Format: PDF (Printable Document)
File Language: English
File Pages: 72
File Size: 7.83 MB (Speed Download Link)
Brand: Kohler
Model: ZCS Automatic Transfer Switches
Book No: tp5660
Type of Document: Operation and Installation Manual
$ 40
These Kohler ZCS automatic transfer switches sit between your utility feed and your generator, usually in commercial buildings, farms, or light industrial sites where you can’t afford long outages. This manual is what I’d keep on the bench or tablet when I’m wiring in a new switch, checking operation after a power event, or chasing odd transfer behavior. For example, if the switch hesitates going back to utility after a storm, this book walks you through how to verify settings, confirm signals, and test the sequence safely.
Applications & Use Cases
FAQ
Q: Can I keep this manual on a tablet in the field?
A: Yes, it’s practical to use digitally; you can zoom in on diagrams and search terms while standing at the switchgear.
Q: Is it worth printing sections of this manual?
A: Printing the key wiring and test procedures is handy for marking notes, taping near the enclosure, and keeping clean copies in the maintenance binder.
Safety Note
Always isolate all power sources and verify absence of voltage before opening or working inside any transfer switch.
Safety Precautions and Instructions . . . . . . . . . I
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
List of Related Materials . . . . . . . . . . . . . . . . . . . . . i
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . ii
Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Product Indentification . . . . . . . . . . . . . . . . . . . . . . . ii
Section 1. Specifications . . . . . . . . . . . . . . . . . . . 1
1.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Part Number Model Code . . . . . . . . . . . . . . . . . . . . 3
1.5 Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.7 Application Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Section 2. Operation . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Automatic Operation . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2.1 Failure of Normal Power . . . . . . . . . . . . . . 10
2.2.2 Restoration of Normal Power . . . . . . . . . . 10
2.3 Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3.1 Programmed Transition Switch,
40–260 Amps . . . . . . . . . . . . . . . . . . . . . . . 12
2.3.2 Programmed Transition Switch,
400–3000 Amps . . . . . . . . . . . . . . . . . . . . . 13
2.3.3 Standard Switch, 800–3000 Amps . . . . . . 14
Section 3. Accessories . . . . . . . . . . . . . . . . . . . . . 15
3.1 Programmed Transition . . . . . . . . . . . . . . . . . . . . . . 15
3.1.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1.2 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2 Other Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Section 4. Scheduled Maintenance . . . . . . . . . . 17
4.1 Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . 18
4.1.1 General Inspection . . . . . . . . . . . . . . . . . . . 19
4.1.2 Other Inspections and Service . . . . . . . . . 19
4.2 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2.1 Weekly Generator Set Exercise . . . . . . . . 19
4.2.2 Monthly Automatic Control System
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.3 Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Section 5. Diagrams and Drawings . . . . . . . . . . 21
Section 6. Installation . . . . . . . . . . . . . . . . . . . . . . 55
6.1 Upon Receipt of Unit . . . . . . . . . . . . . . . . . . . . . . . . 55
6.1.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.1.2 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.1.3 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.1.4 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.2 Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . 56
6.3 Check Manual Operation . . . . . . . . . . . . . . . . . . . . . 56
6.4 Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.4.1 AC Power Connections . . . . . . . . . . . . . . . 58
6.4.2 Generator Start Connection . . . . . . . . . . . 59
6.4.3 Accessory and Controller Connections . . 59
6.5 Prepare the Generator Set for Operation . . . . . . . 59
6.6 Functional Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.6.1 Voltage Check . . . . . . . . . . . . . . . . . . . . . . . 60
6.6.2 Automatic Operation Test . . . . . . . . . . . . . 61
6.7 Controller Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.8 Ensure Warranty Registration . . . . . . . . . . . . . . . . . 61
Appendix A. Glossary of Abbreviations . . . . . . A-1
