191
Models:
KSSB
30- 1200 Amps
TP-7191 4/21
Product Identification Information
Accessories
- Alarm Board
- Battery Module
- California OSHPD Approval
- Controller Disconnect Switch
- Current Monitoring
- Digital Meter
- Heater
- IBC Seismic Certification
- I/O Module, Standard (max. 4) qty:
- I/O Module, High Power (max. 4) qty:
- Load Shed
- Line-Neutral Monitoring
- Supervised Transfer Switch
- Surge Protection Device (SPD)
-
-
-
-
Table of Contents
Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
List of Related Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Section 1 Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 Model Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Section 2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Receipt of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2.2 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2.3 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2.4 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4 IBC Seismic Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.5 Manual Operation, Model KSS Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5.1 Manual Operation, 30- 230 Amp Switches . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5.2 Manual Operation, 230A/600V and 260- 1200 Amp Switches . . . . . . . . 17
2.6 Controller Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.6.1 Controller Input and Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.6.2 Harness Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.6.3 Controller Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.7 Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.7.1 Source and Load Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.7.2 Engine Start Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.7.3 Auxiliary Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.8 Communication and Accessory Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.9 Functional Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Section 3 Communication and Accessory Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.2 Communication Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.2.1 USB Port SiteTech Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.2.2 Modbus Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.2.3 Ethernet Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.3 Accessory Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.3.1 Accessory Module Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.3.2 Input/Output (I/O) Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.3.3 External Battery Supply Module (EBSM) . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.3.4 Alarm Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.4 Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Section 4 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Section 5 Functional Tests and Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.2 Manual Operation Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.3 Voltage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.4 Lamp Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
This manual provides installation instructions for the The equipment service requirements are very important
Kohlerr Model KSSB Automatic Transfer Switch (ATS). to safe and efficient operation. Inspect parts often and
Model KSSB transfer switches are equipped with the perform required service at the prescribed intervals.
Kohler MPACr 1200 controller. See the controller Operation manual for the service
schedule. Obtain service from an authorized service
Model KSSB is used in some places in this manual to distributor/ dealer to keep equipment in top condition.
indicate that this document applies to an updated
version of the model KSS automatic transfer switch. The
letter B is NOT used in the model designation or Quick List of Related Literature
Ship (QS) specification numbers used for ordering the
product. A separate manual covers the transfer switch controller
and related accessories. The Service Manual contains
A separate manual provided with the transfer switch service instructions for transfer switch power switching
covers the transfer switch controller operation. See List devices and electrical controls.
of Related Materials for the document part number.
The following table lists the part numbers for related
Information in this publication represents data available literature.
at the time of print. Kohler Co. reserves the right to
change this literature and the products represented Literature Item Part Number
without notice and without any obligation or liability Specification Sheet, Model KSSB G11-150
whatsoever. Specification Sheet, Decision-Makerr
MPAC 1200 Controller G11-127
Read this manual and carefully follow all procedures Operation Manual, Decision-Makerr
TP-6866
and safety precautions to ensure proper equipment MPAC 1200 Controller
operation and to avoid bodily injury. Read and follow the Wiring Diagram Manual, Model KC/KSSB TP-7195
Safety Precautions and Instructions section at the Service Manual, Model KC/KSSB TP-6920
beginning of this manual. Keep this manual with the
equipment for future reference.
GM21291
Record the transfer switch model designation in the boxes. The transfer switch model designation defines
characteristics and ratings as explained below.
Note: The letter B is not used after KSS in the model designation shown on the ATS nameplate or used for
ordering the product.
Transition Enclosure
S: Standard A: NEMA 1 D: NEMA 4
B: NEMA 12 F: NEMA 4X
Controller C: NEMA 3R G: Open Unit
A: Decision-Makerr MPAC 1200, Automatic
B: Decision-Makerr MPAC 1200, Non-Automatic Current, Amps
0030 0200 0600
Voltage/Frequency 0070 0230 0800
C: 208 Volts / 60 Hz K: 440 Volts / 60 Hz 0104 0260 1000
D: 220 Volts / 50 Hz M: 480 Volts / 60 Hz 0150 0400 1200
F: 240 Volts / 60 Hz N: 600 Volts / 60 Hz
G: 380 Volts / 50 Hz P: 380 Volts / 60 Hz Connections
H: 400 Volts / 50 Hz R: 220 Volts / 60 Hz S: Standard
J: 416 Volts / 50 Hz S: 400 Volts/ 60 Hz
Note: Some selections are not available for every model.
Contact your Kohler distributor for availability.
Ip: Equipment importance factor 10. Rebar reinforcing in the housekeeping pad is
required for all installations.
ap: In-structure equipment amplification factor
11. Concrete and rebar reinforcing must be designed
Refer to the International Building Coder for more in accordance with ACI 318- 05.
information.
12. Wall-mounted equipment must be installed to a
General Seismic Installation Notes (for ATS only): rebar reinforced structural concrete wall that is
seismically designed and approved by the
1. Anchors used for seismic installation must be engineer of record to resist the added seismic
designed in accordance with ACI 355.2- 04. loads from components being anchored to the wall.
Suggested manufacturers include Simpson,
Ramset, and Hilti. 13. Floor-mounted equipment (with or without a
housekeeping pad) must be installed to a rebar
2. Anchors must be installed to a minimum reinforced structural concrete floor that is
embedment of 8x the anchor diameter. seismically designed and approved by the
engineer of record to resist the added seismic
3. Anchors must be installed in minimum 4000 psi loads from components being anchored to the
compressive strength normal weight concrete. floor.
Concrete aggregate must comply with ASTM C33.
Installation in structural lightweight concrete is not 14. When installing to a floor or wall, rebar interference
permitted unless otherwise approved by the must be considered.
structural engineer of record.
15. Equipment attached to any structural floor or wall
4. Anchors must be installed to the required torque other than those constructed of structural concrete
specified by the anchor manufacturer to obtain and designed to accept the seismic loads from the
maximum loading. mounted equipment are beyond the scope of this
specification.
5. Anchors must be installed to the anchor spacing
required to obtain maximum load and edge 16. Installation to light-weight concrete over steel
distance required to obtain maximum load unless decking is beyond the scope of this specification.
otherwise approved by the structural engineer of
record. 17. Installation to concrete block or cinder block walls
is beyond the scope of this specification.
6. Anchors used for seismic installation must be
designed and rated to resist seismic loading in
Servicing the transfer switch. Hazardous voltage will 2. To manually operate the transfer switch, turn the
cause severe injury or death. Deenergize all power sources attached handle by hand. See Figure 2-3. The
before servicing. Turn off the main circuit breakers of all maintenance handle turns in the opposite direction
transfer switch power sources and disable all generator sets of the weight. It should operate smoothly without
as follows: (1) Press the generator set off/reset button to shut any binding. If it does not, check for shipping
down the generator set. (2) Disconnect power to all battery
damage or construction debris.
chargers. (3) Disconnect all battery cables, negative (- ) leads
first. Reconnect negative (- ) leads last when reconnecting the
battery cables after servicing. Follow these precautions to 3. Return the transfer switch to the Normal position.
prevent the starting of generator sets by an automatic transfer
switch, remote start/stop switch, or engine start command
from a remote computer. Before servicing any components
2
inside the enclosure: (1) Remove all jewelry. (2) Stand on a
dry, approved electrically insulated mat. (3) Test circuits with a
voltmeter to verify that they are deenergized.
1
Note: A manual operation handle is provided on the
transfer switch for maintenance purposes only. Do
not use the manual operation handle to transfer
the load with the power connected.
DANGER
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure. 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
The 260- 1200 amp standard-transition models use a
detachable manual operating handle.
1. Disable the generator set to prevent starting and Figure 2-4 Detachable Handle Storage (typical)
disconnect all power sources before manually
operating the transfer switch.
2 N
E 2
E
3
N
E
283 3
1. Handle
2. Hub
3. Position indicators (right side of contactor):
O = open, C = closed
N
Figure 2-5 Manual Operation, 260- 600 Amp
Switches
3 4
2 5
1
6
8 GM85884
TB1
12
6
Output 2 NO
Output 1 NO
Output 2 C
Output 1 C
Output 2 NC
Output 1 NC
Input 2B
Input 1B
Input 2A
Input 1A 1
7
1
2 GM85844
NC = normally closed
NO = normally open
C = common 6866
NOTICE
Foreign material contamination. Cover the transfer switch
during installation to keep dirt, grit, metal drill chips, and other
debris out of the components. Cover the solenoid mechanism
Accidental starting. during installation. After installation, use the manual operating
Can cause severe injury or death. handle to cycle the contactor to verify that it operates freely.
Do not use a screwdriver to force the contactor mechanism.
Disconnect the battery cables before
working on the generator set.
Remove the negative (- ) lead first 2.7.1 Source and Load Connections
when disconnecting the battery. Determine the cable size. Refer to the transfer switch
Reconnect the negative (- ) lead last
dimension drawing to determine the cable size and
when reconnecting the battery.
number of cables required for the transfer switch. Make
sure that the cables are suitable for use with the transfer
Servicing the transfer switch. Hazardous voltage will switch lugs. Watertight conduit hubs may be required for
cause severe injury or death. Deenergize all power sources
before servicing. Turn off the main circuit breakers of all
outdoor use.
transfer switch power sources and disable all generator sets Drill the entry holes. Cover the transfer switch to
as follows: (1) Press the generator set off/reset button to shut
down the generator set. (2) Disconnect power to all battery
protect it from metal chips and construction grit. Then
chargers. (3) Disconnect all battery cables, negative (- ) leads drill entry holes for the conductors at the locations
first. Reconnect negative (- ) leads last when reconnecting the shown on the enclosure drawings. Remove debris from
battery cables after servicing. Follow these precautions to the enclosure with a vacuum cleaner.
prevent the starting of generator sets by an automatic transfer
switch, remote start/stop switch, or engine start command Note: Do not use compressed air to clean the switch.
from a remote computer. Before servicing any components Cleaning with compressed air can cause debris
inside the enclosure: (1) Remove all jewelry. (2) Stand on a to lodge in the components and damage the
dry, approved electrically insulated mat. (3) Test circuits with a switch.
voltmeter to verify that they are deenergized.
sensitive load devices from malfunctioning or CONNECTIONS. USE 60 C MIN. CU WIRE FOR
CONTROLS.
operating in reverse.
1 USE COPPER OR ALUMINUM WIRE
FOR POWER TERMINALS
RECOMMENDED TIGHTENING 483500- 007
TORQUE 600 IN- LBS REV B
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.
32 30
Auxiliary Position Indicating Contacts
(rated 10 amps @ 32 VDC/250 VAC)
13 11
Number of Contacts Indicating
Normal, Emergency
Switch Rating, STANDARD
Amps Standard Optional
30- 230 2, 2 1, 1 12 10
260- 1200 8, 8 —
Figure 2-17 Auxiliary Contacts
35 33
OPTIONAL
36 34
ref GM10757
3.1 Introduction 1
This section explains the connection of communication
cables and selected accessories.
GND1
B1 (+)
A1 (- )
shielded twisted-pair cable to connect to the RS-485
connectors on the controller’s terminal strip TB2 for
serial connections. For connection to a PC, use a USB to
1 3
RS-485 converter.
GND1
B1 (+)
A1 (- )
ground. Leave the other end of the shield disconnected.
Tighten the connections to 0.5 Nm (4.4 in. lb.). Cable shield
GM85884
USB port RS-485 * Servicing the transfer switch. Hazardous voltage will
cause severe injury or death. Deenergize all power sources
USB to RS-485
In Device before servicing. Turn off the main circuit breakers of all
port converter transfer switch power sources and disable all generator sets
Out
PC as follows: (1) Press the generator set off/reset button to shut
RS-485 *
Terminating resistor [,
The Ethernet communication accessory board is
(121 Ohms) required for connection to the Ethernet. The Ethernet
communication board is an optional accessory for the
* Use Belden #9841 or equivalent shielded, twisted-pair MPAC 1200 controller. The communication board
communication cable for RS-485 connections. Ground
one end of the cable shield. Leave the other end of the
connects to the controller board as shown in Figure 3-5.
cable shield disconnected.
[ Long cables and high communication speeds will require
a terminating resistor. Use 121 ohm resistor X-6058-27. 1
1
2
GM85884
Modbusr TCP/IP
Ethernet Modbusr TCP/IP MPAC
Category 5e Network Category 5e Controller with
Ethernet comm.
board
IP xx.xx.xx.03
PC
IP xx.xx.xx.02 Note: The PC and the ATS must be on the same subnet.
Note: A crossover cable can be used to connect the PC
to the ATS controller through the Ethernet port.
MPAC
Controller with
Modbusr TCP/IP Ethernet comm.
Category 5e board
Ethernet IP xx.xx.xx.03
Modbusr
TCP/IP Network
Device
RS-485
PC
IP xx.xx.xx.01 Last device
Terminating resistor
(121 Ohms)
3
GM42186
4
1. Input LEDs 1 and 2
2. Input connector (see Figure 3-14)
3. Output connector
4. Output LEDs 3- 5 for outputs 1, 2, and 3
1
refGM41093
4
DIP Switch 2
1 2 Address 1. Connector P20
GM42227-A
The alarm module is required for preferred source Alarm Operation, Chicago Alarm Mode
selection. To enable the preferred source selection, set
DIP switch 1 to ON. Then see the controller operation Chicago Alarm mode requires the horn to sound and a
manual for instructions to select Source N or Source E lamp or LED to light when the switch is in the emergency
as the preferred source. (non-preferred) position. The horn continues to sound
unless the alarm silence button is pressed. When the
External Alarm fault is cleared, the alarm silence is ended and reset for
the next alarm.
A customer-supplied external alarm horn can be
connected to the alarm module at terminal block TB14. For Chicago Alarm Mode, use the Common Alarm
Connect to the normally open or normally closed contact Setup menu to assign the necessary faults and
as recommended by the alarm manufacturer’s conditions to the audible alarm. See the controller
instructions. See Figure 3-20. operation manual for instructions to assign common
faults. Be sure to assign the Contactor in Standby
condition to trigger the audible alarm.
Item Specification
Wire Size #12-22 AWG Cu A remote alarm or indicator light can also be connected
500 mA @ 120 VAC
to the alarm board to indicate the alarm condition, as
Contact Voltage Rating described previously. See External Alarm.
250 mA @ 240 VAC
2
3
GM71056
1. Circuit breaker
2. Relative humidity adjustment control
3. 120 VAC power connection terminal block (or transformer for
some kits)
Regular preventive maintenance ensures safe and See the Service Assistance section in this manual for
reliable operation and extends the life of the transfer how to locate a local distributor/dealer.
switch. Preventive maintenance includes periodic
testing, cleaning, inspection, and replacement of worn The transfer switch controller Operation Manual
or missing components. contains the Service Schedule and other maintenance
information. Refer to the Operation Manual shipped with
Have maintenance or service performed by a local the transfer switch, or see Figure 4-1 for the Operation
authorized distributor/dealer. Maintenance and service Manual part number.
must comply with all applicable codes and standards.
Keep records of all maintenance or service.