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Kohler KSS - User Manual

Kohler KSS
126 pages
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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

Table of Contents

Questions and Answers:

Kohler KSS Specifications

General IconGeneral
BrandKohler
ModelKSS
CategorySwitch
LanguageEnglish

Summary

Service

Automatic Transfer Switches Overview

Title page for Automatic Transfer Switches service manual.

Safety Precautions and Instructions

Accidental Starting Safety

Procedures to prevent accidental generator set starting.

Hazardous Voltage and Electrical Shock Precautions

Warnings and precautions regarding electrical hazards.

Grounding and Electrical Safety Guidelines

Guidelines for safe electrical grounding and handling.

Short Circuits and Jewelry Removal Warnings

Hazards of short circuits and removing jewelry before servicing.

Transfer Switch Servicing Safety Procedures

Precautions for servicing transfer switches and internal components.

Testing Live Electrical Circuits Safety

Safety procedures for testing live electrical circuits.

Heavy Equipment and Moving Parts Safety

Safety guidelines for handling heavy equipment and moving parts.

Electrostatic Discharge (ESD) Prevention

Measures to prevent damage to electronic components from ESD.

Introduction

List of Related Materials

Lists part numbers for related literature and manuals.

Service Assistance

Contact Information and Support Channels

Provides contact details and methods for obtaining service and support.

Section 1 Scheduled Maintenance

1.1 Introduction to Scheduled Maintenance

Overview of preventive maintenance for transfer switches.

1.2 Inspection and Service Procedures

Procedures for internal and external inspection and service tasks.

1.3 Transfer Switch Testing Procedures

Periodic testing procedures to ensure transfer switch reliability.

1.4 Service Schedule and Intervals

Schedule of recommended maintenance tasks and intervals.

1.5 Viewing Maintenance Records

Navigating screens to view last maintenance dates and operation info.

1.6 Resetting Data and Parameters

Procedures for resetting maintenance records, event history, and parameters.

Section 2 Controller Troubleshooting

2.1 Initial Checks for Operation

Initial checks to perform when troubleshooting transfer switch operation.

2.2 Controller Backup Battery Management

Information about the controller's backup battery and replacement needs.

2.3 Viewing Event History Log

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

2.4 System Settings Configuration

Checking and configuring system voltage, frequency, and phase settings.

2.5 Time Delay Settings Review

Checking adjustable time delay settings for transfer switch operation.

2.6 Common Alarm Functions

Understanding functions assigned to common alarms and their indications.

2.7 Warnings and Faults Identification

Identifying and understanding ATS warnings and faults.

2.8 Events and Faults Troubleshooting Tables

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

2.9 Controller Troubleshooting Table

A table listing controller problems, possible causes, checks, and corresponding sections.

Section 3 Transfer Switch Troubleshooting

3.1 Initial Checks for Mechanism

Basic checks for transfer switch mechanism problems.

3.2 Transfer Switch Troubleshooting Table

Table of potential problems, causes, and remedies for transfer switch issues.

3.3 System Power Verification

Procedures for verifying power to the ATS and checking source voltage.

3.4 Contact Inspection and Testing

Using millivolt drop test to identify damaged contacts.

3.5 Rectifier Testing Procedure

Procedure for testing rectifier diodes using an ohmmeter.

3.6 Solenoid and Coil Testing

Procedures for testing solenoid coil resistance and operation.

Section 4 Controller Test and Replacement

4.1 User Interface Panel Overview

Description of the user interface pushbuttons, LEDs, and display.

4.2 Controller Hardware Identification

Identification of controller circuit boards, connectors, and components.

4.3 Controller Power Supply and Battery

Procedures for checking controller power, line voltage, and backup battery.

4.4 Sequence of Operation

Explanation of controller power-up and source failure operational sequences.

4.5 System Test Procedures

Procedures for testing generator set startup and simulated source failures.

4.6 Exercise Schedule and Operation

How to schedule and run exercise runs for the generator set.

4.7 Engine Start Contact Testing

Procedure for checking engine start contacts and troubleshooting.

4.8 Controller DIP Switch Configuration

Description and function of controller DIP switches for setup.

4.9 Calibration Procedures

Procedures for calibrating voltage and current sensing.

4.10 Position Microswitch Testing

Testing the operation of position microswitches.

4.11 Programmed-Transition Interface Board

Information on the PTIB and its relays.

4.12 File Transfer via USB Port

Procedures for transferring configuration files and application code via USB.

4.13 Controller Application Program Update

How to download and install new controller application code.

4.14 Controller Replacement and Handling

Procedures for replacing the controller, including configuration and safe handling.

Section 5 Component Replacement, Model KGS;KGP

5.1 Introduction to KGS;KGP Replacement

Introduction to component replacement for KGS/KGP models.

5.2 Contact Assembly Procedures

Procedures for removing and replacing contact assemblies for 800-1200, 1600-2000, and 3000 Amp models.

5.3 Auxiliary Switch Replacement

Procedure for removing and replacing auxiliary switches.

Section 6 Component Replacement, Model KSS

6.1 Introduction to KSS Component Replacement

Introduction to component replacement for KSS standard-transition switches.

6.2 Microswitch Replacement Procedures

Procedures for replacing microswitches on 40-260 Amp and 400-600 Amp models.

6.3 Power Panel Replacement

Procedure for replacing the power panel.

6.4 Arc Chute Replacement

Procedure for replacing arc chutes.

6.5 Limit Switch Assembly Replacement

Procedure for replacing the limit switch assembly.

6.6 Solenoid and Rectifier Replacement

Procedures for replacing solenoids and rectifiers on 40-225 Amp and 400-600 Amp models.

Section 7 Component Replacement, Model KSP

7.1 Introduction to KSP Component Replacement

Introduction to component replacement for KSP programmed-transition switches.

7.2 Component Replacement for 100-400 Amp Models

Procedures for disassembling, reassembling, and replacing components on 100-400 Amp KSP models.

7.3 Component Replacement for 600 Amp Models

Procedures for replacing components on 600 Amp KSP models.

Appendix A Abbreviations

List of Abbreviations Used in Publication

A list of abbreviations and their meanings found in the manual.

Appendix B Screen Summaries

Overview of Controller View Screens

Lists items shown in the various View screens for quick reference.

Overview of Controller Setup Screens

Lists items shown in the various Setup screens for quick reference.

Appendix C Noise and Wiring Practices

Minimizing Electrical Noise with Wiring Practices

Guidelines for good system design and wiring practices to minimize noise.

Types of Circuits and Noise Considerations

Discusses five types of circuits and their noise emission/rejection capabilities.

Appendix D Common Hardware Application Guidelines

Proper Fastening Techniques and Bolt;Screw Length

Information on identifying proper fastening techniques and bolt/screw length.

Washer and Nut Usage Rules

Guidelines for using washers and nuts with common hardware.

Acceptable Hardware Combinations

Visual guide to acceptable hardware combinations and types.

Appendix E General Torque Specifications

American Standard Fasteners Torque Specifications

Torque specifications for American Standard fasteners.

Metric Fasteners Torque Specifications

Torque specifications for metric fasteners.

Appendix F Common Hardware Identification

Identification of Screw, Nut, and Washer Styles

Identification of common screw, bolt, stud, nut, and washer styles.

Fastener Hardness Grades and Sample Dimensions

Explanation of fastener hardness grades and sample dimensions.

Appendix G Common Hardware List

American Standard Common Hardware

List of part numbers and dimensions for American Standard hardware.

Metric Common Hardware

List of part numbers and dimensions for Metric hardware.

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