TP 5990

Operation and Installation
Automatic Transfer Switches
Models:
G120 G220
Controls: Solid-State Power Switching Device: 100 and 200 Amperes
TP-5990 11/03c
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 Accessory Number Accessory Description
Table of Contents
Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside front cover Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Component Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 Application Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.1 G120 Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.2 G220 Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 Automatic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.1 Failure of Normal Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.2 Restoration of Normal Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 Exerciser Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.1 Exerciser Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.2 Exerciser Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I i i 1 1 1 1 2 3 3 3 3 4 5 5 5 5 6 6 6 7
Section 3 Maintenance and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3.1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3.2 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Section 4 Drawings and Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Section 5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 Upon Receipt of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.2 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.3 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.4 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 Contactor Manual Operation Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.1 Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.2 Generator Engine Start Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 Initial Startup and Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.1 Manually Select the Normal Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.2 Select the Exerciser Function and Close the Enclosure . . . . . . . . . . . . . 5.5.3 Prepare the Generator Set for Operation . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.4 Connect the Power Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.5 Perform a System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.6 Complete the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.7 Ensure Warranty Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 19 19 19 19 19 19 20 20 21 22 23 23 23 23 23 23 23 24
Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
TP-5990 11/03
Table of Contents
Safety Precautions and Instructions

A transfer switch, like any other electromechanical device, can pose potential dangers to life and limb if improperly maintained or operated. The best way to prevent accidents is to be aware of potential dangers and act safely. Please read and follow the safety precautions and instructions below to prevent harm to yourself and others. This manual contains several types of safety precautions and instructions which are explained below. SAVE THESE INSTRUCTIONS.
Accidental Starting
WARNING
Battery
WARNING
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. 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.
Sulfuric acid in batteries. Can cause severe injury or death. Wear protective goggles and clothing. Battery acid may cause blindness and burn skin.
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.
Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery. Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid.
WARNING
NOTICE
Notice communicates installation, operation, or maintenance information that is safety related but not hazard related. Safety decals affixed to the transfer switch in prominent places advise the operator or service technician of potential hazards and how to act safely. The decals are reproduced here to improve operator recognition. Replace missing or damaged decals. Explosion. Can cause severe injury or death. Relays in the battery charger cause arcs or sparks. Locate the battery in a well-ventilated area. Isolate the battery charger from explosive fumes.
TP-5990 11/03
Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases.
Grounding the transfer switch. Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present. Open main circuit breakers of all power sources before servicing equipment. Configure the installation to electrically ground the transfer switch and related equipment and electrical circuits to comply with applicable codes and standards. Never contact electrical leads or appliances when standing in water or on wet ground, as the chance of electrocution increases under such conditions. 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. 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. Hazardous voltage can cause severe injury or death. Deenergize all power sources before servicing. Open 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.
Hazardous Voltage/ Electrical Shock

DANGER
Heavy Equipment
WARNING
Hazardous voltage. Will cause severe injury or death. Disconnect all power sources before opening the enclosure.
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.
DANGER
Hazardous voltage. Will cause severe injury or death. Only authorized personnel should open the enclosure.
II
TP-5990 11/03
Moving Parts
WARNING
NOTICE
When replacing hardware, do not substitute with inferior grade hardware. Screws and nuts are available in different hardness ratings. To indicate hardness, American Standard hardware uses a series of markings, and metric hardware uses a numeric system. Check the markings on the bolt heads and nuts for identification.
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.
Airborne particles. Can cause severe blindness.
injury
or
Wear protective goggles and clothing when using power tools, hand tools, or compressed air.
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
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.
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.
TP-5990 11/03
III
Notes
IV
TP-5990 11/03
Introduction
This manual provides operation and installation instructions for Kohlerr Model G120 and G220 transfer switches with solid-state electrical controls. 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.
Service Assistance
For professional advice on generator power requirements and conscientious service, please contact your nearest Kohler distributor or dealer.
D Consult the Yellow Pages under the heading
GeneratorsElectric
D Visit
China North China Regional Office, Beijing Phone: (86) 10 6518 7950 (86) 10 6518 7951 (86) 10 6518 7952 Fax: (86) 10 6518 7955 East China Regional Office, Shanghai Phone: (86) 21 6288 0500 Fax: (86) 21 6288 0550 India, Bangladesh, Sri Lanka India Regional Office Bangalore, India Phone: (91) 80 3366208 (91) 80 3366231 Fax: (91) 80 3315972 Japan, Korea North Asia Regional Office Tokyo, Japan Phone: (813) 3440-4515 Fax: (813) 3440-2727 Latin America Latin America Regional Office Lakeland, Florida, USA Phone: (863) 619-7568 Fax: (863) 701-7131
X:in:008:001a
the Kohler Power Systems website at KohlerPowerSystems.com or review the appropriate literature or documents included with the product
D Look at the labels and stickers on your Kohler product
D Call toll free in the US and Canada 1-800-544-2444 D Outside the US and Canada, call the nearest regional
office Africa, Europe, Middle East London Regional Office Langley, Slough, England Phone: (44) 1753-580-771 Fax: (44) 1753-580-036 Asia Pacific Power Systems Asia Pacific Regional Office Singapore, Republic of Singapore Phone: (65) 264-6422 Fax: (65) 264-6455
TP-5990 11/03
Introduction
Notes
ii
Service Assistance
TP-5990 11/03
Section 1 Specifications
1.1 Purpose
An automatic transfer switch (ATS) transfers critical electrical loads from a normal (preferred) source of electrical power to an emergency (standby) source when the normal source fails to maintain a minimum voltage level. When the normal source fails, the ATS signals the generator set(s) to start. When the emergency source reaches a minimum voltage level, the ATS transfers the load from the normal source to the emergency source. The ATS continuously senses the normal source and transfers the load back to the normal source when the normal source returns. After transfer of the load back to the normal source, the ATS removes the generator set start signal, allowing the generator set(s) to shut down. The power switch contains two sets of multipole contacts. One set of contacts selects power from the normal source and the other set selects power from the emergency source. Mechanical interlocks within the switch ensure that only one set of contacts is closed at a time ensuring load servicing without cross-coupling of power sources.
Normal (Utility) Power Emergency (Generator) Power Generator Start Generator Power Switching Device Electrical Controls Automatic Transfer Switch
1.2 Component Overview

The ATS components include the power switching device (contactor), the electrical controls, and the exerciser. See Figure 1-1. The power switching device transfers power from the normal or emergency sources to the load. See Figure 1-2. The electrical controls electrically actuate the switch to select a power source, and the switch mechanically latches into the selected position. The switch also includes a provision for manual mechanical operation in emergency nonpowered conditions. The electrical controls monitor power sources, control the contactor, and signal the generator to start when needed. The exerciser runs the generator set weekly if enabled.
2 1 3 4
To Load
TS-002
Figure 1-2
Typical ATS Block Diagram
1.3 Nameplate
A nameplate is attached to the inside of the ATS enclosure cover. See Figure 1-3. The nameplate label includes a model and serial number and provides characteristic and rating information that affects installation and operation. Copy the model and serial number from the nameplate into the spaces provided in the Service Assistance section of this manual for use when requesting service or parts.
TRANSFER SWITCH FOR EMERGENCY SYSTEMS TYPE ENCLOSURE MFG. DATE MATERIAL MODEL SERIAL NO. AMPS WIRES POLES VOLTS PHASE HERTZ ACCESSORIES:
5
1. 2. 3. 4. 5. Power switching device (contactor) Enclosure Electrical controls (solid-state) Enclosure cover Exerciser switch
5990101
R LISTED TRANSFER SWITCH FOR EMERGENCY SYSTEMS R LR 58301
GM21291-E
Figure 1-3
Typical Transfer Switch Nameplate
Figure 1-1
ATS Components
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1.4 Model Number

Use Figure 1-4 to record and interpret the transfer switch model number.
Record the transfer switch part number in the boxes below. The transfer switch part number defines characteristics and ratings as explained in the accompanying chart. Model Controls Voltage and Frequency Poles Wires Enclosure Current Rating
Kohlerrr Model Number Key This chart explains the Kohlerr transfer switch model number code. The sample model number shown is for a Model G120 automatic transfer switch that uses a 250-volt maximum contactor power switching device with solid-state electrical controls rated at 240 volts, 60 hertz, 1 phase, 2 pole, and 3 wires in a NEMA Type 1 enclosure with a current rating of 200 amperes. Not all possible combinations are available. Model G120: Model G120 transfer switch, 250-volt maximum contactor * G220: Model G220 transfer switch, 250-volt maximum contactor Electrical Controls 1: Solid-state Voltage and Frequency 63: 220 Volt, 50 Hz 64: 240 Volt, 60 Hz 68: 208 Volt, 60 Hz (G120 only)
SAMPLE PART NUMBER
G120-164233-0200
Number of Poles and Phases 2: 2 Pole, 1 Phase 3: 3 Pole, 3 Phase (G120 only)
Number of Wires 3: 3 Wire 4: 4 Wire
Enclosure 3 = NEMA type 3R Current Rating Numbers indicate the current rating of the switch in amperes. * To be discontinued
Figure 1-4
Transfer Switch Model Number Code
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1.5 Standard Features

D G120 transfer switches are UL 1008 listed and CSA
D Ambient operating temperature range
--4_ to 140_F (--20_ to 60_C)
certified
D G220 transfer switches are UL 1008 listed and UL
D Ambient storage temperature range
--22_ to 158_F (--30_ to 70_C)
listed to Canadian safety standards

D Contactors are rated 250 VAC maximum, 60 or 50 Hz D The G120 ATS is available with 2 or 3 poles, single-
D Humidity range 5 to 85% noncondensing D Provision for test switch
1.6 Application Data

See Figure 1-5 for application data including the range of wire sizes for transfer switch power terminals.
UL-Listed Solderless Screw-Type Terminals for External Power Connections Switch Rating, Rating amps 100 200 Normal, Emergency, and Load Terminals Cables per Pole 1 1 Range of Wire Sizes #8 to 3/0 (copper or aluminum) #8 to 3/0 (copper only)
or three-phase
D The G220 ATS is a 2-pole, single-phase transfer
switch only
D NEMA type 3R enclosure D Integrated
solid-state logic controller with conformally coated printed circuit board for protection against harsh environments at 160 VAC and pickup fixed at 190 VAC
D Single-phase switches: normal source dropout fixed D Three-phase switches: normal source dropout fixed
Figure 1-5
Application Data
at approximately 80% of nominal for single-phase failure and pickup fixed at approximately 90% of nominal (G120 only)
D Emergency source voltage sensing one phase:
1.7 Ratings
1.7.1 G120 Ratings
dropout fixed at 160 VAC and pickup fixed at 190 VAC

D Time Delay Engine Start (TDES) fixed at 3 seconds D Time Delay Normal to Emergency (TDNE) fixed at
2 seconds
D Time Delay Emergency to Normal (TDEN) fixed at
The following tables provide contactor withstand and closing current ratings (WCR) per UL 1008 standards. Figure 1-6 provides WCR when used with given types of fuses and circuit breakers. Figure 1-7 provides WCR for 100 and 200 ampere switch sizes when coordinated with specific manufacturers circuit breakers.
Withstand and Closing Ratings per UL 1008 and CSA, Maximum Current (amps) When Used With 400 Amps A Maximum Class J, RK5, or RK1 Fuse 200,000 200,000 When Coordinated With Molded-Case Circuit Breakers Any, 400 Amps Maximum 10,000 10,000 Specific Manufacturers (see Figure 1-8) 22,000 22,000
12 seconds
D Time Delay Engine Cooldown (TDEC) fixed at
2 minutes
D User-enabled generator exerciser: starts and runs
the generator unloaded for a 20-minute period once a week

D Contactor electrically and mechanically interlocked D Contactor
Switch Rating (amps) 100 200
* UL 1008 listed and CSA certified at 240 vac maximum.
manually operable for maintenance
Figure 1-6
purposes
G120 Withstand and Closing Current Ratings
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Specific Manufacturers Molded-Case Circuit Breakers * WCR, RMS Symmetrical Amperes Maximum Size (amps) 100 150 250 400 100 250 400 125 250 400 100 150 225 250 400
Manufacturer FCL, FB Tripac Cutler-Hammer/ Westinghouse g FD, FDC, HFD HJD, JD, JDB, JDC
Type or Class
HKD, KD, KDB, KDC, LA Tripac, LCL, DK FC, FH, FI Square D 22,000 ITE/Siemens KA, KC, KH, KI LA, LC, LE, LH, LI, LX, LXI CED6, ED6, HED4, HED6, ED4 CFD6, FD6, FXD6, HFD6 CJD6, HJD6, HHJD6, HHJXD6, JD6, JXD6, SCJD6, SHJD6, SJD6 TB1 SEL, SEP, TEL, THED, THLC1 GE TFK, TFL, THFK, THLC2 SFL, SFP, TFJ SGL4, SGP4, TB4, THJK4, THLC4, TJJ, TJK4, TLB4
* UL 1008 listed and CSA certified at 240 vac maximum.
Figure 1-7
G120 Withstand and Closing Current Ratings (WCR) With Coordinated Circuit Breakers, 240 V Maximum, UL and CSA Listings
1.7.2
G220 Ratings
heating equipment where the sum of motor full-load ampere ratings and the ampere ratings of other loads do not exceed the ampere rating of the switch and the tungsten load does not exceed 30 percent of switch rating at 240 VAC maximum.
Figure 1-8 lists contactor withstand and closing ratings (WCR) for 100 and 200 ampere switches with specific manufacturers circuit breakers per UL 1008 standards. The ATS is suitable for control of motors, electric discharge lamps, tungsten filament lamps and electric
Specific Manufacturers Molded-Case Circuit Breakers*

Transfer Switch Model Switch Rating, Amps WCR, RMS Symmetrical Amperes Maximum Size (amps) 100 125 150 100 125 225 250 400 250 400 250 225 250
Manufacturer Cutler-Hammer Cutler Hammer
Type or Class FCL, FB QCHW FDC FI ED4, CED6, ED6, HED4, HED6 BHW, FD, HFD, JDB, JD, HJD JD, JDB, HJD, JDC DK, KD, KDB, HKD, KDC, LCL, LA KI LE, LX, LXI FD6-A, FXD6-A, HFD6, CFD6 TFL, THLC2 SF, SFL, SFP
100
22,000 Square D ITE/Siemens
G220
200 22 000 22,000
Cutler-Hammer Cutler Hammer
Square D ITE/Siemens GE
* UL 1008 listed at 240 vac maximum.
Figure 1-8
G220 Withstand and Closing Current Ratings With Coordinated Circuit Breakers, 240 V Maximum, UL and CSA Listings
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Section 2 Operation
2.1 Automatic Operation
The ATS controller monitors the normal and emergency power sources and determines when a power source has failed or is acceptable and controls the system accordingly. Built-in time delays ensure that the power source is stable before the load is transferred. Failure of a power source occurs when its voltage on one or more phases falls below the dropout voltage level. A power source is acceptable when its voltage on one or more phases rises above the pickup voltage level and stays above the dropout voltage level. A power source is restored when it becomes acceptable again after failure. See Section 1.5, Specifications, for voltage sensing and pickup and dropout voltage specifications. Typical ATS operation occurs in two separate automatic sequences.
D Failure of normal power and the resulting transfer to
controller determines that the emergency source is acceptable, the controller starts a time delay called Time Delay Normal to Emergency (TDNE). TDNE allows emergency power source stabilization before load connection. When TDNE ends, the controller signals the contactor to connect the load to the emergency source. After load transfer the switch mechanically latches in the emergency position, supplying emergency source power to the load until normal power source restoration and stabilization.
2.1.2
Restoration of Normal Power
When the normal power source is restored, the controller starts a time delay called Time Delay Emergency to Normal (TDEN). If the normal source fails before TDEN ends, the time delay resets. TDEN ensures normal power source stabilization before load reconnection. When the controller determines that the normal power source has maintained an acceptable level and TDEN ends, the controller signals the contactor to reconnect the load to the normal source. After load transfer the switch mechanically latches in the normal position and the controller starts a 2-minute time delay called Time Delay Engine Cooldown (TDEC). TDEC allows the engine and generator to run unloaded and cool down before shutdown. When TDEC ends, the controller signals the generator set to shut down.
Time Delay Engine Start (TDES) Normal to Emergency (TDNE) Emeergency to Normal (TDEN) Engine Cooldown (TDEC) Duration 3 seconds 2 seconds 12 seconds 2 minutes
emergency power.
D Restoration of normal power and the resulting
transfer back to normal power.
2.1.1
Failure of Normal Power
When the normal power source fails, the controller starts a time delay called Time Delay Engine Start (TDES). See Figure 2-1 for ATS time delays. TDES prevents unnecessary generator start-up during short normal power interruptions. If the normal power source is restored before TDES ends, the controller resets the time delay. If the normal power failure persists and TDES ends, the controller issues a signal to start the standby (emergency) generator to produce the emergency power source. After signalling the generator to start, the controller monitors the emergency power source. When the
Figure 2-1
Time Delays
TP-5990 11/03
Section 2 Operation
2.2 Exerciser Function

The exerciser function, when enabled, automatically starts and runs the generator set unloaded (the ATS does not transfer the load to the emergency source) for 20 minutes once a week. Exercising the generator set helps to ensure that the generator set starts when emergency power is needed. An exerciser switch selects exerciser functions. Automatic operation overrides the exerciser function. The loss of all power sources for an extended period can result in the loss of the exerciser set time. See Section 2.2.2, Exerciser Power Requirements.
The exerciser switch selects the following exerciser functions when power is available. See Section 2.2.2, Exerciser Power Requirements.
D Set (
). Placing the switch in the set position and releasing the switch sets the exerciser: the exercisers internal one-week timer is reset and the exerciser starts and runs the generator set for a 20-minute period. Subsequent weekly 20-minute exercise periods start at the same day and time the exerciser was set.
D Run ( ). Returning the switch to the run position
2.2.1
Exerciser Switch
enables the exerciser. The controller starts and runs the generator set unloaded for 20 minutes on the same day and time each week the exerciser was set.
D Disable (
An exerciser switch is located inside the ATS enclosure. See Figure 1-1 and Figure 2-2.
). Placing the switch in the disable position prevents the exerciser from starting and running the generator. The exercisers internal one-week timer continues to run and the exercisers set day and time are not lost. The ATS, however, starts the generator automatically when the normal power source fails.
4
EXERCISER
5990202
Replace the enclosure cover on the ATS enclosure and tighten the screws that hold it in place after viewing or making changes to the exerciser switch setting.
1. 2. 3. 4.
Exerciser switch Set position Disable position Run position
2.2.2
Exerciser Power Requirements
Figure 2-2
Exerciser Switch
DANGER
An internal one-week timer for the exerciser function maintains its setting for up to 90 seconds after power loss on both the normal and emergency sources. When the normal power source fails, the generator must start and run to provide emergency power within approximately 90 seconds or the system loses the previously set day and time for the exerciser. When power loss on both the normal and emergency power sources lasts longer than approximately 90 seconds, the exerciser is set to the day and time that either power source returns. Then, if the exerciser switch is in the Run ( ) position, the controller starts and runs the generator set unloaded for 20 minutes one week from the day and time of power source return and on subsequent weeks at the same day and time.
Hazardous voltage. Will cause severe injury or death. Disconnect all power sources before opening the enclosure. 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.
Note: The exerciser switch is set during installation and normally does not require adjustment. Line voltage is present on some components inside the ATS enclosure when power sources are applied. Only trained and qualified personnel should open the ATS enclosure when power is present. Read and follow all safety decals inside the enclosure and avoid contact with line voltage.
6 Section 2 Operation TP-5990 11/03
2.3 Manual Operation

To test or troubleshoot the transfer switch, manually operate the contactor as described in the procedure below. Note: A contactor in normal and serviceable condition transfers smoothly without binding when operated manually. Do not place the transfer switch into service if the contactor does not manually operate smoothly without binding; contact an authorized service distributor to service the contactor.
Servicing the transfer switch. Hazardous voltage can cause severe injury or death. Deenergize all power sources before servicing. Open 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.
WARNING
Manual Operation Procedures 1. Prevent the generator set that provides the emergency power source to the transfer switch from starting.
a. Move the generator set master switch to the OFF position. b. Disconnect power to the generator engine start battery charger, if installed. c. Disconnect all generator engine start batteries, negative (--) leads first. 2. Disconnect or turn off both the normal and emergency power sources by opening upstream circuit breakers or switches to the transfer switch. Note: The manual operation handle is provided for maintenance purposes only. Do not attempt to use the manual operation handle to transfer the load. 3. Remove the cover on the front of the transfer switch enclosure. Use Procedure 1 for Model G120 switches. Use Procedure 2 for Model G220 switches. Procedure 1, for Model G120 transfer switches, shown in Figure 2-3
DANGER
1. Insert a #2 Phillips screwdriver or similar tool with an electrically-insulating handle into the hole located on the flywheel at the left of the contactor. See Figure 2-3. A mark on the outer part of the flywheel shows the switch position when viewed
TP-5990 11/03
Section 2 Operation
from the front of the enclosure. The letter E is visible if the switch is in the emergency position (load is connected to the emergency [standby] power source). The letter N is visible if the switch is in the normal position (load is connected to the normal [utility] power source). 2. Move the tools handle up to rotate the flywheel to manually operate the switch into the emergency position. Move the tools handle down to rotate the flywheel to manually operate the switch into the normal position. See Figure 2-3. 3. Manually operate the switch to select the normal position for automatic operation. 4. Remove the tool used to manually operate the switch. Procedure 2, for Model G220 transfer switches, shown in Figure 2-4 1. Slide the large end of the manual operation handle over the manual operation lever on the left side of the contactor. See Figure 2-4. Move the handle up to place the transfer switch in the Normal Source position, or down to place the contactor in the Emergency Source position. Note: Do not attempt to move the manual operation lever without using the handle. 2. Move the handle up to place the transfer switch in the Normal Source position for normal operation. 3. Remove the handle and store it in a convenient location near the tansfer switch. Procedure to return the transfer switch and generator set to automatic operation
1. 2. 3. 4. 5. 6.
b. Reconnect power to the generator engine start battery charger, if installed. c. Move the generator set master switch to the AUTO (automatic) position. The generator set may start and run until the Time Delay Engine Cooldown (TDEC) ends (see NOTE above).
6 3 1 2 1
3 4
5
5990
Flywheel Mark shows switch in the normal position Tool inserted into hole in flywheel Move up to select the emergency position Mark shows switch in the emergency position Move down to select the normal position
Figure 2-3
Model G120 Contactor with Flywheel (Procedure 1)
CN
3 C NO NC SCN
1. Replace the cover on the transfer switch enclosure and tighten the screws that hold it in place. 2. Reconnect power supplies to the transfer switch. Note: When power is applied to the transfer switch, the engine start contacts remain closed until Time Delay Engine Cooldown (TDEC) ends. 3. Return the generator set to automatic operation. a. Reconnect the generator engine start battery cables, negative (--) leads last.
NL1
NL2
SCE NC NO C 8 7 EL1 EL2
CE
1 1. Manual operation handle 2. Manual operation lever
2
tp6223
Figure 2-4
Model G220 Contactor with Manual Operation Handle (Procedure 2)
Section 2 Operation
TP-5990 11/03
Section 3 Maintenance and Testing

3.1 Maintenance
Preventive maintenance ensures safe and reliable operation and extends the life of the transfer switch. Preventive maintenance includes periodic testing, cleaning, inspection, and replacement of worn or missing components. Keep the outside of the transfer switch clean and dry. Have any other maintenance and service performed only by trained and qualified personnel following all applicable codes and standards. Keep a record of all maintenance and service. Your local authorized distributor/dealer can provide complete preventive maintenance and service to keep the transfer switch in top condition. Contact your local authorized distributor/dealer for additional information.
DANGER
Hazardous voltage. Will cause severe injury or death. Disconnect all power sources before opening the enclosure. 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. Open 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.
WARNING
NOTICE
TP-5990 11/03
Have an authorized service distributor/dealer perform periodic (at least annual) preventive maintenance of the transfer switch including the following.
3.2 Testing
Start and run the generator set weekly. See Section 2.2, Exerciser Function, to set and enable the exerciser function to start and run the generator set once a week for 20 minutes. Test the transfer switch operation monthly. To test, disconnect the normal power source by opening circuit breakers or switches to cause the transfer switch to automatically start the generator set and transfer the load to the emergency power source. When the switch has transferred the load to the emergency power source, reconnect the normal power source and verify that the transfer switch retransfers to the normal power source and shuts down the generator set after TDEC ends. See Section 2.1, Automatic Operation.
Preventive Maintenance
D Clean and inspect the transfer switch. D Tighten control and power terminals to torque
specifications.
D Clean the contactor external operating mechanism
when contaminated by debris and relubricate the mechanism using the lubricant recommended by the manufacturer.
D Perform any other maintenance, tests, or service that
maintains the safe and reliable operation of the switch.
10
TP-5990 11/03
Section 4 Drawings and Diagrams

Check the transfer switch nameplate to determine the model number for your transfer switch. See Figure 4-1 and Figure 4-2. Then locate the appropriate drawings in Figure 4-3.
ADV-6834
Figure 4-2
ADV-6428
Model G220 Transfer Switch
Figure 4-1 G120
Model G120 Transfer Switch

Diagram or Drawing
Enclosure Dimensions Wiring Diagram Schematic Diagram
Transfer Switch Model
Drawing No.
ADV-6428-A 362139-D 362140-C ADV-6834 GM25943-A GM25944-A
Page
13 14 15 16 17 18
G220
Enclosure Dimensions Wiring Diagram Schematic Diagram
Figure 4-3
Drawing Numbers and Locations
TP-5990 11/03
11
Notes
12
TP-5990 11/03
.32 [8]
10.50 [267]
LOAD GROUND CONNECTION WIRE RANGE-#4-#14 NORMAL 24.09 [612] 18.00 [457] NEUTRAL ASSEMBLY 100 AMP-WIRE RANGE1/0-14 CU, 1/0-12 AL 200 AMP-WIRE RANGE250 MCM-6 (CU ONLY)
3.09 [78]
CONTACTOR WIRE RANGE-3/0-#8 (100 AMP.-CU OR AL) (200 AMP.-CU ONLY)
9.63 [245]
4.23 [107]
7.90 [201]
100 AMP
8.43 [214]
8.15 [207]
7.70 [196]
7.50 [190] 200 AMP
Enclosure Dimension Drawings, NEMA 1 and 3R, 100 and 200 Amp, Model G120, ADV-6428-A
7 6 5 4 3 2
TP-5990 11/03
.32 [8] 14.19 [360] TOP AND BOTTOM CONDUIT ENTRY AREA (USE APPROVED WATERTIGHT FITTINGS FOR OUTSIDE APPLICATIONS) 18.15 [461] 12.00 [305] 11.42 [290] 3.07 [78] REMOVABLE COVER LOGIC EXERCISER MODE SWITCH NOTE: 1. NUMBERS IN [ ] ARE MILLIMETERS 2. DIMENSIONS ARE FOR REFERENCE ONLY. .74 [19] 3. WEIGHT IS APPROX 50 LBS. (23 KG.) 6.81 [173] .98 [25] 18.00 [457] .344 [8.7] (4 PLACES) GASKETED WASHER REQUIRED FOR NEMA 3R PAD LOCKABLE HASP 100 AMP 2.42 [62] 2.16 [55] 200 AMP 6.00 [152] 11.18 [284] 7 6 5 4 3 100 AMP NEMA 3R SHOWN (VIEW SHOWN WITHOUT DOOR IN PLACE) 100/200 AMP NEMA 1 AND 3R 2 1
1 REV DATE REVISION BY M F - 4-21-98 NEW DRAWING. [54307] GFR A 4-7-99(A-1) TITLEBLOCK UPDATED ADDED [58348]SAM
2.04 [52]
EMERGENCY
4.23 [107]
.18 [5]
.58 [15]
.84 [21] 200 AMP
4. REFER TO OPERATORS MANUAL PRIOR TO INSTALLATION AND OPERATION OF THE SWITCH.
13
4 2
REV DATE REVISION
3 1
A B 112; [58492] C D 8- 10- 99 (A- 1) J2 WAS J1, ENABLE WAS RUN [59561] 8- 10- 99 (D- 1) LEAD CODE NOTE ADDED [59156] 5- 5- 99 (A- 1) J1 3, 2, 1 WAS 1, 2, 3, 112 WAS 110 & 110 WAS 11- 2- 98 4- 7- 98 NEW DRAWING. [54307]
TS (B)
104 (J1-14)
NA (J1-12) NA (SCN-C)
NB (J1-9)
TS (A)
103 (J1-10)
NC (NC)
NA (NA) NB (NB) EC (EC)
15 15 3
J1
13 13 K2 1 1 K3
EA (EA)
SCN
SCE
104 (BR-AC1) 101 (SCN-NO)
103 (BR-AC2) NC (NC) 102 (SCE-NO)
B
C
EA(EL1) EB EC(EL2)
EA (EA)
NO
EC (EC) NA (NA)
EA (J1-3) EA (J1-3)
102 (J1-4)
101 (J1-13)
EC (SCE-C) EC (J1-6)
Wiring Diagram, 100 and 200 Amperes, Model G120, 362139-D

105 (TB1-1) 106 (TB1-2) VS C2 108 (VS-C1) 109 (VS-C) 107 (VS-L3)
1 3 1 2 3 4 5 6 2
TB1 TB2
AC1
NC (J1-7) NC (J1-15)
14
L1 109 (TB2-6) 108 (TB2-5) L2 L3 C1 C POINT TO POINT CODE: LEAD NUMBER (DEVICE TO-POSITION ON DEVICE) 107 (TB1-3) 106 (VS-L2) 105 (VS-L1) SEE NOTE 1
1 2 3 JP1 JP2 JP3 JP4 NA NSC TEST GND ESC GND NB NC 3PH ES3 ES3D ES4
BY
M F
GFR KAR
BTW JS JS
BR
AC2
C
A B
NA(NL1) NB NC(NL2)
CONTACTOR LOGIC
C
NA LED1 EA LED2 LED3 ES
TS (BR-(+)) TS (BR-(-))
R15 NUV
R20 EUV
P1
B
NR ER
CRB CRBD
ER
ERD
NR
NRD
GND +12UF 1 2 LED4 NR 1 2 LED5 ER JP5 JP6 3
P2
TB4 JUMPER
TB5
J2
3 2 1
S1 112 111 110 1 2 3
SET (MOMENTARY) ENABLE
SEE NOTE 2
DISABLE
UNLESS OTHERWISE SPECIFIED 1) DIMENSIONS ARE IN INCHES 2) TOLERANCES ARE: .XXX .XX .X FRACTIONS .010 .030 .060 ANGLES 1/2 SURFACE FINISH MAX. TITLE
NOTE: 1. CUT JP3 WHEN INSTALLING VS. 2. OMIT CENTER POLE FOR 1 3. FOR SCHEMATIC SEE 362140.
APPROVALS
DRAWN CHECKED APPROVED
DATE
DIAGRAM, WIRING
GFR JJC 4- 7- 98 5- 14- 98
SCALE PLOTTED
NONE
CAD NO. DWG. NO.
362139.DWG
SHEET
1-1
TP-5990 11/03
100/200 AMP.
GH
5- 15- 98
362139 3 2 1
4 2
REV DATE REVISION
3 1
A B UPDATED [58492] 5- 5- 99 (A- 2) S1 3 WAS 1 & 1 WAS 3; (C- 1) S1 CHART 11- 2- 98 4- 6- 98 NEW DRAWING. [54307]
BY
M F
GFR KAR
BTW
NA
NB
NC
EA
EC
104
103
ER
ERD
NR
NRD
GND
NA
NB
NC
NSC
TEST
GND
ESC
GND
3PH
ES3
ES3D
TB1
TB2
TB3
TB5
SET
COM
P2-1 J2-1
P2 -2 J2-2
DISABLE
JP2 JP1 JP3
JP4
ES4
JP5
JP6
+12V
105
106
107
NC
108
109
110
111
112
L1
L2
L3
C1
C2
Schematic Diagram, 100 and 200 Amperes, Model G120, 362140-C

C WAS RUN [59561] 8- 10- 99 (B- 3) TB4- 2 WAS TB4- 1, TB4- 1 WAS TB4- 2; (C- 1) ENABLE
TP-5990 11/03
(LB) LL1(LA) LL2(LC) NEUTRAL GND EL1(EA) (EB) EL2(EC) CONTACTOR S1 SET ENABLE DISABLE AC2 BR + AC1 JUMPER 102 J1-10 P1-10 NR NR ER ER P1-1 J1-1 J1-4 P1-4 J1-13 J1-14 TB4 -2 TB4 -1 P1-14 P1-13 NR NR SCE NO C TS SCN 101 NO C NC J1-15 P1-15 P1-7 J1-7 A B 1 2 3 EA EC J1-3 P1-3 J1-6 P1-6 LEGEND * MOMENTARY NA P2-3 J2-3 BR ER ERD ESC J JP NR NRD NSC P S1 SCE SCN TS VS 3 NOTE: 1. TEST SWITCH PROVIDED BY OTHERS. (CUT JP2 WHEN INSTALLING) 2. ENGINE START CONTACTS RATED 30 VOLT, 1 AMP. WIRING PROVIDED BY OTHERS. 3. VS PROVIDED ON 3 APPLICATIONS ONLY. JP3 JUMPER MUST BE REMOVED. (SEE NOTE 3) 4. CONTACTOR SHOWN IN NORMAL WITH NO POWER APPLIED. 5. FOR WIRING DIAGRAM SEE 362139. 100/200 AMP. 2 S1
JS
NL1(NA)
(NB)
NL2(NC)
J1 -12
J1 -9
P1 -12
P1 -9
LOGIC BOARD
BRIDGE RECITIFIER EMERGENCY RELAY EMERGENCY RELAY DISCONNECT EMERGENCY SOURCE CONTROL JACK ON-BOARD JUMPER NORMAL RELAY NORMAL RELAY DISCONNECT NORMAL SOURCE CONTROL PLUG EXERCISER MODE SWITCH EMERGENCY COIL CLEARING LIMIT SWITCH NORMAL COIL CLEARING LIMIT SWITCH TRANSFER SOLENOID 1 ES3D ES3,4 3 (1 VOLTAGE SENSING MODULE SENSING ON LOGIC BOARD) ENGINE START DISABLE ENGINE START
TEST ENGINE START (SEE NOTE 2) SWITCH (SEE NOTE 1)
VS
APPROVALS
DATE
SCHEMATIC, WIRING
GFR JJC GH 4- 7- 98 5- 14- 98 5- 15- 98
SCALE PLOTTED

3
NONE
CAD NO. DWG. NO.
362140.DWG
SHEET
1-1
362140 2 1
15
Enclosure Dimension Drawing, Model G220, ADV-6834
16
TP-5990 11/03
JP1 JP2
NSC TEST GND ESC GND 3PH JP3
4 C NO NC SCN NL1 NL2 J1 P1 13 K2 K3 1 13 1 15 3 15 3 NA LED1
CN 3 LOGIC
NL2 (TS--NL2)
NL1 (TS--NL1)
EL2 (TS--EL2)
EL1 (TS--EL1)
103(TS--CN--3)
LED3 EA LED2 ES R15 NUV R20 EUV
NN(TS--N)
ES3 ES3D ES4 JP4
EL2(TS--EL2)
104(TS--CN--4) NL2 (TS--NL2)
108(TS--CE--8)
CRB CRBD
CE
ER ERD NR NRD GND +12UF
Wiring Diagram, 100 and 200 Ampere, Model G220, GM25943-A

7 REVDATE 6 5 4 3 2 1 REVISION
TP-5990 11/03
NL1 (J1--12) NL2 (J1--7) NL2 (J1--15) 1 2 3 TB1 1 2 3 4 5 6 TB2 NANBNC 1 2 3 TS SCE NC NO EL1 NR EL2 C 8 7 ER P2 LED5 ER JP6 JP5 TB5 1 2 3 4 5 6 1 2 3 LED4 NR 1 2 TB4 EL2 (J1--6) EL2 (J1--14) EL1 (J1--3) JUMPER 3 2 1 J2 DISABLE 112 111 110 ENABLE SET (MOMENTARY) S1 1 2 3 NEUTRAL (N) EN(TS--SCE--NC) NN(TS--SCN--NC) POINT TO POINT CODE: LEAD NUMBER (DEVICE TO--POSITION ON DEVICE) FOR SCHEMATIC SEE GM25944. 7 6 5 4 3 100/200 AMP 2 1
BYM F
103(TS--SCN--C) 104(J1--10)
EN(TS--N)
107(TS--CE--7)
108(J1--1)
107(TS--SCE--C)
17
4 2
REV DATE REVISION
3 1
NC
SCN
SCE
103
107
NL1
NL2
EL1
104
NL2 JUMPER J1--7 J1--10 P1--10 NR NR ER ER P1--1 P1--4 P1--7 P1--13 NR NR TB4 --2 TB4 --1 P1--14 J1--13 J1--14 J1--1 J1--4 EL2
108
EL2
ER
ERD
NR
NRD
GND
NA
NB
NC
NSC
TEST
GND
ESC
GND
3PH
ES3
ES3D
ES4
+12V
TB1
TB2
TB3
TB5
SET
COM
P2--1 J2--1 S1
P2 --2 J2--2
DISABLE
110
111
A
(SEE NOTE 1) (SEE NOTE 2)
TEST SWITCH
ENGINE START
1 2 3 * MOMENTARY
2 S1
1
112
Schematic Diagram, 100 and 200 Amperes, Model G220, GM25944-A

NEUTRAL GND LL1 LL2 EL1 EL2 NC C NOTE: 1. TEST SWITCH PROVIDED BY OTHERS. (CUT JP2 WHEN INSTALLING) 7 RE 8 CE 2. ENGINE START CONTACTS RATED 30 VOLT, 1 AMP. WIRING PROVIDED BY OTHERS. 3. CONTACTOR SHOWN IN NORMAL WITH NO POWER APPLIED. 4. FOR WIRING DIAGRAM SEE GM25943. 3 CN 4 RN LEGEND J1--3 P1--3 J1--6 P1--6 CE CN ES3D ES3,4 ER ERD ESC J(#) JP(#) NR NRD NSC P(#) P2--3 J2--3 RE RN S1 SCE SCN TB(#) SET ENABLE DISABLE TRANFER COIL (EMERGENCY TRANSFER) TRANSFER COIL (NORMAL TRANSFER) ENGINE START DISABLE ENGINE START EMERGENCY RELAY EMERGENCY RELAY DISCONNECT EMERGENCY SOURCE CONTROL JACK ON--BOARD JUMPER NORMAL RELAY NORMAL RELAY DISCONNECT NORMAL SOURCE CONTROL PLUG JP2 JP1 JP3 JP4 JP5 JP6
APPROVALS
18
BRIDGE RECTIFER (NORMAL TRANSFER) BRIDGE RECTIFIER (EMERGENCY TRANSFER) EXERCISER MODE SWITCH EMERGENCY COIL CLEARING LIMIT SWITCH NORMAL COIL CLEARING LIMIT SWITCH TERMINAL BLOCK
DATE
BY
M F
DFS AJH
CONTACTOR
NL1
NL2
J1 --12
J1--15
P1 --12
P1--15
LOGIC BOARD
SCHEMATIC, WIRING
DFS EB 4-8-03 4-9-03
SCALE PLOTTED
NONE
CAD NO. DWG. NO.
GM25944.DWG
SHEET
1-1
TP-5990 11/03
100/200 AMP.
AJH
4-8-03
GM25944 3 2 1
Section 5 Installation
Kohlerr transfer switches are shipped factory wired and tested, ready for installation. The installation process includes mechanical mounting; electrically wiring the unit to the normal and emergency power sources, to the load circuits, and to the generator; and initial setup and testing. Have installation performed only by trained and qualified personnel following all applicable codes and standards.
5.1.3
Unpacking
Unpack the transfer switch immediately after receipt and inspect for shipping damage. Failure to perform an immediate inspection impedes recovery of losses caused by shipping damage. Use care when unpacking to avoid damaging any transfer switch components. Remove dirt and packing material that may have accumulated in the transfer switch or any of its components. If the equipment has been stored at cold temperatures, allow equipment to warm to room temperature for 24 hours (minimum) before unpacking to prevent condensation on the electrical apparatus.
5.1 Upon Receipt of Unit

5.1.1 Inspection
At time of delivery, inspect the transfer switch for signs of shipping damage. If damage and/or rough handling is evident, file a damage claim immediately with the transportation company and promptly notify the distributor/dealer.
5.1.4
Storage
5.1.2
Lifting WARNING
Do not remove the protective packing until ready for final installation. Protect the transfer switch at all times from excessive moisture, construction grit, and metal chips. Avoid storage in low temperature and high humidity areas where condensation could occur on the unit.
5.2 Mechanical Installation

WARNING
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. Airborne particles. Can cause severe blindness. injury or
See Figure 5-1 for the approximate weight of each transfer switch covered in this manual. Carefully lift the enclosure to avoid damage to the transfer switch. Ensure that the front cover is in place and that the cover screws are tight when moving the unit.
Transfer Switch Rating, amps 100 Approximate Weight, kg (lb.) 21 (46) 22 (48) 21 (47) 22 (48)
Wear protective goggles and clothing when using power tools, hand tools, or compressed air.
Poles, No. 2 3 2
To plan the installation, use the dimensions given on the enclosure dimension drawings in Section 4. Select the mounting site to comply with electrical code restrictions for the enclosure type. Mount the transfer switch as close to the load and power sources as possible. Ensure adequate space for transfer switch servicing and opening of the enclosure. Vertically mount the 100- or 200-ampere automatic transfer switches covered in this manual to a rigid supporting structure, such as a wall, using 1/4-inch hardware. For mounting, use the four holes on the top and bottom of each unit. When mounting the unit, plumb the enclosure to avoid any distortion of the enclosure.
Section 5 Installation 19
200
Figure 5-1
Approximate Transfer Switch Weight
TP-5990 11/03
Place washers behind the key holes to shim the enclosure to a plumb condition. Seal the mounting holes for installing the unit outdoors.
5.3 Contactor Manual Operation Test

Follow steps 1 through 3 in Section 2.3 to manually operate the contactor power switching device to verify that it operates smoothly without binding. If the contactor does not operate smoothly without binding, stop the test and call an authorized service distributor to service the contactor before proceeding.
Grounding the transfer switch. Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present. Open main circuit breakers of all power sources before servicing equipment. Configure the installation to electrically ground the transfer switch and related equipment and electrical circuits to comply with applicable codes and standards. Never contact electrical leads or appliances when standing in water or on wet ground, as the chance of electrocution increases under such conditions. 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. Open 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.
5.4 Electrical Wiring

WARNING
All internal electrical connections are prewired. The only wiring necessary for installing the transfer switch is to connect the transfer switch to external devices and power sources. Observe all applicable national, state, and local electrical codes during installation. See Section 4 for schematic diagrams and enclosure drawings. Install DC, control, and communication system wiring in separate raceways, cables, or conduit from AC power wiring.
DANGER
20
TP-5990 11/03
5.4.1
Line Connections
All conductors should enter the enclosure at the locations shown on the drawings. When drilling entry holes for any conductors, cover the transfer switch components for protection from metal chips and construction grit. Remove any debris from the enclosure with a vacuum cleanerusing compressed air for this purpose can lodge contaminants in components and cause damage.
4
1 2
Use watertight conduit hubs approved for outdoor use for installing the transfer switch outdoors. Cable sizes are shown in Section 1.6, Application Data, and on the transfer switch specification sheet. Before connecting wiring cables to terminal lugs, remove surface oxides from cables by cleaning with a wire brush. If using aluminum conductors, apply a joint compound to cables. After tightening terminal lugs, carefully wipe off excess joint compound. Connection points for the normal power, emergency power, and load are clearly marked on the transfer switch and drawings. See Section 4. Be sure to heed the phase markings (A, B, C, and N). Note: Connect source and load phases as indicated by the markings and drawings. Improper connections may cause short circuits or cause phase-sensitive load devices to malfunction or operate in reverse. Note: When making power connections to the power switching device, leave sufficient slack in the power leads to reach all of the power connecting lugs. Connect the normal, emergency, and load conductors to the clearly marked terminals on the contactor. Verify that all connections are consistent with drawings before tightening the contactor terminal lugs. Tighten the connections to the torque values shown in Figure 5-3. Connect the neutral wires to the neutral terminals and tighten the lugs to the torque values shown in Figure 5-3. Connect the ground wires to the ground terminal and tighten to the torque values shown in Figure 5-4. Neutral Connections for 120VAC Coils, Model G220 Switches Model G220 coils operate at 120 VAC. Refer to Figure 5-2 and the wiring diagrams in Section 4 for required neutral connections.
TP-5990 11/03 1. 2. 3. 4. Normal source connection Emergency source connection Load connection Neutral connection
ADV-6834
Figure 5-2
Model G220 Connections (also see the wiring diagram in Section 4)

Torque Nm
8.5 12 12 17 17 20 20 28
Wire Size (AWG or MCM) 8 6 4 2 1 1/0 2/0 3/0
In. Lb.
75 110 110 150 150 180 180 250
Ft. Lb.
6.2 9.2 9.2 13 13 15 15 21
Figure 5-3
Tightening Torque for Terminal Lugs

Torque Nm
4.0 4.0 4.0 4.5 5.1 5.1
Wire Size (AWG or MCM) 14 12 10 8 6 4
In. Lb.
35 35 35 40 45 45
Ft. Lb.
2.9 2.9 2.9 3.3 3.8 3.8
Figure 5-4
Tightening Torque for Ground Screw Terminal
21
5.4.2
Generator Engine Start Connection WARNING
Procedure to Connect the Generator Engine Start Circuit 1. Prevent the emergency power source generator set from starting: a. Move the generator set master switch to the OFF position. b. Disconnect power to the generator engine start battery charger, if installed. c. Disconnect all generator engine start battery cables, negative (--) leads first. 2. Connect the generator set remote engine start signal inputs to the engine start terminals ES3 and ES4 on the transfer switch controller circuit board. See Figure 5-5. 3. Tighten the terminal screws to 1.0 Nm (9 in. lb.) of torque.
1 2 3 4
NOTICE
The transfer switch controller provides a contact closure across terminals ES3 and ES4 to signal the generator set to start. See Figure 5-5. The location of the terminal block is marked by an orange decal within the enclosure.
A-353529
1. 2. 3. 4. 5.
Normal Acceptable (NA) LED Emergency Acceptable (EA) LED Engine start terminal ES3 Engine start terminal ES4 Engine Start (ES) LED
Figure 5-5
Controller Terminals and LEDs
22
TP-5990 11/03
5.5 Initial Startup and Setup

Perform the following procedures before placing the transfer switch into normal service.
move the generator set master switch to the AUTO (automatic) position. The generator set should start.
5.5.4
Connect the Power Sources
5.5.1
Manually Select the Normal Position
Note: Close and secure the transfer switch enclosure cover before applying power. Connect the normal and emergency power sources to the transfer switch by closing upstream circuit breakers or switches. When power is applied to the transfer switch, the engine start contacts remain closed and the generator set continues to run at least until Time Delay Engine Cooldown (TDEC) ends. If the transfer switch determines that the normal power source is acceptable, the transfer switch runs the generator set for TDEC and then signals the generator set to shut down by opening the engine start contacts. The Engine Start LED lights. If the transfer switch determines that the normal power source is unacceptable at any time, the transfer switch begins an automatic sequence to transfer the load to the emergency source as if TDES had ended. The engine start contacts remain closed and the generator set continues to run. See Section 2.1.1. The transfer switch sets the exerciser function when power is first applied. If the exerciser switch is in the Run ( ) position, the first exercise period occurs one week after power is first applied and on subsequent weeks at the same day and time. See Section 2.2.
Manually operate the contactor to the normal position by following steps 1 through 3 in Section 2.3.
5.5.2
Select the Exerciser Function and Close the Enclosure DANGER
Move the exerciser switch to the Run ( ) position to enable the weekly generator exerciser. Move the exerciser switch to the Disable ( ) position to disable the weekly exerciser. See Section 2.2. Replace the transfer switch enclosure cover and tighten the screws that hold it in place.
5.5.3
Prepare the Generator Set for Operation WARNING
5.5.5
Perform a System Test
Hazardous voltage. Moving rotor. Can cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place.
With normal power present, test the system by disconnecting the normal power source and verifying that the system responds as described in Section 2.1.1, starting the generator set automatically and transferring the load to the emergency power source. When the transfer switch has transferred the load to the emergency source, reconnect the normal power source and verify that the system operates as described in Section 2.1.2, retransferring the load to the normal source and shutting down the generator set after TDEC.
Prepare the emergency power source generator set for operation. Check the oil level, coolant level, fuel supply, batteries, and items specified by the generator set installation or operation checklist or manual. Reconnect generator engine start battery cables, negative (--) leads last; reconnect power to the generator engine start battery chargers, if installed; and
TP-5990 11/03
5.5.6
Complete the Installation
Ensure that the normal and emergency power sources are connected to the transfer switch. To set the exerciser to a different day and time, see Section 2.2. Replace the cover on the transfer switch enclosure and tighten the screws that hold it in place.
23
5.5.7
Ensure Warranty Registration
The transfer switch seller must complete a Start-up Notification Form and submit it to the manufacturer within 60 days of the initial start-up date. The Start-up Notification Form covers all equipment in the standby system. Standby systems not registered within 60 days of the initial start-up date are automatically registered using the manufacturers ship date as the start-up date.
24
TP-5990 11/03
Appendix A Abbreviations
The following list contains abbreviations that may appear in this publication.
A, amp ABDC AC A/D ADC adj. ADV AHWT AISI ALOP alt. Al ANSI ampere after bottom dead center alternating current analog to digital analog to digital converter adjust, adjustment advertising dimensional drawing anticipatory high water temperature American Iron and Steel Institute anticipatory low oil pressure alternator aluminum American National Standards Institute (formerly American Standards Association, ASA) anticipatory only American Petroleum Institute approximate, approximately as required, as requested as supplied, as stated, as suggested American Society of Engineers American Society of Mechanical Engineers assembly American Society for Testing Materials after top dead center automatic transfer switch automatic auxiliary audiovisual average automatic voltage regulator American Wire Gauge appliance wiring material battery before bottom dead center battery charger, battery charging battery charging alternator Battery Council International before dead center brake horsepower black (paint color), block (engine) block heater brake mean effective pressure bits per second brass before top dead center British thermal unit British thermal units per minute Celsius, centigrade calorie California Air Resources Board circuit breaker cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code certificate, certification, certified cubic feet per hour cfm CG CID CL cm CMOS cubic feet per minute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate (semiconductor) cogen. cogeneration com communications (port) coml commercial Coml/Rec Commercial/Recreational conn. connection cont. continued CPVC chlorinated polyvinyl chloride crit. critical CRT cathode ray tube CSA Canadian Standards Association CT current transformer Cu copper cu. in. cubic inch cw. clockwise CWC city water-cooled cyl. cylinder D/A digital to analog DAC digital to analog converter dB decibel dBA decibel (A weighted) DC direct current DCR direct current resistance deg., degree dept. department dia. diameter DI/EO dual inlet/end outlet DIN Deutsches Institut fur Normung e. V. (also Deutsche Industrie Normenausschuss) DIP dual inline package DPDT double-pole, double-throw DPST double-pole, single-throw DS disconnect switch DVR digital voltage regulator E, emer. emergency (power source) EDI electronic data interchange EFR emergency frequency relay e.g. for example (exempli gratia) EG electronic governor EGSA Electrical Generating Systems Association EIA Electronic Industries Association EI/EO end inlet/end outlet EMI electromagnetic interference emiss. emission eng. engine EPA Environmental Protection Agency EPS emergency power system ER emergency relay ES engineering special, engineered special ESD electrostatic discharge est. estimated E-Stop emergency stop etc. et cetera (and so forth) exh. ext. F fglass. FHM fl. oz. flex. freq. FS ft. ft. lbs. ft./min. g ga. gal. gen. genset GFI GND, gov. gph gpm gr. GRD gr. wt. HxWxD HC HCHT HD HET hex Hg HH HHC HP hr. HS hsg. HVAC HWT Hz IC ID IEC IEEE IMS in. in. H2O in. Hg in. lbs. Inc. ind. int. int./ext. I/O IP ISO J JIS exhaust external Fahrenheit, female fiberglass flat head machine (screw) fluid ounce flexible frequency full scale foot, feet foot pounds (torque) feet per minute gram gauge (meters, wire size) gallon generator generator set ground fault interrupter ground governor gallons per hour gallons per minute grade, gross equipment ground gross weight height by width by depth hex cap high cylinder head temperature heavy duty high exhaust temperature, high engine temperature hexagon mercury (element) hex head hex head cap horsepower hour heat shrink housing heating, ventilation, and air conditioning high water temperature hertz (cycles per second) integrated circuit inside diameter, identification International Electrotechnical Commission Institute of Electrical and Electronics Engineers improved motor starting inch inches of water inches of mercury inch pounds incorporated industrial internal internal/external input/output iron pipe International Organization for Standardization joule Japanese Industry Standard
AO API approx. AR AS ASE ASME assy. ASTM ATDC ATS auto. aux. A/V avg. AVR AWG AWM bat. BBDC BC BCA BCI BDC BHP blk. blk. htr. BMEP bps br. BTDC Btu Btu/min. C cal. CARB CB cc CCA ccw. CEC cert. cfh
TP-5990 11/03
Appendix A-1
kilo (1000) kelvin kiloampere kilobyte (210 bytes) kilogram kilograms per square centimeter kgm kilogram-meter kilograms per cubic meter kg/m3 kHz kilohertz kJ kilojoule km kilometer kOhm, k kilo-ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt-hour kWm kilowatt mechanical L liter LAN local area network L x W x H length by width by height lb. pound, pounds lbm/ft3 pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display ld. shd. load shed LED light emitting diode Lph liters per hour Lpm liters per minute LOP low oil pressure LP liquefied petroleum LPG liquefied petroleum gas LS left side Lwa sound power level, A weighted LWL low water level LWT low water temperature m meter, milli (1/1000) M mega (106 when used with SI units), male cubic meter m3 m3/min. cubic meters per minute mA milliampere man. manual max. maximum MB megabyte (220 bytes) MCM one thousand circular mils MCCB molded-case circuit breaker meggar megohmmeter MHz megahertz mi. mile mil one one-thousandth of an inch min. minimum, minute misc. miscellaneous MJ megajoule mJ millijoule mm millimeter mOhm, m milliohm MOhm, M megohm MOV metal oxide varistor MPa megapascal mpg miles per gallon mph miles per hour MS military standard m/sec. meters per second
k K kA KB kg kg/cm2
mean time between failure mean time between overhauls mounting megawatt milliwatt microfarad normal (power source) not available, not applicable natural gas National Bureau of Standards normally closed National Electrical Code National Electrical Manufacturers Association NFPA National Fire Protection Association Nm newton meter NO normally open no., nos. number, numbers NPS National Pipe, Straight NPSC National Pipe, Straight-coupling NPT National Standard taper pipe thread per general use NPTF National Pipe, Taper-Fine NR not required, normal relay ns nanosecond OC overcrank OD outside diameter OEM original equipment manufacturer OF overfrequency opt. option, optional OS oversize, overspeed OSHA Occupational Safety and Health Administration OV overvoltage oz. ounce p., pp. page, pages PC personal computer PCB printed circuit board pF picofarad PF power factor ph., phase PHC Phillips head crimptite (screw) PHH Phillips hex head (screw) PHM pan head machine (screw) PLC programmable logic control PMG permanent-magnet generator pot potentiometer, potential ppm parts per million PROM programmable read-only memory psi pounds per square inch pt. pint PTC positive temperature coefficient PTO power takeoff PVC polyvinyl chloride qt. quart, quarts qty. quantity R replacement (emergency) power source rad. radiator, radius RAM random access memory RDO relay driver output ref. reference rem. remote Res/Coml Residential/Commercial RFI radio frequency interference RH round head
MTBF MTBO mtg. MW mW F N, norm. NA nat. gas NBS NC NEC NEMA
RHM rly. rms rnd. ROM rot. rpm RS RTV SAE
round head machine (screw) relay root mean square round read only memory rotate, rotating revolutions per minute right side room temperature vulcanization Society of Automotive Engineers scfm standard cubic feet per minute SCR silicon controlled rectifier s, sec. second SI Systeme international dunites, International System of Units SI/EO side in/end out sil. silencer SN serial number SPDT single--pole, double--throw SPST single--pole, single--throw spec, specs specification(s) sq. square sq. cm square centimeter sq. in. square inch SS stainless steel std. standard stl. steel tach. tachometer TD time delay TDC top dead center TDEC time delay engine cooldown TDEN time delay emergency to normal TDES time delay engine start TDNE time delay normal to emergency TDOE time delay off to emergency TDON time delay off to normal temp. temperature term. terminal TIF telephone influence factor TIR total indicator reading tol. tolerance turbo. turbocharger typ. typical (same in multiple locations) UF underfrequency UHF ultrahigh frequency UL Underwriters Laboratories, Inc. UNC unified coarse thread (was NC) UNF unified fine thread (was NF) univ. universal US undersize, underspeed UV ultraviolet, undervoltage V volt VAC volts alternating current VAR voltampere reactive VDC volts direct current VFD vacuum fluorescent display VGA video graphics adapter VHF very high frequency W watt WCR withstand and closing rating w/ with w/o without wt. weight xfmr transformer
A-2 Appendix
TP-5990 11/03
KOHLER CO. Kohler, Wisconsin 53044 Phone 920-565-3381, Fax 920-459-1646 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPowerSystems.com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65)264-6422, Fax (65)264-6455
TP-5990 11/03c
E 1998, 2003 by Kohler Co. All rights reserved.

TP 5990

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Operation and Installation

Automatic Transfer Switches

Product Identification Information

Transfer Switch Identification Numbers

Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Safety Precautions and Instructions

Safety Precautions and Instructions

Hazardous Voltage/ Electrical Shock

Safety Precautions and Instructions

Airborne particles. Can cause severe blindness.

Safety Precautions and Instructions

Safety Precautions and Instructions

D Look at the labels and stickers on your Kohler product

1.2 Component Overview

Typical ATS Block Diagram

Typical Transfer Switch Nameplate

1.4 Model Number

SAMPLE PART NUMBER

Number of Wires 3: 3 Wire 4: 4 Wire

Transfer Switch Model Number Code

1.5 Standard Features

D Ambient operating temperature range

--4_ to 140_F (--20_ to 60_C)

D Ambient storage temperature range

--22_ to 158_F (--30_ to 70_C)

listed to Canadian safety standards

D Humidity range 5 to 85% noncondensing D Provision for test switch

1.6 Application Data

dropout fixed at 160 VAC and pickup fixed at 190 VAC

the generator unloaded for a 20-minute period once a week

Switch Rating (amps) 100 200

* UL 1008 listed and CSA certified at 240 vac maximum.

manually operable for maintenance

G120 Withstand and Closing Current Ratings

* UL 1008 listed and CSA certified at 240 vac maximum.

Specific Manufacturers Molded-Case Circuit Breakers*

Manufacturer Cutler-Hammer Cutler Hammer

22,000 Square D ITE/Siemens

Cutler-Hammer Cutler Hammer

* UL 1008 listed at 240 vac maximum.

Restoration of Normal Power

transfer back to normal power.

Failure of Normal Power

2.2 Exerciser Function

D Run ( ). Returning the switch to the run position

Exerciser switch Set position Disable position Run position

Exerciser Power Requirements

2.3 Manual Operation

Model G120 Contactor with Flywheel (Procedure 1)

SCE NC NO C 8 7 EL1 EL2

1 1. Manual operation handle 2. Manual operation lever

Model G220 Contactor with Manual Operation Handle (Procedure 2)

Section 3 Maintenance and Testing

Section 3 Maintenance and Testing

maintains the safe and reliable operation of the switch.

Section 3 Maintenance and Testing

Section 4 Drawings and Diagrams

Model G220 Transfer Switch

Figure 4-1 G120

Model G120 Transfer Switch

Transfer Switch Model

Enclosure Dimensions Wiring Diagram Schematic Diagram