Kohler KSS Series User manual

Models:
KSS/KSP
40 to 1000 Amperes
TP-6447 10/12d
Installation
Automatic Transfer Switches

Product Identification Information
Product identification numbers determine service parts.
Record the product identification numbers in the spaces
below immediately after unpacking the products so that
the numbers are readily available for future reference.
Record field-installed kit numbers after installing the kits.
Transfer Switch Identification Numbers
Record the product identification numbers from the
transfer switch nameplate.
Model Designation
Serial Number
Accessories
-Alarm Board
-Current Monitoring
-Battery Module
-Standard I/O Module (max. 4) qty:
-High Power I/O Module (max. 4) qty:
-Line-Neutral Monitoring
-Supervised Transfer Switch
-Digital Power Meter
-Battery Charger
-Logic Disconnect Switch
-Load Shed
-
-
-
-
Controller Identification
Record the controller description from the generator set
operation manual, spec sheet, or sales invoice.
Controller Description
Software Version Number
Record the software version number.
Software Version Number

Table of Contents
TP-6447 10/12 Table of Contents 3
Safety Precautions and Instructions 5........................................................
Introduction 7...............................................................................
List of Related Materials 7.....................................................
Service Assistance 8........................................................................
Section 1 Product Description 9.............................................................
1.1 Purpose 9.............................................................
1.2 Nameplate 9...........................................................
1.3 Model Designation 10....................................................
Section 2 Installation 11......................................................................
2.1 Introduction 11..........................................................
2.2 Receipt of Unit 11........................................................
2.2.1 Inspection 11....................................................
2.2.2 Storage 11......................................................
2.2.3 Lifting 11........................................................
2.2.4 Unpacking 12....................................................
2.3 Installation 12...........................................................
2.4 Manual Operation Check 13...............................................
2.4.1 Manual Operation Procedure, Standard-Transition Switches 13........
2.4.2 Manual Operation Procedure, Programmed-Transition Switches 15.....
2.5 Controller 16............................................................
2.5.1 Controller Connection 16..........................................
2.5.2 Controller Ground 16.............................................
2.5.3 Other Connections 16............................................
2.6 Electrical Wiring 16.......................................................
2.6.1 Source and Load Connections 17..................................
2.6.2 Engine Start Connection 19.......................................
2.6.3 Auxiliary Contacts 19.............................................
2.6.4 Accessories 19..................................................
2.7 Programmed-Transition Interface Board (PTIB) 22............................
2.8 Final Equipment Inspection 22.............................................
2.9 Functional Tests 22......................................................
2.10 System Setup 22........................................................
2.11 Exerciser Setup 22.......................................................
2.12 Warranty Registration 22..................................................
Section 3 Functional Tests 23.................................................................
3.1 Introduction 23..........................................................
3.2 Manual Operation Test 23.................................................
3.3 Lamp Test 23............................................................
3.4 Voltage Check 23........................................................
3.5 Automatic Operation Test 24...............................................
Appendix A Abbreviations 25..................................................................

TP-6447 10/124
Notes

TP-6447 10/12 5Safety Precautions and Instructions
Safety Precautions and Instructions
IMPORTANT SAFETY INSTRUCTIONS.
Electromechanical equipment,
including generator sets, transfer
switches, switchgear, and
accessories, can cause bodily harm
and pose life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be
aware of potential dangers and act
safely. Read and follow all safety
precautions and instructions. SAVE
THESE INSTRUCTIONS.
This manual has several types of
safety precautions and instructions:
Danger, Warning, Caution, and Notice.
DANGER
Danger indicates the presence of a
hazard that will cause severe
personal injury, death,or
substantial property damage.
WARNING
Warning indicates the presence of a
hazard that can cause severe
personal injury, death, or
substantial property damage.
CAUTION
Caution indicates the presence of a
hazard that will or can cause minor
personal injury or property damage.
NOTICE
Notice communicates installation,
operation, or maintenance information
that is safety related but not hazard
related.
Safety decals affixed to the equipment
in prominent places alert the operator
or service technician to potential
hazards and explain how to act safely.
The decals are shown throughout this
publication to improve operator
recognition. Replace missing or
damaged decals.
Accidental Starting
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery.
WARNING
Disabling the generator set.
Accidental starting can cause
severe injury or death. Before
working on the generator set or
connected equipment, disable the
generator set as follows: (1) Move the
generator set master switch to the OFF
position. (2) Disconnect the power to
the battery charger. (3) Remove the
battery cables, negative (--) lead first.
Reconnect the negative (--) lead last
when reconnecting the battery. Follow
these precautions to prevent starting of
the generator set by an automatic
transfer switch, remote start/stop
switch, or engine start command from a
remote computer.
Hazardous Voltage/
Moving Parts
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.
DANGER
Hazardous voltage.
Will cause severe injury or death.
Only authorized personnel should
open the enclosure.
DANGER
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
Moving parts.
WARNING
Grounding electrical equipment.
Hazardous voltage can cause
severe injury or death. Electrocution
is possible whenever electricity is
present. Ensure you comply with all
applicable codes and standards.
Electrically ground the generator set,
transfer switch, and related equipment
and electrical circuits. Turn off the
main circuit breakers of all power
sources before servicing the
equipment. Never contact electrical
leads or appliances when standing in
water or on wet ground because these
conditions increase the risk of
electrocution.
Removing the transfer switch from
bypass/isolation models.
Hazardous voltage can cause
severe injury or death. Bypass and
isolate the transfer switch before
removing it from the enclosure. The
bypass/isolation switch is energized.
Do not touch the isolation contact
fingers or the control circuit terminals.
Installing the battery charger.
Hazardous voltage can cause
severe injury or death. An
ungrounded battery charger may
cause electrical shock. Connect the
battery charger enclosure to the
ground of a permanent wiring system.
As an alternative, install an equipment
grounding conductor with circuit

TP-6447 10/126 Safety Precautions and Instructions
conductors and connect it to the
equipment grounding terminal or the
lead on the battery charger. Install the
battery charger as prescribed in the
equipment manual. Install the battery
charger in compliance with local codes
and ordinances.
Connecting the battery and the
battery charger. Hazardous voltage
can cause severe injury or death.
Reconnect the battery correctly,
positive to positive and negative to
negative, to avoid electrical shock and
damage to the battery charger and
battery(ies). Have a qualified
electrician install the battery(ies).
Short circuits. Hazardous
voltage/current can cause severe
injury or death. Short circuits can
cause bodily injury and/or equipment
damage.Do not contact electrical
connections with tools or jewelry while
making adjustments or repairs.
Remove all jewelry before servicing
the equipment.
Servicing the transfer switch.
Hazardous voltage can cause
severe injury or death. Deenergize
all power sources before servicing.
Turn off the main circuit breakers of all
transfer switch power sources and
disable all generator sets as follows:
(1) Move all generator set master
controller switches to the OFF
position. (2) Disconnect power to all
battery chargers. (3) Disconnect all
battery cables, negative (--) leads first.
Reconnect negative (--) leads last
when reconnecting the battery cables
after servicing. Follow these
precautions to prevent the starting of
generator sets by an automatic
transfer switch, remote start/stop
switch, or engine start command from a
remote computer. Before servicing any
components inside the enclosure: (1)
Remove all jewelry. (2) Stand on a dry,
approved electrically insulated mat.
(3) Test circuits with a voltmeter to
verify that they are deenergized.
Making line or auxiliary
connections. Hazardous voltage
can cause severe injury or death. To
prevent electrical shock deenergize
the normal power source before
making any line or auxiliary
connections.
Servicing the transfer switch
controls and accessories within the
enclosure. Hazardous voltage can
cause severe injury or death.
Disconnect the transfer switch controls
at the inline connector to deenergize
the circuit boards and logic circuitry but
allow the transfer switch to continue to
supply power to the load. Disconnect
all power sources to accessories that
are mounted within the enclosure but
are not wired through the controls and
deenergized by inline connector
separation. Test circuits with a
voltmeter to verify that they are
deenergized before servicing.
Testing live electrical circuits.
Hazardous voltage or current can
cause severe injury or death. Have
trained and qualified personnel take
diagnostic measurements of live
circuits. Use adequately rated test
equipment with electrically insulated
probes and follow the instructions of
the test equipment manufacturer when
performing voltage tests. Observe the
following precautions when performing
voltage tests: (1) Remove all jewelry.
(2) Stand on a dry, approved
electrically insulated mat. (3) Do not
touch the enclosure or components
inside the enclosure. (4) Be prepared
for the system to operate automatically.
(600 volts and under)
Airborne particles.
Can cause severe injury or
blindness.
Wear protective goggles and clothing
when using power tools, hand tools,
or compressed air.
WARNING
Heavy Equipment
Unbalanced weight.
Improper lifting can cause severe
injury or death and equipment
damage.
Use adequate lifting capacity.
Never leave the transfer switch
standing upright unless it is securely
bolted in place or stabilized.
WARNING
Notice
NOTICE
Hardware damage. The transfer
switch may use both American
Standard and metric hardware. Use
the correct size tools to prevent
rounding of the bolt heads and nuts.
NOTICE
Improper operator handle usage.
Use the manual operator handle on the
transfer switch for maintenance
purposes only. Return the transfer
switch to the normal position. Remove
the manual operator handle, if used,
and store it in the place provided on the
transfer switch when service is
completed.
NOTICE
Foreign material contamination.
Cover the transfer switch during
installation to keep dirt, grit, metal drill
chips, and other debris out of the
components. Cover the solenoid
mechanism during installation. After
installation, use the manual operating
handle to cycle the contactor to verify
that it operates freely. Do not use a
screwdriver to force the contactor
mechanism.
NOTICE
Electrostatic discharge damage.
Electrostatic discharge (ESD)
damages electronic circuit boards.
Prevent electrostatic discharge
damage by wearing an approved
grounding wrist strap when handling
electronic circuit boards or integrated
circuits. An approved grounding wrist
strap provides a high resistance (about
1 megohm), not a direct short,to
ground.

TP-6447 10/12 7Introduction
Introduction
This manual provides operation and installation
instructions for KohlerrModel KSS/KSP Automatic
Transfer Switches. A separate manual provided with the
transfer switch covers the transfer switch controller
operation. See List of Related Materials for the
document part number.
Information in this publication represents data available
at the time of print. Kohler Co. reserves the right to
change this literature and the products represented
without notice and without any obligation or liability
whatsoever.
Read this manual and carefully follow all procedures and
safety precautions to ensure proper equipment
operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section at the
beginning of this manual. Keep this manual with the
equipment for future reference.
The equipment service requirements are very important
to safe and efficient operation. Inspect parts often and
perform required service at the prescribed intervals.
Obtain service from an authorized service distributor/
dealer to keep equipment in top condition.
List of Related Materials
A separate manual covers the transfer switch controller
and related accessories. Separate manuals contain
service and parts information for transfer switch power
switching devices and electrical controls.
The following table lists the part numbers for related
literature.
Literature Item Part Number
Specification Sheet, Model KSS/KSP G11-108
Operation Manual, MPACt1500 Controller TP--6714
Parts Catalog, Transfer Switch and
Controller TP-6433
Service Manual, Model KSS/KSP/KGS/KGP TP-6461

TP-6447 10/128 Service Assistance
Service Assistance
For professional advice on generator power
requirements and conscientious service, please contact
your nearest Kohler distributor or dealer.
DConsult the Yellow Pages under the heading
Generators—Electric.
DVisit the Kohler Power Systems website at
KohlerPower.com.
DLook at the labels and stickers on your Kohler product
or review the appropriate literature or documents
included with the product.
DCall toll free in the US and Canada 1-800-544-2444.
DOutside the US and Canada, call the nearest regional
office.
Headquarters Europe, Middle East,Africa
(EMEA)
Kohler Power Systems
3 rue de Brennus
93200 Saint Denis
France
Phone: [phone]
Fax: [phone]
Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: [phone]
Fax: [phone]
China
North China Regional Office, Beijing
Phone: [phone]
(86) 10 6518 7951
(86) 10 6518 7952
Fax: [phone]
East China Regional Office, Shanghai
Phone: [phone]
Fax: [phone]
India, Bangladesh, Sri Lanka
India Regional Office
Bangalore, India
Phone: [phone]
(91) 80 3366231
Fax: [phone]
Japan, Korea
North Asia Regional Office
Tokyo, Japan
Phone: [phone]
Fax: [phone]
Latin America
Latin America Regional Office
Lakeland, Florida, USA
Phone: [phone]
Fax: [phone]

TP-6447 10/12 9Section 1 Product Description
Section 1 Product Description
1.1 Purpose
An automatic transfer switch (ATS) transfers electrical
loads from a normal (preferred) source of electrical
power to an emergency (standby) source when the
normal source falls outside the acceptable electrical
parameters.
When the normal (preferred) source fails, the ATS
signals the emergency (standby) source generator set
to start. When the emergency (standby) source reaches
acceptable levels and stabilizes, the ATS transfers the
load from the normal (preferred) source to the
emergency (standby) source. The ATS continuously
monitors the normal (preferred) source and transfers the
load back when the normal (preferred) source returns
and stabilizes. After transferring the load back to the
normal (preferred) source, the ATS removes the
generator start signal, allowing the generator set to shut
down.
Figure 1-2 shows a typical installation block diagram.
Figure 1-1 Automatic Transfer Switch
Power
Switching
Device
To Load
Automatic Transfer Switch
Electrical
Controls
Normal
(Utility)
Power
Emergency
(Generator)
Power Generator
Start Generator
TS-003
Figure 1-2 Typical ATS Block Diagram
1.2 Nameplate
A nameplate attached to the controller cover on the
inside of the enclosure door includes a model
designation, a serial number, ratings, and other
information about the transfer switch. See Figure 1-3.
The serial number is also shown on a label inside the
transfer switch enclosure.
Copy the model designation, serial number, and
accessory information from the nameplate to the spaces
provided in the Product Identification Information
section inside the front cover of this manual for use when
requesting service or parts.
GM21291
Figure 1-3 Typical Transfer Switch Nameplate

TP-6447 10/1210 Section 1 Product Description
1.3 Model Designation
Model
K: Kohler Transfer Switch
Controls
D: MPACt1500
Microprocessor Controls, Automatic
F: MPACt1500
Microprocessor Controls, Non-Automatic
Number of Poles/Wires
Enclosure
Mechanism
S: Specific-Breaker Rated
Transition
S: Specific-Breaker Rated
P: Programmed-Transition
Power Connections
S: Standard
C: 208 Volts/60 Hz
D: 220 Volts/50 Hz
F: 240 Volts/60 Hz
G: 380 Volts/50 Hz
H: 400 Volts/50 Hz
J: 416 Volts/50 Hz
K: 440 Volts/60 Hz
M: 480 Volts/60 Hz
P: 380 Volts/60 Hz
R: 220 Volts/60 Hz
Voltage/Frequency
N: 2-pole, 3-wire, solid neutral
T: 3-pole, 4-wire, solid neutral
V: 4-pole, 4-wire, switched neutral
A: NEMA 1[
B: NEMA 12
C: NEMA 3R
D: NEMA 4
F: NEMA 4X
G: Open unit
Model Controls Voltage Poles Enclosure Current Rating Connection
s
Mechanism Transition
Current Rating: Numbers indicate the current
rating of the switch in amperes:
[NEMA 1 enclosure standard. Other types available
to order.
Record the transfer switch model designation in the boxes. The transfer switch model designation defines
characteristics and ratings as explained below.
Sample Model Designation: KSP-DCTA-0100S
]Standard--transition models only.
0040 ]
0080 ]
0100
0150 ]
0200
0225 ]
0260 ]
0400
0600
0800 ]
1000 ]

TP-6447 10/12 11Section 2 Installation
Section 2 Installation
2.1 Introduction
Kohlerrtransfer switches are shipped factory-wired,
factory-tested, and ready for installation. Have the
equipment installed only by trained and qualified
personnel. Verify that the installation complies with
applicable codes and standards. Installation includes
the following steps:
DUnpack and inspect the transfer switch upon receipt.
DVerify that the transfer switch voltage and frequency
ratings match the voltages and frequencies of the
sources.
DMount the transfer switch.
DCheck the manual operation.
DWire the normal power source (utility), emergency
power source (generator set), and load circuits.
DConnect the generator set engine start leads.
DConnect accessories, if provided.
DConnect and initialize the electrical controls, as
required.
DCheck voltages and operation.
Protect the switch against damage before and during
installation.
Note: A protective device such as a molded-case circuit
breaker or fused disconnect switch MUST be
installed on both sources of incoming power for
circuit protection and use as a disconnect device.
The functional tests in Section 3 are a necessary part of
the installation. Be sure to perform the functional tests,
which include voltage checks and operation tests,
before putting the transfer switch into service.
2.2 Receipt of Unit
2.2.1 Inspection
At the time of delivery, inspect the packaging and the
transfer switch for signs of shipping damage. Unpack
the transfer switch as soon as possible and inspect the
exterior and interior for shipping damage. If damage
and/or rough handling is evident, immediately file a
damage claim with the transportation company.
2.2.2 Storage
Store the transfer switch in its protective packing until
final installation. Protect the transfer switch at all times
from moisture, construction grit, and metal chips. Avoid
storage in low-temperature and high-humidity areas
where moisture could condense on the unit. See
Figure 2-1 for acceptable storage temperatures.
Item Specification
Storage temperature -- 4 0 °Cto70°C(--40°F to 158°F)
Operating temperature -- 2 0 °Cto85°C(--4°F to 185°F)
Humidity 5% to 95% noncondensing
Figure 2-1 Environmental Specifications
2.2.3 Lifting
Unbalanced weight.
Improper lifting can cause severe
injury or death and equipment
damage.
Use adequate lifting capacity.
Never leave the transfer switch
standing upright unless it is securely
bolted in place or stabilized.
WARNING

TP-6447 10/1212 Section 2 Installation
See Figure 2-2 or Figure 2-3 or the dimensional drawing
for the weight of the transfer switch. Use a spreader bar
to lift the transfer switch. Attach the bar only to the
enclosure’s mounting holes or lifting brackets; do not lift
the unit any other way. Close and latch the enclosure
door before moving the unit.
Amps
Weight kg (lb.)
2-Pole 3-Pole 4-Pole
40--225 28 (62) 30 (65) 31 (68)
260--400 52 (115) 56 (123) 59 (131)
600 179 (395) 183 (403) 186 ( 410)
800 N/A 226 (498) 236 (520)
1000 N/A 231 (509) 241 ( 531)
Figure 2-2 Approximate Transfer Switch Weights,
Standard-Transition Models, NEMA Type
1 and 3R Enclosures
Amps
Weight kg (lb.)
2-Pole 3-Pole 4-Pole
100--200 52 (115) 56 (123) 59 (131)
400 52 (115) 56 (123) 59 (131)
600 179 (395) 183 (403) 186 ( 410)
Figure 2-3 Approximate Transfer Switch Weights,
Programmed-Transition Models, NEMA
Type 1 and 3R Enclosures
2.2.4 Unpacking
Allow the equipment to warm to room temperature for at
least 24 hours before unpacking to prevent
condensation on the electrical apparatus. Use care
when unpacking to avoid damaging transfer switch
components. Remove dirt and packing material that
may have accumulated in the transfer switch or any of its
components.
Note: Do not use compressed air to clean the switch.
Cleaning with compressed air can cause debris to
lodge in the components and damage the switch.
2.3 Installation
NOTICE
Foreign material contamination. Cover the transfer switch
during installation to keep dirt, grit, metal drill chips, and other
debris out of the components. Cover the solenoid mechanism
during installation. After installation, use the manual
operating handle to cycle the contactor to verify that it
operates freely. Do not use a screwdriver to force the
contactor mechanism.
NOTICE
Hardware damage. The transfer switch may use both
American Standard and metric hardware. Use the correct
size tools to prevent rounding of the bolt heads and nuts.
Check the system voltage and frequency. Compare
the voltage and frequency shown on the transfer switch
nameplate to the source voltage and frequency. Do not
install the transfer switch if the system voltage and
frequency are different from the nominal normal (utility)
source voltage and frequency or the nominal emergency
source voltage and frequency shown on the generator
set nameplate.
Plan the installation. Use the dimensions given on the
enclosure dimension (ADV) drawings. Select a
mounting site that complies with local electrical code
restrictions for the enclosure type. Mount the transfer
switch as close to the load and power sources as
possible. Allow adequate space to fully open the
enclosure and to service the switch. Provide cable
bending space and clearance to live metal parts.
Outdoor installations. Transfer switches with
NEMA 3R, 4, or 4X enclosures can be installed
outdoors. In locations with very high ambient
temperatures, installation in a shaded area or a location
with the enclosure door facing away from direct sunlight
is recommended.
Prepare the foundation. Ensure that the supporting
foundation for the enclosure is level and straight. For
bottom cable entry, if used, install conduit stubs in the

TP-6447 10/12 13Section 2 Installation
foundation. Refer to the enclosure dimension drawing
for the conduit stub locations. When pouring a concrete
floor, use interlocking conduit spacer caps or a wood or
metal template to maintain proper conduit alignment.
Install the ATS. For easy access during installation and
wiring, remove the front door of the enclosure. Open the
door and disconnect the cable plug that connects the
front door components to the internal components.
Disconnect the grounding wire between the door and the
enclosure. For NEMA type 1 and 3R enclosures,
squeeze the release pins on each hinge together and
remove the door. See Figure 2-4. Set the door out of the
way to protect the controls. Cover the internal
components of the transfer switch mechanism to keep
debris out of the components.
1
6126
1. Hinge release pins
Figure 2-4 Hinge Release Pins
Vertically mount 40- through 400-amp transfer switches
to a wall or other rigid vertical supporting structure. Use
the template on the shipping carton to locate the
mounting holes in the wall. Level the template before
marking and drilling the holes. Clearance holes through
the back of each enclosure are provided for mounting.
Use shims to plumb the enclosure. Verify that the door
hinges are vertical to avoid distortion of the enclosure or
door. Vacuum any debris out of the enclosure.
Bolt 600-amp automatic transfer switches directly to
floor mounting pads. Shim the enclosure so that the
enclosure is plumb.
2.4 Manual Operation Check
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.
DANGER
NOTICE
Improper operator handle usage. Use the manual operator
handle on the transfer switch for maintenance purposes only.
Return the transfer switch to the normal position. Remove the
manual operator handle, if used, and store it in the place
provided on the transfer switch when service is completed.
A manual operation handle is provided with the transfer
switch for maintenance purposes only. Use the manual
operation handle to check the manual operation before
energizing the transfer switch. Use the following manual
operation procedures to verify that the contactor
operates smoothly without binding.
Note: A contactor in normal and serviceable condition
operates smoothly without binding. Do not place
the transfer switch into service if the contactor
does not operate smoothly; contact an authorized
distributor/dealer to service the contactor.
2.4.1 Manual Operation Procedure,
Standard-Transition Switches
Note: Never use the maintenance handle to transfer the
load with the power connected. Disconnect both
power sources before manually operating the
switch.
1. Remove the maintenance handle from its storage
location inside the enclosure. See Figure 2-5
through Figure 2-7.
2. Attach the maintenance handle:
a. 40--600 Amp switches: Insert the maintenance
handle into the hole in the shaft on the left side
of the operator as shown in Figure 2-5 or
Figure 2-6.
b. 800--1000 Amp switches: Slide the
maintenance handle over the square shaft on
the left side of the operator as shown in
Figure 2-7.

TP-6447 10/1214 Section 2 Installation
3. Move the maintenance handle up or down as
shown in the corresponding figure to manually
operate the transfer switch. It should operate
smoothly without any binding. If it does not, check
for shipping damage or construction debris.
4. Return the transfer switch to the Normal position.
5. Remove the maintenance handle and return it to the
storage location.
1. Handle storage location
2. Insert handle here for manual operation
1
tp6225
2
Figure 2-5 Manual Operation, 40--260 Amp
Standard-Transition Switches
tp6225
1
2
1. Handle storage location
2. Insert handle here for manual operation
Figure 2-6 Manual Operation, 400--600 Amp
Standard-Transition Switches
2
tp6447
1. Handle storage location inside enclosure
2. Shaft (attach handle here)
3. Move maintenance handle down and release to manually operate
3
1
Figure 2-7 Manual Operation, 800--1000 Amp Standard-Transition Switches

TP-6447 10/12 15Section 2 Installation
2.4.2 Manual Operation Procedure,
Programmed-Transition Switches
Note: Never use the manual operation handle to
transfer the load with the power connected.
Disconnect both power sources before manually
operating the switch.
1. Check the contactor position, indicated by the A
and B position indicators. See Figure 2-8. One
position indicator will display ON to indicate the
source position. If both indicators display OFF, the
transfer switch is in the OFF position.
1
tp6225
1. Shaft (attach handle here)
2. Trip button
3. Select button
4. Source 1 (A) position indicator (ON/OFF)
5. Source 2 (B) position indicator (ON/OFF)
2
3
4
5
Figure 2-8 Manual Operation, Programmed-
Transition Switches (handle not shown)
2. If the transfer switch is not in the OFF position, use
a screwdriver or other tool to push the TRIP button.
See Figure 2-8. Check that both position indicators
display OFF.
3. Slide the manual operating handle (provided with
the switch) over the shaft on the left side of the
switch. See Figure 2-8.
4. Move the switch to the A (Source 1) or B (Source 2)
position as follows:
a. To move the switch to position A (Source 1),
move the manual operation handle up and then
release the handle. Verify that the A position
indicator displays ON.
b. To move the switch to position B (Source 2), use
a screwdriver or other tool to push the SELECT
button. Hold the SELECT button in and move
the manual operation handle up and then
release the handle. Verify that the B position
indicator displays ON.
Note: Always move the manual operation handle
UP and then release it.
5. Remove the manual operation handle and store it in
a convenient location.
6225
Move handle up and
then release.
Figure 2-9 Manual Operating Handle, Programmed-
Transition Switches

TP-6447 10/1216 Section 2 Installation
2.5 Controller
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.
DANGER
NOTICE
Electrostatic discharge damage. Electrostatic discharge
(ESD) damages electronic circuit boards. Prevent
electrostatic discharge damage by wearing an approved
grounding wrist strap when handling electronic circuit boards
or integrated circuits. An approved grounding wrist strap
provides a high resistance (about 1 megohm), not a direct
short, to ground.
The controller’s logic board is mounted in a plastic
housing on the inside of the transfer switch enclosure
door.
2.5.1 Controller Connection
Verify that the contactor harness is connected to the
controller (through the logic disconnect switch, if
equipped). See the controller Operation manual. See
list of Related Materials in the Introduction for document
numbers.
Note: Verify that the power is disconnected before
connecting or disconnecting the contactor
harness.
2.5.2 Controller Ground
Verify that the grounding wire is connected from the
controller to the stud on the door and to the inside of the
enclosure. This connection provides proper grounding
that does not rely upon the door hinges.
2.5.3 Other Connections
Refer to the transfer switch wiring diagram or the
controller Operation Manual for the following controller
and accessory connections.
DInputs and outputs
DCommunications connections
DAccessory connections
2.6 Electrical Wiring
The transfer switch is factory-wired and tested. Field
installation includes connecting the sources, loads,
generator start circuit(s), and auxiliary circuits, if used.
Note: An approved protective device such as a
molded-case circuit breaker or fused disconnect
switch MUST be installed on both sources of
incoming power for circuit protection and use as a
disconnect device.
Refer to the wiring diagrams provided with the transfer
switch. Observe all applicable national, state, and local
electrical codes during installation.
Install DC, control, and communication system wiring
in separate conduit from AC power wiring.
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery.
WARNING
Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on the
generator set or connected equipment, disable the generator
set as follows: (1) Move the generator set master switch to the
OFF position. (2) Disconnect the power to the battery
charger. (3) Remove the battery cables, negative (--) lead
first. Reconnect the negative (--) lead last when reconnecting
the battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote
start/stop switch, or engine start command from a remote
computer.
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.
DANGER

TP-6447 10/12 17Section 2 Installation
Making line or auxiliary connections. Hazardous voltage
can cause severe injury or death. To prevent electrical
shock deenergize the normal power source before making
any line or auxiliary connections.
Grounding electrical equipment. Hazardous voltage can
cause severe injury or death. Electrocution is possible
whenever electricity is present. Ensure you comply with all
applicable codes and standards. Electrically ground the
generator set and related equipment and electrical circuits.
Turn off the main circuit breakers of all power sources before
servicing the equipment. Never contact electrical leads or
appliances when standing in water or on wet ground because
these conditions increase the risk of electrocution.
NOTICE
Foreign material contamination. Cover the transfer switch
during installation to keep dirt, grit, metal drill chips, and other
debris out of the components. Cover the solenoid mechanism
during installation. After installation, use the manual
operating handle to cycle the contactor to verify that it
operates freely. Do not use a screwdriver to force the
contactor mechanism.
2.6.1 Source and Load Connections
Determine the cable size. Refer to the transfer switch
dimension drawing to determine the size and number of
conductors that can be used. Make sure that the cables
are suitable for use with the transfer switch lugs.
Watertight conduit hubs may be required for outdoor
use.
Drill the entry holes. Cover the internal components of
the ATS to protect them from metal chips and
construction grit. Then drill entry holes for the
conductors at the locations shown on the enclosure
drawings. Remove debris from the enclosure with a
vacuum cleaner.
Note: Do not use compressed air to clean the switch.
Cleaning with compressed air can cause debris to
lodge in the components and damage the switch.
Install and test the power conductors. Leave
sufficient slack in the conductors to reach all of the
power connecting lugs on the power switching device.
Test the power conductors after pulling them into
position and before they are connected to verify that they
are not defective and that they were not damaged during
installation.
Connect the cables. Be careful when stripping
insulation from the cables; avoid nicking or ringing the
conductor. Clean cables with a wire brush to remove
surface oxides before connecting them to the terminals.
Apply joint compound to the connections of any
aluminum conductors.
Refer to the wiring diagram provided with the switch.
The connection points on the contactor are labeled
Normal, Emergency, and Load. Be sure to follow the
phase markings (A, B, C, and N). For single-phase
systems, connect to A and C.
Note: Connect the source and load phases as
indicated by the markings and drawings to
prevent short circuits and to prevent phase-
sensitive load devices from malfunctioning or
operating in reverse.
Verify that all connections are consistent with drawings
before tightening the lugs. Tighten all lug connections to
the torque values shown in Figure 2-10. Carefully wipe
off any excess joint compound after tightening the
terminal lugs.
Socket Size Across Flats, in.
Bolt Torque
Nm Ft. lb.
1/8 5 4
5/32 11 8
3/16 14 10
7/32 16 12
1/4 23 17
5/16 31 23
3/8 42 31
1/2 57 42
9/16 68 50
Figure 2-10 Tightening Torque for Lugs

TP-6447 10/1218 Section 2 Installation
ADV-6736
Figure 2-11 Interconnection Diagram

TP-6447 10/12 19Section 2 Installation
2.6.2 Engine Start Connection
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery.
WARNING
Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on the
generator set or connected equipment, disable the generator
set as follows: (1) Move the generator set master switch to the
OFF position. (2) Disconnect the power to the battery
charger. (3) Remove the battery cables, negative (--) lead
first. Reconnect the negative (--) lead last when reconnecting
the battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote
start/stop switch, or engine start command from a remote
computer.
Prevent the generator set from starting by moving the
generator set master switch to the OFF position;
disconnecting power to the generator engine start
battery charger, if installed; and disconnecting all
generator engine start battery cables, negative (--) leads
first.
Connect the generator set remote starting circuit to the
engine start terminals located on the transfer switch
contactor assembly. See Figure 2-13 through
Figure 2-18 for the locations of the engine start
terminals, which are labeled on the unit with a red decal.
Refer to the generator set installation manual for wire
size specifications.
The engine start contact ratings are shown in
Figure 2-12.
2.6.3 Auxiliary Contacts
Connect the auxiliary contacts to customer-supplied
alarms, remote indicators, or other devices. Auxiliary
contacts provide contacts that close when the transfer
switch is in the Normal position and contacts that close
when the transfer switch is in the Emergency position.
Refer to the schematic diagram provided with the
transfer switch to identify which auxiliary contacts are
closed on Normal and which are closed on Emergency.
Figure 2-13 through Figure 2-18 show the locations of
the auxiliary contacts for different models. The auxiliary
contact ratings are shown in Figure 2-12.
Contacts Resistive Load Inductive Load
Motor Load
NC NO
Engine Start Contacts 2A@30VDC N/A N/A N/A
Auxiliary Contacts, KSS (40--600A) 15 A @ 250 VAC N/A N/A N/A
Auxiliary Contacts, KSS
(800--1000A)
15 A @ 480 VAC 15 A @ 250 VAC;
6 A @ 500 VAC
5 A @ 125 VAC;
3 A @ 250 VAC;
1.5 A @ 500 VAC
2.5 A @ 125 VAC;
1.5 A @ 250 VAC;
0.75 A @ 500 VAC
Auxiliary Contacts, KSP 15 A @ 480 VAC 15 A @ 250 VAC;
6 A @ 500 VAC
5 A @ 125 VAC;
3 A @ 250 VAC;
1.5 A @ 500 VAC
2.5 A @ 125 VAC;
1.5 A @ 250 VAC;
0.75 A @ 500 VAC
Figure 2-12 Contact Ratings

TP-6447 10/1220 Section 2 Installation
tp6225
1. Engine start terminal location
2. Auxiliary contacts
1
2
Figure 2-13 Engine Start and Auxiliary Contact
Locations, 40--225 Amp
Standard-Transition Switches
tp6225
1
1. Engine start terminal location
2. Auxiliary contacts
2
Figure 2-14 Engine Start and Auxiliary Contact
Locations, 400--600 Amp
Standard-Transition Switches
tp6447
1. Engine start connection
2. Auxiliary contacts
1
2
Figure 2-15 Engine Start and Auxiliary Contact
Locations, 800--1000 Amp
Standard-Transition Switches