Kohler 340 KN Series Instruction Manual

NonautomaticTransferSwitches
Models:
340
KN-Series
Logic:
Relay
Contactor:
30-4000 Amperes
TP-5585 3/92a
Operation and
Installation
U.S.A.Plant ISORegistered

Contents
Safety Precautions& Instructionsi..........................
Ratings 1...................................................
Installation 1...............................................
Unpacking 1..............................................
Lifting 1..................................................
Mounting 2...............................................
Line Connections2...................................................
AuxiliaryConnections4....................................
Engine-Starting Connections5.............................
FunctionalTests5........................................
ManualOperation Check 5.................................
Voltage Checks 8.........................................
ElectricalOperation Test9.................................
SwitchPosition & Source Indicators 11.......................
TransferSwitchPosition Lamps11......................................
SourceAvailable Lamps11.............................................
Control Switches 11..........................................
“TransferTo”Normal-Emergency 11.....................................
GeneratorStop-Start(ifequipped)12....................................
AlarmSilenceSwitch(ifequipped)12....................................
TransferSwitch Operation 12.................................
NormalPowerLoss 12.....................................
NormalPowerReturn 13....................................
Wiring Diagrams& Drawings 15..............................
Interconnection Diagrams15................................
EnclosureDimensions15...................................
ContactorWiring 15........................................
Schematics 15.............................................
Wiring Diagrams15........................................

Safety Precautions
i
SafetyPrecautions&Instructions
ATransferSwitch,like anyother
electro-mechanicaldevicecan posepotential
dangerstolife and limbifimproperly
maintainedorimprudentlyoperated.Thebest
safeguardsagainstaccidentareto be ever
mindfulofthepotentialdangersand toalways
use good common sense. Inthe interestof
safety,some generalprecautionsrelating to
operation ofatransferswitchfollow.Keep
theseinmind.Thismanualcontains several
typesofsafetyprecautionswhich are
explained below.Examplesofvarious
precautionarystatementsusedinthismanual
are alsoshown.
DANGER
Dangerisused toindicatethe presence ofa
hazardwhichwill causesevere personal
injury,death,orsubstantialpropertydamage
if the warning isignored.
WARNING
Warning isused toindicatethe presence ofa
hazardwhichcan causesevere personal
injury,death,orsubstantialpropertydamage
if the warning isignored.
CAUTION
Caution isused toindicatethe presence ofa
hazardwhichwillorcancauseminorpersonal
injuryorpropertydamage if the warning is
ignored.
NOTE
Noteisused to notifypeople ofinstallation,
operation,ormaintenanceinformation which
isimportantbutnothazard-related.
HAZARDOUS VOLTAGE/
ELECTRICALSHOCK
Disconnectpowersourcesbefore
servicing.Barriermustbe installed after
adjustments,maintenance,orservicing.
WARNING
Hazardous voltage.
Cancause severeinjuryor death.
(under 600 Volt)
Disconnectpowersourcesbefore
servicing.Barriermustbe installed after
adjustments,maintenance,orservicing.
DANGER
Hazardous voltage.
Will cause severeinjuryor death.
(600 Volt and above)

ii Safety
Do notopen enclosure until all power
sourcesare disconnected.
WARNING
Hazardous voltage.
Cancause severeinjuryor death.
(under 600 Volt)
Do notopen enclosure until all power
sourcesare disconnected.
DANGER
Hazardous voltage.
Will cause severeinjuryor death.
(600 Volt and above)
Hazardous voltage cancause severe
injuryor death. Disconnectset fromload by
opening line circuitbreakerorby
disconnecting generatoroutputleadsfrom
transferswitch and heavilytaping endsof
leads.Ifhigh voltage istransferred toload
during test, personal injuryand equipment
damage mayresult. The GENERATOR
SAFEGUARD BREAKERMUSTNOTBE
USEDINPLACEOFLINECIRCUIT
BREAKER!
Hazardous voltage cancause severe
injuryor death. The TransferSwitchis
energized;proceed withcare!High voltage
can cause personal injury,damage
equipment, orlead tofuturefailures.Remove
watch,rings,andjewelrythatcan causeshort
circuits.
Hazardous voltage cancause severe
injuryor death. The TransferSwitchis
energized;proceed withcare!High Voltage
can cause personal injury,damage
equipment, orlead tofuturefailures.Remove
rings,watches,and jewelrythatcan cause
shortcircuits.Thistestshouldbedoneonlyby
a qualified electrician.Followmanufacturer’s
instructionswhen operating tester.
Hazardous voltage cancause severe
injuryor death. To prevent the possibilityof
electricalshock,de-energizethe normal
powersourceto be connectedtotheTransfer
Switch beforemaking anyline orauxiliary
connections.
Hazardous voltage cancause severe
injuryor death. De-energize both normal
and emergency powersourcesbefore
proceeding.MoveGeneratorMasterSwitch
on controllertoOFF position and disconnect
batterynegative(--) beforeworking on
transferswitch!Turnthe transferswitch
selectorswitchtothe OFF position.

Safety Precautions
iii
Hazardous voltage cancause severe
injuryor death. Disconnectinnerpanel
harness atin-line connector.Thiswill
de-energizecircuitboard and logic circuitry,
butallowtransferswitchtocontinue tosupply
utilitypowerto necessarylighting and
equipment.Hazardousvoltagewillexistifany
accessoriesmounted toinnerpanelareNOT
wired through and de-energized byharness
separation.Such accessoriesmaybe atline
voltage.
Hazardous voltage cancause severe
injuryor death. Keep everyone awayfrom
the setand take precautionsto prevent
unqualified personnelfromtampering.Have
the setand electricalcircuits serviced onlyby
qualified technicians.Wiring should be
inspected at the recommended interval
shownintheserviceschedule--replaceleads
thatarefrayed orin poorcondition.Do not
operate electricalequipmentwhen standing
inwater,on wetground,orwhen yourhands
arewet.
Hazardous voltage cancause severe
injuryor death. Disconnectharness plug
beforeinstalling anyaccessoriesinvolving
connection totransformerassemblyprimary
terminals.Terminalsare atline voltage!
NOTE
HARDWAREDAMAGE!Transferswitchmay
make use ofbothAmerican standard and
metrichardware.Besureto usethe correct
sizetoolsto preventrounding ofboltheads
and nuts.
NOTE
Amanualoperatorhandleisprovided on the
TransferSwitchformaintenance purposes
only.ReturntheTransferSwitchtotheNormal
position.Removemanualoperatorhandle(if
used)andstoreitontheTransferSwitchinthe
place provided when serviceis completed.

Installation
1
Ratings
The rating label isattached tothe transfer
switch.Datarelatingto eachspecific switchis
included on the nameplate.Unitinstallation
mustnotexceed the rated capacityof the
switch as shownonthe nameplate.
Forlocation of the transferswitchinthe
systemseeFigure 1.The switchshouldbeas
closeaspossibletothecriticalelectricalloads
connected toit.
Normal
Source
Transfer
Switch
Emergency
Source
Loads
Figure 1. TransferSwitch Location
Installation
Kohlertransferswitchesarefactorywiredand
tested. Installation requiresmounting,
connection ofutility,load,emergency cables
and anyauxiliary contact/controlcircuits.Do
notremove protective packing until readyfor
completeinstallation.Protectswitch atall
timesfromexcessivemoisture,construction
grit, and metalchips.
Unpacking
Carefullyunpackoruncrateswitch and check
fordamage.Reportanydamageimmediately
tothe KohlerDistributor.
Lifting
Anylifting devicesmustbe attached tothe
switch’smountingholesorliftingeyesonly.Do

asco
Installation Procedures
2
notlift the switch atanyotherpoints.Protect
arcbarriersfromimpactatall times.
Mounting
All enclosed switcheshavethe controlpanel
mounted on the cabinetdoor.Foropen-type
switches,mount the controlpaneltothe right
of the transferswitch.
Disconnect power sources before servicing.
Barrier must be installed after adjustments,
maintenance, or servicing.
WARNING
Hazardous voltage.
Can cause severe injury or death.
(under 600 Volt)
Hazardous voltage cancause severe
injuryordeath.De-energizebothnormaland
emergency powersourcesbefore
proceeding.Movethe generatormaster
switchonthe controllertothe OFF position
and disconnectbatterynegative(--) before
working on the transferswitch!
Disconnect power sources before servicing.
Barrier must be installed after adjustments,
maintenance, or servicing.
DANGER
Hazardous voltage.
Will cause severe injury or death.
(600 Volt and above)
Hazardousvoltagewillcausesevereinjury
or death. De-energize both normaland
emergency powersourcesbefore
proceeding.Movethe generatormaster
switchonthe controllertothe OFF position
and disconnectbatterynegative(--) before
working on the transferswitch!
LineConnections
Wiring Diagramsarefurnished at the back of
thismanual. Interconnection diagrams
(3-pole and 2-pole)arefurnished toshow
actual lead wiring.
All conductors should enterenclosure
adjacent tothe transferswitchterminals.
Protect the transferswitchfrom metalchips
and construction gritatall times.Standard
terminal lugsaresolderless screwtype and
will accept the conductorsizeslisted on
installation drawings.
Do notrun cablesbehind the transferswitch.
Cables can be bundled tothe side of the
switch.Maintain properelectricalclearance
between the livemetalpartsand grounded
metal.Usecablespacersprovidedon70,104
and 150-Amp,600-Voltclass switches.
Spacersare notrequired on 240-Voltclass
switches.
On225--400-Ampswitches,removethecover
shieldsfromthe switchtoconnectpower
cablestothe Emergency lugsand switched
neutral lugs(Accessory36).
Connectsource and load conductorsto
clearlymarked contactorterminal lugs.
Removesurface oxidesfromconductorsby
cleaning withawire brush.When aluminum
conductorsareused,applyoxidationinhibitor
toconductors.Tightenlugsandcarefullywipe

Installation
3
awayexcessoxidationinhibitor.Tightencable
lugstothe torque specified inthe following
table.Note
Application ofoxidation inhibitoris
requiredforallaluminumterminations.
ContactorTightening Torque
Ratedinch pounds
Amps(Nm)
30 -- 104 50 (5.6)
150 200 (22.6)
225 -- 400 600 (67.8)
600 -- 1200 500 (56.5)
1600 -- 4000 Suitablefor
BusBarLugs
Table:Tightening Torque Values
for Lug Connectors
Do not open enclosure until all power sources
are disconnected.
WARNING
Hazardous voltage.
Can cause severe injury or death.
(under 600 Volt)
Hazardous voltage cancause death or
severeinjury!On 225--400-Ampswitches,
reinstallthecovershieldsovertheemergency
lugsand overlapping neutral(accessory36)
lugs.Iftheseshieldsarenotinplacewhenthe
switchisenergized, the lugswill be exposed.
Touching these energized lugs can resultin
shock,burns,ordeath.
Do not open enclosure until all power sources
are disconnected.
DANGER
Hazardous voltage.
Will cause severe injury or death.
(600 Volt and above)
Hazardous voltagewill cause death or
severeinjury!On 225--400-Ampswitches,
reinstallthecovershieldsovertheemergency
lugsand overlapping neutral(accessory36)
lugs.Iftheseshieldsarenotinplacewhenthe
switchisenergized, the lugswill be exposed.
Touching these energized lugswill resultin
shock,burns,ordeath.

asco
Installation Procedures
4
Figure 2. In-LineDisconnectPlug
All internalconnectionsaremade at the
factory.The transferswitch and the control
paneleach havetheirownwire harness.The
twoharnessesaretobejoinedtogetherbythe
in-line disconnectplug.Plug halvesare
separated forshipment. The plug mustbe
engaged afterinstallation is completed.See
Figure 2.
AuxiliaryConnections
Connectauxiliary circuitwiresto appropriate
controlpanelterminalsas shown on the
appropriate diagram(see contactorwiring
diagramsinthe “Wiring Diagrams”section).
Anyauxiliary contactconnectionsare
customerspecified and shouldbeshown on
the installation’splans.Standard auxiliary
contactsinclude one setclosed inthe normal
position and one setclosed inthe emergency
position.Additionalcontactsofbothtypesare
optional.
Note anyoptionalaccessoriesthatmayhave
been furnished on this switch,and make
auxiliary connectionsifnecessary.

Installation
5
Engine-Starting Connections
The engine-starting connectionsarelocated
on the transferswitchcontactor.Ared decal
nearthe contactorpointsto engine-start
terminals.Engine-start terminal locationsare
alsodescribedoninterconnectiondiagramsin
thisbook.Connectengine-startsignalwiresto
terminals3and4onthecontactor.SeeFigure
3.
Figure 3. TypicalEngine Starting Connections
30--150-Amp Contactor Shown
FunctionalTests
FunctionalTesting consistsof three parts:
manual operation, voltage checks and
electrical operation.
Caution
Performthesechecks inthe order
given,in orderto avoid damaging the
switch.
Read and understand all instructionson
installation drawingsand labelsaffixed tothe
switch.Note anyoptionalaccessoriesthat
have been furnished withthe switch and
reviewtheiroperation.
First, check the transferswitch nameplatefor
ratedvoltage.Itshouldbethesameasnormal
line voltage and emergency line voltage as
indicated on the generatorsetnameplate.
Manual Operation Check
1.Performthe manualoperation testbefore
attempting to electricallytest the
automatictransferswitch.The intentisto
verifythat the contactorand all auxiliary
switchesoperatesmoothlyand that there
isnodamagefromshippingorinstallation.
2.Open both the normaland emergency
sourcecircuitbreakers.