Kohler ZCS series Instruction Manual

AutomaticTransferSwitches
Models:
ZCS
Contactors:
40 to 3000 Amperes
TP-5660 11/98
Operation and
Installation

TP-5660 11/98 Table ofContents
TableofContents
SafetyPrecautions and InstructionsI.........
Introduction i...............................
ListofRelated Materialsi.....................
Service Assistance ii.........................
ServiceInformation ii..........................
Product Indentification ii.......................
Section 1.Specifications 1...................
1.1Purpose 1...................................
1.2Components1...............................
1.3Nameplate 2.................................
1.4PartNumberModelCode 3....................
1.5StandardFeatures4..........................
1.6Ratings4....................................
1.7Application Data 7............................
Section 2.Operation 9.......................
2.1Startup 9....................................
2.2AutomaticOperation 9.........................
2.2.1Failure ofNormalPower10..............
2.2.2Restoration ofNormalPower10..........
2.3ManualOperation 11...........................
2.3.1Programmed Transition Switch,
40--260 Amps12.......................
2.3.2Programmed Transition Switch,
400--3000 Amps13.....................
2.3.3StandardSwitch,800--3000 Amps14......
Section 3.Accessories 15.....................
3.1Programmed Transition 15......................
3.1.1Description 15..........................
3.1.2Adjustment15..........................
3.2OtherAccessories16..........................
Section 4.ScheduledMaintenance 17..........
4.1Inspection and Service 18.......................
4.1.1GeneralInspection 19...................
4.1.2OtherInspectionsand Service 19.........
4.2Testing 19....................................
4.2.1WeeklyGeneratorSetExercise 19........
4.2.2MonthlyAutomaticControlSystem
Test19................................
4.3ServiceSchedule 20...........................
Section 5.Diagrams and Drawings 21..........
Section 6. Installation 55......................
6.1Upon ReceiptofUnit55........................
6.1.1Inspection 55..........................
6.1.2 Lifting 55..............................
6.1.3Unpacking 56..........................
6.1.4Storage 56.............................
6.2MechanicalInstallation 56.......................
6.3Check ManualOperation 56.....................
6.4ElectricalWiring 56............................
6.4.1ACPowerConnections58...............
6.4.2GeneratorStartConnection 59...........
6.4.3Accessoryand ControllerConnections59. .
6.5Preparethe GeneratorSet forOperation 59.......
6.6FunctionalTests60............................
6.6.1Voltage Check 60.......................
6.6.2AutomaticOperation Test61.............
6.7ControllerSetup 61............................
6.8EnsureWarrantyRegistration 61.................
AppendixA.GlossaryofAbbreviationsA-1......

TP-5660 11/98 SafetyPrecautionsand InstructionsI
SafetyPrecautions and Instructions
Atransferswitch,like anyother
electromechanicaldevice,can pose
potentialdangerstolife and limbif
improperlymaintained oroperated.
The bestwayto preventaccidentsisto
be aware ofpotentialdangersand act
safely.Pleaseread and followthe
safetyprecautionsand instructions
belowto preventharmtoyourselfand
others.Thismanualcontains several
typesofsafetyprecautionsand
instructionswhichare explainedbelow.
SAVE THESE INSTRUCTIONS.
DANGER
Dangerindicatesthe presence ofa
hazardthatwill causeseverepersonal
injury,death,orsubstantialproperty
damage.
WARNING
Warning indicatesthe presence ofa
hazardthatcan causeseverepersonal
injury,death,orsubstantialproperty
damage.
CAUTION
Caution indicatesthe presence ofa
hazardthatwill orcan causeminor
personal injuryorpropertydamage.
NOTICE
Noticecommunicatesinstallation,
operation,ormaintenanceinformation
thatisimportantbutnothazardrelated.
Safetydecalsaffixed tothe transfer
switchin prominentplacesadvisethe
operatororservicetechnician of
potentialhazardsandhowtoactsafely.
The decalsarereproduced hereto
improve operator recognition.Replace
missing ordamaged decals.
AccidentalStarting
Accidentalstarting.
Cancause severeinjuryordeath.
Disconnectbattery cablesbefore
working on generatorset. (Remove
negative(--) lead firstwhen
disconnecting battery.Reconnect
negative(--) lead lastwhen
reconnecting battery.)
WARNING
Disabling thegeneratorset.
Accidentalstarting cancause
severeinjuryordeath.Before
working on the generatorsetor
connected equipment, disablethe
generatorsetasfollows:1)Movethe
generatorsetmasterswitchtothe OFF
position.2)Disconnectpowertothe
battery charger.3)Remove battery
cables,negative(--) lead first.
Reconnectnegative(--) lead lastwhen
reconnecting battery.Followthese
precautionsto preventstarting of
generatorsetbyan automatictransfer
switch,remotestart/stop switch,or
engine startcommand fromaremote
computer.
Battery
Sulfuric acidin batteries.
Cancause severeinjuryordeath.
Use protective gogglesand clothes.
Batteryacidcan cause permanent
damage to eyes,burnskin,and eat
holesinclothing.
WARNING
Battery acid.Sulfuric acidin
batteries cancause severeinjuryor
death.Sulfuricacidin battery can
cause permanentdamage to eyes,
burnskin,and eatholesinclothing.
Always wearsplash-proofsafety
goggleswhen working nearthebattery.
Ifbatteryacidissplashed inthe eyesor
on skin,immediatelyflushthe affected
area for15 minuteswithlarge
quantitiesofclean water.Seek
immediatemedicalaidinthe case of
eyecontact. Neveradd acidto a
batteryafterplacing the batteryin
service,asthismayresultinhazardous
spattering ofbatteryacid.

TP-5660 11/98II SafetyPrecautionsand Instructions
Explosion.
Cancause severeinjuryordeath.
Relays in battery chargercause
arcs orsparks.
Locate batteryin a well-ventilated
area. Isolate battery chargerfrom
explosivefumes.
WARNING
Batterygases.Explosion cancause
severeinjuryordeath.Battery
gases can cause an explosion.Do not
smokeorpermitflameorsparktooccur
neara batteryatanytime,particularly
when itis charging.Avoidtouching
terminalswithtools,etc., to prevent
burnsand sparks thatcouldcause an
explosion.Removewristwatch,rings,
and anyotherjewelrybefore handling
battery.Neverconnectnegative(--)
battery cableto positive(+)connection
terminalofstartersolenoid.Do nottest
battery condition by shorting terminals
together.Sparks couldignite battery
gasesorfuelvapors.Ventilate any
compartmentcontaining batteriesto
preventaccumulation ofexplosive
gases.To avoidsparks,do notdisturb
battery chargerconnectionswhile
batteryischarging.Always turnbattery
chargeroff before disconnecting
battery connections.Removenegative
(--) lead firstwhen disconnecting
battery.Reconnectnegative(--) lead
lastwhen reconnecting battery.
HazardousVoltage/
ElectricalShock
Hazardous voltage.
Cancause severeinjuryordeath.
Disconnectall powersourcesbefore
opening enclosure.
(under600 Volt)
WARNING
Hazardous voltage.
Will cause severeinjuryordeath.
Disconnectall powersourcesbefore
opening enclosure.
(600 Volt and above)
DANGER
Hazardous voltage.
Cancause severeinjuryordeath.
Disconnectpowersourcesbefore
servicing. Install barrierafter
adjustments,maintenance,or
service.
(under600 Volt)
WARNING
Hazardous voltage.
Will cause severeinjuryordeath.
Disconnectpowersourcesbefore
servicing. Install barrierafter
adjustments,maintenance,or
servicing.
(600 Volt and above)
DANGER
Hazardous voltage.Movingrotor.
Cancause severeinjuryordeath.
Operate generatorsetonlywith all
guardsand electricalenclosuresin
place.
WARNING
Grounding thetransferswitch.
Hazardous voltage cancause
severeinjuryordeath.Electrocution
ispossiblewheneverelectricityis
present. Open maincircuitbreakersof
all powersourcesbeforeservicing
equipment. Configurethe installation
to electricallyground the transfer
switch and related equipmentand
electricalcircuitstocomplywith
applicablecodesand standards.
Nevercontactelectrical leadsor
applianceswhen standing inwateror
on wetground,asthe chance of
electrocution increasesundersuch
conditions.
Installing battery charger.
Hazardous voltage cancause
severeinjuryordeath.Electrical
shock mayoccurifbattery chargeris
notelectricallygrounded.Connect
battery chargerenclosureto ground of
a permanentwiring system.Asan
alternative,install an equipment
grounding conductorwithcircuit
conductorsand connect to equipment
grounding terminalorlead on battery
charger.Performbattery charger
installation asprescribed in equipment
manual. Install battery chargerin
compliancewithlocalcodesand
ordinances.
Connecting battery and battery
charger. Hazardous voltage can
cause severeinjuryordeath.
Reconnectbattery correctlyto avoid
electricalshock and damage to battery
chargerand battery(ies).Have a
qualified electrician install battery(ies).

TP-5660 11/98 SafetyPrecautionsand InstructionsIII
Installing accessories to
transformerassembly. Hazardous
voltage cancause severeinjuryor
death.To prevent the possibilityof
electricalshock,disconnectharness
plug beforeinstalling anyaccessories
involving connection totransformer
assemblyprimaryterminals76,77,78,
and 79.Terminalsare atline voltage!
(Models with E33+,S340, S340+, 340,
R340, orR33 controls only.)
Installing accessories to
transformerassembly. Hazardous
voltage cancause severeinjuryor
death.To prevent the possibilityof
electricalshock,disconnectharness
plug beforeinstalling anyaccessories
whichwill be connected totransformer
assemblyprimaryterminalson
microprocessorlogicmodels.
Terminalsare atline voltage!
Making lineorauxiliary
connections. Hazardous voltage
cancause severeinjuryordeath.To
prevent the possibilityofelectrical
shock,deenergizethe normalpower
source beforemaking anyline or
auxiliary connections.
Shortcircuits. Hazardous
voltage/currentcancause severe
injuryordeath.Shortcircuits can
cause bodilyinjuryand/orequipment
damage.Do notcontactelectrical
connectionswithtoolsorjewelrywhile
making adjustmentsor repairs.
Removewristwatch,rings,and jewelry
beforeservicing equipment.
Servicing thetransferswitch.
Hazardous voltage cancause
severeinjuryordeath.Deenergizeall
powersourcesbeforeservicing.Open
maincircuitbreakersofall power
sourcestothe transferswitch and
disable all generatorsetsasfollows:
1)Move all generatorsetmaster
controllerswitchestothe OFFposition.
2)Disconnectpowerto all battery
chargers.3)Disconnectall battery
cables,negative(--) leadsfirst.
Reconnectnegative(--)leadslastwhen
reconnecting battery cablesafter
servicing.Followthese precautionsto
preventstarting ofgeneratorsetsbyan
automatictransferswitch,remote
start/stop switch,orengine start
command fromaremotecomputer.
Servicing transferswitchcontrols
and accessories withinthe
enclosure. Hazardous voltage can
cause severeinjuryordeath.
Disconnect transferswitchcontrolsat
the inline connectorto deenergizethe
circuitboardsand logic circuitrybut
allowthe transferswitchtocontinue to
supplypowertothe load.Disconnect
all powersourcesto anyaccessories
mountedwithintheenclosurebutwhich
are notwired through the controlsand
deenergized byinline connector
separation.Testcircuitswith a
voltmetertoverifythat theyare
unpowered beforeservicing.
Heavy Equipment
Unbalancedweight.
Improperlift cancause severe
injuryordeathand/orequipment
damage.
Use adequatelifting capacity.
Neverleavetransferswitchstanding
uprightunless itis securelybolted in
place orstabilized.
WARNING

TP-5660 11/98IV SafetyPrecautionsand Instructions
Moving Parts
Hazardous voltage.Movingrotor.
Cancause severeinjuryordeath.
Operate generatorsetonlywith all
guardsand electricalenclosuresin
place.
WARNING
Notice NOTICE
Hardwaredamage!Transferswitch
mayuse bothAmerican Standard and
metrichardware.Usethe correctsize
toolsto preventrounding ofboltheads
and nuts.
NOTICE
Whenreplacing hardware,do not
substitutewithinferiorgrade
hardware.Screwsand nutsare
availablein differenthardness ratings.
American Standard hardware usesa
seriesofmarkingsandmetrichardware
usesa numeric systemtoindicate
hardness.Check markingson bolt
head and nutsforidentification.
NOTICE
Improperoperatorhandleusage!
Usethe manualoperatorhandle
provided on the transferswitchfor
maintenance purposesonly.Return
the transferswitchtothe normal
position.Removemanualoperator
handle,ifused,and storeiton the
transferswitchinthe place provided
when serviceis completed.
NOTICE
Foreign materialcontamination!
Covertransferswitch during
installation tokeep dirt, grit, metaldrill
chips,etc., outofcomponents.Cover
solenoidmechanismduring
installation.Afterinstallation,use
manualoperating handleto position
contactorto ensurethatitoperates
freely.Do notuseascrewdriverto
forcecontactormechanism.
NOTICE
Electrostaticdischargedamage!
Electrostaticdischarge (ESD)
damageselectronic circuitboards.
Preventelectrostaticdischarge
damage bywearing an approved
grounding wriststrap when handling
electronic circuitboardsorintegrated
circuits.An approved grounding wrist
strap providesa high resistance(about
1megohm),not a directshort, to
ground.

TP-5660 11/98 Introduction i
Introduction
Thismanualprovidesoperation and installation
instructionsforKohlerModelZCSautomatictransfer
switchesthatusea40-to3000-amperecontactorasthe
powerswitching device.
All information inthispublication representsdata
availableattimeofprint. KohlerCo.reservestherightto
change thisliterature and the productsrepresented
withoutincurring obligation.
Read through thismanualand carefullyfollowall
proceduresand safetyprecautionsto ensure proper
equipmentoperation and to avoid bodilyinjury.Read
and followthe SafetyPrecautionsand Instructions
section at the beginning of thismanual.Keep this
manualwith equipment forfuturereference.
Equipmentservicerequirementsareminimalbutare
veryimportanttosafeandefficientoperation;therefore,
inspectpartsoften and performrequired service at the
prescribed intervals.An authorized service distributor
ordealer (authorized servicecenter) should perform
required servicetokeep equipmentintop condition.
ListofRelatedMaterials
Thismanualcoversoperation and installation
information forthe transferswitch’spowerswitching
device.Decode the transferswitch partnumbermodel
code fromthe transferswitch nameplate and verifythat
the transferswitch’spowerswitching devicematches
thatwhatis shown on the frontcoverof thismanual
before proceeding with operation orinstallation.
Aseparate operation and installation manualthat
coversinformation specifictothe transferswitch’s
electricalcontrols(logiccontroller) completesoperation
and installation instructionsforthe transferswitch.
Three typesofelectricalcontrolsare available on the
ModelZCStransferswitch,andeachtypeis coveredin
aseparatemanual.The following tableliststhe
available electricalcontrolsand the related operation
and installation manualpartnumbers.
ElectricalControls
Operation/
Installation
Manual
E33+(SolidState)TP-5662
S340+(SolidState)TP-5663
M340+(Microprocessor) TP-5664
Separatemanuals coverservice and partsinformation
fortransferswitch powerswitching devicesand
electricalcontrols.Thefollowingtableliststheavailable
manualsand the related manualpartnumbers.
PowerSwitching Device Service/Parts
Manual
ZCS/ZCB(Contactor) TP-5668
ElectricalControlsService/Parts
Manual
E33+(SolidState)TP-5670
S340+(SolidState)TP-5671
M340+(Microprocessor) TP-5672
Transferswitcheswithmicroprocessorelectrical
controlsand communication accessories can be
monitored and controlledwith apersonalcomputerand
software.Thefollowingtableliststheavailablemanuals
and partnumbers.
CommunicationsItem
Operation/
Installation
Manual
RemoteMonitoring and Control
Communications(Monitor) SoftwareTP-5823
CommunicationsKitsTT-847

TP-5660 11/98ii Introduction
Service Assistance
Service Information
Forsales,service,orotherinformation aboutaKohler
GeneratorDivision product, contactalocalauthorized
distributorordealerfirst.
Tolocatealocalauthorized distributorordealer
DLookon the productortheinformation includedwith
the product
DConsult the YellowPagesunderthe heading
Generators—Electric
DVisit the KohlerGeneratorDivision Web site at
www.kohlergenerators.com
DCall1-800-544-2444(insidetheU.S.A.andCanada)
or920-565-3381 (outside the U.S.A.and Canada)
ProductIdentification
To ensurethe supplyofcorrectpartsand information,
writethe productidentification numbersinthe spaces
below.Recordthe identification numbersimmediately
afterunpacking the products sothat the numbersare
readilyavailableforfuturereference.Recordthe
field-installed kitnumbersafterinstalling the kit.
T
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a
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S
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i
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I
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o
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N
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b
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s
Recordthe productidentification numbersfromthe
transferswitch nameplate.
PartNumber
SerialNumber
AccessoryNumberAccessoryDescription

TP-5660 11/98 Specifications1
Section 1.Specifications
1.1Purpose
An automatictransferswitch(ATS)transfers critical
electrical loadsfroma normal(preferred)source of
electricalpowerto an emergency (standby)source
when the normalsourcefailstomaintainminimum
voltage and/orfrequency levels.
Upon normalsourcefailure, the ATSsignalsthe
generatorset tostart. When the emergency source
reachesaminimumvoltage and/orfrequency level, the
ATStransfersthe load fromthe normalsourcetothe
emergency source.The ATScontinuously sensesthe
normalsourceand transferstheload backtothenormal
sourcewhenthenormalsourcereturns.Aftertransferof
theloadbacktothenormalsource,theATSremovesthe
generatorsetstartsignal,allowing the generatorset to
shutdown.
1.2Components
Atypicaltransferswitchconsistsof functionalunits
mounted in an enclosurewith a hinged frontdoor.See
Figure 1-1.The powerswitching deviceconnectsthe
load tothe normaloremergency sourcesofpower.An
innerpanelmounted on theinside of the enclosuredoor
containstheelectricalcontrols(logic controller) circuitry
thatmonitorspowersources,controlsthe power
switching device,and signalsthe generatortostart
when needed.Enclosure door-mounted controlsand
indicatorsallowthe operatortocontrolthe transfer
switch operation mode and obtainsystemstatus
information.Awire harness withinline connectorsto
facilitatecomponentreplacementand door removal
connectsthe innerpaneltothe powerswitching device.
Controlsand indicatorson the transferswitch are
determined bythe logic controllerand installed
accessories.Fordetails see the operation and
installation manualforthe logic controllerspecified by
the partnumbermodelcode on the transferswitch
nameplate.See Sections1.3 and 1.4to determine the
logic controlleron the transferswitch.See Listof
Related Materialsinthe Introduction section inthis
manual.
14
TS-001
6
23
5
1.Powerswitching device
2.Enclosure
3.Enclosure door
4. Innerpanelelectricalcontrols(logic controller)
5.Controlsand indicators(mounted on enclosure door)
6.Neutral lug
Figure 1-1.TypicalTransferSwitchComponents
The powerswitching devicetransferspowerfromthe
normaloremergency powersourcetothe load.See
Figure 1-2.The controllerelectricallyactuatesthe
powerswitching devicetoselecta powersource,and
theswitchmechanicallylatchesinthe selectedposition.
The switch alsoincludesa provision formanual
mechanicaloperation in emergency nonpowered
conditions.Withinthe switch aretwosetsofmultipole
contacts.One setofcontacts selectspowerfromthe
normalsource and the othersetselectspowerfromthe
emergency source.The twosetsofcontactsare
mechanicallyinterlocked withinthe switch,ensuring
thatonlyone setofcontactsis closed simultaneously.
Mechanical interlocking ensuresload servicing without
cross-coupling of the powersources.
Interface
Power
Switching
Device
To Load
AutomaticTransferSwitch
Logic
Controller
Normal
(Utility)
Power
Emergency
(Generator)
PowerGenerator
StartGenerator
TS-002
Figure 1-2.TypicalTransferSwitchBlock Diagram

TP-5660 11/982 Specifications
1.3Nameplate
Anameplate providing characteristicand rating
information thataffectsoperation,installation,and
servicing isattached tothe inside of the transferswitch
enclosure door.See Figure 1-3.
Copythe partnumberintothe blank spacesprovided in
Figure 1-4 and then useFigure 1-4tointerpret the part
number.
Copythe partnumber, factory-installed accessory
numbers,andserialnumberfromthenameplateintothe
spacesprovided inthe ServiceAssistancesection in
thismanualforusewhen requesting service orparts.
AUTOMATICTRANSFERSWITCH
PARTNO.
SERIALNO.
VOLTS
PHASE
HERTZ
AMPS
WIRES
POLES
TS-003
1
32
1.Location forpartnumberused toidentifytype ofATS.
2.Location forfactory-installed accessorynumbers.
3.Location forthe ATSserialnumber.
Figure 1-3.TypicalTransferSwitchNameplate