Kohler KGS User Manual

Automatic Transfer Switches
Models:
KSS/KSP/KGS/KGP
Power Switching Device:
Standard and Bypass/Isolation
30 to 4000 Amperes
Electrical Controls:
MPACt 1500
TP-6461 1/08
Service

Kohler KGS Specifications

General

Brand	Kohler
Model	KGS
Category	Switch
Language	English

Summary

Automatic Transfer Switches

Safety Precautions and Instructions

Accidental Starting Hazards

Covers dangers and procedures for preventing accidental generator set starting.

Hazardous Voltage and Electrical Shock

Details dangers associated with high voltage and electrical shock risks.

Moving Parts Hazards

Addresses dangers related to moving parts and necessary precautions.

Electrical Safety and Operational Warnings

Electrical Grounding and Wiring Practices

Guidelines for safe electrical grounding, wiring, and avoiding short circuits.

Servicing and Testing Live Circuits

Precautions for servicing the transfer switch and testing live electrical circuits.

Heavy Equipment and Solenoid Safety

Safety considerations for heavy equipment, solenoids, and hardware.

Specific Operational Notices

Handle Usage and Contamination Notices

Notices on proper handle usage, foreign material contamination, and ESD prevention.

Introduction

List of Related Materials

Lists part numbers for related literature and manuals for comprehensive system information.

Service Assistance

Section 1 Scheduled Maintenance

1.1 Introduction

Explains the importance of preventive maintenance for transfer switch longevity and safety.

1.2 Inspection and Service

Details procedures for inspecting and servicing the transfer switch.

1.3 Testing Procedures

Outlines periodic testing requirements to ensure reliable operation.

1.4 Service Schedule

Provides a schedule of recommended maintenance tasks and intervals.

Section 1 Maintenance Records and Data Reset

1.5 View Maintenance Records

Guides on how to check last transfer switch maintenance dates and operation history.

1.6 Reset Data Procedures

Instructions for resetting maintenance records, event history, and default parameters.

Section 2 Controller Troubleshooting

2.1 Initial Checks

Steps to perform initial checks when troubleshooting transfer switch operation.

2.2 Controller Backup Battery

Information on the controller's backup battery and when it needs replacement.

2.3 View Event History

How to check the event history log for faults, transfers, and other events.

Controller System Settings and Delays

2.4 System Settings

Covers checking and setting system voltage, frequency, and phase parameters.

2.5 Time Delays

Explains how to check and adjust time delay settings for transfer switch operation.

Controller Alarms and Faults

2.6 Common Alarms

Details functions assigned to common alarms and their activation.

2.7 Warnings and Faults

Lists ATS warnings and faults, their types, and conditions.

Controller Fault Reset and Module Status

2.7.1 Fault Reset Procedures

Instructions for clearing faults and resetting the system alert LED.

2.7.2 Module Status Change

Troubleshooting steps for module status change messages and disconnections.

Controller Module Status Conflict Resolution

2.7.3 Module Status Conflict

Procedure to resolve module status conflicts when replacing modules.

Controller Events and Faults Listing

2.8 Events and Faults

Tables listing faults, alarms, possible causes, and suggested checks.

Controller Troubleshooting Table

2.9 Controller Troubleshooting Table

A table to help identify and correct controller-related problems.

Section 3 Transfer Switch Troubleshooting

3.1 Initial Checks

Basic checks to perform before troubleshooting transfer switch mechanisms.

3.2 Transfer Switch Troubleshooting Table

A table listing potential problems, causes, and remedies for transfer switch issues.

Transfer Switch System Power Checks

3.3 System Power Checks

Procedures to verify power to the ATS and perform voltage/frequency checks.

Transfer Switch Contact Inspection

3.4 Contacts

Guidance on identifying damaged contacts and replacing the power panel assembly.

Solonoid and Rectifier Testing

3.5 Rectifier Test Procedures

Instructions for testing rectifiers using an ohmmeter or diode checker.

3.6 Solenoid Tests

Procedures for testing solenoid coil resistance and operation.

Solenoid Operation Principles

3.6.2 Solenoid Operation

Descriptions and diagrams of solenoid coil operation for different models.

KSS Standard Transition Solenoid Diagrams (40-225A)

3.6.3 KSS Standard Transition Solenoid Diagrams (40-225A)

Illustrates solenoid operation for KSS standard transition switches.

KSS Standard Transition Solenoid Diagrams (400-600A)

3.6.4 KSS Standard Transition Solenoid Diagrams (400-600A)

Illustrates solenoid operation for KSS standard transition switches.

KSP Programmed-Transition Solenoid Diagrams

3.6.5 KSP Programmed-Transition Solenoid Diagrams

Diagrams showing solenoid operation for KSP programmed-transition models.

KGS Open Transition Solenoid Diagrams

3.6.6 KGS Open Transition Solenoid Diagrams

Diagrams of solenoid operation for KGS open transition bypass/isolation switches.

KGP Programmed-Transition Solenoid Diagrams (150-400A)

3.6.7 KGP Programmed-Transition Solenoid Diagrams (150-400A)

Diagrams for KGP programmed-transition bypass/isolation switches.

KGP Programmed-Transition Solenoid Diagrams (600-3000A)

3.6.8 KGP Programmed-Transition Solenoid Diagrams (600-3000A)

Diagrams for KGP programmed-transition bypass/isolation switches.

Section 4 Controller Test and Replacement

4.1 User Interface Panel

Overview of the transfer switch controller's user interface, display, and LEDs.

Controller Interface Features

4.1.3 Lamp Test and Pushbutton Functions

Procedure for testing controller LEDs and explanation of pushbutton functions.

Controller Circuit Boards and Connectors

4.2 Controller Circuit Boards and Connectors

Identification of controller circuit boards and connection ports.

Controller Power Supply Checks

4.3 Controller Power Supply and Checks

Guidance on checking controller power supply and line voltage.

Controller Backup Battery and Direct Powering

4.3.2 Controller Backup Battery

Information on the controller backup battery and replacement.

4.3.3 Powering Controller Directly

Procedure for powering the controller directly using a service kit.

Controller Sequence of Operation

4.4 Sequence of Operation

Explanation of controller power-up and source failure/return sequences.

System Test Procedures

4.5 System Test Procedures

Guides on performing unloaded, loaded, and auto-loaded system tests.

Generator Set Exercise Sequences

4.6 Exercise Sequences

Details on scheduling and running generator set exercise runs.

Engine Start Test Procedures

4.7 Engine Start Test Procedure

Procedure for checking continuity across engine start contacts.

Controller DIP Switches and Calibration

4.8 Controller DIP Switches

Explanation of DIP switch functions for password and maintenance modes.

4.9 Calibration Procedures

Instructions for calibrating voltage and current settings.

Controller Interface Board and Microswitch Tests

4.10 Position Microswitch Test

Procedure to test the operation of position microswitches.

4.11 Programmed-Transition Interface Board

Information on the PTIB and its replaceable relays.

USB File Transfer and Configuration

4.12 File Transfer via USB Port

Guide to transferring configuration files and application code via USB.

Controller Application Program Updates

4.13 Controller Application Program Updates

Instructions for downloading and loading new controller application code versions.

Controller Replacement Procedures

4.14 Controller Replacement

Steps for replacing the controller, including configuration and handling precautions.

Section 5 Component Replacement, Model KGS/KGP

5.1 Introduction

Introduces component removal and replacement procedures for KGS/KGP models.

5.2 Contact Assembly Removal and Replacement

Detailed procedures for removing and replacing contact assemblies for different amp models.

Auxiliary Switch Replacement

5.3 Auxiliary Switch Removal and Replacement

Step-by-step instructions for removing and replacing auxiliary switches.

Section 6 Component Replacement, Model KSS

6.1 Introduction

Introduces component replacement procedures for KSS standard-transition transfer switches.

Microswitch Replacement Procedures

6.2 Microswitch Replacement

Procedures for replacing microswitches on KSS models.

Power Panel and Arc Chute Replacement

6.3 Power Panel Replacement

Instructions for replacing the power panel assembly on KSS transfer switches.

6.4 Arc Chute Replacement

Steps for removing and replacing arc chutes on KSS transfer switches.

Limit Switch Assembly Replacement

6.5 Limit Switch Assembly Replacement

Procedure for replacing the limit switch assembly.

Solenoid and Rectifier Replacement

6.6 Solenoid and Rectifier Replacement

Procedures for replacing solenoids and rectifiers on KSS models.

Section 7 Component Replacement, Model KSP

7.1 Introduction

Introduces component replacement procedures for KSP programmed-transition transfer switches.

7.2 Component Replacement, 100--400 Amp Models

Procedures for disassembling and reassembling KSP 100-400 Amp models.

KSP Component Replacement: PCBs and Coils

7.2.3 Printed Circuit Board Replacement (100-400A)

Steps for replacing the printed circuit board on KSP models.

7.2.4 Closing Coil Replacement (100-400A)

Procedure for replacing the closing coil on KSP models.

7.2.5 Select Coil Replacement (100-400A)

Procedure for replacing the select coil on KSP models.

KSP Trip Coil and Arc Chute Replacement

7.2.6 Trip Coil Replacement (100-400A)

Procedure for replacing the trip coil on KSP models.

7.2.7 Arc Chute Replacement (100-400A)

Procedure for replacing arc chutes on KSP models.

KSP 600 Amp Model Component Replacement

7.3 Component Replacement, 600 Amp Models

Procedures for replacing components on KSP 600 Amp models.

7.3.1 Closing Coil Replacement (600A)

Procedure for replacing the closing coil on KSP 600 Amp models.

KSP 600 Amp Model Adjustments and Replacements

7.3.2 Shaft Adjustment (600A)

Instructions for adjusting the movable steel shaft on KSP 600 Amp models.

7.3.3 Auxiliary Switch Replacement (600A)

Procedure for replacing auxiliary switches on KSP 600 Amp models.

KSP 600 Amp Trip Coil and Select Coil Replacement

7.3.4 Trip Coil Replacement (600A)

Procedure for replacing the trip coil on KSP 600 Amp models.

7.3.5 Select Coil Replacement (600A)

Procedure for replacing the select coil on KSP 600 Amp models.

KSP 600 Amp PCB and Arc Chute Replacement

7.3.6 Printed Circuit Board Replacement (600A)

Procedure for replacing the printed circuit board on KSP 600 Amp models.

7.3.7 Arc Chute Replacement (600A)

Procedure for replacing arc chutes on KSP 600 Amp models.

Appendix A Abbreviations

Appendix B Screen Summaries

View Screens

Lists items displayed on the controller's View screens for quick reference.

Setup Screens

Lists items found in the controller's Setup screens for configuration.

Appendix C Noise and Wiring Practices

Appendix D Common Hardware Application Guidelines