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Kohler G220 User Manual

Kohler G220
68 pages
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Automatic Transfer Switches
Models:
G220
Electrical Controls:
Solid-State
Power Switching Device:
Contactors:
100 and 200 Amperes
TP-6322 9/04
Service and Parts

Table of Contents

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Kohler G220 Specifications

General IconGeneral
Amperage20 A
Current Rating20 A
MaterialThermoplastic
ColorWhite
Mounting TypeWall Mount
Actuator TypeToggle
TypeToggle

Summary

Safety Precautions and Instructions

Accidental Starting Warnings

Warnings about accidental generator starting and how to prevent it.

Battery Safety Precautions

Warnings about battery acid hazards and explosion risks.

Hazardous Voltage and Electrical Shock

Detailed warnings and precautions regarding hazardous voltage.

Heavy Equipment Lifting Safety

Warning about improper lifting and weight handling.

Moving Parts and Hazardous Voltage

Warnings about moving parts and associated hazardous voltage.

Important Operational Notices

Notices on hardware, contamination, and electrostatic discharge.

Introduction to the ATS Manual

Related Literature

Lists related literature for operation and installation.

Service Assistance Information

Section 1 General Information

Purpose of the Automatic Transfer Switch

Explains the function of an automatic transfer switch (ATS).

ATS Component Overview

Lists and describes the main components of the ATS.

Transfer Switch Nameplate Details

Describes the information found on the transfer switch nameplate.

Interpreting the Model Number

Explains how to interpret the transfer switch model number.

Power Terminal Application Data

Provides wire size ranges for transfer switch power terminals.

Section 2 Operation Procedures

Power-Up Procedure

Outlines the power-up procedure after maintenance.

Automatic Operation Sequence

Describes ATS monitoring and transfer logic.

Exerciser Function and Controls

Explains the generator exerciser function and switch.

Manual Operation and Testing

Provides steps for manual operation and testing.

External Test Switch Connection

Describes connecting an external test switch.

Section 3 Scheduled Maintenance

General Inspection and Service

General guidance on inspection and service.

Contactor Inspection and Overheating Signs

How to inspect contacts and address overheating.

Periodic Testing Procedures

Importance and procedures for periodic testing.

Other Maintenance Tests

Describes millivolt drop and insulation breakdown tests.

Section 4 Troubleshooting Guide

General Connection Troubleshooting

General checks for faulty connections.

System Power Troubleshooting

Troubleshooting issues related to system power.

Troubleshooting Chart Overview

Lists problems, causes, and corrective actions.

AC and DC Voltage Checks

Checking AC system and DC controller voltages.

Engine Start Circuit Troubleshooting

Detailed steps for engine start circuit issues.

Exerciser Circuit Troubleshooting

Troubleshooting exerciser circuit problems.

Contactor Operation Troubleshooting

Troubleshooting contactor mechanical and electrical issues.

NR/ER Relays and Controller Circuitry

Troubleshooting NR/ER relays and controller circuitry.

Controller Operation Sequence Test

Testing the controller's automatic operation sequence.

Emergency Source Sensing Troubleshooting

Troubleshooting emergency source sensing issues.

Normal Source Sensing Troubleshooting

Troubleshooting normal source sensing issues.

Section 5 Drawings and Diagrams

Section 6 Service Part Replacement

Component Servicing Precautions

Safety steps before and after servicing components.

Contactor Assembly Service

Procedures for contactor assembly removal and installation.

Solenoid Assembly Service

Procedures for solenoid assembly disassembly and replacement.

Microswitch Replacement Procedures

Procedures for microswitch replacement.

Controller PCB Assembly Handling

Handling and replacement of the controller PCB.

Other Service Parts Procedures

Generic procedures for other service parts.

Section 7 Service Parts Identification

General Parts Information

How to find and identify service parts.

Contactor G220 Parts List

Parts list and illustration for the G220 Contactor.

Control Module Parts List

Parts list and illustration for control modules.

Enclosure Parts Lists

Parts lists for NEMA Type 1 and Type 3R enclosures.

Lug and Switch Parts

Parts lists for neutral lugs and auxiliary switches.

Appendix A Abbreviations

Appendix B Hardware Application Guidelines

Appendix C General Torque Specifications

Appendix D Common Hardware Identification

Appendix E Common Hardware List

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