Kipor KPEC Series User manual

1
KPEC Series
User Manual of ATS Cabinet
www.kipor.com

2
Content
Safety
1. ATS general introduction
1.1 Definition and working principle
1.2 Applications
1.3 ATS switching mode
1.4 ATS switching control
1.5 ATS
2. Brief introduction for KPEC series ATS cabinet
2.1 Brief introduction for KPEC series ATS cabinet
2.2 Brief introduction for automatic transfer switching (ATS)
2.3 Model definition for KPEC series ATS cabinet
3. Operation manual for KPEC series ATS cabinet
3.1 Introduction for KPEC series cabinet
3.2 Cabinet
3.3 Electrical component
Standard component
Optional component
3.4 Installation
3.5 Operation
KPD100 controller
3.6 Trial run of ATS cabinet
Trial run at manual mode
Trial run at automatic mode
Normal operation of ATS cabinet
Regular maintenance
How to obtain maintenance service
4. Trouble shooting
5. Vendor list (options and accessories)
Vendor list
Options
Guarantee
6. Attachment

3
Safety
This manual contains following safety marks, which indicate the potential dangers. Please
read carefully to learn when the dangers occur so as to take necessary method to protect
the personnel and equipment.
Indicates the direct injury that can lead serious injury or even death.
Indicates the dangerous and unsafe operation that can lead serious
injury or even death.
Indicates the dangerous and unsafe operation that can lead personal
injury or product/property damage.
Electric shock may cause serious personal injury or even death.
There is possible electric shock that may cause serious personal injury or even death upon
the high voltage of transfer switch components. Please read and observe the following
advices.
Keep the transfer switch cabinet closed and locked. Make sure only the authorized
personnel can have the key.
High voltage in the cabinet may cause serious shock injury, so all the maintenance and
repair concerning the transfer switch should only be done by electrician or authorized
personnel.
If it is necessary to open the cabinet:
1. Turn the operation selection switch of generator set to “OFF”.
2. Power off the battery charger.
3. Power off the generator or its starting battery. (Remove the negative grounding lead
firstly.)
4. Power off the ATS AC power supply. If it is required by operation guide to switch off AC
power on ATS, special caution for electric shock should be exercised.
General precautions
When operating electrical equipment, place a rubber insulation mat upon the dry wooden
platform on the metal or cement base.
Forbid wet dress (especially wet shoes) or wet skin surface exposed in electrical
equipment operation.
Jewelries are good conductors of electricity. Remove them when operating the electrical
equipment.
Do wear the safety glasses when maintaining the ATS. Forbid smoking around the battery.

4
Do not operate the machine with mental or physical fatigue, or after drinking or taking
medicine.
Warn that incorrect maintain or parts replacing may cause death,
serious personal injury or equipment damage.

5
1. ATS general introduction
1.1 Definition and working principle
ATS is short for automatic transfer switch. It is mostly used in emergency power supply system,
automatically switching the load circuit from one power supply to another (standby power supply)
and insuring the continuous and reliable running of important load.
1.2 Applications
(1) Switch between the grid and standby power supply (i.e. generator set)
Applicable to the system of standby power supply (i.e. generator set) or one-way power grid. The
transfer switch can automatically detect power fault of the grid, send start signal to standby
generator set and switch the load.
(2) Switch between generators
Applicable to the system with several generator sets as the main power supply. If the main
generator set goes wrong, the transfer switch will send start signal to the second generator set and
switch the load.
(3) Switch between the grids
Applicable to the multiple power grids without a standby generator set. If one grid goes wrong, the
transfer switch will automatically connect the load to the second one.
(4) Triplicate power supply
A. Applicable to the single standby power supply and dual grid system.
The grid transfer switch controls the power supplied by dual grid according to the predetermined
order. If power supply of both the grids goes wrong, the transfer switch will send start signal to
standby generator set and switch the load.
B. Applicable to the single grid and dual standby power supply system.
If the grid goes wrong, the transfer switch will send start signal to the main standby generator set
and switch the load. If the main standby generator set goes wrong, the transfer switch will send
start signal to the second standby generator set and switch the load.
1.3 ATS switching mode
(1) Open-loop switching (in-phase switching, power-off switching)
Off after On is the basic switching mode: Firstly switch off the first power supply, and then switch on
the second power supply. Users can monitor both the power supplies and start switch with the
in-phase monitor (or sync check function) in the controller, so as to avoid the problem of
out-of-phase.
Application: emergency power system, regulation specified power system and optional standby
power system; resistive load; small motor load.

6
(2) Delayed switching (program controlled switching)
Similar to the open-loop switching. Firstly switch off the first power supply, and then switch on the
second power supply after an adjustable delayed period. This adjustable period is enough for the
residual voltage to attenuate before connecting to the second power supply.
Application: Inductive (motor) load, recommendation of some UPS and VFD manufacturer.
(3) Closed-loop switching (parallel switching)
Off after On switching can make continuous power supply. Through the instant parallel of power
supply (<100ms) during the switching period, Seamless load switching from one power supply to
another is achieved.
Application: especially important load power supply, including hospitals and data centers.
(4) Isolated bypass switching
Automatic maintenance for main ATS. No need for cutting off the load power supply. Through the
parallel of two switches, the main ATS can be drew and maintained after switching to bypass
supply. The bypass switch increases redundancy to the system.
Application: especially important load power supply and maintenance, including hospitals and data
centers.
1.4 ATS switching control
ATS switching is controlled by ATS controller. The controller is generally used for inspecting the
work condition of monitored power supply (double lines). When the monitored power supply goes
wrong (e.g. phase failure, under voltage, loss of voltage or frequency deviation), the controller
sends operation signal and ATS automatically switches from one power supply to another. This
digital and intelligent ATS controller features the advantages of excellent performance, adjustable
parameter, close accuracy, high reliability and convenient in use.
ATS controller can be installed at following positions:
(1) At the ATS cabinet;
(2) On the generator set* or other user specified installation position;
* = Generator set controller has the ATS controlling function.
1.5 ATS
ATS is classified into two types: PC grade (integrated type) and CB grade (breaker type).
(1) PC grade: integrated type. It is the special switch for dual power switching, features the benefits
of compact structure, self interlock, rapid switching speed (within 0.3s), safety and reliability, but
requires a short circuit to protect the electric appliance.
(2) CB grade: equipped with over-current tripper. The main contact can be connected and used for
breaking the short circuit current, featuring the function of overload and short circuit protection.
(3) Contactor-type: applies reversible contactor with mechanical interlocking, more economical,
without short circuit protection.

7
2. Brief introduction for KPEC series ATS cabinet
KIPOR KPEC series ATS cabinet applies intelligent controller KPD100 and automatic transfer
switching (ATS), and shells with cabinet of IP32 and IP54 protection grade. It can realize the
manual/auto switching on multi power supply system at various switching modes according to the
various customer requirements.
2.1 Brief introduction for KPEC series ATS cabinet
KPEC series ATS cabinet is the KPD100 intelligent controller and ATS control system researched
and developed by KIPOR, which integrates the digital, intellectual and networking technology,
realizes manual/auto switching control between standby and main power, and obtains the data
measuring, alarm protection and 3 remote functions. It features compact design, convenient wiring,
simple handling and reliable operation.
2.2 Brief introduction for automatic transfer switching (ATS)
Automatic transfer switching (ATS) features:
(1) Conform to the international standard.
There is standard from International Electrotechnical Commission especially for ATS, i.e.
IEC60947-6-1. Automatic transfer switching (ATS) accords with this standard and has passed the
certificate of KEMA testing institute.
(2) Integrated design.
(3) Dual interlock of mechanical and electrical. ATS has reliable mechanical interlock and will never
power on two supply lines simultaneously. This is controlled by the ATS controller through the
control over electromagnetic drive coil.
(4) Electromagnetic drive switch, with high speed.
Depend upon the unique electromagnetic coil driving, with the switching time within 0.2s (open-loop
switching mode). As electrical switching on both the two power lines may generate electric arc
conduction (about 0.12s), the actual time of load power off will not exceed 0.5s.
(5) Internal mechanical state remaining mechanism
ATS is driven by electromagnetic power. The coil only works during switching, therefore greatly
increase the lifespan of the actuating element.
(6) High withstanding capability to short circuit
ATS is to switch between two power supplies, bearing no protection function. When short circuit or
overload occurs, ATS only can withstand but not trip. So it is not until the breaker trips will not the
ATS stop withstanding the high current. This withstanding capability may equal or exceed the short
circuit breaking capability of ATS front-end circuit breaker.

8
2.3 Model definition for KPEC series ATS cabinet:
Rules for the serial number of KPEC series ATS cabinet are as following:
(1) KPEC= general purpose ATS cabinet of open-loop or delayed switching (option) mode:
(2) Pole number: 2, 3 or 4
2 poles: single-phase generator set
3 poles: single-phase dual voltage or three-phase three-line generator set
4 poles: three-phase four-line generator set
(3) Current ratings:
26A, 50A, 75A, 100A, 125A, 160A, 200A, 250A, 320A, 400A, 630A, 800A, 1000A, 1250A, 1600A,
2000A, 2500A, 3000A, 3200A
The types of 26A、50A、75A are equipped with ABB contactor.
(4) Voltage code:
A: single-phase 110V~120V
B: single-phase 220V~240V
C: three-phase three-line 110/190V、115/200V、120/208V、127/220V、133/230V、139/240V
D: three-phase four-line 220/380V，230/400V，240/415V
E: single-phase dual voltage 110/220V，115/230V，120/240V
(5) Control type
P：DC12V
Q：DC24V
(6) Frequency
5：50Hz
6：60Hz
(7) Structure type
2：IP32 indoor use (wall mounted type)
3：IP54 outdoor weatherproof cabinet (floor type)
(8) Options for surge protector (lightning protector):
A: without surge protector (lightning protector)
B: with surge protector

9
Voltage rating of the battery charger DC output is the same to the option in “control type”, with the
maximum output of 6A.
(9) Distributed by the factory.
Remark:
KPEC series ATS cabinet can obtain the optimal power switching effect when using together with
the generator set of KIPOR.

10
3. Operation manual for KPEC series ATS cabinet
This manual covers the KPEC series ATS cabinet produced by KIPOR.
This manual contains the operation, installation and maintaining information of KPEC series ATS
cabinet.
3.1 Introduction for KPEC series ATS cabinet
This is an open-loop (or delayed switching, optional) general purpose ATS cabinet (see fig.3-1,
ATS control function is inbuilt at the KPD100 intelligent controller). It will never power on two supply
lines simultaneously. The grid line works with a generator set (emergency power supply) as
standby power and loads connect to the ATS common terminal (see fig.3-2). The controller
monitors voltage and frequency range tolerable to the power supply and controls the transfer switch
to switch between power supplies automatically. Normally, the loads are supplied by grid (see fig.
3-3). When the grid supply is off, the loads will be switched to be supplied by generator set (see
fig.3-4). As the grid supply recovers, the loads will be switched back to grid.
Fig.3-1 KPA series ATS cabinet: 200A, 4-pole transfer switch

11
Fig.3-2 Wiring diagram for 200A 4-pole transfer switch
Fig.3-3 ATS power supply diagram: grid power – load
Fig.3-4 ATS power supply diagram: generator power – load

12
3.2 Cabinet
There are two types of cabinets for KPEC series ATS use: IP32 and IP54. IP32 cabinet is designed
to prevent the foreign matters with diameter over 2.5mm and the water with 15°incidence angle
from entering, while IP54 cabinet is designed to prevent dust and water from all directions.
(1) Cabinet
Refer to fig. 3-5 and fig.3-1 for dimension and outline drawing for IP32 cabinet
Refer to fig. 3-6 and fig.3-2 for dimension and outline drawing for IP54 cabinet
Fig.3-5 IP32 cabinet outline drawing
Fig.3-1 Approximate dimension of IP32 cabinet
Switching current grade Height（H）Width（W）Thickness（D）Thickness（D1）
100、200（single-phase）500mm 450mm 230mm 45mm
26、50、75、100、125、
160、200（three-phase）650mm 500mm 230mm 45mm
250 、320 、400
(three-phase) 800mm 600mm 230mm 45mm
500、630（three phase）1000mm 800mm 310mm 45mm

13
Fig.3-6 IP54 cabinet outline drawing
Fig.3-2 Approximate dimension of IP54 cabinet
Specification Switching current grade Height（H）Width（W）Thickness（D）
Three-phase 26、50、75、100、125、160、
200 863mm 500mm 285mm
Three-phase 250、320、400 1163mm 600mm 285mm
Three-phase 630、800、1000、1250、1600 1500mm 760mm 660mm
From fig.3-7 to fig.3-10 some examples of cabinet are displayed

14
Fig.3-7-1 Floor type internal components: 40-200A, 4-pole switch
Fig.3-7-2 Floor type internal components: 40-200A, 4-pole switch

15
Fig.3-8 Wall-mounted type internal components: 100A and 200A, 2-pole switch
Fig.3-9-1 Wall-mounted type internal components: 250A-400A, 4-pole switch

16
Fig.3-9-2 Floor type internal components: 250-400A, 4-pole switch
Fig.3-10 Floor type internal components: 630-1600A, 4-pole switch

17
3.3 Electrical components
This part explains the standard and optional parts of ATS cabinet electrical controlling system (refer
to figures from 4-7 to 4-9).
Incorrect calibration or regulation may cause death, serious personal injury and/or equipment
damage. The one who calibrates or regulates must be qualified technicians.
There is electric shock hazard in the cabinet and behind the door. Opening the door may cause
serious personal injury. So special attention must be paid that body, tools, jewelries, clothes, hair
etc. should be away from the electric contactor.
Standard components:
A. KPD100 intelligent controller
KPD100 intelligent controller (fig.3-11) is installed on the ATS cabinet. ATS switching is controlled
by KPD100 intelligent controller obtaining the built-in ATS controlling function (with default
installation on the generator set). Green light on the display panel indicates the state of transfer
switch as following:
Grid power indicator – it turns light when the grid voltage is normal and turns red when abnormal.
Grid power supply indicator – it turns light when the grid is supplying power to load.
Generator power indicator– it turns light when the generator is normal and turns red when
abnormal.
Generator power supply indicator - it turns light when the generator is supplying power to load.
Fig.3-11 ATS display panel on the cabinet door
Details about KPD100 intelligent controller please see Part 5 of this chapter.

18
B. ATS transfer switch:
The transfer switch (refer to fig.3-7 - 3-10), which avoids powering on two power supplies
simultaneously through a mechanical interlock mechanism, completes load transfer between two
power supplies by opening and closing the contactor. It may have 2 poles, 3 poles or 4 poles. The
electromagnetic mechanical actuating part may be controlled by the transfer switch controller or
manually switched by hand operation.
Hand operation on the transfer switch can be explained as following, taken the 4-pole 200A transfer
switch as an instance:
Make use of the spare operating handle and insert the manual operated axle, then the manual
switching on transfer switch is ready. It should be operated with zero load by qualified personnel as
following procedure:
There is electric shock hazard if operate at load bearing state, which may cause serious personal
injury or even death. Do not try to manually operate switches when there is load. Cut off both the
power supplies before manual operation.
1. Make sure there is no load on the transfer switch.
2. Open the door of ATS cabinet.
3. Remove fuse F2, F5 to cut off the power supply (fig.3-14).。
Switch to A side
a. Place the handle on converting axle.
b. Rotate the axle until the switch is locked.
c. Status window on the transfer switch indicates “ON”
(Fig.3-12). Fig.3-12
Switch to B side
a. Place the handle on converting axle.
b. Rotate the axle until the switch is locked.
c. Status window on the transfer switch indicates “ON”
(Fig.3-13). Fig.3-13
Attentions: Remember to convert the load of transfer switch to effective power supply (if both the
power supplies are effective, convert to grid).
Remove the hand operated handle before switching to auto mode, otherwise the operation of ATS
may make the handle throw away at high speed, which may cause serious personal injury. Place
the hand operated handle at safe position (e.g. at the bottom of the cabinet).

19
1. Make sure the hand operated handle has been removed and placed at safe positon.
2. To return to auto mode, relay the fuse F2, F5 to recover power supply.
3. Close the door of cabinet.
C. Terminal block X1
Control cable between the generator set and ATS cabinet needs to be connected through the
terminal block. Arrange of the terminal block is displayed in Fig.4-13.
Fig.3-14 Terminal block X1

20
D. Battery charger
When the grid supplies power and the generator set is idle, battery charger will charge the battery
of generator set to ensure ample power of the battery.
BAC series automatic battery charger works according to the charge characteristics of battery. Its
charging mode is “constant variable current”, i.e., when the battery terminal voltage is below the
default value, the charge current is constant; when the battery terminal voltage is above the default
value, the charge current gradually decreases with the increase of battery terminal voltage. As the
voltage reaches threshold value, the charging turns to be floating charge. Then the charging current
only compensates the self discharge of battery and longtime charge will not harm the battery. In
other words, this charger not only can maintain the full charge state of battery, but also can ensure
its service life. It has the functions of output short circuit protection and battery reverse protection.
The charger output voltage and max output current can be regulated（increase in clockwise,
decrease in counterclockwise）. The regulating range for 12V charger is 10-16V (default set is
13.8V), for 24V charger is 20-31V (default set is 27.6V), and for current is 2-4A (default set is 4A).
Optional components:
Surge protector (SPD)
Surge protecting system applies combined SPD, which is composed of voltage switching type
component and voltage limiting type component. The protection mode can be optional differential
mode (phase to phase and phase to midline) and common mode (phase to grounding and midline
to grounding) according the customer’s need. It complies with:
Lightning protection and grounding design standard of mobile communication base (YD5068-98)
Lightning protection technology standard of communication program power system (YD5078-98)
Thunder and lightning overvoltage protection program design standard of communication bureau
(YD5098-2001)
3.4. Installation
3.4.1 Overview
These installation suggestions apply for typical installation. They contain almost all the options or
adjustable options of the factory design. However, as there are various installation methods, it is
impossible to provide suggestion for all the situations. If you can not find solution in this manual,
please contact the nearest KIPOR distributor for support.
3.4.2 Safety concern
With correct installation, maintenance and operation, the well-designed ATS cabinet can provide
safe and effective service. The safety and reliability of the whole system lie on a lot of other factors
that can be controlled by non-manufactures. To avoid the potential hazard, please carry through the
mechanical and electrical wiring strictly in strict accordance with requirement of the manual. All the