Tp6127 - MPAC 1000 Controller & Service Manual

Service
Automatic Transfer Switches
Models:
KCT/KCP/KBT/KBP
Power Switching Device:
Standard and Bypass/Isolation
30 to 4000 Amperes
Electrical Controls:
MPAC 1000t
TP-6127 9/02
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
x:in:007:001
Table of Contents
Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside front cover

Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Section 1 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.1 General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.2 Internal Inspections and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.1 Weekly Generator Set Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.2 Monthly Automatic Operation Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.3 Other Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Section 2 Controller Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Introduction to Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 PC Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 Event History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4 Troubleshooting Transfer Switch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.5 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5.1 Service Required LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5.2 Auxiliary Switch Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5.3 Failure to Acquire Standby Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5.4 Failure to Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5.5 Phase Rotation Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5.6 I/O Module Faults and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Section 3 Controller Test and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1 Initial Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1.1 Lamp Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1.2 Service Required Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2 Controller LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.3.1 Transfer Switch Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.3.2 Controller Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.3.3 Powering the Controller Directly (Service Kit GM25479) . . . . . . . . . . . . 22
3.4 Controller Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.5 Test Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.6 Engine Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.7 Position Microswitch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.8 DIP Switch Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.9 System Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.9.1 Controller Source Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.9.2 Voltage, Frequency, and Phase Rotation Checks . . . . . . . . . . . . . . . . . . 29
3.9.3 Voltage and Frequency Pickup and Dropout Settings . . . . . . . . . . . . . . . 31
3.10 Meter Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.11 Time Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.12 Programmed-Transition Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.13 Controller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
TP-6127 9/02 Table of Contents

Table of Contents, continued
Section 4 Transfer Switch Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4.1 Transfer Switch Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.2 Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.3 Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.4 Solenoid Coil, Rectifier, and Snubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.4.1 Solenoid Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.4.2 Rectifier and Snubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.5 Solenoid Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.5.1 Open-Transition 30--1200 Amp and 4000 Amp Open Transition Models . .
42
4.5.2 1600--3000 Amp Open-Transition Models . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.5.3 150--400 Amp 2- and 3-Pole Programmed-Transition Models . . . . . . . . 47
4.5.4 150--400 Amp 4-Pole and 600--1200 Amp Programmed-Transition Models
49
4.5.5 1600--3000 Amp Programmed-Transition Models . . . . . . . . . . . . . . . . . . 51
Section 5 30--200 Amp Transfer Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.2 Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.3 Operator Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.4 Main Contact Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.5 Coil Control Contact Test and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.5.1 Coil Control Contact Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.5.2 Coil Control Contact Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Section 6 225--400 Amp Open-Transition Transfer Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.2 Main Contact Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.4 Coil Control Contact Test and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.4.1 Coil Control Contact Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.4.2 Contact Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
6.4.3 Coil Control Contact Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Section 7 150--400 Amp Programmed-Transition Transfer Switches and Bypass/Isolation
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7.2.1 Movable Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7.2.2 Stationary Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.3.1 Removing the Coil Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.3.2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.3.3 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7.3.4 Installing Coil Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7.4 Control Contact Test & Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
7.4.1 Test and Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
7.4.2 Test Control Contact Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Table of Contents TP-6127 9/02

Section 8 600--1200 Amp Transfer Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

8.1 Maintenance Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
8.2 Main and Arcing Contact Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
8.2.1 Arc Chute and Barrier Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
8.2.2 Contact Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
8.2.3 Movable Arcing Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
8.2.4 Movable Main Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
8.2.5 Stationary Arcing Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
8.2.6 Stationary Contact Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . 96
8.2.7 Arc Chute and Barrier Reinstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
8.3 Solenoid Coil and Solenoid Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . 97
8.3.1 Solenoid Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
8.3.2 Solenoid Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
8.4 Coil Control Contact Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Section 9 600--800 Amp Bypass/Isolation Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
9.1.1 Main Contact Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
9.1.2 Stationary Contacts Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
9.1.3 Stationary Contacts Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
9.1.4 Movable Contacts Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
9.2 Transfer Switch Barrier Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 110
9.2.1 Barrier Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
9.2.2 Barrier Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
9.3.1 Coil Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
9.3.2 Coil Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
9.3.3 Core Tube and Core Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
9.3.4 Core Tube and Core Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
9.3.5 Coil Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
9.3.6 Coil Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
9.4 Control Contact Test and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
9.5 TS Control Contact Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Section 10 600--800 Amp Programmed-Transition Bypass/Isolation Switches . . . . . . . . . . . . . . . . . . 121
10.1.1 Tools Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
10.2.1 Disassembly of Movable Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
10.2.2 Reassembly of Movable Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
10.2.3 Disassembly of Stationary Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
10.2.4 Reassembly of Stationary Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
10.3.1 Removal of Coil Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
10.3.2 Coil Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
10.3.3 Core Tube and Core Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
10.3.4 Core Tube and Core Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
10.3.5 Coil Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
10.3.6 Installation of Coil Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
TP-6127 9/02 Table of Contents

Section 11 1600--3000 Amp Open-Transition Switches and 1000--3000 Amp Bypass/Isolation

Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
11.1 Maintenance Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
11.2 Main Contact Inspection and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
11.2.1 Contact Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
11.2.2 Contact Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
11.3 Main and Arcing Contact Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
11.4 Solenoid Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Section 12 4000 Amp Open-Transition Transfer Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
12.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
12.3 Coil Control Contact Test and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
12.4 TS Control Contact Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Appendix B Common Hardware Application Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Appendix C General Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Appendix D Common Hardware Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Appendix E Common Hardware List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Table of Contents TP-6127 9/02

Safety Precautions and Instructions
IMPORTANT SAFETY Safety decals affixed to the equipment Battery

INSTRUCTIONS. Electromechanical in prominent places alert the operator
equipment, including generator sets, or service technician to potential
transfer switches, switchgear, and hazards and explain how to act safely. WARNING
accessories, can cause bodily harm The decals are shown throughout this
and pose life-threatening danger when publication to improve operator
improperly installed, operated, or recognition. Replace missing or
maintained. To prevent accidents be damaged decals.
aware of potential dangers and act
safely. Read and follow all safety
precautions and instructions. SAVE
Accidental Starting Sulfuric acid in batteries.
Can cause severe injury or death.
THESE INSTRUCTIONS.
WARNING Wear protective goggles and
This manual has several types of safety clothing. Battery acid may cause
precautions and instructions: Danger, blindness and burn skin.
Warning, Caution, and Notice.
WARNING
DANGER Accidental starting.
Danger indicates the presence of a Disconnect the battery cables before
hazard that will cause severe working on the generator set.
personal injury, death, or substantial Remove the negative (--) lead first
property damage. when disconnecting the battery. Explosion.
Reconnect the negative (--) lead last Can cause severe injury or death.
when reconnecting the battery. Relays in the battery charger
WARNING cause arcs or sparks.
Disabling the generator set. Locate the battery in a well-ventilated

Warning indicates the presence of a area. Isolate the battery charger from
Accidental starting can cause
hazard that can cause severe explosive fumes.
severe injury or death. Before
personal injury, death, or substantial
working on the generator set or
property damage.
connected equipment, disable the
generator set as follows: (1) Move the
generator set master switch to the OFF
CAUTION
position. (2) Disconnect the power to
the battery charger. (3) Remove the
Caution indicates the presence of a battery cables, negative (--) lead first.
hazard that will or can cause minor Reconnect the negative (--) lead last
personal injury or property damage. when reconnecting the battery. Follow
these precautions to prevent starting of
NOTICE
the generator set by an automatic
Notice communicates installation, transfer switch, remote start/stop
operation, or maintenance information switch, or engine start command from a
that is safety related but not hazard remote computer.
related.
TP-6127 9/02 Safety Precautions and Instructions I

Battery electrolyte is a diluted Battery short circuits. Explosion
sulfuric acid. Battery acid can cause can cause severe injury or death.
DANGER
severe injury or death. Battery acid Short circuits can cause bodily injury
can cause blindness and burn skin. and/or equipment damage.
Always wear splashproof safety Disconnect the battery before
goggles, rubber gloves, and boots generator set installation or
when servicing the battery. Do not maintenance. Remove all jewelry Hazardous voltage.
open a sealed battery or mutilate the before servicing the equipment. Use Will cause severe injury or death.
battery case. If battery acid splashes in tools with insulated handles. Remove
Only authorized personnel should
the eyes or on the skin, immediately the negative (--) lead first when open the enclosure.
flush the affected area for 15 minutes disconnecting the battery. Reconnect
with large quantities of clean water. the negative (--) lead last when
Seek immediate medical aid in the case reconnecting the battery. Never WARNING
of eye contact. Never add acid to a connect the negative (--) battery cable
battery after placing the battery in to the positive (+) connection terminal
service, as this may result in hazardous of the starter solenoid. Do not test the
spattering of battery acid. battery condition by shorting the
terminals together.
Battery acid cleanup. Battery acid Hazardous voltage. Moving rotor.
can cause severe injury or death. Can cause severe injury or death.
Battery acid is electrically conductive
and corrosive. Add 500 g (1 lb.) of
Hazardous Voltage/ Operate the generator set only when
all guards and electrical enclosures
bicarbonate of soda (baking soda) to a Electrical Shock are in place.
container with 4 L (1 gal.) of water and
mix the neutralizing solution. Pour the DANGER Grounding electrical equipment.
neutralizing solution on the spilled
Hazardous voltage can cause
battery acid and continue to add the
severe injury or death. Electrocution
neutralizing solution to the spilled is possible whenever electricity is
battery acid until all evidence of a present. Open the main circuit
chemical reaction (foaming) has breakers of all power sources before
ceased. Flush the resulting liquid with Hazardous voltage.
Will cause severe injury or death. servicing the equipment. Configure the
water and dry the area. installation to electrically ground the
Disconnect all power sources before generator set, transfer switch, and
Battery gases. Explosion can cause
opening the enclosure. related equipment and electrical
severe injury or death. Battery gases
circuits to comply with applicable codes
can cause an explosion. Do not smoke and standards. Never contact
or permit flames or sparks to occur near DANGER electrical leads or appliances when
a battery at any time, particularly when standing in water or on wet ground
it is charging. Do not dispose of a because these conditions increase the
battery in a fire. To prevent burns and risk of electrocution.
sparks that could cause an explosion,
avoid touching the battery terminals
Hazardous voltage.
with tools or other metal objects.
Will cause severe injury or death.
Remove all jewelry before servicing the
equipment. Discharge static electricity Disconnect all power sources before
from your body before touching servicing. Install the barrier after
batteries by first touching a grounded adjustments, maintenance, or
metal surface away from the battery. To servicing.
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.
II Safety Precautions and Instructions TP-6127 9/02

Welding the generator set. Can Servicing the transfer switch. Heavy Equipment
cause severe electrical equipment Hazardous voltage can cause
damage. Before welding the generator severe injury or death. Deenergize all
set perform the following steps: power sources before servicing. Open WARNING
(1) Remove the battery cables, the main circuit breakers of all transfer
negative (--) lead first. (2) Disconnect switch power sources and disable all
all engine electronic control module generator sets as follows: (1) Move all
(ECM) connectors. (3) Disconnect all generator set master controller
generator set controller and voltage switches to the OFF position. (2)
regulator circuit board connectors. Disconnect power to all battery
(4) Disconnect the engine battery- chargers. (3) Disconnect all battery Unbalanced weight.
charging alternator connections. cables, negative (--) leads first. Improper lifting can cause severe
injury or death and equipment
(5) Attach the weld ground connection Reconnect negative (--) leads last when
damage.
close to the weld location. reconnecting the battery cables after
servicing. Follow these precautions to Use adequate lifting capacity.
Installing the battery charger. prevent the starting of generator sets Never leave the transfer switch
Hazardous voltage can cause by an automatic transfer switch, remote standing upright unless it is securely
severe injury or death. An start/stop switch, or engine start bolted in place or stabilized.
ungrounded battery charger may command from a remote computer.
cause electrical shock. Connect the Before servicing any components
battery charger enclosure to the ground inside the enclosure: (1) Remove all
of a permanent wiring system. As an jewelry. (2) Stand on a dry, approved Moving Parts
alternative, install an equipment electrically insulated mat. (3) Test
grounding conductor with circuit
conductors and connect it to the
circuits with a voltmeter to verify that WARNING
they are deenergized.
equipment grounding terminal or the
lead on the battery charger. Install the Testing live electrical circuits.
battery charger as prescribed in the Hazardous voltage or current can
equipment manual. Install the battery cause severe injury or death. Have
charger in compliance with local codes trained and qualified personnel take Hazardous voltage. Moving rotor.
and ordinances. diagnostic measurements of live Can cause severe injury or death.
circuits. Use adequately rated test
Connecting the battery and the equipment with electrically insulated Operate the generator set only when
battery charger. Hazardous voltage probes and follow the instructions of the all guards and electrical enclosures
can cause severe injury or death. test equipment manufacturer when are in place.
Reconnect the battery correctly, performing voltage tests. Observe the
positive to positive and negative to following precautions when performing
negative, to avoid electrical shock and voltage tests: (1) Remove all jewelry.
WARNING
damage to the battery charger and (2) Stand on a dry, approved electrically
battery(ies). Have a qualified insulated mat. (3) Do not touch the
electrician install the battery(ies). enclosure or components inside the
Short circuits. Hazardous enclosure. (4) Be prepared for the
voltage/current can cause severe system to operate automatically.
injury or death. Short circuits can (600 volts and under) Spring-loaded parts.
cause bodily injury and/or equipment Can cause severe personal injury
Removing the transfer switch from or property damage.
damage. Do not contact electrical bypass/isolation models.
connections with tools or jewelry while Hazardous voltage can cause Wear protective goggles when
making adjustments or repairs. severe injury or death. Bypass and servicing spring-loaded parts. Hold
Remove all jewelry before servicing the isolate the transfer switch before parts securely during disassembly.
equipment. removing it from the enclosure. The
Making line or auxiliary bypass/isolation switch is energized.
connections. Hazardous voltage Do not touch the isolation contact
can cause severe injury or death. To fingers or the control circuit terminals.
prevent electrical shock deenergize the
normal power source before making
any line or auxiliary connections.
TP-6127 9/02 Safety Precautions and Instructions III

Disassembling the solenoid. NOTICE NOTICE
Spring-loaded parts can cause When replacing hardware, do not Foreign material contamination.
severe personal injury or property substitute with inferior grade Cover the transfer switch during
damage. The spring in the solenoid hardware. Screws and nuts are installation to keep dirt, grit, metal drill
assembly exerts substantial force on available in different hardness ratings. chips, and other debris out of the
the coil. Hold the coil assembly To indicate hardness, American components. Cover the solenoid
securely when removing the screws. Standard hardware uses a series of mechanism during installation. After
markings, and metric hardware uses a installation, use the manual operating
numeric system. Check the markings handle to cycle the contactor to verify
Notice on the bolt heads and nuts for that it operates freely. Do not use a
identification. screwdriver to force the contactor
NOTICE mechanism.
Hardware damage. The transfer NOTICE
switch may use both American Improper operator handle usage. NOTICE
Standard and metric hardware. Use Use the manual operator handle on the Electrostatic discharge damage.
the correct size tools to prevent transfer switch for maintenance Electrostatic discharge (ESD)
rounding of the bolt heads and nuts. purposes only. Return the transfer damages electronic circuit boards.
switch to the normal position. Remove Prevent electrostatic discharge
the manual operator handle, if used, damage by wearing an approved
and store it in the place provided on the grounding wrist strap when handling
transfer switch when service is electronic circuit boards or integrated
completed. circuits. An approved grounding wrist
strap provides a high resistance (about
1 megohm), not a direct short, to
ground.
IV Safety Precautions and Instructions TP-6127 9/02

Introduction
This manual provides service and parts information for beginning of this manual. Keep this manual with the
Kohlerr Model KCT/KCP transfer switches and Model equipment for future reference.
KBT/KBP Bypass/Isolation switches with MPAC 1000t
electrical controls. It includes operation, The equipment service requirements are very important
troubleshooting, repair, and maintenance procedures to safe and efficient operation. Inspect parts often and
for the transfer switches and electrical controls. perform required service at the prescribed intervals.
Obtain service from an authorized service
A personal computer and Setup Program software are distributor/dealer to keep equipment in top condition.
essential for troubleshooting the transfer switch. The
MPACt Setup Program Software Operation and Figure 1 lists the part numbers for related literature.
Installation Manual part number is shown in Figure 1. Separate operation and installation manuals contain
operation and installation information not provided in
The information included in this manual is intended this manual. Refer to the parts catalog for instructions to
solely for use by trained and qualified service personnel obtain replacement parts.
of authorized service distributors/dealers.
Document Part
Information in this publication represents data available Document Number
at the time of print. Kohler Co. reserves the right to Model KCT/KCP ATS Operation and
Installation Manual TP-6126
change this literature and the products represented
without notice and without any obligation or liability Model KBT/KBP Bypass/Isolation Switch
TP-6128
Operation and Installation Manual
whatsoever.
MPACt Setup Program Operation Manual TP-6135
Read this manual and carefully follow all procedures Model KCT/KCP/KBT/KBP Parts Catalog TP-6158
and safety precautions to ensure proper equipment Model KCT/KCP/KBT/KBP Wiring Diagram
Manual TP-6169
operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section at the Figure 1 Related Literature
TP-6127 9/02 Introduction i

Service Assistance
For professional advice on generator power China

requirements and conscientious service, please contact North China Regional Office, Beijing
your nearest Kohler distributor or dealer. Phone: (86) 10 6518 7950
(86) 10 6518 7951
D Consult the Yellow Pages under the heading (86) 10 6518 7952
Generators—Electric Fax: (86) 10 6518 7955
D Visit the Kohler Power Systems website at East China Regional Office, Shanghai
kohlergenerators.com Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
D Look at the labels and stickers on your Kohler product India, Bangladesh, Sri Lanka
or review the appropriate literature or documents India Regional Office
included with the product Bangalore, India
Phone: (91) 80 3366208
D Call toll free in the US and Canada 1-800-544-2444 (91) 80 3366231
Fax: (91) 80 3315972
D Outside the US and Canada, call the nearest regional
office Japan, Korea
North Asia Regional Office
Africa, Europe, Middle East Tokyo, Japan
London Regional Office Phone: (813) 3440-4515
Langley, Slough, England Fax: (813) 3440-2727
Phone: (44) 1753-580-771
Latin America
Fax: (44) 1753-580-036
Latin America Regional Office
Asia Pacific Lakeland, Florida, USA
Power Systems Asia Pacific Regional Office Phone: (863) 619-7568
Singapore, Republic of Singapore Fax: (863) 701-7131
Phone: (65) 264-6422 X:in:008:001a
Fax: (65) 264-6455
ii Service Assistance TP-6127 9/02

Section 1 Scheduled Maintenance
1.1 Introduction WARNING

Regular preventive maintenance ensures safe and
reliable operation and extends the life of the transfer
switch. Preventive maintenance includes periodic
testing, cleaning, inspecting, and replacing of worn or
missing components. Section 1.4 contains a service Hazardous voltage.
schedule of recommended maintenance tasks.
Disconnect all power sources before
A local authorized distributor/dealer can provide opening the enclosure.
complete preventive maintenance and service to keep (600 volts and under)
the transfer switch in top condition. Unless otherwise
specified, have maintenance or service performed by an
authorized distributor/dealer in accordance with all
WARNING
applicable codes and standards.
Keep records of all maintenance or service.
Replace all barriers and close and lock the enclosure Hazardous voltage.
door after maintenance or service and before reapplying Can cause severe injury or death.
power. Disconnect all power sources before
servicing. Install the barrier after
adjustments, maintenance, or
WARNING servicing.
(600 volts and under)
WARNING
Accidental starting.
Disconnect the battery cables before
working on the generator set.
Hazardous voltage. Moving rotor.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last Operate the generator set only when
when reconnecting the battery. all guards and electrical enclosures
are in place.
Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on the Grounding electrical equipment. Hazardous voltage can
generator set or connected equipment, disable the generator cause severe injury or death. Electrocution is possible
set as follows: (1) Move the generator set master switch to the whenever electricity is present. Open the main circuit
OFF position. (2) Disconnect the power to the battery charger. breakers of all power sources before servicing the equipment.
(3) Remove the battery cables, negative (--) lead first. Configure the installation to electrically ground the generator
Reconnect the negative (--) lead last when reconnecting the set, transfer switch, and related equipment and electrical
battery. Follow these precautions to prevent starting of the circuits to comply with applicable codes and standards. Never
generator set by an automatic transfer switch, remote contact electrical leads or appliances when standing in water
start/stop switch, or engine start command from a remote or on wet ground because these conditions increase the risk of
computer. electrocution.
TP-6127 9/02 Section 1 Scheduled Maintenance 1

NOTICE
WARNING
Hardware damage. The transfer switch may use both
American Standard and metric hardware. Use the correct size
tools to prevent rounding of the bolt heads and nuts.
NOTICE
Hazardous voltage. When replacing hardware, do not substitute with inferior
Can cause severe injury or death. grade hardware. Screws and nuts are available in different
Disconnect all power sources before hardness ratings. To indicate hardness, American Standard
servicing. Install the barrier after hardware uses a series of markings, and metric hardware
adjustments, maintenance, or uses a numeric system. Check the markings on the bolt heads
servicing. and nuts for identification.
(600 volts and under) NOTICE

Short circuits. Hazardous voltage/current can cause Electrostatic discharge damage. Electrostatic discharge
severe injury or death. Short circuits can cause bodily injury (ESD) damages electronic circuit boards. Prevent
and/or equipment damage. Do not contact electrical electrostatic discharge damage by wearing an approved
connections with tools or jewelry while making adjustments or grounding wrist strap when handling electronic circuit boards
repairs. Remove all jewelry before servicing the equipment. or integrated circuits. An approved grounding wrist strap
provides a high resistance (about 1 megohm), not a direct
Testing live electrical circuits. Hazardous voltage or short, to ground.
current can cause severe injury or death. Have trained and
qualified personnel take diagnostic measurements of live
circuits. Use adequately rated test equipment with electrically 1.2 Inspection and Service
insulated probes and follow the instructions of the test
equipment manufacturer when performing voltage tests.
Observe the following precautions when performing voltage 1.2.1 General Inspection
tests: (1) Remove all jewelry. (2) Stand on a dry, approved
External Inspection. Inspect the transfer switch
electrically insulated mat. (3) Do not touch the enclosure or
components inside the enclosure. (4) Be prepared for the
weekly.
system to operate automatically.
D Look for any signs of vibration, leakage, excessive
noise, high temperature, contamination, or
Servicing the transfer switch. Hazardous voltage can deterioration.
cause severe injury or death. Deenergize all power sources
before servicing. Open the main circuit breakers of all transfer D Remove accumulations of dirt, dust, and other
switch power sources and disable all generator sets as contaminants from the transfer switch’s exterior with
follows: (1) Move all generator set master controller switches a vacuum cleaner or by wiping with a dry cloth or
to the OFF position. (2) Disconnect power to all battery brush. Do not use compressed air to clean the switch
chargers. (3) Disconnect all battery cables, negative (--) leads because it can cause debris to lodge in the
first. Reconnect negative (--) leads last when reconnecting the
components and damage the switch.
battery cables after servicing. Follow these precautions to
prevent the starting of generator sets by an automatic transfer D Replace any worn, missing, or broken external
switch, remote start/stop switch, or engine start command
components with manufacturer-recommended
from a remote computer. Before servicing any components
replacement parts. Contact a local authorized
inside the enclosure: (1) Remove all jewelry. (2) Stand on a
dry, approved electrically insulated mat. (3) Test circuits with a
distributor/dealer for part information and ordering.
voltmeter to verify that they are deenergized.
D Tighten loose external hardware.
Servicing the transfer switch controls and accessories
within the enclosure. Hazardous voltage can cause Contact an authorized distributor/dealer to inspect and
severe injury or death. Disconnect the transfer switch service the transfer switch when any wear, damage,
controls at the inline connector to deenergize the circuit boards deterioration, or malfunction of the transfer switch or its
and logic circuitry but allow the transfer switch to continue to components is evident or suspected.
supply power to the load. Disconnect all power sources to
accessories that are mounted within the enclosure but are not
wired through the controls and deenergized by inline
connector separation. Test circuits with a voltmeter to verify
that they are deenergized before servicing.
2 Section 1 Scheduled Maintenance TP-6127 9/02

1.2.2 Internal Inspections and Part Replacement and Tightening. Replace worn,
Maintenance missing, broken, deteriorated, or corroded internal
components with manufacturer-recommended
Internal Inspection. Have an authorized distributor/ replacement parts. Contact a local authorized
dealer perform an annual inspection of the transfer distributor/dealer for part information and part ordering.
switch. Inspect the switch more frequently if it is located Tighten loose internal hardware.
in a dusty or dirty area or when any condition noticed
during an external inspection may have affected internal Terminal Tightening. Loose connections on the
components. Disconnect all power sources, open the power circuits can lead to overheating or explosion.
transfer switch enclosure, and inspect internal Tighten all lugs to the torque values on the label on the
components. Look for: switch. See Figure 1-1 for a typical label.
D Accumulations of dirt, dust, moisture, or other Tighten engine start, input/output, and auxiliary
contaminants connections to the torque indicated on the decals affixed
to the unit.
D Signs of corrosion
D Worn, missing, or broken components SUITABLE FOR CONTROL OF MOTORS, ELEC

DISCHARGE AND TUNGSTEN LAMPS, ELEC HEAT--
ING EQPT, WHERE THE SUM OF MOTOR FULL--
LOAD AMPS AND AMPS OF OTHER LOADS DOES
D Loose hardware NOT EXCEED THE SWITCH AMP RATING AND THE
TUNGSTEN LOAD DOES NOT EXCEED100% OF
SWITCH RATING, 240V MAX.
WHEN PROTECTED BY A CIRCUIT BREAKER
D Wire or cable insulation deterioration, cuts, or WITHOUT AN ADJUSTABLE SHORT--TIME RESPONSE
ONLY OR BY FUSES THIS TRANSFER SWITCH IS
RATED FOR USE ON A CIRCUIT CAPABLE OF
abrasions DELIVERING NOT MORE THEN THE RMS SYMM
AMPS AT THE VOLTAGE SHOWN.
RMS SYMM
AMPS MAX AMPS
D Signs of overheating or loose connections: X1000 VOLTS BREAKER/MFR/TYPE MAX
35 480 ANY ANY ANY PER NEC
discoloration of metal, melted plastic, or a burning 22 600 ANY ANY ANY PER NEC
42 480 GE SGL4,SGP4,TB4, 400

odor THLC4,TLB4 400
SGLA,SGL6,SGP6,TB6 600
SKHA,SKL8,SKP8,TKL 800
D Other evidence of wear, damage, deterioration, or 42 480 I--T--E CJD6,HHJD6, 400

HHJXD6,HJD6,SCJD6,SHJD6 400
malfunction of the transfer switch or its components CLD6,HHLD6,HHLXD6,HLD6, 600
SCLD6,SHLD6 600
CMD6,HMD6,HND6,MD6,MXD6, 800
SCMD6,SHMD6,SMD6,SND6 800
Cleaning. Use a vacuum cleaner or a dry cloth or brush 42 480 SQUARE D LC,LI 600
to remove contaminants from internal components. Do MH 800
42 480 WESTH HKD,KDC,LCL, 400

not use compressed air to clean the switch because it TRI--PAC LA 400
HLD 600
can cause debris to lodge in the components and TRI--PAC NB 800
42 480 ABB S5 400

damage the switch. S6 800
42 480 MERLIN GERIN 600
CJ600
Lubrication. Maintain the transfer switch lubrication. If
the transfer switch is subject to extremely dusty or
abnormal operating conditions, relubricate all
movements and linkages yearly. Relubricate the
solenoid operator if the TS coil is replaced. Do not use
oil; order the lubrication kit shown in the Parts Catalog. 200 480 FUSE ANY CLASS J 600
USE 75 °C MIN. CU/AL WIRE FOR POWER
CONNECTIONS. USE 60 °C MIN. CU WIRE FOR
CONTROLS.
Disconnect power and manually operate the transfer
switch mechanism to verify that it operates smoothly 1 USE COPPER OR ALUMINUM WIRE
FOR POWER TERMINALS
without binding. If lubricating the outer mechanism of RECOMMENDED TIGHTENING
TORQUE 600 IN--LBS
483500--007
REV B
the transfer switch does not eliminate binding, replace
the transfer switch assembly.
1. Torque specification 007
Periodically oil the enclosure door locks and screws.

Figure 1-1 Typical Rating/Torque Label

Signs of Overheating. Replace components damaged layer of silvery-colored metal, is worn through to the
by overheating and locate the cause of the overheating. metal below. Check the condition of the arc chutes. If
Overheating could be caused by loose power the arc chutes show signs of disintegration, replace the
connections, overloading, or a short circuit in the arc chute assembly.
system. After tightening the power terminals, perform a
millivolt drop test to locate areas with high contact
resistance. See Section 1.3.3. Check the line circuit
breakers in the system to be sure that they do not allow
the load to exceed the switch rating. Use the controller
troubleshooting and schematics to locate a control
circuit short.
Wire Repair or Replacement. Replace wiring when

there is any doubt about its condition, or when there is
extensive damage or deterioration. If the damaged or
deteriorated wires are part of a wiring harness, replace
the entire wiring harness.
Power Circuit Wiring. Have damage to line voltage

and power circuit wiring evaluated and repaired or
replaced by a qualified electrician.
1
Control Circuit Leads. Repair minor damage to leads 6126
in low power and control circuits operating up to 250 1. Arc chute assemblies
volts. Carefully splice and insulate the connections. Figure 1-2 150 Amp Model Transfer Switch
Tape minor control circuit wire insulation cuts or
abrasions. Repair moderately damaged leads, where
conductors are cut or insulation is damaged over
1
sections shorter than about 100 mm (4 in.) or less than
about 25% of the length of the wire, by cutting out the
damaged section and splicing in wire of the same type.
Use UL-listed insulated (250 V minimum) connectors
and follow the connector manufacturer’s instructions.
Fabricate new leads using the same type of wire and
UL-listed insulated (250 V minimum) connectors and
follow the connector manufacturer’s instructions.
Transfer Switch Inspection. Remove the arc chute

assemblies or covers at the front of the transfer switch
and inspect the main contacts inside the transfer switch.
See Figure 1-2 and Figure 1-3. Remove surface
deposits with a clean cloth. Do not use an emery cloth or
a file. Discoloration of the contact surface does not
6127
affect performance. If the contacts are pitted, show
signs of overheating, or are worn, replace the contacts. 1. Barrier/pole cover
The contacts are worn if the contact surface material, a Figure 1-3 400 Amp Model Transfer Switch

1.3 Testing WARNING
Periodic testing is important in any transfer switch
application. It helps to ensure that the generator set will
start and the transfer switch mechanisms and control
circuits will operate when needed.
Hazardous voltage.
1.3.1 Weekly Generator Set Exercise Only authorized personnel should
Use the plant exerciser to start and run the generator set open the enclosure.
once a week to maximize the reliability of the emergency (600 volts and under)
power system. See the transfer switch operation and
Testing live electrical circuits. Hazardous voltage or
installation manual for additional information about the current can cause severe injury or death. Have trained and
exerciser. qualified personnel take diagnostic measurements of live
circuits. Use adequately rated test equipment with electrically
1.3.2 Monthly Automatic Operation Test
Test the transfer switch’s automatic control system Observe the following precautions when performing voltage
monthly. See Section 3.5 or the transfer switch tests: (1) Remove all jewelry. (2) Stand on a dry, approved
operation and installation manual for the test procedure.
Verify that the expected sequence of operations occurs system to operate automatically.
as the switch transfers the load to the emergency source (600 volts and under)
when a normal source failure occurs or is simulated.
After the switch transfers the load to the emergency Millivolt Drop Test Procedure
source, end the test and verify that the expected
sequence of operations occurs as the transfer switch 1. Apply a balanced load of at least 10% of the switch
retransfers to the available normal source and signals rating. (Currents of 10 amps or greater will give
the generator set to shut down after a cooldown period. more accurate results than lower currents.)
Note: The ATS will not transfer the load during the test 2. Carefully measure the voltage on each phase of
sequence if the Test DIP switch is set to the both sources from the source lug to the load lug.
unloaded position. Take several readings to ensure accuracy. The
readings may be erratic because of the small
voltage measured, load fluctuations, and meter
1.3.3 Other Tests circuit contact resistances.
Every Year Note: To obtain accurate readings, keep the meter

as far as possible from current-carrying
Measure the voltage drop to help locate high-resistance conductors and the meter leads as short,
contacts in the ATS. The test procedure measures the direct, and at right angles to current-carrying
voltage drop across a contact and the current in the conductors as possible. This minimizes the
circuit, then uses those measured values to find the effect of induced voltages (transformer
contact resistance. effect) in the vicinity of the current-carrying
conductors.
The purpose of the test is to locate any contact that has
significantly higher resistance than others. An 3. Use an ammeter to measure the current flow
unusually high voltage across one set of contacts may through the circuit.
signal unacceptably high resistance in the contacts.
4. Calculate the contact resistance using the
Run the test with the ATS under a moderate and following formula:
balanced load. Use the following procedure to take
R=V÷I
voltage measurements and calculate resistances for
each phase of both Source N and Source E.

Where:
WARNING
V = measured voltage in millivolts
I = measured current in amps
R = calculated resistance in milliohms
Compare the calculated values for resistance (R) to the

values in the table in Figure 1-4. If the calculated Hazardous voltage.
resistance is significantly higher (2 times larger or more) Can cause severe injury or death.
than the value shown in the table, disconnect power, Only authorized personnel should
check the connections and lug torques, and repeat the open the enclosure.
test. If the second measurement also indicates that the (600 volts and under)
resistance is too high, replace the contact. See the ATS
Parts Catalog for replacement part ordering information. Testing live electrical circuits. Hazardous voltage or
Refer to the Table of Contents in the front of this manual current can cause severe injury or death. Have trained and
to locate the contact replacement procedure for your qualified personnel take diagnostic measurements of live
switch.
Maximum Contact Observe the following precautions when performing voltage
Transfer Switch Rating,
Resistance, Milliohms tests: (1) Remove all jewelry. (2) Stand on a dry, approved
Amps
(m9)
30--200 0.250 components inside the enclosure. (4) Be prepared for the
225--400 0.200 system to operate automatically.
600--800 0.175 (600 volts and under)
1000--1200 0.085
2. Use a hi-pot tester or meggar to check the
1600--3000 0.050 insulation resistance phase-to-phase and
Figure 1-4 Maximum Contact Resistance phase-to-neutral, and phase-to-ground if neutral
and ground are isolated. For a hi-pot tester, the
maximum potential is 500 VAC and the maximum
Every Three Years
test time is 1 second.
Test the wire insulation. Use the following procedure to
check for insulation breakdown and replace any faulty 3. Verify that the measured insulation resistance
components. exceeds 1.24 megohms (MW).
4. If the hi-pot tester indicates wire insulation

Wire Insulation Breakdown Test Procedure breakdown or if the measured resistance is less
than 1.24 MW, isolate the leakage current using an
1. Disconnect all power sources by opening
instrument designed for this purpose. Replace the
upstream circuit breakers or switches to the
faulty components.
transfer switch. Disconnect the load from the
transfer switch by opening circuit breakers or Note: You may need to disconnect power
switches leading from the transfer switch. conductors from the lugs to isolate the
Disconnect the transfer switch wiring harness from problem. If you disconnect the power
the controller at connector P1. conductors, see the transfer switch
operation and installation manual for
reconnection instructions.
Every Five Years

Check the normal and emergency source setpoint
calibration according to the procedures in Section 3.9,
System Settings.

1.4 Service Schedule
Follow the service schedule below for the recommended service intervals. The transfer switch operator can perform
tasks marked by an X. Have an authorized distributor/dealer inspect the switch annually and perform all service
marked by a D.
Adjust,
See Visually Repair, or
System Component or Procedure Section Inspect Check Replace Clean Test Interval
ELECTRICAL SYSTEM
Check for signs of overheating or loose connections:
1.2.2 X X Y
discoloration of metal, melted plastic, or a burning odor.
Check the transfer switch’s external operating
mechanism for cleanliness. Clean and relubricate if 1.2.2 X D D Y
dirty.*
Check wiring insulation for deterioration, cuts, or X Y
abrasion Repair or replace wiring to regain the
abrasion. 122
1.2.2
properties of the original wiring. D D D Y
Check the transfer switch’s main power switching
1.2.2 D D D Y
mechanisms’ mechanical operation and integrity.
Tighten control and power wiring connections to
1.2.2 D D Y
specifications.
Check the transfer switch’s main power switching
contacts’ condition. Clean or replace the main contacts 1.2.2 D D D Y
or replace the transfer switch assembly as necessary.
Perform a millivolt drop test to check for high contact
resistances on power circuits. Tighten connections,
clean main contacts, or adjust or replace main contacts 1.3.3 D D D D Y
or transfer switch assembly to eliminate high contact
resistances.
Test wire and cable insulation for electrical breakdown. 1.3.3 D Every 3 Years
Check calibration of voltage-sensing circuitry and
1.3.3 D D Every 5 Years
setpoints, and recalibrate circuitry as necessary.
CONTROL SYSTEM
Exercise the generator set without load. 1.3.1, O/I/M X W
Test the transfer switch’s automatic control system. O/I/M X X M
Test all LED indicators, time delays, and remote control
O/I/M D D D D Y
systems for operation.
GENERAL EQUIPMENT CONDITION
Inspect the outside of the transfer switch for any signs
of excessive vibration, leakage, high temperature, 1.2.1 X X M
contamination, or deterioration.*
Check that all external hardware is in place, tightened,
1.2.1 X X X M
and not badly worn.
Inspect the inside of the transfer switch for any signs of X M
vibration, leakage, noise, high temperature,
122
1.2.2
contamination, or deterioration. Check for metal
D D D Y
discoloration, melted plastic, or a burning odor.*
Check that all internal hardware is in place, tightened, X M
122
1.2.2
and not badly worn. D D Y
* Service more frequently if the ATS operates in extremely dusty or dirty areas.
See Section: Read these sections carefully for additional information before attempting maintenance or service.
Visually Inspect: Examine these items visually.
Check: Requires physical contact with or movement of system components, or the use of nonvisual indications.
Adjust, Repair, or Replace: Includes tightening hardware and lubricating the mechanism. May require replacement of components depending
upon the severity of the problem.
Clean: Remove accumulations of dirt and contaminants from external transfer switch’s components or enclosure with a vacuum cleaner or by
wiping with a dry cloth or brush. Do not use compressed air to clean the switch because it can cause debris to lodge in the components and cause
damage.
Test: May require tools, equipment, or training available only through an authorized distributor/dealer.
Symbols used in the chart:
O/I/M=See the transfer switch operation/installation manual. M=Monthly
X=The transfer switch operator can perform these tasks. Q=Quarterly
D=An authorized distributor/dealer must perform these tasks. S=Semiannually (every six months)
W=Weekly Y=Yearly (annually)

Notes

Section 2 Controller Troubleshooting
2.1 Introduction to DANGER

Troubleshooting
Use a personal computer running the MPAC Setup
Program as a troubleshooting tool. The program’s
event log and system setting displays are useful tools for Hazardous voltage.
identifying the cause of most problems. Refer to the Will cause severe injury or death.
Setup Program Operation Manual for instructions
throughout this Troubleshooting section.
opening the enclosure.
Refer to the wiring diagrams provided with the switch or
the Wiring Diagram Manual when troubleshooting the DANGER
transfer switch and controller.
Disconnect power to the transfer switch before opening

the enclosure to connect a personal computer. Read
and follow all safety precautions.
Hazardous voltage.
open the enclosure.
Servicing the transfer switch. Hazardous voltage can

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
prevent the starting of generator sets by an automatic transfer
Observe the following precautions when performing voltage
TP-6127 9/02 Section 2 Controller Troubleshooting 9

2.2 PC Connection Note: The controller must have power in order to
communicate with the PC. A cable to power the
Refer to the Setup Program Operation Manual for controller through a 120 VAC wall outlet is
hardware requirements and communication available. See Section 3.3.3.
information. Use a null modem cable to connect a
personal computer (PC) to the controller’s serial port, To verify that the controller is communicating with the
P6. See Figure 2-1. PC, open the Source Information window in the Setup
Program and check the source voltages. If no voltage is
shown, there is no communication. Verify that the
1 2 controller has power and that “Connect” has been
toggled on in the Setup Program. Check the COM port
3 used by the computer. If necessary, select a different
11 COM port and check for voltage readings again, and
repeat until communication is established. Refer to
TP-6135, Setup Program Operation Manual, for more
information.
4
Note: Do not start a transfer test with the enclosure door
5 open.
6
Before starting a test sequence, disconnect the PC from
the controller or bring the null modem cable out of the
10 enclosure at the bottom of the door. [Use a straight 9-pin
extension cable, if necessary, to a maximum length of
15 m (50 ft.)] Close and lock the door. Tighten the door
screws, checking to make sure that the communication
cable is not pinched by the door. See Section 3.5 for test
procedures. Follow all safety precautions when running
a test.
2.3 Event History

Use the MPAC Setup Program to view the event history
9 7
8 GM21364 log. The log lists the 100 most recent transfer switch
events, including transfers and DIP switch setting
changes as well as faults and alarms. Refer to TP-6135,
Setup Program Operation Manual, for instructions to
1. I/O board connection (P3) view the event history.
2. User interface connections
3. DIP switches The following tables list the faults and alarms that may
4. Serial port for PC connection (P6) be included in the event history log, the possible causes
5. Preferred source switch connection (P7)
6. Supervised transfer switch connection (P8) for each problem, and suggested procedures to identify
7. Programmed-transition interface board (PTIB) connection and correct the source of the problem. The event history
(factory connection) (P9) log also lists transfers and other normal events not
8. Ground wire
9. Transfer switch harness connection
shown in these tables.
10. Serial number decal
11. Terminal strip (inputs, output, Modbus connections) (TB1) The event history log can be saved to an electronic file.
Refer to the Setup Program Operation Manual for
Figure 2-1 Controller Board Component Locations instructions to save the event log to a file.
(cover removed)
10 Section 2 Controller Troubleshooting TP-6127 9/02

System Events and Faults
Fault or Event Message Possible cause Check
Overfrequency, Underfrequency Frequency settings Check that the system frequency setting
matches the actual source frequency
(50 or 60 Hz).
Check the over/underfrequency pickup
and dropout settings. See Section 3.9.3
and the Setup Program Operation
Manual.
Check that the frequency debounce
setting is long enough to prevent
nuisance faults caused by brief
frequency variations.
Source availability, stability Check that the source frequency
matches the nominal system frequency
and stays within the range of the pickup
and dropout settings.
Source connections Check for loose connections. Check
wiring.
Overvoltage, Undervoltage Voltage settings Check that the system voltage setting
matches the actual source voltage.
Check the over/undervoltage pickup and
dropout settings. See Section 3.9.3 and
the Setup Program Operation Manual.
Check that the voltage debounce setting
is long enough to prevent nuisance
faults caused by brief voltage dips or
spikes.
Source availability, stability Check that the source voltage matches
the nominal system voltage and stays
within the range of the pickup and
dropout settings.
Source connections Check for loose connections. Check
wiring.
Calibration error Check the ATS meter calibration. See
TP-6135, Setup Program Operation
Manual
Loss of Phase Single/three phase setting Check that the controller single/three
phase setting matches the source.
One phase of the source has been lost Check that all phases of the source are
available.
Source connections Check for loose connections.
Phase Rotation Error Phase rotation setting Check that the controller phase rotation
setting matches the source phase
rotation (ABC or CBA). Check the
source connections to the transfer
switch and verify that A,B, and C are
connected to the appropriate lugs.
Change the controller phase rotation
setting or rewire the source connections
if necessary.

Fault or Event Message Possible cause Check
Failure to Transfer Source not available Check source voltage, frequency,
stability.
Controller does not recognize an Check switches, circuit breakers for
available source open circuit.
Check voltage and frequency settings
(see above) and compare to measured
source parameters.
Check source connections to the ATS.
Transfer switch mechanism problem See Section 4.1, Transfer Switch
Troubleshooting.
Auxiliary Switch Fault or Controller cannot determine the transfer Check wiring and connections to
Auxiliary Switch Open switch position position microswitches. See the
schematic drawing for connections.
Test position microswitch operation.
Replace microswitch if necessary.
Transfer switch in intermediate position.
Manually operate the transfer switch,
following safety precautions and
instructions in the ATS
Operation/Installation manual.
Check the control contact operation.
Inspect for signs of coil damage or
overheating and replace coil if
necessary. See the Table of Contents
for coil and control contact test
procedures for your unit.
Failure to Acquire Standby Generator set did not start See “Failure to Start Generator Set,”
below.
Open circuit breaker Check and close ATS source and
generator set circuit breakers.
ATS does not recognize the standby Check source voltage, frequency, phase
source rotation settings and compare to actual
values.
Check for loose source connections.
Check for open switch or circuit breaker.
Check ATS meter calibration.
Failure to Start Generator Set Generator set master switch not in Move generator set master switch to the
AUTO AUTO position.
Loose engine start connection Check connections.
No engine start command from ATS See Section 3.6.
Other generator set problem Troubleshoot the generator set. See
generator set service manual.
I/O Module Not Found The controller does not detect an I/O Check I/O module connections and
module at the expected address address DIP switch settings. See
Section 2.5.6.
I/O Module Not Installed Controller detects a connected I/O Use the Setup Program to check the
module that has not been set up through number of I/O modules configured.
the setup program Check the I/O module address DIP
switches. See Section 2.5.6.
I/O Module Comms Lost Communication to an installed I/O Check I/O module connections. See
module has been lost Section 2.5.6.
Low Battery Voltage Low generator set engine starting Check battery voltage and connections.
battery See generator set manuals.
Figure 2-2 Event History

2.4 Troubleshooting Transfer Switch Operation
Problem Possible Cause Check
Generator set engine does not start Engine start time delay is running Check the time delay LED on the user
interface. Wait for time delays to expire.
Check time delay settings. See Section
3.11.
Loose engine start connection Check connections. Tighten
connections and/or replace wiring if
necessary.
No engine
g start signal
g from the ATS Normal source available.
Exerciser inhibited.
Maintenance DIP switch enabled (see
Section 3.8).
Generator set master switch not in the Move generator set master switch to the
AUTO position AUTO position.
Other generator set problem Troubleshoot the generator set. See the
generator set Operation and Service
Manuals.
Generator set engine runs when it ATS does not recognize the Normal Check connections, voltage and
should not source frequency settings, phase rotation,
calibration. Check for open switches or
circuit breakers.
ATS not in the expected position Check the ATS position LEDs. Check
the position of the preferred source
selector switch, if equipped.
Exerciser is running Check the Exercise LED on the
controller user interface. Push the
Exercise button to end an exercise run.
A test sequence is running Check the Test LED on the controller
user interface. Push the Test button to
end a test sequence.
Engine cooldown time delay operating Check the Time Delay LEDs on the ATS
controller user interface and the active
time delay window.
window Check the ATS
controller engine cooldown time delay
setting. See Section 3.11.
Check generator set controller engine
cooldown setting. See the generator set
controller Operation Manual.
Engine start connection closed Check wiring and connections. Also
see Section 3.6.
Generator set master switch not in Move the generator set master switch to
AUTO the AUTO position.
Other generator set problem Disconnect the engine start leads from
the ATS. If the engine continues to run,
troubleshoot the generator set. See the
generator set Operation and Service
Manuals.
Inphase monitor does not operate Inphase monitor function not enabled Check that the inphase monitor option
on the ATS controller is selected. See
the Setup Program Operation and
Installation Manual.
Transfer angle setting Check the transfer angle setting. See
the Setup Program Operation and
Installation Manual.
Inphase monitor option not available Not available on programmed-transition
(programmed-transition models) models. Center-OFF position makes
the inphase monitor option unnecessary.

Exerciser does not start generator set Exerciser not set Press exercise button to set time.
Check exercise mode and calendar
settings.
Check that exercise run duration is not Use the Setup Program to check
set to zero exerciser settings.
Loose or open engine start connection Check wiring and connections
Engine start problem See “Generator set engine does not
start,” in this table. Also see Section
3.6.
Exerciser does not run regularly or at all Exerciser not set Press exercise button to set time.
Check exercise mode and calendar
settings.
Exercise DIP switch #3 set to disable Check and change DIP switch setting.
Exercise interval different than expected Check 1 week/2 week DIP switch and
calendar settings
ATS does not transfer Unloaded test or exercise Check DIP switch positions
Pre-transfer load control time delays Check Time Delay and Load Control
operating Active LEDs and Active Time Delay
window in the Setup Program. Check
the time delay settings.
Supervised transfer control switch Move to Transfer or AUTO position.
(optional) in manual position See the ATS Operation Manual,
TP-6126.
Maintenance DIP switch enabled Check DIP switch position. See Section
3.8.
Connected source available Check the Source Available LEDs.
Preferred source switch (optional) in Check the position of the preferred
emergency position and emergency source switch and the Source Available
available LEDs.
Supervised transfer control switch Check the position of the supervised
(optional) in the manual position transfer control switch, if equipped.
Move the switch to the TRANSFER or
AUTO position, as appropriate for the
application. See the transfer switch
operation and installation manual for
more detailed information.
Transfer switch problem Troubleshoot the transfer switch. See
Section 4 for instructions.
No LEDs illuminated No power to the controller Check that the transfer switch harness
is connected to the controller.
No power
p to the transfer switch Check source connections.
Check that source switches or circuit
breakers are closed.
Check that one source is available.
One or more faulty LEDs Press the Lamp Test button to check the
operation of all LEDs. Replace the
controller if one or more LEDs do not
light. If no LEDs light, troubleshoot
power and connections to the controller.
Controller needs resetting Reset the controller and then press
Lamp Test. See Section 3.4.

Source available LED off when Source Malfunctioning LED Press the Lamp Test button to check the
is available operation of all LEDs. Replace the
controller if one or more LEDs do not
light. If no LEDs light, troubleshoot
power and connections to the controller.
Source settings do not match actual Check settings. See Section 3.9.
source parameters
Incorrect ATS meter calibration Check calibration. See Section 3.10.
Position LED not lit Position microswitch malfunction Check the operation of the position
microswitches.
Transfer switch in intermediate position Manually operate the transfer switch
and check the position LED operation.
Follow the safety precautions and
instructions in the ATS
Operation/Installation Manual.
Check the control contact operation;
See the Table of Contents for control
contact test procedures for your unit.
Check for evidence of solenoid coil
damage. Replace the coil if necessary.
See the Table of Contents to locate coil
replacement procedures for your model
transfer switch.
LEDs not functioning See “No LEDs illuminated” in this table.
Figure 2-3 Transfer Switch Troubleshooting

2.5 Faults Service Required LED illuminates. Some conditions
that may cause this fault are failure of the generator set
This section describes transfer switch faults indicated to start, no voltage output from the generator, or an error
by the Service Required LED on the controller’s user in sensing the voltage output from the generator set.
interface. Refer to the table in Section 2.3 for
recommendations for correcting the faults described The fault clears when the system acquires a standby
below. source. Depress the Lamp Test button until the LEDs
flash to clear the Service Required LED.
2.5.1 Service Required LED
2.5.4 Failure to Transfer
The following faults cause the Service Required LED to
flash, indicating that immediate service is required: If the unit fails to transfer on command, the controller
waits 1 second and then initiates another 200 msec
D Auxiliary switch fault
attempt to transfer. If the in-phase monitor is operating,
D Auxiliary switch open the system waits 1 second and then begins monitoring
D Failure to acquire standby source the source phases in preparation for transfer. When the
D Failure to transfer sources are in phase, the system attempts to transfer.
D Phase rotation fault After three unsuccessful attempts to transfer, the
D Input/output module faults system stops attempting to transfer and generates a
fault. The Service Required LED illuminates.
Find and correct the cause of the fault before trying to
reset the controller. The cause of the fault may be The fault clears when the transfer switch transfers
shown by the other LEDs on the user interface; check successfully. Depress the Lamp Test button until the
the Source Available, Position, Load Control, Time LEDs flash to clear the Service Required LED.
Delay, Exercise, and Test LEDs to diagnose the cause of
the faults. If the LEDs do not reveal the cause of the fault
2.5.5 Phase Rotation Faults
condition, connect a PC to the controller and use the
Setup Program to view the event history. The event A fault occurs if the phase rotation of an input channel
history lists fault conditions and transfers. See the does not match the system’s phase rotation direction
software operation manual for more information and setting (ABC or CBA). The unit will not transfer to a
instructions. source if the source’s phase rotation does not match the
system setting. If the system detects a phase rotation
After correcting the fault condition, press the Lamp Test fault in the connected source, it attempts to transfer to an
button for approximately 5 seconds until the LEDs flash alternate source that has the correct phase rotation.
twice to clear the Service Required LED. The controller logs phase rotation faults in the event
history.
2.5.2 Auxiliary Switch Faults
If the system detects phase rotation faults on both
An Auxiliary Switch Fault occurs if the controller cannot sources, the Service Required LED lights. The system
determine the transfer switch switch position. The does not transfer from the connected source.
Service Required LED flashes.
Check the transfer switch position and compare it to the 2.5.6 I/O Module Faults and Diagnostics
position LED indicators on the controller’s user When power is applied to the system, the controller
interface. attempts to initiate communication with each connected
I/O board. The following faults may occur on powerup if
The fault clears when the controller can detect the
the I/O modules are not correctly installed, addressed,
switch position. Depress the Lamp Test button until the
or configured in the setup software. Check the LED on
LEDs flash to clear the Service Required LED.
each I/O module for diagnostic information in the case of
a fault.
2.5.3 Failure to Acquire Standby
Source Diagnostic LED. Each I/O module has a diagnostic
LED that lights or flashes to indicate the I/O board status
A fault occurs if the unit attempts to start the generator as described in the table in Figure 2-4.
set but the standby source does not appear after the
Acquire Standby Source to Failure time delay. The

I/O Module Not Found. If the system does not detect I/O module address DIP switches are set correctly.
an I/O module at an expected address, the Service Check the diagnostic LED.
Required LED flashes and the software logs the
message, “I/O Module Not Found”. Check that the I/O Module Communications Lost. If communication
number of I/O modules installed matches the number to an I/O module that was previously installed and
expected by the setup program. Check that the I/O working is lost, the Service Required LED flashes and
modules are connected and the address DIP switches the software logs the message “I/O Module
are set correctly. Check the diagnostic LED to verify that Communications Lost.” Check the I/O module
the module is receiving power and communicating with connections and diagnostic LED.
the controller.
Diagnostic
I/O Module Not Installed. If the software detects an I/O I/O board Status LED
module that is connected but not expected by the setup Unpowered Off
program, the Service Required LED flashes and the Operating correctly On, Steady
software logs the message, “I/O Module Not Installed.” Power but no communication with Quick Flash
The system ignores the board if it does not find the setup control board (2 Hz)
definition. Check that the number of I/O modules No defined program at I/O module Slow Flash
expected in the Setup Program matches the number of address (0.5 Hz)
modules installed on the transfer switch. Check that the Figure 2-4 I/O Module Diagnostic LED

Notes

Section 3 Controller Test and Replacement
3.1 Initial Tests 3.2 Controller LEDs

Perform these initial tests to check the ATS controller Check the Service Required LED for fault indication.
operation. See Figure 3-1. To reset the service required LED,
press and hold the LAMP TEST button until all LEDs
Figure 3-2 shows the locations of the pushbuttons and flash, which takes approximately 5 seconds.
LEDs on the controller’s user interface.
Use the LEDs on the controller’s user interface to check
the status of the transfer switch. Watch the LEDs during
3.1.1 Lamp Test
test and exercise sequences to track the transfer switch
If no LEDs on the controller’s user interface are operation. See Figure 3-3.
illuminated, press the LAMP TEST button. If the
controller has power, all LEDs on the user interface will Service Required
light when the button is pressed. LED Illumination Fault (See Section 2.5)
Flashing
g Auxiliary Switch Fault
If no LEDs light when the LAMP TEST button is pressed, Auxiliary Switch Open
proceed to Section 3.3.1 to check for power to the Failure to Acquire Standby Source
transfer switch and controller.
Failure to Transfer
I/O Module Communications Lost
3.1.2 Service Required Reset I/O Module Not Installed
Hold the LAMP TEST button for approximately 5 I/O Module Not Found
seconds until the LEDs flash to reset the Service Phase Rotation Fault
Required LED. Remote Common Fault
Steady External Low Battery
Figure 3-1 Service Required LED
1. User interface panel location, typical GM211077A
Figure 3-2 User Interface Panel
TP-6127 9/02 Section 3 Controller Test and Replacement 19

LED Indicator Color LED Illumination
Exercise Amber Steady: Unloaded exercise is running.
Slow Flash: Loaded exercise is running.
Rapid Flash: When EXERCISE button is pressed and held, rapid flashing indicates the
exercise has been started and set. Rapid flashing at any other time indicates that the
exercise is inhibited by the Exerciser Disable/Enable DIP switch setting.
Load Control Active Amber Steady: Pre/post-transfer load control or peak shave functions are operating.
Not in Auto Red Rapid Flash: ATS is not set for automatic operation or a load shed (forced transfer to
OFF) sequence is active.
Position N Red Steady: Transfer switch is in Normal position.
Position E Red Steady: Transfer switch is in Emergency position.
Position Off/ Amber Steady: Transfer switch is in Off position (programmed-transition models only).
In-Phase Sync
Rapid Flash: In-phase monitor is operating (open-transition models only).
Service Required Red Steady: Fault. Non-emergency is maintenance required.
Rapid Flash: Fault. Immediate maintenance is required
Source N Available Green Steady: Source N is available.
Source E Available Green Steady: Source E is available.
Test Red Steady: Unloaded test is running.
Slow Flash: Loaded test is running.
Time Delay LED Bar Amber LEDs step down to indicate time remaining in an active time delay or exercise period.
Figure 3-3 User Interface LED Indicators
20 Section 3 Controller Test and Replacement TP-6127 9/02

3.3 Power Supply 3.3.1 Transfer Switch Power
If no LEDs light when the LAMP TEST button is pressed,
DANGER check for power to the controller and the transfer switch.
Verify that the transfer switch wiring harness is
connected to the controller. See Figure 3-4. Check for
open circuit breakers or switches. Follow the voltage
check procedure in Section 3.9.2, Voltage, Frequency,
Hazardous voltage. and Phase Rotation Checks, to check voltage at the
Source N (normal) or Source E (emergency) lugs.
DANGER
Hazardous voltage.
open the enclosure.

to the OFF position. (2) Disconnect power to all battery 1
tp6127
qualified personnel take diagnostic measurements of live 1. Transfer switch harness connection to controls, controller
circuits. Use adequately rated test equipment with electrically connector P1
equipment manufacturer when performing voltage tests. Figure 3-4 Transfer Switch Harness Connection to
Observe the following precautions when performing voltage Control Board, Typical

3.3.2 Controller Power Supply 3.3.3 Powering the Controller Directly
(Service Kit GM25479)
Check for voltage to the controller using the following
procedure: On occasion it is necessary to supply 120 VAC power
directly to the controller for testing. Use the cable in
Procedure to Check Voltage to the Controller Service Kit GM25479 to supply power to the controller
from a 120 VAC wall outlet. Disconnect the controller
1. Disconnect power to the transfer switch by opening from the transfer switch and connect cable GM25481 to
circuit breakers or switches. the controller’s P1 connector. See Figure 3-5. Plug the
2. Disconnect the transfer switch wiring harness from cable into a 120 VAC wall outlet to power the controller
the controller at the 24-pin connector. during testing.
3. Reapply power to the transfer switch. Note: Do not connect 120 VAC power to any other
location on the controller.
4. Check for voltage across the wiring harness pins.
Observe all Safety Precautions when checking the
voltage.
a. If Source N is available, check for line voltage

across pins 4 and 12 of the transfer switch
wiring harness connector.
b. If Source E is powering the transfer switch,

check for line voltage across pins 6 and 7 of the
connector.
If there is no power to the pins checked in step 4, check

the wiring harness and replace it if necessary.
GM21364
1
1. Service kit power cable connection location (controller

connector P1)
Figure 3-5 120 VAC Connection Location (P1)
3.4 Controller Reset

If the controller is not responding and you have verified
that there is power to the transfer switch controller, try
resetting the controller. The controller can be reset
without disconnecting power. Use the following
procedure.
Controller Reset Procedure

1. Hold the LAMP TEST button until the LEDs flash.
Do not release the button.
2. Continue to hold the LAMP TEST button in and

press the End Time Delay button. The LEDs will
flash when the controller resets.

3.5 Test Sequence DANGER
Use the following procedure to run a test to check the
transfer switch operation. Watch the LEDs on the
controller’s user interface as the time delays run and
Source E becomes available when the generator set
Hazardous voltage.
starts. The TEST LED flashes to indicate a loaded test,
or lights steadily to indicate a test without load. For a
loaded test, watch the position LEDs to verify that the Only authorized personnel should
open the enclosure.
ATS transfers the load.
To set the TEST DIP switch for a loaded or unloaded
test, refer to Section 3.8 for instructions on setting the Automatic Operation Test Procedure
controller DIP switches. 1. Close and lock the transfer switch enclosure door.
To monitor the individual time delays during the test, Tighten the door screws.
connect a personal computer running the Setup
2. Check the controller LED indicators to verify that
Program. Close and lock the transfer switch door before the Position N and Source N Available indicators
initiating a test sequence. Use the Active Time Delay are lit.
window to monitor the time delays as they run. See the
Setup Program Operation Manual for further 3. Press the lamp test button and check that all
instructions. controller LEDs illuminate.
The test sequence simulates a loss of the normal 4. Verify that the generator set master switch is in the
source, starts the generator set, and transfers the load AUTO position.
to the emergency source (if the TEST DIP switch is set
for a loaded test), executing all time delays that are set 5. Press the TEST button on the controller to start the
test. The TEST LED flashes to indicate that the
up to operate during a loss of the normal source. When
ATS controller is set up to transfer the load during
the test is ended in step 8 of the procedure, the transfer the test. (If the TEST LED lights steadily, the ATS
switch transfers the load back to the normal source and controller is set up to run the test without
removes the engine start signal, executing all transferring the load. The test sequence will start
programmed time delays. the generator set but will not transfer to Source E.)
Refer to Figure 3-6 and Figure 3-7 for flowcharts 6. Verify that the generator set starts after the engine
showing the test sequence of operation without and with start delay times out. Check that the Source E
load. Available LED lights.
Note: If the standby source fails during a test, the ATS 7. Verify that the switch transfers the load to Source E.
will immediately attempt to transfer to the
preferred source. a. Open-Transition Models: After the
preferred-to-standby time delay, verify that the
Optional Switches. If the ATS is equipped with a
Position N LED goes out and the Position E
preferred source switch, check the switch position LED lights, indicating that the switch has
before proceeding with the automatic operation test. transferred the load to Source E.
The test procedure assumes that Source N is the
preferred source. b. Programmed-Transition Models: After the
preferred-to-off time delay, verify that the
If the transfer switch is equipped with a supervised Position N LED goes out and the Position OFF
transfer switch, verify that it is set to the Auto position. LED lights. After the off-to-standby time delay,
See the transfer switch Operation and Installation check that the Position E LED lights, indicating
that the switch has transferred the load to
Manual for more information about optional switches.
Source E.
Note: Close and lock the enclosure door before starting
the test procedure. 8. Push the Test button to end the test.

9. Verify that the switch transfers the load back to
Source N. Test started
a. Open-Transition Models: After the

standby-to-preferred time delay, verify that the Time delay engine
Position E LED goes out and the Position N start (TDES)
LED lights, indicating that the switch has
transferred the load to Source N.
Generator set engine start
b. Programmed-Transition Models: After the contacts close
standby-to-off time delay, verify that the
Position E LED goes out and the Position OFF
LED lights. After the off-to-preferred time Load bank control output
activated (as programmed*)
delay, check that the Position N LED lights,
indicating that the switch has transferred the
load to Source N. Test ended
Note: The generator set may have an engine

cooldown time delay that causes the Load bank control output
generator set engine to run after the transfer deactivated (as programmed*)
switch engine start signal is removed.
Time delay engine cooldown (TDEC)

(as programmed)* (default = 0)

signal removed
* See the Setup Program Operation Manual.
Figure 3-6 Test Without Load Sequence

Test started A
Time delay engine start (TDES)

Test ended
Generator set engine start contacts close

Standby-to-preferred time delay
Pre-transfer load control (as programmed*)

Preferred-to-standby time delay

In-phase monitor or transfer to off
(as programmed*)
In-phase monitor or transfer to off

(as programmed*)
Transfer to preferred source
Transfer to standby source

Post-transfer load control (as programmed*)

Time delay engine cooldown (TDEC)
(as programmed*) (default = 0)
A
Generator set engine start contacts open
Figure 3-7 Test with Load Sequence

3.6 Engine Start 5. Press the EXERCISE button to initiate an exercise
run and verify that the engine start contacts close.
Check for continuity across the engine start contacts
during a test or exercise sequence. Refer to the transfer 6. Press the EXERCISE button again to end the
switch schematic diagram provided with the unit or to the exercise run. Verify that the engine start contacts
Wiring Diagram Manual. Refer to the flowcharts in open.
Figure 3-6 through Figure 3-10 for the test and exercise
If the ATS engine start contacts do not close during the
operation sequences. Allow time for the engine start
Engine Start Contact Test Procedure, replace the ATS
and engine cooldown time delays (if not set to zero)
controls.
during the test.
If the generator set engine does not start, check the
Start with the transfer switch in the Source N position.
engine start connections to the generator set. Verify that
the generator set master switch is in the AUTO position.
DANGER Troubleshoot the generator set if the engine start
connections are good but the engine does not start.
Hazardous voltage.
open the enclosure.

Observe the following precautions when performing voltage
Engine Start Test Procedure
1. Connect an ohmmeter or test lamp across pins 8

and 9 of connector P1 (the transfer switch
harness-to-controller connection). See
Figure 3-8.
1 GM21364
2. Verify that the engine start contacts are open
before starting the test.
3. Press the Test button to initiate a test sequence and

verify that the engine start contacts close after the 1. Transfer switch harness connection, P1
engine start time delay.
Figure 3-8 Transfer Switch Harness-to-Controller
4. Press the Test button again to end the test. Verify Connection, P1
that the engine start contacts open after the engine
cooldown time delay (if not set to zero).

EXERCISE button pressed or scheduled EXERCISE button pressed or scheduled
exercise signaled to begin exercise signaled to begin

Generator set engine start (immediate)
Time delay preferred to standby

Load bank control output
activated (as programmed*)

Exercise time period ends or
EXERCISE button pressed
In-phase monitor or transfer to off (as programmed*)
Load bank control output

deactivated (as programmed*) Transfer to standby source
Time delay engine cooldown Post-transfer load control (as programmed*)

(as programmed*)
Exercise time period ends or

Generator set engine start signal removed EXERCISE button pressed

Time Delay standby to preferred
Figure 3-9 Exercise without Load Sequence
In-phase monitor or transfer to off (as programmed*)
Transfer to preferred source
Time delay engine cooldown (as programmed*)
Generator set engine start signal removed
Figure 3-10 Exercise with Load Sequence

3.7 Position Microswitch Test The Maintenance DIP switch inhibits transfer during
ATS service.
Disconnect power to the transfer switch and use an
ohmmeter or test lamp to check the operation of the Before opening the transfer switch enclosure to check or
position microswitches. Manually operate the switch change the DIP switch settings, open the circuit
and check for continuity across pins 10 and 13 of the breakers to disconnect the power to the transfer switch.
connector P1 for Source E and pins 10 and 14 for
Source N. The DIP switches are located on the controller’s main
logic board on the inside of the enclosure door.
Figure 3-18 shows the locations of the switches on the
3.8 DIP Switch Positions controller circuit board. A decal on the logic assembly
housing shows the DIP switch positions and settings
DANGER (see Figure 3-11). It is not necessary to remove the logic
assembly cover to see or adjust the DIP switches.
Check the DIP switch settings and adjust if necessary
for the application.
Note: Changing the position of the 1 week/2 week

Hazardous voltage.
exercise DIP switch after the exerciser has been
set does not change the time of the next
Disconnect all power sources before scheduled exercise. The new DIP switch setting
opening the enclosure. becomes effective after the next scheduled
exercise. See the ATS Operation and Installation
DIP switches on the main logic board control the test and Manual for more information about the exerciser.
exercise functions. The factory settings for the DIP
switches are shown in Figure 3-11. Close and lock the enclosure door before energizing the
transfer switch.
Figure 3-11 Logic Assembly Decal Showing DIP Switch Settings

3.9 System Settings Use the procedure in the next section to measure the
source voltage, frequency, and phase rotation, and
If the ATS does not recognize the source, check that the compare the measured values to the controller settings.
source voltage and frequency settings on the controller Follow the instructions in the Software Operation and
match the actual source parameters. Installation manual to change the controller settings if
they do not match the measured source parameters.
Compare the controller settings to the ratings on the
ATS nameplate and to the measured source
parameters using the following instructions. 3.9.2 Voltage, Frequency, and Phase
Rotation Checks
3.9.1 Controller Source Settings The voltage, frequency, and phasing of the transfer
switch and the power sources must be the same to avoid
Use a personal computer running the Setup Program to damage to loads and the transfer switch. Compare the
check the controller’s source voltage, frequency, and
voltage and frequency ratings of the utility source,
phase settings in the Source Information window. See
transfer switch, and generator set, and verify that the
TP-6135, Software Operation and Installation Manual,
ratings are all the same.
for instructions.
Read and understand all instructions on installation
Check the controller settings and compare them to the drawings and labels on the switch. Note any optional
voltage rating, frequency rating, and number of phases accessories that have been furnished with the switch
shown on the ATS nameplate. The nameplate is and review their operation.
attached to the cover of the controller assembly, which is
mounted on the inside of the transfer switch door. See Note: Source N is the source connected to the normal
Figure 3-12 for an illustration of the nameplate. side of the transfer switch. Source E is the source
connected to the emergency side of the transfer
Note: The system voltage and frequency shown on the switch.
ATS nameplate must match the Source N and
Source E voltage and frequency settings. Do not The voltage check procedure requires the following
enter settings that do not match the nameplate equipment:
ratings of the ATS.
D A digital voltmeter (DVM) with electrically insulated
probes capable of measuring the rated voltage and
frequency
3 D A phase rotation meter

1
2
DANGER
4
5
6
Hazardous voltage.
open the enclosure.

GM21291 insulated probes and follow the instructions of the test
1. Model designation equipment manufacturer when performing voltage tests.
2. Serial number Observe the following precautions when performing voltage
3. Factory-installed accessory numbers tests: (1) Remove all jewelry. (2) Stand on a dry, approved
4. Voltage rating electrically insulated mat. (3) Do not touch the enclosure or
5. Frequency rating
6. Number of phases (single or three)
Figure 3-12 Typical Transfer Switch Nameplate (600 volts and under)

Voltage, Frequency, and Phase Rotation 8. If the source is a generator set, stop the generator
Measurement Procedure set by moving the master switch to the OFF
position.
Note: Perform voltage checks in the order given to
avoid damaging the transfer switch. 9. Disconnect Source N by opening upstream circuit
breakers or switches.
1. Verify that the generator set master switch is in the
OFF position and both power sources are 10. Manually operate the transfer switch to position N.
disconnected from the transfer switch. 11. Repeat steps 4 through 8 for Source E. Then
2. Disconnect the power switching device and proceed to step 12.
controller wiring harnesses at the inline disconnect 12. Disconnect both sources to the transfer switch by
plug, if they are connected. opening the circuit breakers or switches.
3. Manually operate the transfer switch to position E. 13. Connect the power switching device and controller
See the Transfer Switch Operation and Installation wiring harnesses together at the inline disconnect
Manual for manual operation instructions. plug.
4. If Source N is a generator set, move the generator Note: Do not connect or disconnect the controller
set master switch to the RUN position. The wiring harness when the power is
generator set should start. connected.
5. Close the Source N circuit breaker or switch.
14. Close and lock the transfer switch enclosure door.
6. Use a voltmeter to check the Source N (normal)
15. Reconnect both power sources by closing the
phase-to-phase and phase-to-neutral (if
circuit breakers or switches.
applicable) terminal voltages and frequency.
16. Move the generator set master switch to the AUTO
a. If Source N is the utility and the measured input position.
does not match the voltage and frequency
shown on the transfer switch nameplate, Note: If the engine cooldown time delay setting is
STOP! The transfer switch does not match the not set to zero (default setting), the
application—order the correct transfer switch. generator set may start and run until the
Time Delay Engine Cooldown (TDEC) ends.
b. If Source N is a generator set and the generator
set output voltage and frequency do not match
the nominal system voltage and frequency
shown on the transfer switch nameplate, follow
the manufacturer’s instructions to adjust the
generator set. The automatic transfer switch
will only function with the rated system voltage
and frequency specified on the nameplate.
7. Use a phase rotation meter to check the phase
rotation at the Source N (normal) terminals.
Rewire the transfer switch Source N terminals to
obtain the correct phase sequence if necessary.
Note: The default setting for the phase rotation on
the controller is ABC. If the application uses
a phase rotation of CBA, use the Setup
Program to change the phase rotation
setting on the controller.

3.9.3 Voltage and Frequency Pickup Parameter Default Adjustment Range
and Dropout Settings Overfrequency
101% of pickup 101%--105% of pickup
dropout
Figure 3-13 illustrates the relative values of the voltage
pickup and dropout settings. Typical frequency pickup Overfrequency
110% of nominal 105%--120% of nominal
pickup
and dropout settings relate to the nominal source
frequency in a similar way. Underfrequency
pickup
If the source voltage rises above the overvoltage Underfrequency
99% of pickup 95%--99% of pickup
dropout setting or falls below the undervoltage dropout dropout
setting for a time longer than the debounce time, the Frequency dropout
3 sec. 0.1--15 sec.
controller will consider the source as failed. The source time
voltage must return to a level within the range of the Figure 3-15 Frequency Settings
pickup values for the controller to recognize the source
as restored.
3.10 Meter Calibration
Choose pickup and dropout settings that allow a
tolerable variation in the source parameters to prevent
DANGER
nuisance transfers caused by small changes in the
source voltage and frequency.
Hazardous voltage.
132 V Overvoltage Dropout Will cause severe injury or death.
125 V Overvoltage Pickup
120 V Nominal Voltage open the enclosure.
108 V Undervoltage Pickup Testing live electrical circuits. Hazardous voltage or

97 V Undervoltage Dropout circuits. Use adequately rated test equipment with electrically
tp6127 insulated probes and follow the instructions of the test
Figure 3-13 Relationship Between Voltage Pickup Observe the following precautions when performing voltage
and Dropout Settings (default settings tests: (1) Remove all jewelry. (2) Stand on a dry, approved
shown) electrically insulated mat. (3) Do not touch the enclosure or
Parameter Default Adjustment Range (600 volts and under)
Overvoltage
110% of nominal 105%--135% of nominal The transfer switch controls are calibrated at the factory
dropout
and should not require recalibration in the field.
Overvoltage pickup 95% of dropout 95%--100% of dropout
However, if recalibration is necessary, measure the
Undervoltage source voltages as instructed in Section 3.9.2, record
pickup
the measured values, and then enter the measured
Undervoltage
90% of pickup 75%--98% of pickup values into the appropriate spaces in the Meter
dropout
Calibration window in the Setup Program. See
Voltage dropout
0.5 sec. 0.1--9.9 sec.
TP-6135, Software Operation and Installation Manual,
time for more information about using the Setup Program.
Figure 3-14 Voltage Settings

3.11 Time Delays 3.12 Programmed-Transition
Check the time delays when troubleshooting problems Interface Board
with the transfer switch operation. The programmed-transition interface board (PTIB)
contains two replaceable 10-amp relays, K1 (NR1) and
Use the Active Time Delay Window in the Setup
K2 (ER1). See Figure 3-17. Refer to the operation
Program and observe the time delay LEDs on the
sequence diagrams in Section 4.5 and to the schematic
controller’s user interface to identify which time delays
diagram provided with the transfer switch to
are executing at any given time. Open the Active Time
troubleshoot the relays.
Delay window and then press the TEST button on the
controller’s user interface to initiate a test and observe
as each programmed time delay executes. Compare
the operation to the test sequence illustrated in the
flowcharts in Figure 3-6 or Figure 3-7.
Some time delays run serially (one after another) and

others run at the same time, so that the Time Delay
LEDs on the controller interface may appear to reach
zero and then start stepping down again to track another
time delay.
Use the Time Delay and Load Control Time Delay

windows in the Setup Program to check the settings for
the adjustable time delays. Figure 3-16 shows the
factory settings and adjustment ranges for the
adjustable time delays.
Adjustable Time Delays

Adjustment 1
Time Delay Default Range
Engine start 3 sec. 0--6 sec.*
Preferred to standby 1 sec.
Standby to preferred 15 min.
Engine cooldown 0 min.
Failure to acquire standby source 1 min.

3 2
Pretransfer to preferred signal 3 sec.
tp6158
Pretransfer to standby signal 3 sec. 0--60

0 60 min.*
min. 1. Programmed-Transition Interface Board (PTIB)
Post-transfer to preferred signal 0 sec. 2. K2 (ER1) Relay
3. K1 (NR1) Relay
Post-transfer to standby signal 0 sec.
Figure 3-17 Programmed-Transition Interface
Off to standby
(programmed-transition only) 1 sec.
Board
Off to preferred
(programmed-transition only) 1 sec.
* Adjustable in 1 second intervals
Figure 3-16 Factory Settings, Time Delays

3.13 Controller Replacement Servicing the transfer switch. Hazardous voltage can
Always check for open switches or circuit breakers, before servicing. Open the main circuit breakers of all transfer
loose connections, or faulty wiring before replacing any switch power sources and disable all generator sets as
parts. Reset the controller as described in Section 3.4
before replacing it. Replace the controller only if the
troubleshooting and test procedures in this manual first. Reconnect negative (--) leads last when reconnecting the
indicate conclusively that the controller is damaged or battery cables after servicing. Follow these precautions to
inoperative. prevent the starting of generator sets by an automatic transfer
Replace the entire controller assembly and plastic from a remote computer. Before servicing any components
housing. Controller parts are not offered separately. inside the enclosure: (1) Remove all jewelry. (2) Stand on a
Save the old controller’s plastic cover, which includes dry, approved electrically insulated mat. (3) Test circuits with a
the transfer switch nameplate, for use with the new voltmeter to verify that they are deenergized.
controller.
Controller Replacement Procedure
New controllers are shipped with the factory default
settings for the system settings, including voltage, 1. Move the generator set master switch to the OFF
frequency, number of phases, phase rotation, and other position.
user-adjustable settings. After installing a new
2. Disconnect the generator set engine starting
controller, use a personal computer running the Setup
battery, negative (--) lead first.
Program to change the settings, if necessary. Refer to
the Setup Program Operation and Installation Manual 3. Disconnect power to the transfer switch by opening
for instructions. switches or circuit breakers to the switch.
Disconnect power to the transfer switch before starting 4. Open the transfer switch enclosure.
to disconnect the controller. Observe the following
safety precautions to avoid injury or equipment damage. 5. Check the voltage at the source connections to
verify that the power is off.
DANGER 6. Disconnect the transfer switch harness at the
connector on bottom of the controller. See
Figure 3-18.
7. Disconnect the programmed-transition board, if

Hazardous voltage. equipped, from the controller at connector P9.
8. Label each input/output lead connected to the main
Disconnect all power sources before logic board terminal strip and then disconnect the
I/O leads.
9. Disconnect I/O modules (if equipped) at connector

DANGER P3.
10. Disconnect the preferred source switch and

supervised transfer switch (if equipped) from the
controller board connectors P7 and P8.
Hazardous voltage.
Will cause severe injury or death. 11. Disconnect the controller ground wire at the ring
terminal on the enclosure door.
open the enclosure. 12. Support the controller assembly and remove four
nuts at the corners.

1 2 1
3
2
11
5
6
10
3
GM21079
1. Hinges
2. Access openings to DIP switches and PC connection
3. Latch
9 7
8 GM21364 Figure 3-19 Controller Housing Cover
15. Replace the entire assembly with a new controller.

Secure the four nuts at the corners and tighten
1. I/O board connection (P3)
them to no more than 6.8 Nm (5 ft. lbs. or 60 in lbs.)
2. User interface connections torque.
3. DIP switches
4. Serial port for PC connection (P6) 16. Connect the controller ground wire at the ring
5. Preferred source switch connection (P7) terminal on the enclosure door.
6. Supervised transfer switch connection (P8)
7. Programmed-transition interface board (PTIB) connection
(factory connection) (P9) 17. Connect the programmed-transition board, if
8. Ground wire equipped, to the controller at connector P9.
9. Transfer switch harness connection
10. Serial number decal 18. Connect the I/O leads to the main logic board
11. Terminal strip (inputs, output, Modbus connections) (TB1)
terminal strip, using the labels attached in step 8 to
connect the leads to the appropriate terminals.
Figure 3-18 Controller Board Component Locations
(cover removed) 19. Connect I/O modules (if equipped) at connector
P3.
13. Carefully remove the controller assembly,
including the user interface panel, which is part of 20. Connect the preferred source switch and
the assembly. supervised transfer switch (if equipped) to the
controller board connectors P7 and P8.
14. Remove the plastic cover from the old controller
and save it to install on the new controller 21. Connect the transfer switch harness to the
assembly. To remove the cover, depress the latch connector on bottom of the controller.
at the bottom of the cover. Swing the cover open on
its hinges and lift it off. See Figure 3-19. 22. Check the controller’s DIP switch settings and
adjust them if necessary.
Note: The old cover includes the transfer switch
nameplate, which must remain with the
transfer switch.

23. Remove the plastic cover from the new controller 28. Disconnect power to the transfer switch by opening
and replace it with the cover from the old assembly. circuit breakers or switches.
24. Connect the controller communication ribbon 29. Open the enclosure door and remove the
cable to controller serial port P6 and bring the other communications cable.
end of the cable out the door through the bottom of
the enclosure. 30. Close and lock the enclosure door. Tighten any
screws that secure the door.
25. Close and lock the transfer switch enclosure door.
31. Reconnect the generator set engine starting
26. Reconnect power to the transfer switch by closing battery, negative (--) lead last.
circuit breakers or switches.
32. Move the generator set master switch to the AUTO
Note: Power to the controller is required in order to position.
check and adjust the controller settings. If all
the power sources are generator sets, 33. Reconnect power to the transfer switch.
reconnect the normal source generator set
engine starting battery and move the 34. Press the LAMP TEST button on the front of the
generator set master switch to the AUTO controller and verify that all LEDs light.
position.
35. If the calendar mode exerciser is not being used,
27. Connect a personal computer and use the Setup press the EXERCISE button on the controller user
Program to check the system settings and adjust interface to set the exercise time and start an
them, if necessary. Check the system voltage, exercise run. The generator set should start. Refer
frequency, number of phases, phase rotation, time to the transfer switch Operation and Installation
delays, and other user-adjustable settings. Set up Manual for more information about the exerciser.
inputs/outputs and the in-phase monitor, if
applicable. Refer to the Setup Program Operation
and Installation Manual for instructions.

Notes

Section 4 Transfer Switch Troubleshooting
4.1 Transfer Switch Section 3.9.2, Voltage, Frequency, and Phase Rotation
Checks, to measure the source voltage. Observe all
Troubleshooting Safety Precautions when taking voltage
When troubleshooting the transfer switch mechanism, measurements. Verify that the measured voltage
always check for simple causes first: broken or loose matches the transfer switch rated voltage.
wires, corroded contacts, exposure to dirt or foreign
material, etc.
4.2 Troubleshooting Table
Check the time delays, source settings, and other Use the table in Figure 4-1 to diagnose transfer switch
system parameters as described in Sections 2 and 3 problems. See Sections 5 through 10 for transfer switch
before concluding that there is a mechanical problem test and service procedures. Refer to the Table of
with the transfer switch. Many transfer problems can be Contents to find the transfer switch test and service
traced to inappropriate controller settings. procedures for your unit.
Verify that the voltage on the nameplate matches the
actual nominal source voltage. Use the procedure in
Condition Possible Cause Check for

Failure to transfer Mechanical binding
g Jammed or damaged solenoid.
Faulty or worn core spring.
Bent main contact shaft.
Jammed main contacts. Check for foreign object.
Contact lever or pushbutton jammed against
solenoid counterweight. See the Table of Contents
for control contact test procedures for your model
transfer switch.
Loose hardware.
Accumulation of dirt or other foreign material.
Electrical malfunction Damaged or wrong coil. Check for signs of
overheating.
Damaged or wrong rectifier and/or snubber.
Damaged or wrong resistor (not used on all
models).
Loose or broken wires.
Corroded or fused contacts.
Coil control contact operation. See the Table of
Contents for control contact test procedures for your
model transfer switch.
Improperly wired harness
Wrong voltage. Check system voltage, controller
system voltage and over/undervoltage pickup and
dropout settings, and controller meter calibration.
See Sections 2 and 3.
Chattering noise when attempting Coil control contact operation See the Table of Contacts for test procedures for
to transfer your model transfer switch.
Low voltage Check source voltage and connections.
Incorrect spring See the Table of Contents for coil replacement
instructions for your model transfer switch.
Wrong coil Check coil voltage rating.
Figure 4-1 Transfer Switch Troubleshooting
TP-6127 9/02 Section 4 Transfer Switch Troubleshooting 37

4.3 Contacts 4.4.2 Rectifier and Snubber
Use the millivolt drop test in Section 1.3.3 to identify Models rated over 240 volts include a snubber to protect
damaged contacts. Replace contacts that have high the rectifier. See Figure 4-2 for the snubber location.
resistance.
A damaged rectifier or coil probably indicates a
Refer to the Table of Contents to find the contact damaged snubber as well. Replace the snubber
replacement procedures for your model transfer switch. whenever the rectifier is replaced. The snubber is
included with the rectifier kit. On smaller models (240
volts and below) that were not originally equipped with a
4.4 Solenoid Coil, Rectifier, and snubber, installation of the snubber included with the
Snubber replacement rectifier kit is optional.
1
4.4.1 Solenoid Coil
Measure the coil resistance to check for a damaged coil.
Coil resistances are listed in Figure 4-4. Most damaged
coils will result in an open circuit (very high resistance).
2
Replace the coil if an open circuit or a resistance value
significantly different from the resistance shown in the
table is found. Replace the rectifier and snubber (if
used) whenever the coil is replaced. See Section 4.4.2.
Refer to the Table of Contents to find the coil

replacement procedures for your model transfer switch.
1. Snubber, typical tp6158

2. Rectifier, typical
Figure 4-2 Snubber and Rectifier Locations

(typical; 30--104 amp. model shown)
38 Section 4 Transfer Switch Troubleshooting TP-6127 9/02

Coil DC
Type Resistance
(ATS or Bypass Number of Poles (ohms)
Switch) Type Amps and Type Voltage ±10% @ 20ºC
ATS Open
p Transition 30--200 2-Pole 208 41.4
240 67.8
415 212
480 256
600 343
3-Pole,, 208 25.7
S
Switched Neutral, 240 41.4
Overlapping Neutral
415 133.7
480 168.3
600 256
Programmed
g Transition 150/225/260/400
/ / / 2-Pole 208 15.02
240 25.7
415 41.4
480 102.3
600 102.3
3-Pole 208 15.02
240 25.7
415 41.4
480 67.8
600 102.3
Switched Neutral,, 208 11.3
O
Overlapping Neutral 240 25.7
415 41.4
480 67.8
600 102.3
Open
p Transition 225/260/400
/ / 2-Pole 208 15.02
240 25.7
415 41.4
480 102.3
600 102.3
3-Pole 208 15.02
240 15.02
415 41.4
480 67.8
600 102.3
O
415 41.4
480 67.8
600 102.3
Open
p and Programmed
g 600/800/1000/1200 2-Pole,, 3-Pole,, 208 4.8
Transition S
Overlapping Neutral
415 19
480 28
600 43
1600/2000/3000 2-Pole,, 3-Pole,, 208 2.2
S
Overlapping Neutral
415 8.5
480 13.5
600 21.3
Figure 4-3 Coil Resistances, Automatic Transfer Switches

Coil DC
Type Number of Poles Resistance
(ATS or Bypass and Type (ohms)
Switch) Type Amps (2), (3), (B3), (C3) Voltage ±10% @ 20ºC
Bypass/
yp / Open
p Transition 150/225/260/400
/ / / 2-Pole 208 15.02
Isolation Switch
S 240 25.7
415 41.4
480 102.3
600 102.3
3-Pole 208 15.02
240 15.02
415 41.4
480 67.8
600 102.3
O
415 41.4
480 67.8
600 102.3
Programmed
g Transition 150/225/260/400
/ / / 2-Pole 208 15.02
240 25.7
415 41.4
480 102.3
600 102.3
3-Pole 208 15.02
240 25.7
415 41.4
480 67.8
600 102.3
O
415 41.4
480 67.8
600 102.3
Open
p and Programmed
g 600/800
/ 2-Pole,, 3-Pole,, 208 9.8
Transition S
Overlapping Neutral
415 37.4
480 49.8
600 84.4
1000/1200/1600/2000/3000
/ / / / 2-Pole,, 3-Pole,, 208 2.2
S
Overlapping Neutral
415 8.5
480 13.5
600 21.3
Figure 4-4 Coil Resistances, Bypass/Isolation Switches

4.5 Solenoid Operation Control contacts (TS or CN and CE) control the amount
of time that power is applied to the solenoid coil. The
This section contains descriptions and diagrams of the contacts open before the operating mechanism reaches
solenoid coil operation. For complete diagrams, refer to Top Dead Center (TDC). Inertia carries the mechanism
the schematic diagrams provided with the transfer through TDC, and a spring in the solenoid assembly (or
switch. a second coil on some larger models) moves the
mechanism into the Source E (or standby) position.
The ATS controller monitors the connected source and
detects source failure, either a complete loss of the When Source N (or the preferred source) is restored, the
source or a source parameter that is outside the controller starts the standby-to-preferred time delay.
acceptable range. The controller starts the engine start When the time delay ends, the controller’s K1 (NR) relay
time delay. If power is restored before the time delay closes, applying power to the solenoid coil and initiating
ends, the controller resets the time delay and continues transfer back to Source N (or the preferred source).
to monitor the source. If the source failure persists and
the time delay ends, the controller closes the engine Programmed-transition models stop in the OFF position
start contacts to signal the Source E generator set to for a programmed length of time during transfer. The
start. transfer-to-OFF sequence is controlled by the NR1 and
ER1 relays on the programmed-transition interface
When Source E (or the standby source) becomes interface board (PTIB).
available, the controller starts the preferred-to-standby
time delay (if not set to zero). When the time delay ends, The controller K1 and K2 relays and the PTIB relays are
relay K2 (ER) in the controller closes, applying power to replaceable.
the solenoid coil and initiating transfer.
Note: Always check all wiring and connections before
Note: The K1 (NR) and K2 (ER) relays are energized for replacing parts.
only 200 milliseconds to initiate transfer.
Figure 4-5 explains the notation used in the solenoid
The solenoid power circuits vary for different ATS operation diagrams in Figure 4-6 through Figure 4-17.
models. The following sections describe and illustrate
the transfer sequence for the different models.
Legend:
NR, ER: Controller relays. Energized for 200 milliseconds to initiate transfer.
ERR, SER: Transfer switch relays.
NR1, ER1: Programmed-transition interface board relays.
TS (MUS), CN, CE: Coil control contacts (microswitches) = closed = open
P Coil, S Coil: Solenoid operator coils
Power through the coil

circuit.
Figure 4-5 Legend for Solenoid Operation Diagrams

4.5.1 Open-Transition 30--1200 Amp and 4000 Amp Open Transition Models
K1 K1 K2
Source N position, Source N TS NR NR ER TS
available. The solenoid coil is not
energized. NA EA
+ -- COIL
NC EC
TS TS
K1 K1 K2
NR NR ER
K1 K1 K2
Source N position, Source N lost. TS NR NR ER TS
The coil is energized if Source E is
available. The transfer switch is ready NA EA
to transfer to Source E.
+ -- COIL
NC EC
TS
TS
K1 K1 K2
NR NR ER
K1 K1 K2
Source E position, Source E available. TS NR NR ER TS
The solenoid coil is not energized.
NA EA
+ -- COIL
NC EC
TS TS
K1 K1 K2
NR NR ER
Source E position, Source N TS

K1 K1 K2
NR NR ER TS
available. The controller is calling for
transfer to Source N. The coil is NA EA
energized and the transfer switch will
transfer to Source N.
+ -- COIL
NC EC
TS TS
K1 K1 K2
NR NR ER
Figure 4-6 30--1200 Amp and 4000 Amp Open-Transition Models, Transfer to Source N and Transfer Back to
Source E

4.5.2 1600--3000 Amp Open-Transition Models
Source N position, Source N available. The solenoid coils are not energized.
NR ER
EA ERR EC
ERR
SER SER
--
TS (MUS)
P
16 15 COIL
ERR
+
--
TS (MUS)
S
14 13 COIL
+
TS (MUS)
20 19
TS (MUS)
18 17
ERR
ERR
SER
SER
NR
NA SER NC
Figure 4-7 1600--3000 Amp Open-Transition Models, Source N Position

Transfer to Source E, step 1. Source N lost, Source E available. ERR is energized for 200 mseconds. TS 15--16
closes to energize the P coil. TS 15--16 reopens just before Top Dead Center (TDC).
NR ER
EA ERR EC
ERR
SER SER
--
TS (MUS)
P
16 15 COIL
ERR
+
--
TS (MUS)
S
14 13 COIL
+
TS (MUS)
20 19
TS (MUS)
18 17
ERR
ERR
SER
SER
NR
NA SER NC
Transfer to Source E, step 2. After Top Dead Center, TS 13--14 closes to energize the S Coil.
NR ER
EA ERR EC
ERR
SER SER
--
TS (MUS)
P
16 15 COIL
ERR
+
--
TS (MUS)
S
14 13 COIL
+
TS (MUS)
20 19
TS (MUS)
18 17
ERR
ERR
SER
SER
NR
NA SER NC
Figure 4-8 1600--3000 Amp Open-Transition Models, Transfer to Source E

Source E position, Source E available. The solenoid coils are not energized.
NR ER
EA ERR EC
ERR
SER SER
--
TS (MUS)
P
16 15 COIL
ERR
+
--
TS (MUS)
S
14 13 COIL
+
TS (MUS)
20 19
TS (MUS)
18 17
ERR
ERR
SER
SER
NR
NA SER NC
Figure 4-9 1600--3000 Amp Open-Transition Models, Source E Position, Source E Available

Transfer to Source N, step 1. Source N available. SER is energized for 200 mseconds. TS 17--18 closes to energize
the P coil. TS 17--18 reopens just before Top Dead Center (TDC).
NR ER
EA ERR EC
ERR
SER SER
--
TS (MUS)
P
16 15 COIL
ERR
+
--
TS (MUS)
S
14 13 COIL
+
TS (MUS)
20 19
TS (MUS)
18 17
ERR
ERR
SER
SER
NR
NA SER NC
Transfer to Source N, step 2. After Top Dead Center, TS 19--20 closes to energize the S Coil.
NR ER
EA ERR EC
ERR
SER SER
--
TS (MUS)
P
16 15 COIL
ERR
+
--
TS (MUS)
S
14 13 COIL
+
TS (MUS)
20 19
TS (MUS)
18 17
ERR
ERR
SER
SER
NR
NA SER NC
Figure 4-10 Open-Transition 1600--3000 Amp Models, Transfer to Source N

4.5.3 150--400 Amp 2- and 3-Pole Programmed-Transition Models
Replaceable relays ER1 and NR1 are mounted on the programmed-transition interface board (PTIB). Relays ER1
and NR1 are energized for only 200 msec during the transfer sequence.
Source N position, Source N available.

CN ER NR NR CN
EC NC
70 69
71 72
70 69
71 72
ER1 NR1 NR1 CE
CE
--
--
CE CN
COIL COIL
+
CE ER1 NR1 NR1 CE
9 8 6 7
EA NA
9 8 6 7
ER NR NR CN
CN
Source N position, Source N lost, transfer to OFF.

ER NR NR CN
CN
EC NC
70 69
71 72
70 69
71 72
ER1 NR1 NR1 CE
CE
--
--
CE CN
COIL COIL
+
ER1 NR1 NR1

CE CE
9 8 6 7
EA NA
9 8 6 7
CN ER NR NR CN
OFF position, Source E available, transfer to Source E.

CN ER NR NR CN
EC NC
70 69
71 72
70 69
71 72
ER1 NR1 NR1 CE
CE
--
--
CE CN
COIL COIL
+
CE ER1 NR1 NR1 CE
9 8 6 7
EA NA
9 8 6 7
ER NR NR CN
CN
Figure 4-11 150--400 Amp 2- and 3- Pole Programmed-Transition Models, Transfer from Source N to Source E

Source E position, Source E available.
CN ER NR NR CN
EC NC
70 69
71 72
70 69
71 72
ER1 NR1 NR1 CE
CE
--
--
CE CN
COIL COIL
+
CE ER1 NR1 NR1 CE
9 8 6 7
EA NA
9 8 6 7
ER NR NR CN
CN
Source E position, Normal available, transfer to OFF.

CN ER NR NR CN
EC NC
70 69
71 72
70 69
71 72
ER1 NR1 NR1 CE
CE
--
--
CE CN
COIL COIL
+
CE ER1 NR1 NR1 CE
9 8 6 7
EA NA
9 8 6 7
CN ER NR NR CN
Off position, Source N available, transfer to Source N.

CN ER NR NR CN
EC NC
70 69
71 72
70 69
71 72
ER1 NR1 NR1 CE
CE
--
--
CE CN
COIL COIL
+
CE ER1 NR1 NR1 CE
9 8 6 7
EA NA
9 8 6 7
CN ER NR NR CN
Figure 4-12 150--400 Amp 2- and 3- Pole Programmed-Transition Models, Transfer from Source E to Source N

4.5.4 150--400 Amp 4-Pole and 600--1200 Amp Programmed-Transition Models
Replaceable relays ER1 and NR1 are mounted on the ER1 and NR1 are energized for only 200 msec during
programmed-transition interface board (PTIB). Relays the transfer sequence.
Source N position, Source N available.

CN ER NR NR CN
EC NC
19 20 16 15
19 20 16 15
CE
CE ER1 NR1 NR1
--
--
CE CN
COIL COIL
+
CE ER1 NR1 NR1 CE
17 18 14 13
EA NA
17 18 14 13
ER NR NR CN
CN
Source N position, Source N lost, transfer to OFF.

CN ER NR NR CN
EC NC
19 20 16 15
19 20 16 15
CE
CE ER1 NR1 NR1
--
--
CE CN
COIL COIL
+
CE ER1 NR1 NR1 CE
17 18 14 13
EA NA
17 18 14 13
CN ER NR NR CN
OFF position, Source E available, transfer to Source E.

CN ER NR NR CN
EC NC
19 20 16 15
19 20 16 15
CE
CE ER1 NR1 NR1
--
--
CE CN
COIL COIL
+
CE ER1 NR1 NR1 CE
17 18 14 13
EA NA
17 18 14 13
ER NR NR CN
CN
Figure 4-13 150--400 Amp 4-Pole and 600--1200 Amp Programmed-Transition Models, Transfer from Source N
to Source E

Source E position, Source E available.
CN ER NR NR CN
EC NC
19 20 16 15
19 20 16 15
CE
CE ER1 NR1 NR1
--
--
CE CN
COIL COIL
+
CE ER1 NR1 NR1 CE
17 18 14 13
EA NA
17 18 14 13
ER NR NR CN
CN
Source E position, Source N available, transfer to OFF.

CN ER NR NR CN
EC NC
19 20 16 15
19 20 16 15
CE
CE ER1 NR1 NR1
--
--
CE CN
COIL COIL
+
+
CE ER1 NR1 NR1 CE
17 18 14 13
EA NA
17 18 14 13
ER NR NR CN
CN
Off position, Source N available, transfer to Source N.

CN ER NR NR CN
EC NC
19 20 16 15
19 20 16 15
CE
CE ER1 NR1 NR1
--
--
CE CN
COIL COIL
+
CE ER1 NR1 NR1 CE
17 18 14 13
EA NA
17 18 14 13
ER NR NR CN
CN
Figure 4-14 150--400 Amp 4-Pole and 600--1200 Amp Programmed-Transition Models, Transfer from Source E
to Source N

4.5.5 1600--3000 Amp Programmed-Transition Models
The 1600--3000 amp programmed-transition models pair are energized in sequence, the P coil first and then
use two pairs of solenoid coils. Only the P coil is the S coil after the weight passes through top dead
energized during transfers to the OFF position. During center (TDC).
transfers from OFF to either source, the two coils in the
Source N position, Source N available

SER
EA ERR EC
ERR CE Coil SER
--
ERR
CE
S
14 13 COIL
+
CN Coil
NR ER ER1 NR1
--
--
CN CE
P P
COIL 17 18 16 15 COIL
+
+
NR
CN CE
15 16 18 17
NR1
--
CN
S
COIL 13 14
+
ERR ERR
NR1
SER SER
SER NC
NA
NR
Figure 4-15 1600--3000 Amp Programmed-Transition, Source N Position

Source N position, Source N lost, Source E available, transfer to OFF.
SER
EA ERR EC
ERR CE Coil SER
--
ERR
CE S
14 13 COIL
+
CN Coil
NR ER ER1 NR1
--
--
CN CE
P P
COIL 17 18 16 15 COIL
+
+
NR
CN CE
18 17
15 16 NR1
--
S CN*
COIL
13 14
+
ERR ERR
NR1
SER SER
SER NC
NA
NR
* Coil control contacts close after Top Dead Center.
OFF position, Source E available, transfer from OFF to Source E.

SER
EA ERR EC
ERR CE Coil SER

--
ERR
CE*
S
14 13 COIL
+
CN Coil
NR ER
--
--
CN ER1 NR1
CE
P P
COIL 17 18 16 15 COIL
+
NR
CN CE
18 17
15 16 NR1
--
S CN
COIL
13 14
+
ERR ERR
NR1
SER
SER
SER NC
NA
NR
* Contacts close after Top Dead Center, energizing the S coil.
Figure 4-16 1600--3000 Amp Programmed-Transition, Transfer to Source E

Source E position, Source N available, transfer from Source E to OFF.
SER
EA ERR EC
ERR SER
CE Coil
--
ERR
CE* S
14 13 COIL
+
CN Coil
ER1 NR1
--
--
NR ER
CN CE
P P
COIL 17 18 16 15 COIL
+
NR
+
CN CE*
18 17
15 16
NR1
--
S CN
COIL
13 14
+
ERR ERR
NR1
SER SER
SER NC
NA
NR
* Contacts close after Top Dead Center. The S coil is not energized during transfer to OFF.
OFF position, Source N available, transfer from OFF to Source N.

SER
EA ERR EC
ERR CE Coil SER

--
ERR
CE
S
14 13 COIL
+
CN Coil
NR ER ER1 NR1
--
[
--
CN CE
P P
COIL 17 18 16 15 COIL
+
NR
CN CE
18 17
15 16 NR1
--
CN*
S
COIL
13 14
+
ERR ERR
NR1
SER SER
SER NC
NA
NR
* Contacts close after Top Dead Center, energizing the S coil.

[ Closes when Source N position is reached.
Figure 4-17 1600--3000 Amp Programmed-Transition, Transfer to Source N

Notes

Section 5 30--200 Amp Transfer Switches
5.1 Introduction Manual Operation Procedure
This section contains test and service procedures for 1. Verify that the power sources to the transfer switch
30--200 amp transfer switches. are OFF.
Use the troubleshooting and test procedures in Sections 2. Turn the attached handle to manually operate the
transfer switch. See Figure 5-1. It should operate
2 through 4 to diagnose problems before replacing
smoothly without any binding. If it does not, check
parts. Use the instructions in this section if inspection,
for shipping damage or construction debris.
troubleshooting, or other test procedures reveal
damaged or defective components that require Note: Do not attempt to rotate the U-shaped
replacement. floating weight or permanent damage may
occur.
DANGER
3. Return the transfer switch to the Normal (or Source
N) position.
1
Hazardous voltage.

follows: (1) Move all generator set master controller switches 127a
to the OFF position. (2) Disconnect power to all battery 1. Handle

first. Reconnect negative (--) leads last when reconnecting the Figure 5-1 Manual operation handle, 30--200 amp
battery cables after servicing. Follow these precautions to switches
dry, approved electrically insulated mat. (3) Test circuits with a 5.3 Operator Coil Replacement
The following tools are needed for this procedure:
D Blade screwdriver
5.2 Manual Operation
D 5/16 in. nutdriver
The service procedures in this section call for manual D Pliers
operation of the transfer switch. Refer to the instructions D Voltmeter
in this section to manually operate the switch. Verify that
the power to the transfer switch is disconnected before Note: Always check wiring and connections before
operating it manually. replacing components.
Note: A manual operation handle is provided on the

Operator Coil Disassembly Procedure
transfer switch for maintenance purposes only. Do
not use the manual operation handle to transfer 1. Prevent the generator set from starting by moving
the load with the power connected. the generator set master switch to the OFF
position; disconnecting power to the generator
The 30--200 amp switches have a star-shaped handle engine starting battery charger, if installed; and
for manual operation. The handle is not detachable.
TP-6127 9/02 Section 5 30--200 Amp Transfer Switches 55

disconnecting all generator engine start batteries, b. Place the core tube onto the core spring and
negative (--) leads first. core and press the core tube against the steel
bracket.
2. Disconnect all power sources before opening the
transfer switch enclosure by opening upstream c. Use three hex-head screws with lock washers
circuit breakers or switches to the transfer switch. to secure the core tube retainer. Be sure that
3. Locate the coil assembly at the top left corner of the the stub core extends through the end of the
power switching device. See Figure 5-2. core tube.
4. Disconnect the rectifier: 5. Install the new coil assembly: Slide the spacer ring,
then the spring washer, two insulating washers,
a. Locate the square rectifier mounted on the coil and the coil onto the core tube. The coil leads must
yoke or L-bracket. be on the left and extend toward the operator
mechanism.
b. Note the connections and disconnect the coil
leads and the control wires from the rectifier’s 6. Secure the coil assembly:
push-on terminals.
a. Place the steel L-bracket onto the stub core and
5. Release the coil assembly. Use a screwdriver to secure it with two hex-head screws.
pry the retaining ring out of the groove in the stub
core, which extends through the steel L-bracket. b. Use pliers to slide the retaining ring into the
Then use a 5/16 in. nutdriver to remove two groove in the stub core to secure the stub core
hex-head screws from the front of the L-bracket. in the frame.
6. Remove the steel L-bracket and slide the coil and 7. Replace the rectifier, if necessary: Remove the
coil washers off the core tube. center screw to remove the old rectifier. Install the
new rectifier so that the terminal with the red dot is
Note: If the coil has burned out, also replace the on the upper left.
core tube and core spring. These parts
could be damaged from overheating. 8. Reconnect the coil leads: Connect the coil leads to
the rectifier’s push-on terminals marked with red
7. Remove the core tube: Use a 5/16 in. nutdriver to dot and no dot (DC + and -- output).
remove three hex-head screws. Then remove the
core tube, core tube retainer, and spacer ring (if 9. Reconnect the rectifier: Connect the control wires
used). (AC input) to the rectifier’s push-on terminals
marked with yellow dots.
8. Remove the core spring from the core.
10. Manually operate the switch: Use the manual
operating handle to operate the switch to check the
Operator Coil Assembly Procedure
solenoid assembly. The action should be smooth,
Note: Lubricate new parts with lubrication kit GM24237. without any binding. If not, recheck the solenoid
operator part alignment and lubrication. Return the
1. Insert the stub core into the core tube. switch to the normal position.
2. Lubricate the new core tube and core spring. Apply 11. Reconnect power supplies to the transfer switch.
the lubricant mixture to the inside of the new core, 12. Reconnect the generator engine starting battery
the new core spring, and the core. cables, negative (--) leads last; reconnect power to
the generator engine starting battery charger, if
3. Install the new core spring: Place the lubricated
installed; and move the generator set master
core spring onto the core shoulder.
switch to the AUTO (automatic) position. The
4. Install the new core tube: generator set may start and run until the ATS time
delay engine cooldown (TDEC) expires.
a. Slide the core tube retainer onto the core tube.
56 Section 5 30--200 Amp Transfer Switches TP-6127 9/02

11
1* 12
2*
3*
4*
7*
8*
1. Retaining ring*
2. Coil*
3. Spacer washers* 9*
4. Spring washer*
5. Spacer ring
6. Core tube retainer
7. Core tube*
8. Stub core* 10
9. Core spring*
10. Core
11. L -bracket
12. Rectifier
* Parts included in coil kit 61274210
Figure 5-2 Coil Assembly for 30--200 Amp Switches

5.4 Main Contact Inspection settings can vary to the extremes and still provide
acceptable operation. However, it is necessary that the
1. Prevent the generator set from starting by moving coil control contacts always open before top dead
the generator set master switch to the OFF center (TDC) is reached by the solenoid core. This
position; disconnecting power to the generator feature is inherent to the basic design of the switch.
engine starting battery charger, if installed; and
disconnecting all generator engine start batteries,
negative (--) leads first. 5.5.1 Coil Control Contact Test
2. Disconnect all power sources before opening the The TS coil control contacts on this size transfer switch
transfer switch enclosure by opening upstream are not field-adjustable. If the following test procedure
circuit breakers or switches to the transfer switch. shows that the coil control contacts are not functioning
3. Remove the arc chutes. For each arc chute: as described, replace them.
a. Use a screwdriver to loosen the screws

adjacent to the Emergency source terminal
DANGER
lugs.
b. Slide or lift the arc chute retainer up to release

the arc chute.
Hazardous voltage.
c. Pull the arc chute out of the switch. Will cause severe injury or death.
4. Inspect the main contacts. Use the manual Disconnect all power sources before
operating handle to operate the switch and inspect
all contact surfaces. Discoloration of the contact
surface does not affect performance. If the main Coil Control Contact Test Procedure
contacts are severely eroded due to abnormal
operating conditions, repair or replace the switch. 1. Prevent the generator set from starting by moving
the generator set master switch to the OFF
5. Reconnect power supplies to the transfer switch. position, disconnecting power to the generator
6. Reconnect the generator engine starting battery engine starting battery charger, if installed, and
cables, negative (--) leads last, reconnect power to disconnecting all generator engine start batteries,
the generator engine starting battery charger, if negative (--) leads first.
installed, and move the generator set master 2. Disconnect all power. Then use a voltmeter to
switch to the AUTO (automatic) position. The verify that no voltage is present at the switch
generator set may start and run until the ATS time terminal lugs on both power sources.
3. Locate the TS coil control contact assemblies (see
Figure 5-3 ).
5.5 Coil Control Contact Test and
Replacement 4. To verify the settings of the TS coil control contacts,
proceed as follows:
The manufacturer sets the TS coil control contacts so
that the switch can operate satisfactorily over a voltage a. Refer to Figure 5-4 and Figure 5-6. Two sets of
range of 80 to 110% of the nominal system voltage. The contacts interrupt the control current to the
coil control contact settings may vary from switch to operator coil (TS) in each direction (transfer to
switch to accommodate minor variances in friction and emergency and retransfer to normal). In
tolerances. Figure 5-4, the transfer switch is in the Normal
position and the coil control contacts for the
The adjustments are factory-sealed and usually do not emergency side are closed, ready to allow
require any change over the life of the switch. If it current to flow to the TS coil to transfer to the
becomes necessary to check the settings in the field, Emergency source if the controller signals for
follow the instructions in the test procedure below. The transfer.

b. With all power disconnected, use an ohmmeter
(or a lamp type continuity tester) across each
contact while slowly turning the manual
1 operating handle to determine when the control
contacts open. (Refer to Section 5.2 for manual
operating instructions.) The pairs of coil
clearing contacts do not have to operate
simultaneously, but both must break the circuit
before the main solenoid operator core
reaches top dead center. See Figure 5-5 for
control contact positions.
c. If the coil control contacts do not open before

TDC, use the procedure in Section 5.5.2 to
replace them These contacts are not
field-adjustable.
6127 Control Control

2
Contacts Contacts
1. Main contact position indicator Condition 71--72 & 9--8 70--69 & 6--7
2. Coil control contact assemblies Main contacts in NORMAL
Closed Open
position
Figure 5-3 30--200 Amp Transfer Switches Main contacts in
Open Closed
EMERGENCY position
During transfer from N to E Open before Close after
1 2 TDC TDC
During transfer from E to N Close after Open before
TDC TDC
N=Normal Position
E=Emergency Position
TDC=Top Dead Center of Solenoid core or main contact shaft.
Figure 5-5 Control Contact Positions
61274785
1. Contacts 71-72 and 9-8, for transfers to emergency

2. Contacts 70-69 and 6-7, for transfers to normal
Figure 5-4 TS Coil Control Contact Positions when

the Transfer Switch is in the Normal
Position

3
1
5
4
10
11
7
END VIEW
9
FRONT VIEW
61274785
1. Main solenoid operator
2. Cams
3. Typical set of TS coil control contacts (2 required)
4. Operating button (contacts open when the cam presses the operating button)
5. Double-break control contacts (typical 71--72 contacts shown)
6. Typical 9--8 contacts
7. Contact position indicator (contacts are closed when the button is recessed.)
8. Wiring terminal (qty. 4)
9. TS coil control contact assembly
Figure 5-6 TS Coil Control Contact Locations with Main Solenoid Operator

5.5.2 Coil Control Contact Replacement 5. Install the new right-side control contact assembly
(contacts 70--69 and 6--7). Depress the operating
Under normal conditions the TS Control Contacts do not button (see Figure 5-6) to slide the assembly over
require replacement over the life of the transfer switch. If the cam. Secure the assembly with one #6-32
replacement becomes necessary, use the follwoing round head screw with lock and flat washers. Align
procedure. the assembly so that the screw is approximately
centered in the slot.
Note: Always check wiring and connections before
replacing components. 6. Reconnect the labeled wires to the four similarly
marked screw terminals.
Coil Control Contact Replacement Procedure
7. Install two spacers, then install the new left-side
1. Disconnect all power to the transfer switch as control contact assembly (contacts 71--72 and
instructed in the Test Procedure in Section 5.5. 9--8). Align with the right-side assembly. Secure
the control contact assembly with two hex nuts,
2. Check to verify that the wires connected to the lock washers, and flat washers. Check that the
control contact assembly are marked so they can threaded studs are approximately centered in the
be identified after being disconnected. Add labels slot.
if necessary.
8. Reconnect the four remaining labeled wires to the
3. Disconnect the labeled wires from the control similarly marked screw terminals on the new
contact assembly. left-side control contact assembly.
4. Refer to Figure 5-7. Remove two 5/16I hex nuts 9. Manually operate the switch by turning the manual
with lock and flat washers from the left side of the operator handle. The action should be smooth
control contact assembly. Remove the left control without binding.
contact assembly. Then remove the two spacers
and one #6-32 round head screw with lock and flat 10. Check the control contact continuity. See the test
washers. Remove the right control contact procedure in Section 5.5.
assembly.

1
5 2
4 61274785
1. Cam weight
2. Right (inside) TS coil control contact assembly, 70-69, 6-7
3. #6-32 round head screw with lock washer and flat washer
4. Left (outside) TS coil control contact assembly, 71-72, 9-8
5. Two 5/16 hex nuts with lock washers and flat washers
6. Spacers
7. #6-32 studs, molded into base
Figure 5-7 Replacing TS Control Contact Assemblies

Section 6 225--400 Amp Open-Transition Transfer Switches
This section contains test and service procedures for Manual Operation Procedure
225--400 amp transfer switches.
1. Verify that the power sources to the transfer switch
Use the troubleshooting and test procedures in Sections are OFF.
2 through 4 to diagnose problems before replacing
2. Remove the maintenance handle from the clips on
parts. Use the instructions in this section if inspection,
the left side of the transfer switch frame. See
troubleshooting, or other test procedures reveal
Figure 6-1.
damaged or defective components that require
replacement. 3. Insert the maintenance handle into the hole in the
shaft on the left side of the operator. See
Figure 6-2.
4. Move the maintenance handle up or down as
The service procedures in this section call for manual shown to manually operate the transfer switch.
operation of the transfer switch. Refer to the instructions
in this section to manually operate the switch. Verify that 5. Return the transfer switch to the Normal (or Source
the power to the transfer switch is disconnected before N) position.
operating it manually.
6. Remove the maintenance handle and store it on the
Note: A manual operation handle is provided on the frame in the clips provided.
transfer switch for maintenance purposes only. Do
not use the manual operation handle to transfer NOTICE
the load with the power connected. Improper operator handle usage. Use the manual operator
handle on the transfer switch for maintenance purposes only.
225--400 amp transfer switches have a detachable Return the transfer switch to the normal position. Remove the
handle for manual operation. See Figure 6-1 for the manual operator handle, if used, and store it in the place
typical handle storage location. provided on the transfer switch when service is completed.
127a
1. Maintenance handle
2. Shaft
126 Figure 6-2 Manual Operation, 225--400 Amp

1. Maintenance handle Switches
Figure 6-1 Typical Manual Handle Storage
TP-6127 9/02 Section 6 225--400 Amp Open-Transition Transfer Switches 63

6.2 Main Contact Replacement disconnecting all generator engine start batteries,
negative (--) leads first.
Replace the transfer switch main contacts if inspection,
troubleshooting, or testing indicates that the main 2. Disconnect all power sources to the transfer switch
by opening switches or circuit breakers. Use a
contacts are damaged or excessively worn. See
voltmeter to verify that no voltage is present at the
Section 1.2.2 for inspection information.
transfer switch terminal lugs.
The following tools are needed for this procedure:
3. Remove the barrier/pole cover and arc chutes to
D Phillips screwdriver
gain access to the main contacts.
D Blade screwdriver a. Remove four screws in the corners of the
D 5/32 in. hex key wrench barrier/pole cover and remove the cover.
b. Remove the nylon retainer nuts on both sides of
D 9/16 in. socket wrench
each arc chute. Then tip the chute toward the
D Torque wrench capable of 175 in. lb. shaft while pulling it away from the panel.
D Voltmeter
D Pliers c. Place the arc chutes in a safe place for
reinstallation later.
D Cotton swab or small brush
D Pencil or wood dowel
Movable Contact Disassembly
Use the detachable manual operating handle for The movable contacts are mounted in the shaft. They
maintenance purposes only. Disconnect the power and are secured to the shunts by screws and held in place by
follow the manual operation instructions in the the contact spring retainer. See Figure 6-3.
Operation and Installation manual to move the manual
operating handle up or down as needed during these 1. Remove the contact spring retainer: Use a 5/16 in.
procedures. Do not operate the transfer switch nutdriver to remove four #10-32 hex head screws
manually when the power is connected. with shake washers from the shaft. Then remove
the retainer.
NOTICE
Improper operator handle usage. Use the manual operator Note: The retainer is under spring pressure. Hold
handle on the transfer switch for maintenance purposes only. the retainer with one hand and loosen all
Return the transfer switch to the normal position. Remove the four screws equally to release the pressure.
manual operator handle, if used, and store it in the place
provided on the transfer switch when service is completed. 2. Remove all contact springs: Pull off the contact
springs from the heads of the screws.
Main Contact Replacement Procedure
3. Remove all movable contacts: Remove the 1/4-20
1. Prevent the generator set from starting by moving screws with lock washers from the contacts by
the generator set master switch to the OFF using a hex key wrench. Then remove the contacts
position, disconnecting power to the generator and contact stiffeners.
engine starting battery charger, if installed, and
64 Section 6 225--400 Amp Open-Transition Transfer Switches TP-6127 9/02

1
2*
3*
4*
1. Shunt lug. Apply conductive lubricant

2. Movable contact*
3. Contact stiffener*
4. Contact spring* 6*
5. #10-32 hex head screws*
6. Spring retainer*
5*
7. Shaft
* Parts included in the kit. 6127-4781
Figure 6-3 Movable Contact

Stationary Contact Disassembly
The stationary contacts are mounted in the molded
base. They are secured from the back and screwed to
the terminal lugs. See Figure 6-5.
Clamp
1. Remove all stationary contacts (with terminal lugs): here
Remove the two hex nuts (from the back) from the
threaded studs by using a 7/16 in. socket wrench,
then remove the stationary contact (with terminal
lug) from the molded base.
2. Remove the terminal lugs: Secure each contact

plate in a vise. See Figure 6-4. Remove the
terminal screws (from the back) by using a 9/16 in.
socket wrench. Save the terminal lugs and screws
for reuse.
3. Remove the arc runners: Use a phillips

screwdriver to remove two screws from each arc
runner. Remove the arc runner by pulling it away
6127-4781
from the contact button. Save the screws for reuse.
Figure 6-4 Stationary Contact Secured in a Vise to
Remove and Install the Terminal Lug
and Arc Runner
3*
4
1. Molded base
2. Terminal screws. Tighten to 175 in. lb to prevent overheating.
3. Bevel washer*
4. Clean surface
5. Stepped edge 9*
6. Lug
7. Arc runner*
8. Button
9. Stationary contact* 8
7*
* Parts included in the kit.
6127-4781
Figure 6-5 Stationary Contact

Stationary Contact Reassembly 1/4-20 screw and lock washer. Each screw passes
through the movable contact and contact stiffener
Reassemble as shown in Figure 6-5. into the shunt lug. Use a 5/32 in. hex key wrench to
tighten the screw to 100 in. lb.
1. Reconnect the terminal lugs:
Note: To prevent overheating, torque the movable
a. Make sure that the new contact plate is clean
contact screw to 100 in. lb. To prevent
before reattaching the terminal lug.
binding, check the contact for free
b. Carefully secure each new stationary contact movement in the shaft.
plate in a vise. See Figure 6-4.
3. Install new contact springs: Press a new spring
c. From the back, insert the terminal screw with a onto the head of each screw that secures a
new bevel washer through the stationary movable contact.
contact plate into the terminal lug (with the
4. Install the contact spring retainer:
stepped edge on the side as shown in
Figure 6-5). a. Place the spring retainer onto the springs so
that they seat into the cavities of the retainer.
d. Tighten the terminal screws to 19.8 Nm
(175 in. lb.). b. Compress the springs with the retainer and
hold it in position.
Note: To prevent overheating, torque the terminal
screws to 19.8 Nm (175 in. lb.). c. Use a 5/16 in. nutdriver to install the four
#10-32 hex head screws with shake washers to
2. Install new arc runners.
secure the spring retainer to the shaft. Tighten
a. Carefully secure each new stationary contact the screws.
plate in a vise.
5. Check contact deflection: Lift the tip of each
b. Use two Phillips-head screws to install the new movable contact to verify freedom of movement in
arc runner flat against the plate. Be sure that the shaft. If there is binding, loosen the contact
the formed side faces out, the jaws are on both screw enough to reposition the shunt lug slightly,
sides of the contact button, and the arc runner then retighten the screw to the proper torque.
is positioned as close as possible to the contact Recheck the deflection.
button.
6. Install all arc chutes:
3. Install new stationary contact assemblies: Insert
a. Tip the arc chute while placing it over the
each new stationary contact (with terminal lug &
stationary contact.
arc runner) into the molded base and secure it by
installing two hex nuts with flat and lock washers b. Slide the arc chute toward the shaft (up or
behind the base. Use a 7/16 in. socket wrench to down) until it stops. Then position it so that it is
tighten nuts. centered over the stationary contact, and so the
movable contact does not strike the arc chute
Movable Contact Reassembly plates.
Reassemble as shown in Figure 6-3. c. Secure the arc chute to the panel by using a
screwdriver to install (cw) nylon retainer nuts on
1. Apply conductive lubricant to shunt lugs: Use a both sides of the arc chute. Torque the nuts to
cotton swab or small brush to apply conductive 12–14 in. lb.
lubricant (available from the manufacturer) to the
exposed surface of each shunt lug in the shaft. 7. Use the manual operation handle to slowly operate
the switch, checking the contact clearance with the
Note: Failure to use conductive lubricant between arc chutes.
the shunt lug and contact may cause
overheating. 8. Install the barrier/pole cover: Place the cover
against the arc chutes and use a Phillips
2. Install new movable contacts: Place a new contact screwdriver to install four screws in the cover.
on the shaft and secure it to the shunt lug with the

DANGER 6.3 Operator Coil Replacement
Replace the coil if inspection or test procedures show
that the coil is burned out or shorted.
Hazardous voltage.
Coil Assembly Removal
DANGER
servicing.
Hazardous voltage.
Note: To prevent the possibility of personal injury or
property damage, be sure to install the insulator
backing piece behind the transfer switch when Disconnect all power sources before
reinstalling it. See Figure 6-6. opening the enclosure.
WARNING
1
Spring-loaded parts.
Can cause severe personal injury
or property damage.
Wear protective goggles when

servicing spring-loaded parts. Hold
parts securely during disassembly.
Disassembling the solenoid. Spring-loaded parts can

2 cause severe personal injury or property damage. The
spring in the solenoid assembly exerts substantial force on the
coil. Hold the coil assembly securely when removing the
screws.
127a
1. Insulator backing piece The coil assembly is mounted to the top left corner of the
2. Contactor
base with two screws. Remove it and place it on a work
Figure 6-6 Insulator for 225--400 amp switches bench for disassembly.
1. Close the top main contacts: Use the manual

operator handle to put the switch in the Emergency
position.
2. Disconnect the rectifier: Pull off the four terminal

lugs from the square rectifier mounted on the coil
frame, then bend the wire leads away from the coil
assembly.
3. Remove the clip assembly: Use a 5/32 in. hex key

wrench to remove (cw) two screws with lock
washers from the frame, then remove the coil
assembly.
Note: Hold the coil assembly securely when

removing the screws. The spring exerts
substantial force on the coil assembly.

4. Remove the core spring: Leave the core and link frame. Be sure the coil leads face the end of the
hooked onto the weight pin, but remove the core frame with the large hole and that they face up.
spring from the core.
2. Install the new core tube:
Coil Disassembly a. Drop the stub core into the core tube so that it
The solenoid coil is held in the frame by the core tube. extends through the end of the tube.
The retaining ring secures the core tube and stub core.
b. Align the holes in the coil, insulating washer,
Refer to Figure 6-7 during this procedure.
spring washer, and frame to accept the core
1. Remove the retaining ring: Use a screwdriver to tube.
pry the retaining ring out of the groove in the stub
c. Insert the core tube with stub core through the
core, which extends through the frame.
frame, coil, spacer washer, and spring washer
2. Remove the core tube and stub core: Pull the core so that the stub core extends through the
tube out through the other end of the frame. The frame. Use a pencil or wood dowel in the core
stub core will come out with the core tube. tube, if necessary, to push the stub core
through the frame.
3. Remove the coil and washers: Pull the coil and
washers out the side of the frame. Note: Do not insert any metal tool inside the core
tube.
3. Install the retaining ring: Use pliers to slide the

1* 2 retaining ring into the groove in the stub core to
3*
secure the core tube in the frame.
4* 4. Lubricate the core tube and spring: Apply lubricant
(a mixture of Dow Corning #44 silicone grease and
molybdenum disulfide powder, available from the
5 manufacturer) to the inside of the core tube and to
the new core spring. Then insert the spring into the
core tube.
Coil Assembly Installation

8 1. Install the coil assembly:
a. Place the coil assembly with core spring onto

7* the solenoid core (still connected to the weight
pin).
6*
1. Retainer ring*
b. Compress the spring with downward pressure
61274781
2. Frame while installing the two screws with a 5/32 in.
3. Spacer washer* hex key wrench.
4. Spring washer*
5. Coil c. Tighten the screws to secure the coil assembly
6. Stub core*
7. Core tube*
to the switch base. Note that only the lower left
8. Rectifier and upper right holes in the coil frame are used.
2. Replace the rectifier, if necessary:
Figure 6-7 Coil Replacement a. Remove the center screw to remove the
rectifier.
Coil Reassembly
b. Install the new rectifier turned so its terminal
Position the coil frame on its left side (rectifier on the left) with the red dot is on the upper left.
on the workbench. The end of the frame with the large
hole should be facing you. See Figure 6-7. 3. Reconnect the coil leads: Connect the coil leads,
which have pink connectors, to the rectifier’s
1. Install the new coil: Place a new coil (leads up and push-on terminals marked with a red dot and no dot
facing you), with washers at the far end, into the (DC + and -- output).

4. Reconnect the rectifier: Connect the AC control 6.4.1 Coil Control Contact Test
leads, which have white connectors and come from
the base, to the rectifier’s push-on terminals The adjustments are factory-sealed and usually do not
marked with yellow dots. require any change over the life of the switch. If it
becomes necessary to check the settings in the field,
5. Manually operate the switch: follow the instructions in the Coil Control Contact Test
Procedure. The settings can vary to the extremes and
a. Use the manual handle to operate the switch to still provide acceptable operation. However, it is
check the solenoid assembly. The action
necessary that the coil control contacts always open
should be smooth, without any binding. If not,
before the solenoid core reaches top dead center
recheck the alignment of parts and the solenoid
(TDC).
operator lubrication.
b. Return the switch to the Normal position (top DANGER

main contacts open). Then remove the manual
handle and store it in the clips on the top left
side of the switch.
DANGER Hazardous voltage.

open the enclosure.
Hazardous voltage.
Will cause severe injury or death. DANGER
servicing.
Hazardous voltage.
Note: To prevent the possibility of personal injury or Will cause severe injury or death.
property damage, be sure to install the insulator Disconnect all power sources before
backing piece behind the transfer switch when opening the enclosure.
reinstalling it. See Figure 6-6.
6.4 Coil Control Contact Test and before servicing. Open the main circuit breakers of all transfer
Adjustment follows: (1) Move all generator set master controller switches
This section explains how to test and adjust the TS coil to the OFF position. (2) Disconnect power to all battery
control contacts in 225--400 amp transfer switches.
Only experienced electricians should test and adjust
the switch. Observe all standard safety practices. prevent the starting of generator sets by an automatic transfer
The TS coil control contacts control the duration of time from a remote computer. Before servicing any components
that power is applied to the main solenoid operator (TS inside the enclosure: (1) Remove all jewelry. (2) Stand on a
Coil). For proper operation, it is important that the dry, approved electrically insulated mat. (3) Test circuits with a
contacts open at the proper time during the stroke of the voltmeter to verify that they are deenergized.
solenoid. Improper adjustment will cause failure to
operate at reduced voltages, failure of the main contacts Coil Control Contact Test Procedure
to seat properly, and solenoid failure.
Note: When the normal source breaker opens, the
The manufacturer sets the TS coil control contacts so engine start circuit closes, signalling the
that the switch can operate satisfactorily over a voltage generator set engine to start and run.
range of 80 to 110% of the nominal system voltage. The
1. Prevent the generator set from starting by moving
coil control contact settings may vary from switch to
switch to accommodate minor variances in friction and position; disconnecting power to the generator
tolerances.
engine starting battery charger, if installed; and
negative (--) leads first. 1
transfer switch enclosure by opening upstream
2
circuit breakers or switches to the transfer switch.
Then use a voltmeter to verify that no voltage is
present at the switch terminal lugs on both power
sources. 3
3. Locate the TS coil control contact assembly. See

Figure 6-8 .
4. Check the settings of the TS control contacts:
a. Refer to Figure 6-9. Two sets of contacts

interrupt the control current to the solenoid
operator coil (TS) in each direction (transfer to
emergency and retransfer to normal). In
1. Manual operator handle storage location
Figure 6-9, the transfer switch is in the normal 2. Main position indicator: N=closed on normal
position and the coil control contacts for the E=closed on emergency
emergency side are closed, ready to allow 3. TS coil contact control assembly
current to flow to the TS coil to transfer to the
emergency source if the controller signals for Figure 6-8 Transfer Switch, 225--400 Amp Models
transfer.
1 2
9 3
NORMAL EMERGENCY 5
8 8 6 69 7 71 9
1. Adjustment nut
2. Adjustment range
3. 11/32 in. open-end wrench
4. Operating button 70 6 72 8
5. Upper drive link
6. Typical contacts. The contacts open when the cam presses the operating button.
7. Cams
8. Control contact sets
9. Drive bracket 61274786
Figure 6-9 TS Control Contact Arrangement (transfer switch is in the normal position)

b. With power disconnected, use an ohmmeter 6.4.2 Contact Adjustment
(or a lamp-type continuity tester) across each
contact while slowly turning the manual Contacts 71–72 and 9–8. Refer to Figure 6-12.
operator handle to determine when the control
contacts open. (Refer to Section 6.1 for 1. Use the manual operator handle, if necessary, to
operating handle instructions.) Compare the move the power switching device to the emergency
contact operation to the positions given in position.
Figure 6-11 and verify that both contacts open
before the main solenoid operator core 2. Loosen the #8-32 hex nut that unlocks the drive
reaches top dead center. The pairs of coil bracket from the cam adjustment slot on the right
clearing contacts do not have to operate side of the assembly.
simultaneously.
3. Rotate the cam until its top edge is within 9/32 in.
5. If any of the contacts require adjustment, use the from the side of the drive and stroke setting
following Contact Adjustment Procedures. bracket.
4. Retighten the locking nut and verify the adjustment

as described in the test procedure.
1 2
Note: The setting shown in Figure 6-12 is
satisfactory in most cases. However, to
69 7 71 9 accommodate variances in tolerances,
friction, and 80% minimum operating
voltage, you can vary the setting over the
range of adjustability provided that the
control contacts maintain the positions
70 6 72 8 shown in Figure 6-11.
61274786
5. Reconnect the engine start circuit.

1
Figure 6-10 TS Coil Control Contact Positions when
the Transfer Switch is in the Normal
Position
Control Contacts Control Contacts

Condition 71--72 & 9--8 69--70 & 7--6 9/32 in.
Main contacts in
NORMAL posi- Closed Open
tion
Main contacts in
EMERGENCY Open Closed
position
During transfer 2
Open before TDC Close after TDC
from N to E
1. 11/32 in. wrench
During transfer 2. Drive bracket
Close after TDC Open before TDC 61274786
from E to N
N=Normal Position Figure 6-12 Adjusting TS Control Contacts 71--72
E= Emergency and 9--8. (View from the right side.
TDC=Top Dead Center of solenoid core or main contact shaft
rotation.
Main transfer switch contacts must be
closed on emergency side.)
Figure 6-11 Coil Control Contact Positions

Contacts 69–70 and 7–6. Refer to Figure 6-13. 6.4.3 Coil Control Contact Replacement
1. Use the manual operator handle, if necessary, to Under normal conditions the TS control contacts do not
move the power switching device to the NORMAL require replacement over the life of the transfer switch. If
position. replacement becomes necessary, Use the following
procedure.
2. Loosen the #8-32 hex nut that unlocks the drive
bracket from the cam adjustment slot on the left Note: Always check wiring and connections before
side of the assembly. replacing components.
3. Rotate the cam until its bottom edge is within
9/32 in. from the side of the drive bracket. TS Control Contact Replacement Procedure
4. Retighten the locking nut and verify the adjustment 1. Disconnect all power to the transfer switch as
as described in the test procedure. instructed in the Test and Adjustment Procedure.
2. Refer to Figure 6-14. Disconnect the upper drive

Note: The setting shown in Figure 6-13 is
satisfactory in most cases. However, to link by removing the #10--32 shoulder screw, lock
washer, and hex nut from the left side of the drive
accommodate variances in tolerances,
bracket on the control contact assembly. Then
friction, and 80% minimum operating
voltage, you can vary the setting over the reinstall the hardware onto the loose linkage for
safekeeping.
range of adjustability provided that the
control contacts maintain the positions
3. Disconnect the lower drive link by removing the
shown in Figure 6-11.
#10--32 allen head screw and locknut from the right
side of the drive bracket. Then reinstall the
5. Reconnect the engine start circuit.
hardware into the loose link for safekeeping.
4. Verify that the wires connected to the control

1 contact assembly are marked so they can be
identified after being disconnected. Add labels if
necessary.
5. Disconnect the labeled wires from the control

contact assembly.
Note: Do not pull on the wires. Use a screwdriver

9/32 in.
to pry off the connectors. Pulling may
damage the crimped wire connection.
6. Remove three #8 Phillips head self-tapping screws

from the mounting feet and remove the control
2 contact assembly.
61274786 7. Install the new control contact assembly onto the

switch base. Apply one drop of Loctiter to each
1. Drive bracket mounting screw thread to reform the self-tapping
2. 11/32 in. wrench
holes and secure the assembly.
Figure 6-13 Figure 5. Adjusting TS Control
Contacts 69--70 and 7--6 (view from the 8. Reconnect the lower drive link to the drive bracket
left side; main transfer switch contacts (right side) with the #10--32 allen head screw and
must be closed on normal side) locknut. Check for free play between the locknut
and drive link.
9. Reconnect the upper drive link to the left side of the

drive bracket on the control contact assembly with
the #10--32 shoulder screw, split lock washer, and
hex nut. Check for free play between screw head
and drive bracket.
* Loctite is a registered trademark of the Loctite Corporation.

10. Manually operate the drive linkage. The action 12. Check the control contact adjustment. See the test
should be smooth without any binding. Verify that and adjustment procedures in Sections 6.4.1 and
the cams properly operate the pushbuttons on the 6.4.2 .
control and auxiliary contact assemblies.
11. Reconnect the eight labeled wires to the proper

terminals.
5 4
6
11 7
8
9
61274786
10
1. TS control contact assembly 7. Hex nut
2. Phillips head self-tapping mounting screws 8. Lock washer
3. Locknut, 10-32 9. Drive bracket
4. Lower drive link 10. Upper drive link
5. Allen head screw, 10-32 11. Shoulder screw, 10-32
6. Drive bracket
Figure 6-14 Figure 6. TS Control Contact Assembly Replacement

Section 7 150--400 Amp Programmed-Transition Transfer
Switches and Bypass/Isolation Switches
This section explains how to replace the transfer switch

main contacts and operator coil in 150--400 amp
bypass/isolation switches and programmed-transition
transfer switches (standard or bypass models). This
section also contains instructions for adjusting and
replacing the control contacts in 150--400 amp
bypass/isolation switches.
Figure 7-1 and Figure 7-2 show typical bypass/isolation

switches.
61274796
1. Upper transfer switch
2. Lower transfer switch
Figure 7-2 Typical Programmed-Transition

Bypass/Isolation Switch
1. Transfer switch 61274792
Figure 7-1 Typical Bypass/Isolation Switch
TP-6127 9/02 Section 7 150--400 Amp Programmed-Transition Transfer Switches and Bypass/Isolation Switches 75
7.1 Manual Operation Swing the shaft cover over the shaft after removing the
manual operator handle.
DANGER
7.2 Main Contact Replacement
Refer to the transfer switch Parts Catalog for
instructions to obtain replacement parts.
Hazardous voltage.
Will cause severe injury or death. Tools Needed
open the enclosure.
D Blade screwdriver
Removing the transfer switch from bypass/isolation D 5/32” hex key wrench
models. Hazardous voltage can cause severe injury or
death. Bypass and isolate the transfer switch before D 5/16” nutdriver
removing it from the enclosure. The bypass/isolation switch is D 9/16” nutdriver or socket wrench
energized. Do not touch the isolation contact fingers or the
control circuit terminals. D 11/32” open--end wrench
D Torque wrench (100 in--lb)
A detachable manual operator handle is provided for
maintenance purposes only. The handle is stored on the D Torque wrench (240 in--lb, 20 ft--lb)
upper left side of the switch. D Voltmeter
Note: Bypass and isolate the transfer switch before D Ohmmeter (or continuity tester)
manually operating it. See the bypass/isolation D Pliers
switch Operation and Installation Manual for
instructions. D Cotton swab or small brush
D Pencil or wood dowel
Swing the shaft cover to the left out of the way. Insert the
D Ruler
manual handle into the hole in the shaft, left side of the
operator. See Figure 7-3. Move the handle down and up
DANGER
to manually operate the switch, as needed, in the
following maintenance procedures.
Hazardous voltage.
2 Will cause severe injury or death.
1
open the enclosure.
Removing the transfer switch from bypass/isolation

death. Bypass and isolate the transfer switch before
removing it from the enclosure. The bypass/isolation switch is
1. Handle 61274796 energized. Do not touch the isolation contact fingers or the
2. Shaft cover control circuit terminals.
Figure 7-3 Manual Operator Handle Note: To prevent the possibility of fatal electrical shocks
and burns, bypass, isolate, and remove the
NOTICE transfer switch before working on it. Refer to the
Improper operator handle usage. Use the manual operator bypass/isolation switch Operation and
handle on the transfer switch for maintenance purposes only. Installation Manual for instructions.
Return the transfer switch to the normal position. Remove the
provided on the transfer switch when service is completed.
76 Section 7 150--400 Amp Programmed-Transition Transfer Switches and Bypass/Isolation Switches TP-6127 9/02
Follow these instructions to remove the barrier/pole 2. Install new movable contacts. Place a new contact
cover and arc chutes and gain access to the main on the shaft and secure it to the shunt lug with the
contacts. 1/4--20 screw and lockwasher. Each screw passes
through the movable contact and contact stiffener,
1. Remove the barrier/pole cover: Use a Phillips into the shunt lug. Tighten the screw by using a
screwdriver to remove the four cover screws. Then 5/32” hex key wrench to 100 in--lb.
remove the cover.
Note: To prevent overheating, torque the movable
2. Remove all arc chutes: Use a blade screwdriver to contact screw to 100 in-lbs. To prevent
remove the nylon retainer nuts on both sides of binding, check the contact for free
each chute. Then tip the chute toward the shaft movement in shaft.
while pulling it away from the panel. Place the arc
chutes in a safe place. 3. Install new contact springs. Press a new spring
onto the head of each screw that secures a
movable contact.
7.2.1 Movable Contacts
4. Install the contact spring retainer. Place the spring
Disassembly retainer onto the springs so that they seat into the
cavities of the retainer. Compress the springs with
The movable contacts are mounted in the shaft. They the retainer and hold it in position. Use a 5/16”
are secured to the shunts by screws and held in place by nutdriver to install the four # 10--32 hex head
the contact spring retainer. See Figure 7-4. (Sems) screws with shake washers to secure the
spring retainer to the shaft. Tighten the screws.
1. Remove the contact spring retainer. Use a 5/16”
nutdriver to remove four # 10--32 hex head (Sems) 5. Check contact deflection. Lift the tip of each
screws with shake washers from the shaft, then movable contact to verify freedom of movement in
remove the retainer. the shaft. If there is binding, loosen the contact
screw enough to reposition the shunt lug slightly,
Note: The retainer is under spring pressure. Hold
then retighten the screw to proper torque. Recheck
the retainer with one hand and loosen all
deflection.
four screws equally to release the retainer
pressure. 6. Install all arc chutes. Tip the arc chute while placing
it over the stationary contact. Slide the arc chute
2. Remove all contact springs. Pull off contact
toward the shaft (up or down) until it stops. Then
springs from heads of screws.
position it so that it is centered over the stationary
3. Remove all movable contacts. Remove the 1/4--20 contact, and so the movable contact does not strike
screws with lockwashers from the contacts by the arc chute plates. Secure the arc chute to the
using a 5/32” hex key wrench. Then remove the panel by using a blade screwdriver to install nylon
contacts and contact stiffeners. retainer nuts on both sides of arch chute. Torque
the nuts to 12--14 in lbs.
Reassembly 7. Slowly operate the switch with the manual handle
(see Figure 1). Check contact clearance with the
Reassemble as shown in Figure 7-4.
arc chutes.
1. Apply conductive lubricant to shunt lugs. Use a
8. Install barrier/pole cover. Place the cover against
cotton swab or small brush to apply conductive
the arc chutes. Use a Phillips screwdriver to install
lubricant to the exposed surface of each shunt lug
the four cover screws.
in the shaft.
9. Reinstall the transfer switch. Refer to Section 3 of
Note: Failure to use conductive lubricant between
the Operator’s Manual (Reinstallation and Return
the shunt lug and contact may cause
to Service).
overheating.
1
2*
3*
4*
1. Shunt lug. Apply conductive lubricant

2. Movable contact*
3. Contact stiffener*
4. Contact spring*
5. #10-32 hex head screws* 6*
6. Spring retainer* 5*
7. Shaft
61274796
Figure 7-4 Figure 2. Movable contact.
7.2.2 Stationary Contacts 1. Install new stationary contacts. Insert each new
stationary contact into the molded base and secure
Disassembly it by installing two hex nuts with flat washers behind
the base. Use a 7/16” socket wrench to tighten the
The stationary contacts are mounted in the molded nuts.
base. They are secured from the back and bolted to the
isolation stabs. See Figure 7-5. 2. Reconnect the isolation stabs. From the back of
the molded base, insert the bolt with flat washers
1. Remove all arc runner screws. Use a Phillips through the isolation stab, bushing, and stationary
screwdriver to remove the screw from each arc contact. Secure the connection with the hardware
runner. Remove the arc runner by pulling it away shown in Figure 3. Then use a 9/16” socket wrench
from the contact button. and torque wrench to tighten to 20 ft--lbs or 240
in--lbs.
2. Remove all stationary contacts. Remove the nut
and bolt by using a 9/16” open--end wrench and a Note: To prevent overheating, tighten the
9/16” socket wrench. Also remove the two hex nuts stationary contact to the isolation stab
from the threaded studs by using a 7/16” socket connection to 20 ft--lbs or 240 in--lbs torque.
wrench, then remove the stationary contact from
the molded base. 3. Install new arc runners. Install each arc runner flat
against the plate by using a Phillips screwdriver to
install two screws. Be sure that the formed side is
Reassembly
out, and that the jaws are on both sides of the
Reassemble as shown in Figure 7-5. contact button.
10 1
9
2
3
8
4
1. Molded base
2. Flat washer
3. Bevel washer
4. Nut
5. Arc runner*
6. Button
7. Stationary contact* 7*
8. Bushing
9. Isolation stab
10. Tighten isolation stab to stationary contact connection to 27 Nm (20 ft. lb. or 240 in. lb)
to prevent overheating. 6
5*
61274796
Figure 7-5 Stationary Contact. [Tighten connection to 27 Nm (20 ft. lbs.) to prevent overheatng.]
7.3 Operator Coil Replacement Note: To prevent the possibility of fatal electrical shocks
Refer to th transfer switch Parts Catalog for instructions transfer switch before working on it. Refer to the
to obtain replacement parts. bypass/isolation switch Operation and
Installation Manual for instructions.
7.3.1 Removing the Coil Assembly The coil assembly is mounted to the top left corner of the
base with two screws. Follow these steps to remove the
DANGER coil assembly and place it on a work bench for
disassembly.
1. Close the top main contacts. Use the manual

operator handle to put the switch in the Emergency
Hazardous voltage. position.
2. Disconnect the rectifier. Pull off the four terminal
Only authorized personnel should lugs from the square rectifier mounted on the coil
open the enclosure. frame, then bend the wire leads away from the coil
assembly.
models. Hazardous voltage can cause severe injury or 3. Remove the clip assembly. Use a 5/32” hex key
death. Bypass and isolate the transfer switch before wrench to remove two screws with lockwashers
removing it from the enclosure. The bypass/isolation switch is from the frame, then remove the coil assembly.
control circuit terminals. Note: To prevent the possibility of personal injury
or property damage, hold the coil assembly
WARNING securely when removing screws. The
spring exerts substantial force on the coil
assembly.
4. Remove the core spring. Leave the core and link

hooked onto the weight pin, but remove the core
Spring-loaded parts. spring from the core.
or property damage.
7.3.2 Disassembly
servicing spring-loaded parts. Hold The solenoid coil is held in the frame by the core tube.
parts securely during disassembly. The retaining ring secures the core tube and stub core.
See Figure 4.
cause severe personal injury or property damage. The 1. Remove the retaining ring. Use a blade
spring in the solenoid assembly exerts substantial force on the screwdriver to pry the retaining ring out of the
coil. Hold the coil assembly securely when removing the groove in the stub core that extends through the
screws. frame.
2. Remove the core tube and stub core. Pull the core through the frame, coil, spacer washer, and spring
tube out through the other end of the frame. The washer so that the stub core extends through the
stub core will come out with the core tube. frame. Use a pencil or wood dowel in the core tube,
if necessary, to push the stub core through the
3. Remove the coil and washers. Pull the coil and frame.
washers out the side of the frame.
Note: Do not insert any metal tool inside the core
tube.
3
1* 2 3. Install the retaining ring: Use pliers to slide the
retaining ring into the groove in the stub core to
4 secure the core tube in the frame.
4. Lubricate the core tube and spring: Apply lubricant

8 from lubrication kit 331800 to the inside of the core
tube and to the new core spring. Then insert the
5
spring into the core tube.
7.3.4 Installing Coil Assembly

1. Install the coil assembly: Place the coil assembly
with core spring onto the solenoid core (still
connected to the weight pin). Compress the spring
7* with downward pressure while installing the two
screws with a 5/32” hex key wrench. Tighten the
screws to secure the coil assembly to the switch
base. Note that only the lower left and upper right
6* holes in the coil frame are used.
1. Retainer ring*
2. Frame 2. Replace the rectifier, if necessary. Remove the
3. Spacer washer* center screw to remove the rectifier and install the
4. Spring washer* new rectifier turned so its terminal with the red dot is
5. Coil on the upper left.
6. Stub core*
7. Core tube*
8. Rectifier 3. Reconnect the coil leads. Connect the coil leads
with pink lugs to the rectifier’s push--on terminals
61274796
marked with a red dot and no dot (DC + and --
Figure 7-6 Coil Replacement output).
4. Reconnect the rectifier. Connect the AC control

7.3.3 Reassembly leads with white lugs (from the base) to the
rectifier’s push--on terminals marked with yellow
Position the coil frame on its left side (rectifier on the left) dots.
on the workbench. The end of the frame with the large
hole should be facing you. See Figure 7-6. 5. Use the manual handle to operate the switch to
check the solenoid assembly (see Figure 1). The
1. Install the new coil: Place a new coil (leads up and action should be smooth, without any binding. If
facing you), with washers at the far end, into the not, recheck alignment of parts and lubrication in
frame. Be sure the coil leads face the end of the the solenoid operator. Return the switch to the
frame with the large hole and that they face up. Normal position (top main contacts open). Then
remove the manual handle and store it in the clips
2. Install the new core tube: Drop the stub core into on the top left side of the switch.
the core tube so that it extends through the end of
the tube. Align the holes in the coil, insulating 6. Reinstall the transfer switch. Refer to the
washer, spring washer, and frame to accept the bypass/isolation switch Operation and Installation
core tube. Insert the core tube with stub core manual.
7.4 Control Contact Test & 1. Bypass, isolate, and remove the transfer switch.
See the Operation and Installation Manual.
Adjustment
2. Locate the TS control contact assembly. See
This section explains how to test and adjust the TS Coil
Figure 7-7.
Control Contacts. The TS Control Contacts control the
duration of time that power is applied to the main
solenoid operator (TS Coil). To assure proper 1
operation, it is important that the contacts open at the
proper time during the stroke of the solenoid. Improper
2
adjustment will cause failure to operate at reduced
voltages, failure of the main contacts to properly seat,
and solenoid failure.
The TS Control Contacts are factory set with an

adjustable power supply so that the switch can operate
3
satisfactorily over a voltage range of 80 to 110% of the
nominal system voltage. To accommodate minor
variances in friction and tolerances, it is not unusual for
the control contact settings to vary from switch to switch.
The adjustments are factory sealed and usually do not

require any change over the life of the switch. If it should 1. Manual operator handle storage
become necessary to check adjustments in the field, an 2. Main position indicator:
N=closed on normal
approximation can be made by using the following E=closed on emergency
procedure. The adjustments can vary to the extremes 3. TS control contact assembly 61274792
and still provide acceptable operation. However, it is
important that the TS Control Contacts always open Figure 7-7 Control Contact Assembly Location
BEFORE top-dead-center is reached by the solenoid
core. 3. To verify settings and field adjust the TS control
contacts, proceed as follows:
7.4.1 Test and Adjustment Procedure a. Refer to Figure 7-9. Two sets of contacts
interrupt the control current to the solenoid
DANGER operator coil (TS) in each direction (transfer to
emergency and retransfer to normal). The
pairs of coil clearing contacts do not have to
operate simultaneously, but both must break
the circuit BEFORE the main solenoid operator
core reaches top-dead-center. See Figure 7-8
Hazardous voltage.
for control contact positions.
Only authorized personnel should Control Contacts Control
open the enclosure. Condition 71-- 72 & 9-- 8 Contacts
69-- 70 & 7-- 6
Removing the transfer switch from bypass/isolation Main contacts
Closed Open
models. Hazardous voltage can cause severe injury or closed on N
death. Bypass and isolate the transfer switch before Main contacts
Open Closed
removing it from the enclosure. The bypass/isolation switch is closed on E
energized. Do not touch the isolation contact fingers or the During transfer Open before Close after
control circuit terminals. from N to E TDC TDC
During transfer Close after Open before
Note: To prevent the possibility of fatal electrical shocks from E to N TDC TDC
and burns, bypass, isolate, and remove the N=Normal position E=Emergency position
transfer switch before working on it. Refer to the TDC=Top dead center of solenoid core or main contact shaft.
bypass/isolation switch Operation and Figure 7-8 Control Contact Positions
2
1
for transfer for transfer

to normal to emergency
69 7 71 9
69 7 71 9
70 6 72 8
70 6 72 8
5
4
3 6
10
NORMAL EMERGENCY
8
61274792
11 9
11
1. Upper drive link 7. Operating button
2. Electrical diagram. Control contact positions shown when TS 8. Cutaway side view
contacts are closed on the normal source. 9. Typical control contacts 69, 70. Contacts open when operating
3. Drive bracket button is depressed by cam.
4. #8-32 hex locking nuts 10. Cams
5. Range of adjustment 11. Control contact sets
6. 11/32 in. open end wrench
Figure 7-9 TS Control Contact Arrangement.
b. With power disconnected, use an ohmmeter the drive bracket. Retighten the locking nut and
(or a lamp type continuity tester) across each verify adjustment as described in step 4, sections
contact to determine when the control contacts a and b.
open while slowly turning the manual operator
handle. Refer to Section 7.1, Manual d. If adjustment of contacts 69--70 and 7--6 is
Operation, for operating handle instructions. necessary, refer to Figure 7-11. Make sure the
main contacts of transfer switch are closed on
c. If adjustment of contacts 71--72 and 9--8 is the normal side (see position indicator in
necessary, refer to Figure 7-10. Make sure the Figure 7-7). Use the manual operator handle, if
main contacts of the transfer switch are closed on necessary to move the switch to the normal
emergency (see position indicator in Figure 7-7). position. Loosen the 8--32 hex nut that unlocks
Use the manual operator handle, if necessary, to the drive bracket from the cam adjustment slot
move the switch to the emergency position. on the left side of the assembly. Rotate the cam
Loosen the #8--32 hex nut that unlocks the drive until its bottom edge is within 7 mm (9/32 in.)
bracket from the cam adjustment slot on the right from the side of the drive bracket. Retighten the
side of the assembly. Rotate the cam until its top locking nut and verify adjustment as described in
edge is within 7.1 mm (9/32 in.) from the side of step 4, sections a and b.
e. The settings shown in Figure 7-10 and contact positions as shown in Figure 7-8 are
Figure 7-11 are satisfactory in most cases. maintained.
However, settings can vary over the range of
adjustability to accommodate variances in f. Reinstall the transfer switch. Refer to the
tolerances, friction, and 80% minimum Operator’s Manual.
operating voltage provided that the control
9/32I
1. 11/32 in. wrench

2
2. Drive bracket 61274792
Figure 7-10 Adjusting TS Control Contacts 71--72 and 9--8. View from right side of TS control contact
assembly. Main transfer switch contacts must be closed on emergency side.
9/32I
2
1. Drive bracket
2. 11/32 in. wrench 61274792
Figure 7-11 Adjusting TS Control Contacts 69--70 and 7--6. View from left side of TS control contact assembly.
Main transfer switch contacts must be closed on normal side.
7.4.2 Test Control Contact Replacement 6. Remove three #8 Phillips head self-tapping screws
from the mounting feet and remove the control
Under normal conditions the TS control contacts do not contact assembly.
require replacement over the life of the transfer switch. If
replacement becomes necessary, proceed as follows: 7. Install new control contact assembly onto switch
base. Apply one drop of Loctiter to each mounting
1. Bypass, isolate, and remove the transfer switch. screw thread to reform self tapping holes and
See the Operation and Installation Manual. secure assembly.
2. Refer to Figure 7-12. Disconnect the upper drive 8. Reconnect the lower drive link to the drive bracket
link by removing the #10-32 shoulder screw, (right side) with the #10-32 allen head screw and
lockwasher, and hex nut from the left side of the locknut. Check for free play between the locknut
drive bracket on the control contact assembly. and drive link.
Then reinstall the hardware into the loose linkage
for safekeeping. 9. Reconnect the upper drive link to the left side of the
drive bracket on the control contact assembly with
3. Disconnect the lower drive link by removing the the #10-32 shoulder screw, split lockwasher, and
#10-32 allen head screw and locknut from the right hex nut. Check for free play between screw head
side of the drive bracket. Then reinstall the and drive bracket.
hardware into the loose link for safekeeping.
10. Manually operate the drive linkage. The action
4. Check to assure that the leads connected to the should be smooth without any binding. Be sure the
control contact assembly are marked so they can cams properly operate the pushbuttons on the
be identified after being disconnected. Add labels control and auxiliary contact assemblies.
if necessary.
11. Reconnect the eight labeled leads to the proper
5. Disconnect the labeled leads from the control terminals.
contact assembly.
12. Check the control contact adjustment. See Section
Note: Do not pull on the leads. Pry off connectors 7.4.1, Test and Adjustment Procedure.
with a screw driver. Pulling may damage the
crimped wire connection. * Loctite is a registered trademark of the Loctite Corporation.
1
11
7 5
8
9
6
61274792
10
1. TS control contact assembly 7. Hex nut

2. Phillips head self-tapping mouniting scrrews (3 ea.) 8. Lockwasher
3. #10--32 locknut 9. Drive bracket
4. lower drive link 10. Upper drive link
5. #10-32 allen head screw 11. #10-32 shoulder screw
6. Drive bracket
Figure 7-12 TS Control Contact Assembly Replacement
Section 8 600--1200 Amp Transfer Switches
This section explains how to replace the arcing and main

contacts and the solenoid coil and assembly in
600--1200 amp transfer switches.
DANGER
Hazardous voltage.

chargers. (3) Disconnect all battery cables, negative (--) leads 6127237
battery cables after servicing. Follow these precautions to Figure 8-1 600 Amp Transfer Switch (3-pole with
prevent the starting of generator sets by an automatic transfer switched neutral shown; 600 amp has
switch, remote start/stop switch, or engine start command two-barrel terminal lugs)
Tools Needed
D Safety glasses (for eye protection)
D Straight blade 6 in. screwdriver, 1/4–3/8 in.
D Short handle blade screwdriver
D Ratchet drive, 3/8 in., 6 in. and 12 in. extensions
D Sockets, 3/8 in., 1/2 in., 9/16 in.
D Open-end or box wrenches, 3/8, 7/16, 9/16, and 1/2 in.
D Nutdriver, 5/8 in.
D Torque wrench, 0 to 20 ft. lb. (240 in. lb.)
D Needlenose and regular pliers
D Wire labels
6127237
Figure 8-2 800--1200 Amp. Transfer Switch

(3-pole with solid neutral shown)

8.1 Maintenance Handle handle into the molded hub on the left side of the
operator. See Figure 8-4, Figure 8-3, and
A detachable maintenance handle is provided on the Figure 8-5.
frame of the transfer switch for maintenance purposes
only. After the transfer switch is completely deenergized, 3. Move the maintenance handle up or down as shown
this handle can be used to change the position of the to manually operate the transfer switch to the opposite
contacts and operator mechanism. The windows in the position.
right side of the transfer switch frame indicate which
Note: If Normal and Emergency connections are
contacts are open and closed.
reversed this operation is also reversed.
DANGER 4. Return the transfer switch to the Normal position.

Observe that the window indicators (right side)
show the top shaft O (open) and the bottom shaft C
(closed).
5. Remove the maintenance handle and store it on

Hazardous voltage.
the frame (left side) in the clips provided.

battery cables after servicing. Follow these precautions to 1
2
NOTICE
Improper operator handle usage. Use the manual operator
manual operator handle, if used, and store it in the place 3
provided on the transfer switch when service is completed.
Manual Operation Procedure

1. Deenergize the transfer switch. After deenergizing
both power sources, open the enclosure door. Use
a voltmeter to verify that no electrical power is
6127237
present at the transfer switch terminals.
1. Transfer switch, left side
2. Maintenance handle
2. Install the maintenance handle. Locate and 3. Storage clips
remove the maintenance handle from clips on the
left side of the transfer switch frame. Insert the Figure 8-3 Maintenance Handle and Storage Clips

ATS Position Handle Indicators
E=O
E up upper contacts
open
Normal
N=C
N lower contacts
closed
E=C
E upper contacts
closed
Emergency
N=O
N down lower contacts
open
Figure 8-4 Maintenance Handle Positions
Emergency
handle UP closes the contacts
Normal source
contacts (lower) window
indicators
contact position
O is open indicators (right side)
hub DOWN closes the
Emergency source C is closed
contacts (upper)
Normal con-
tacts
frame
6127237
Figure 8-5 Maintenance Handle Operation and Contact Position Indicators
8.2 Main and Arcing Contact Servicing the transfer switch. Hazardous voltage can
Replacement before servicing. Open the main circuit breakers of all transfer
8.2.1 Arc Chute and Barrier Removal
DANGER first. Reconnect negative (--) leads last when reconnecting the
Hazardous voltage.

The contact assemblies (two for each pole) are located
1
to the right of the operator mechanism.

a voltmeter to verify that no electrical power is
2. Use the maintenance handle (if necessary). Open

the contacts that will be replaced (if not already
open). See Section 8.1.
3. Remove the interphase barriers (one per pole). 2

Use a blade screwdriver to loosen four round head
screws holding each barrier to the arc chutes. Slide
6127237
the barrier up until the keyholes clear the round
head screws, then remove the barrier. See
Figure 8-8. 1. Shaft clamp
2. Movable contact cover
4. Remove the arc chutes. Use a 5/8 in. nutdriver to
remove the two long insulator nuts. Then pull the Figure 8-7 Movable Contact Cover Removal
arc chute outward (off the long threaded rods). See
Figure 8-8.
5. Remove the movable contact cover. Use your 1

thumb and fingers to squeeze the sides inward until
the contact cover is released from the shaft clamp
(both sides). Then remove the movable contact 2
cover. See Figure 8-6 and Figure 8-7.
Squeeze movable
contact cover to
release it 3
2
6127237
Figure 8-6 Movable Contact Cover Release
5
6127237
1. Arc chutes
2. Loosen round head screws (do not remove)
3. Keyslots
4. Barrier
5. Insulator nuts
Figure 8-8 Interphase Barrier Removal

8.2.2 Contact Inspection Note: To prevent the possibility of eye injury, wear
safety glasses when removing the arcing
The main contacts are protected by arcing contacts. The contact spring. The spring may fly off if not
arcing contacts make first and break last to avoid arcing held securely.
at the main contacts. Contact condition should be
checked annually. Contacts should be replaced when 1. Remove the movable contact cover. See Section
contact material becomes severely worn. Discoloration 8.2.1.
is normal. Do not file contacts because it wastes
2. Remove the movable arcing contact spring. Use a
material. Instead use light emery paper to clean the
screwdriver (or spring compressor) to carefully
contact surfaces. If the main contacts require
release the movable arcing contact spring from the
replacement, follow the procedure for Main and Arcing
tab on the shaft clamp. See the note above! Then
Contact Assembly Replacement. If only the arcing
remove the spring and spring retainer. See
contacts require replacement, follow the procedure for Figure 8-11.
Arcing Contact Replacement.
Open the contacts that will be replaced (if not already

open) by using the maintenance handle. See 1
Section 8.1.
8.2.3 Movable Arcing Contacts

Arcing Contacts make first and break last during load
transfer. They protect the main contacts. 2
6127237
1. Arcing contact spring (see WARNING)

2. Movable arcing contact
Figure 8-10 Movable Contact Assembly

237
3. Disconnect the movable arcing contact shunts.
Figure 8-9 Replacement Movable Arcing Contact Use a 5/16 in. open-end or box wrench to remove
Kit (Kit includes 1 movable arcing two SEMS screws that secure the movable arcing
contact with cover, arcing contact contact shunts to the pivot bracket. See
spring, spring bracket, spring retainer, Figure 8-11.
and hardware. A 3-pole switch
requires 6 kits.) 4. Remove the pivot pin from the pivot bracket. Use
needlenose pliers to straighten and remove the
Movable Arcing Contact Replacement Procedure cotter pin that secures the pivot pin. Then remove
the pivot pin, spring bracket, and movable arcing
WARNING contact. See Figure 8-11.
5. Install the new movable arcing contact. Install the

new spring bracket into the pivot bracket. Then
insert the new movable arcing contact into the slot
of the spring bracket. Next insert the new pivot pin
Spring-loaded parts. through the pivot bracket, spring bracket, and
Can cause severe personal injury movable arcing contact. Install the new cotter pin
or property damage. into the end of the pivot pin (spread or bend the
cotter pin to secure the assembly). See
Wear protective goggles when Figure 8-11.

6. Connect the new movable arcing contact shunts. 7. Install the new movable arcing contact spring.
Install two SEMS screws (#10-32 3/8 in.) to Install the new spring retainer onto the tab on the
connect the two shunts of the new movable arcing spring bracket. Then use a screwdriver (or spring
contact to the pivot bracket. Tighten the screws compressor) to carefully install the new movable
with a 5/16 in. open-end or box wrench. See arcing contact spring between the spring retainer
Figure 8-11. and the tab on the shaft clamp. See Figure 8-11.
Note: To prevent the possibility of eye injury, wear 8. Install the new movable contact cover onto the
safety glasses when installing the new movable contact assembly. Use your thumb and
arcing contact spring. The spring may fly off fingers to squeeze the sides inward until the
if not held securely. contact cover is latched onto the metal bracket
(both sides). See Figure 8-6 and Figure 8-7.
1
7
6
1. Cotter pin*
2. Pivot pin*
3. Screws*
3 4. Movable arcing contact assembly*
5. Spring bracket
6. Spring retainer*
7. Arcing contact spring (see WARNING)*
* Included in kit 6127237
Figure 8-11 Movable Arcing Contact Assembly

8.2.4 Movable Main Contacts Then remove the spring and spring retainer. See
Figure 8-13.
Main contacts make last and break first during load
transfer. They carry the electrical load.
Replacement movable main contacts are available as

part of the Movable Contact Assembly, which includes
the main contact and the arcing contact. 8
6127237
Figure 8-12 Replacement Movable Contact Kit (Kit

includes 1 movable contact with cover
and main shunt hardware. A 3-pole
switch requires 6 kits.)
Movable Arcing/Main Contact Replacement

Procedure
WARNING 4
1
3
2
1. Main shunt 6127237
2. Main movable contact
Airborne particles. 3. Movable arcing and main contact assembly*
Can cause severe injury or 4. Movable arcing contact
blindness. 5. Spring retainer*
6. Arcing contact spring (see WARNING)*
Wear protective goggles and clothing 7. Shaft insulator; replace only if badly damaged
when using power tools, hand tools, 8. Shaft clamp*
or compressed air.
* Included in kit
1. Remove the movable contact cover. See page 3. Figure 8-13 Movable Main Contact Assembly
2. Disconnect the main shunt. Use a 3/8 in. open-end 4. Disconnect the main shunt. Use a 3/8 in. open-end
or box wrench to remove the hex nut (with disc and or box wrench to remove the hex nut (with disc and
flat washers) that secures the main shunt to the flat washers) that secures the main shunt to the
bottom of the main movable contact assembly. bottom of the main movable contact assembly.
See Figure 8-13. See Figure 8-13.
Note: To prevent the possibility of eye injury, wear 5. Remove the shaft clamp and movable contact
safety glasses when removing the arcing assembly. Use a 5/16 in. socket wrench to remove
contact spring. The spring may fly off if not the two hex head bolts (with lock washers) that
held securely. secure the movable contact assembly and shaft
clamp to the shaft. See Figure 8-13.
3. Remove the movable arcing contact spring. Use a
screwdriver (or spring compressor) to carefully
release the movable arcing contact spring from the
tab on the metal bracket. See the WARNING first!

Note: Replacing the shaft insulator is usually 8.2.5 Stationary Arcing Contacts
unnecessary. If it is badly damaged, contact
Kohler Co. for assistance. Disassembly and Figure 8-14 shows the replacement stationary arcing
readjustment of the main contact shaft will contact kit. Refer to the ATS Parts Catalog for
be required. instructions to obtain replacement parts.
6. Install the new movable contact assembly.

Position the new movable contact assembly under
the shaft (align protrusions on both side). Secure it
by installing the new shaft clamp and the new
5/16-18 x 1 3/4 in. long hex head bolts with split
237
lock washers. Tighten both bolts to 5 ft. lb., then
continue tightening them to 11 ft. lb. See Figure 8-14 Replacement Stationary Arcing Contact
Figure 8-13. Kit (Includes 1 stationary arcing contact
and mounting screw. 3-pole switch
7. Reconnect the main shunt. Make sure the main requires 6 kits.)
shunt and new movable contact assembly
surfaces are clean (do not use any abrasive).
Stationary Arcing Contact Replacement
Position the main shunt under the movable contact
Procedure
assembly (onto the stud) and secure it with a new
3/8 in. flat washer, new 3/8 in. disc washer (curved 1. Remove the stationary contact assembly. Use a
surface toward nut), and new 3/8 in. hex nut. Use a 3/8 in. socket wrench with 12 in. extension to
3/8 in. open-end or box wrench to tighten nut (cw). remove the hex nut from the base of the stationary
See Figure 8-13. contact assembly. Then remove the washers,
quick connect terminal plate, and stationary
Note: To prevent the possibility of eye injury, wear contact assembly from the stud in the bus plate.
safety glasses when installing the new See Figure 8-15.
arcing contact spring. The spring may fly off
if not held securely. 2. Remove the stationary arcing contact. Use a
3/8 in. socket wrench to remove the hex head
8. Install the new movable arcing contact spring. (SEMS) screw, then remove the stationary arcing
Install the new spring retainer onto the tab on the contact. See Figure 8-16.
spring bracket. Then use a screwdriver (or spring
compressor) to carefully install the new movable 3. Install the new stationary arcing contact. Make
arcing contact spring between spring retainer and sure the arcing contact and contact block surfaces
the tab on the shaft clamp. See Figure 8-13. See are clean (do not use any abrasive). Use a 3/8 in.
the the Note above first! socket wrench to install a new hex head screw
(SEMS 1/4-20 x 3/8 in. long) and a new stationary
9. Install the new movable contact cover. Install the arcing contact onto the contact block. The
new movable contact cover onto the movable rectangular protrusion should align with the
contact assembly. Use your thumb and fingers to rectangular hole in the arcing contact. Tighten the
squeeze the sides inward until the contact cover is screw to 7.5 Nm [5.5 ft. lb. (66 in. lb.)]. See
latched onto the metal bracket (both sides). See Figure 8-16.
Figure 8-6 and Figure 8-7.
Note: Torque the stationary arcing contact
mounting screw to 7.5 Nm [5.5 ft. lb.
(66 in. lb.)] to prevent overheating at the
contact block.

7
1
6
4
5
4
1
2
3
6127237
1. Arcing contact*
2. Contact block
3. These surfaces must be clean
4. SEMS screw (1/4-20 x 3/8 in. long)*
Tighten to 7.5 Nm [5.5 ft. lb. (66 in. lb.)]
* Included in kit
Figure 8-16 Stationary Arcing Contact
4. Reinstall the stationary contact assembly. Make

sure the bus plate and contact assembly surfaces
are clean (do not use any abrasive). Position the
6127237 stationary contact assembly onto the stud in the
bus plate. Use a 3/8 in. socket wrench with 12 in.
extension to install the quick connect terminal
1. Arc chute mounting bracket
2. Main contacts plate, heavy flat washer, new heavy disc washer
3. Arcing contact (curved surface out), and 3/8 in. hex nut to secure
4. Terminal plate the assembly. Tighten to 27.1 Nm (20 ft. lb.)
5. Flat washer torque. See Figure 8-13.
6. Disc washer
7. Hex nut
Note: Torque the stationary contact assembly nut
Note: Tighten hex nut to 20 ft. lb. (240 in. lb.)
to 27.1 Nm (20 ft. lb.) to prevent overheating
Figure 8-15 Stationary Contact Assembly at the bus plate.

8.2.6 Stationary Contact Assembly 8.2.7 Arc Chute and Barrier
Replacement Reinstallation
Replacement stationary contacts (arcing and main) are After the arcing or main contacts are replaced, reinstall
available as an assembly. See Figure 8-17. the arc chutes and interphase barriers as described in
the following procedure.
1. Check the arc chute mounting rods. Make sure the

two threaded rods are installed in the arc chute
support plate. They should extend out from the
plate no more than 82 mm (3.25 in.). The two
treaded rods should have thread sealant to hold
the proper length. See Figure 8-18.
237 2. Reinstall the arc chute. Slide the arc chute (arc
splitters toward the contacts and recess for nuts
Figure 8-17 Replacement Stationary Contact Kit outward) between the two long threaded rods.
(Includes 1 stationary main and arcing Reinstall the two long insulator nuts (round
contact assembly with arc chute shoulder in) and use a 5/8 in. nutdriver to GENTLY
bracket and mounting hardware. A tighten until snug. Do not overtighten these nuts.
3-pole switch requires 6 kits.) See Section 8.2.1.
3. Reinstall the interphase barrier. Install the barrier

Stationary Contact Assembly Replacement
over the arc chutes and slide it up until the four
Procedure
round head screws align in the four keyholes in the
1. Remove the stationary contact assembly. Use a barrier. Then slide the barrier down. Use a blade
3/8 in. socket wrench with 12 in. extension to screwdriver to tighten the four round head screws
remove the hex nut from the base of the stationary to secure the barrier to the arc chute insulator nuts.
contact assembly. Then remove the washers, See Section 8.2.1.
quick connect terminal plate, and stationary
contact assembly from the stud in the bus plate.
See Figure 8-15.
1
2. Install the new stationary contact assembly. Make
sure the bus plate and contact assembly surfaces
are clean (do not use any abrasive). Position the
new stationary contact assembly onto the stud in 2
the bus plate. Use a 3/8 in. socket wrench with
12 in. extension to install the new quick connect 3
terminal plate, new heavy flat washer, new heavy
disc washer (curved surface out), and new 3/8 in.
hex nut to secure the assembly. Tighten to 27.1 Nm
(20 ft. lb.) torque. See Figure 8-15.
82 mm
(3 ¼ in.)
1. Main contacts
2. Arcing contact
3. Threaded rods 6127237
Figure 8-18 Threaded Rods For Arc Chutes

8.3 Solenoid Coil and Solenoid 8.3.1 Solenoid Coil Replacement
Assembly Replacement Solenoid coil kits include only the coil. Refer to the ATS
Parts Catalog for the coil kit part number for your transfer
See Figure 8-19 for the solenoid assembly location.
switch.
Left side of transfer switch shown Solenoid Coil Replacement Procedure

1. Remove the rectifier cover and disconnect the coil
1 leads. Use a blade screwdriver to loosen one
screw (do not remove it), then remove the rectifier
cover. Disconnect the two coil leads from the
2 rectifier. See Figure 8-20.
2. Remove solenoid retaining bracket and coil. Use a

3
3/8 in. socket, open-end, or box wrench to remove
the four SEMS screws from the solenoid retaining
bracket. Then remove the bracket from the top of
the solenoid. Remove the solenoid coil by pulling it
4 upward (off the core tube) and out of the frame. See
Figure 8-21.
4
1. Rectifier cover
2. Solenoid coil
3. Solenoid frame
4. Solenoid weight 6127237
5
Figure 8-19 Solenoid Operator Assembly
1. Screw
2. Rectifier cover
3. Snubber
4. Rectifier
5. Solenoid assembly 6127237
Figure 8-20 Rectifier Cover

3. Install the new solenoid coil. Position the new 8.3.2 Solenoid Assembly Replacement
replacement coil so that the flange end is on top
and the coil leads are on the left side. Install the coil Solenoid assemblies include entire solenoid with frame,
(in this position) into the frame by pushing it coil, core tube, core spring, and core and link.
downward (onto the core tube) and into the frame.
Secure the coil by reinstalling the solenoid
retaining bracket. Use a 3/8 in. socket, open-end,
or box wrench to install four SEMS screws. Tighten
the screws to 7.5 Nm (5.5 ft. lb. or 66 in. lb.)
torque. See Figure 8-21.
4. Connect the new coil and reinstall the rectifier

cover. Install the quick-connect coil leads onto the
237
rectifier terminals (DC). Then install the rectifier
cover onto the top of the solenoid frame. Use a
blade screwdriver to tighten the screw. See Figure 8-22 Replacement Solenoid Assembly with
Figure 8-20. core and link (includes rectifier and
cover, clevis pin, drive link screw, 4
mounting screws, and thread sealant)
5
Solenoid Assembly Replacement Procedure
1. Put the transfer switch in the EMERGENCY position.

The upper contacts must be closed to replace the
solenoid assembly. If necessary, use the
maintenance handle to operate the transfer switch
to the EMERGENCY position. See Section 8.1.
2. Insert the weight locking pin. To prevent the

operator from moving during disassembly insert
4
the clevis pin through the hub and into the bearing
plate. See Figure 8-23.
3. Remove the retaining screw and link pin from the

3 weight. Use a 7/16 in. open-end or box wrench to
remove the retaining screw from the left side of the
weight. Then remove the link pin from the left side
of the weight. See Figure 8-24.
4. Remove the rectifier cover and disconnect the two

wires. Use a blade screwdriver to remove one
1 screw, then remove the rectifier cover. Then
disconnect the two wires coming into the solenoid
2 assembly from the harness. See Figure 8-20.
5. Remove the solenoid assembly. Use a 3/8 in.

open-end or box wrench to remove four SEMS
screws (two at the top, one on either side). See
Figure 8-25.
1. Solenoid frame 6. Transfer the labels from the old solenoid to the new
2. Solenoid core tube one. Carefully remove the nameplate, WCR label,
3. Solenoid coil* and DANGER label from the old solenoid. Then
4. Flange on coil
5. Solenoid retaining bracket apply them to the new solenoid.
* Included in kit 6127237
Figure 8-21 Solenoid Coil

4
1 1
2
2 3
3
2
6127237
1. Bearing plate
2. Pin
3. Hub
4. Weight
Figure 8-23 Weight Locking Pin
1
4
2
1. Mounting rail
2. Mounting screws, four SEMS
1/4-20 x 3/4 in. long*
3. Two protrusions fit into two holes
in solenoid assembly
4. Solenoid assembly*
4 3 * Included in kit 6127237
6127237
Figure 8-25 Solenoid Assembly
1. Weight
2. Link pin 9. Reinstall the link pin and screw it into the weight.
3. Apply Loctiter 242 thread sealant
4. Link retaining screw Install the link pin into the left side of the weight
(through the core link from the solenoid assembly).
Figure 8-24 Retaining Screw and Link Pin Apply Loctiter 242 sealant onto the threads of the
1/4-20 link retaining screw. Then install the screw
7. Install the new solenoid assembly. Position the through the control contact link and link pin into the
new solenoid assembly onto the mounting rail so left side of the weight. Use a 7/16 in. open-end or
that the two protrusions align with the holes in the box wrench to tighten the retaining screw. There
solenoid assembly. The core link should be in the should be some play to allow movement of the
slot in the weight. Use a 3/8 in. open-end or box control contact link. See Figure 8-24.
wrench to install four new 1/4-20 x 3/4 in. long
SEMS screws (two at the top, one on either side. 10. Remove the weight locking pin. To unlock the
See Figure 8-25. weight from the bearing plate, remove the clevis
pin from the hub. This is very important! Otherwise
8. Install the new rectifier cover and connect the two severe damage will occur when transfer switch is
wires. Connect the two wires from the harness reenergized! See Figure 8-23.
(previously disconnected) to the rectifier terminals
(AC). Then install the new rectifier cover onto the Note: To prevent severe damage to the solenoid
solenoid assembly. See Figure 8-20. assembly, remove the clevis pin from the
hub on the left side. Removing the clevis pin
unlocks the weight, allowing free movement
of the operator when it is reenergized.
11. Manually operate the transfer switch. Use the

maintenance handle (page 2) to operate the
transfer switch several times. It should operate
smoothly; if not, recheck the solenoid assembly
installation.

8.4 Coil Control Contact Coil Control Contacts Replacement Procedure
Replacement DANGER
The coil control contact assembly (two pushbutton
switches) is located below the solenoid operator on the
left side of the transfer switch. See Figure 8-26 and
Figure 8-27.
Hazardous voltage.
servicing.

237
Figure 8-26 Coil Control Contact Kit (with mounting switch power sources and disable all generator sets as
hardware)
Left side of transfer switch shown battery cables after servicing. Follow these precautions to

1 a voltmeter to verify that no electrical power is
2. Label the eight wires connected to the control

contacts. Carefully label all wires that are
connected to the control contacts. Then use a
narrow blade screwdriver to disconnect the eight
wires.
3. Remove the control contact assembly. Use a short

handle blade screwdriver to remove two screws
2
with lock and flat washers. Then remove the control
contact assembly. See Figure 8-28.
4. Install the new control contact assembly. Position

the new control contact assembly with its
pushbuttons against the cams on the weight. Use a
short handle blade screwdriver to install two
screws with lock and flat washers. See
1. Cams on weight Figure 8-28.
2. Coil control contacts 6127237
Figure 8-27 Solenoid Operator Assembly

5. Connect the eight labeled wires to the control
contacts. Carefully reconnect the wires
(disconnected in step 2) to the new control contact
assembly.
6. Manually operate the transfer switch. Use the

maintenance handle (see Section 8.1) to operate
the transfer switch several times. You should see
the two indicators change alternately from open to
closed. If not, recheck the installation. See
Figure 8-28.
D
D
D
3
6127237
1. Cams on weight
2. Coil control contact assembly*
3. When installed, these two indicators show one closed and
the other open
4. Pushbuttons
* Included in kit
Figure 8-28 Coil Control Contact Assembly

Notes

Section 9 600--800 Amp Bypass/Isolation Switches
This section explains how to replace the transfer switch D Thread sealant
main contacts, operator coil, and control contacts in D Torque wrench (32 in. lb.)
600- and 800-amp bypass/isolation switches. D Bench vise
Note: To prevent the possibility of fatal electrical shocks D Ruler

transfer switch before working on it. Refer to the 9.1 Manual Operation
bypass/isolation switch Operation and
Installation Manual for instructions. A detachable manual operator handle is provided for
maintenance purposes only. The handle is stored on the
DANGER coil frame, left side of the switch.
Note: To prevent the possibility of personal injury or

property damage, do not manually operate the
transfer switch until it is bypassed and isolated.
Hazardous voltage.
open the enclosure.

control circuit terminals.
Tools Needed
D Medium blade screwdriver
D Voltmeter, ohmmeter
D Needle-nose pliers
D Offset screwdriver
1
D 1/4 in. nutdriver
2
D 1/2 in. nutdriver
D 3/4 in. nutdriver
D 1/4 in. dia. rod or drill
D 1/8 in. hex key wrench
D 3/16 in. hex key wrench
D 5/16 in. open-end wrench
6127-4793
D 7/16 in. socket wrench 1. Transfer switch
D 1/2 in. socket wrench 2. Manual operator handle storage location
D 11/32 in. open-end wrench

Figure 9-1 Transfer Switch
D Loctiter 222
TP-6127 9/02 Section 9 600--800 Amp Bypass/Isolation Switches

103
1 models. Hazardous voltage can cause severe injury or
Note: To prevent the possibility of fatal electrical shocks

2 and burns, bypass, isolate, and remove the
transfer switch before working on it. Refer to the
1. Rotating weight 6127-4793 The barriers and arc chutes must be removed to gain
2. Manual operator handle access to the main contacts. Use the manual operator
handle to put the switch in the NORMAL position to
Figure 9-2 Manual Operator Handle remove the top barrier. Then put the switch in the
EMERGENCY position to remove the bottom barrier.
Insert the manual handle into the hole in the rotating
weight on the left side of the switch. See Figure 9-2. 1. Remove the two barriers (see Section 9.2).
Move the handle down and up to manually operate the
switch, as needed, in the following maintenance 2. Remove all arc chutes. Use a blade screwdriver to
procedures. remove two nylon retainer nuts and fiber clamp
piece on each chute. Then carefully pull the arc
NOTICE chute away from the panel.
handle on the transfer switch for maintenance purposes only. 3. Put the switch in the center position (TDC). Use the
Return the transfer switch to the normal position. Remove the manual handle to open the contacts until a 1/4 in.
manual operator handle, if used, and store it in the place diameter rod (drill bit) can be inserted into the
provided on the transfer switch when service is completed. center hole in the side of the weight. It will hold the
operator in the top-dead-center position and the
9.1.1 Main Contact Replacement contact shaft in a mid position. See Figure 9-3.
DANGER
Hazardous voltage.
open the enclosure.
Section 9 600--800 Amp Bypass/Isolation Switches TP-6127 9/02

104
2 3
6127-4793
6
1. Coil 4. Operator frame side wall

2. Manual operator handle 5. 1/4 in. diameter rod
3. Weight 6. Center hole
Note: Insert rod through sidewall and into the center hole weight to lock weight in TDC (center) position.
Figure 9-3 Rod Inside of Solenoid Operator Weight
Movable Contacts Disassembly screw and flat washer to disconnect the shunt from
the movable main contact.
The movable arcing and main contacts are mounted on
the shaft assembly. The main contacts are screwed to 3. Remove the arcing contact assembly. Use a 1/8 in.
the back side of the two finger blocks and to the shunts. hex key wrench to remove the retaining screw from
The arcing contact assemblies, which extend from the the base of the arcing contact assembly.
ends of the main contacts, are the normal replacement
parts. They make first and break last to protect the main 4. Remove the movable main contacts. Use the
contacts. See Figure 9-4. manual handle again to insert the spacer between
the finger block and panel. Use a 3/16 in. hex key
wrench to remove four socket head screws
Movable Arcing Contacts and Main Contacts
securing the movable arcing contact and movable
1. Close the bottom main contacts. Remove the main contact to the finger blocks. Use a 7/16 in.
1/4 in. rod while using the manual operator handle socket wrench to hold the nut securing the L
to put the switch in the normal position (bottom insulator behind the main contact while removing
contacts closed). See Figure 9-3. the screw. Then remove the movable main contact.
2. Disconnect the main shunts. Use a 1/2 in. socket

wrench to remove the large hex head (SEMS)

105
2 3 4
1. L insulator with hex nut and shake washer

2. Tighten to 11 ft. lb. (15 Nm)
3. Shunt
4. Movable main contact*
5. Finger block
6
6. Movable arcing contact assembly[
7. Retaining screw[
* Indicates parts included in main contact kit.
[ Indicates parts included in arcing contact kit.
6127-4793
] Apply Loctiter 222, 1/8 in. hex key wrench, tighten to 32 in. lb. (3.6 Nm).
Figure 9-4 Movable Contacts
9.1.2 Stationary Contacts Disassembly 3. Remove all stationary arcing contacts. Use a
medium blade screwdriver to remove the flathead
The stationary arcing and main contacts are mounted screw then remove arcing contact.
on the contact pivot blocks. The main contacts are held
in the contact pivot blocks by the arc chute mounting Stationary Main Contacts
brackets. The arcing contacts, which are screwed to the
front of the contact pivot blocks, are the normal 1. Remove the insulator trays. Use a medium blade
replacement parts. They make first and break last to screwdriver to remove two flathead screws from
protect the main contacts. See Figure 9-5. the arc chute mounting brackets, then remove the
insulator tray.
Stationary Arcing Contacts 2. Remove the arc chute mounting brackets. Use a
1. Remove the arc runner plate. Use a medium blade 5/16 in. open end or box wrench and an offset
screwdriver to remove the flathead screw. Place screwdriver to remove two nuts from the screws
your finger behind the plate to catch the spring nut. through the contact pivot block. Then remove both
Then slide the arc runner plate out from under the arc chute mounting brackets.
arcing contact to remove it.
3. Remove the stationary main contacts and springs.
2. Remove the two insulator pieces. Carefully work Use a pair of needle-nose pliers to release the
the large insulator piece out from under the arcing spring leaves from the individual contact segments
contact while pulling it off the two long threaded and work the main contacts out of the pivot block.
rods. Do not bend the insulator severely because it Do not damage the inside of the contact pivot block.
must be reused. Also remove the thin insulator Then remove the contact spring.
shim.

106
9.1.3 Stationary Contacts Reassembly Carefully use a pair of needle-nose pliers to
position the spring leaves close to the pivot block in
Refer to Figure 9-5. the notch in each contact.
1. Apply conductive lubricant to hinge joints. Use a 3. Install arc chute mounting brackets. Place left and
cotton swab or small brush to apply conductive right arc chute mounting brackets on either side of
lubricant (Dynaloy 495) to the inside of the contact the contact pivot block. Then insert two long #8-32
pivot blocks. Also apply a thin film of conductive screws through the brackets and pivot block.
lubricant to the curved surface of each new main Secure the brackets with lockwashers and nuts,
contact segment. and use a 5/16 in. open end or box wrench and an
offset screwdriver to tighten the two nuts.
Note: Failure to apply conductive lubricant to the
main contact hinge joints will cause 4. Check contact deflection. Press in on each
overheating. stationary main contact to verify freedom of
movement and spring pressure. If there is binding,
2. Install new contact segments and springs. Place a check the position of the spring leaves and
new contact spring into the spring base insulator conductive lubrication.
and hold it in place with one hand. With your other
hand carefully install a new contact segment into 5. Install the insulator trays. Place the insulator tray
the contact pivot block. Depress the contact spring mounting tabs behind the arc chute mounting
leaves to work the contact into the center. In a brackets. Fasten the insulator tray with two #6-32
similar manner install the remaining contact flathead screws with lockwashers and nuts. Use a
segments from either side of the pivot block. blade screwdriver to tighten the screws.
11*
10
2
9*
6[ 5 4
7 6127-4793
1. Insulator tray 7. Left arc chute mounting bracket

2. Right arc chute mounting bracket 8. Apply conductive lubricant to main contact hinge joints.
3. Arc runner 9. Stationary main contact segment*
4. Large insulator piece 10. Contact pivot block
5. Small insulator piece 11. Stationary main contact leaf spring*
6. Stationary arcing contact[
[ Indicates parts included in arcing contact kit.
Figure 9-5 Stationary Contacts

107
Stationary Arcing Contacts through the finger block. Use the longer screw to
install the L insulator behind the main contact and
1. Install new stationary arcing contacts. Apply a few secure it with a nut with lock washer. Use a 3/16 in.
drops of Loctiter 222 thread sealant to the threads hex key wrench to tighten the screws.
of the large flat head screw. Then attach each new
contact to the pivot block by using a medium blade Note: Be sure to install the L insulator behind the
screwdriver to install the large flat head screw. main contact.
Tighten the screw.
Apply Loctite r 222 thread sealant to threads of the
2. Install two insulator pieces. Slide the large retaining screw. Install retaining screw through the
insulator piece onto the two long threaded rods. main contact into the base of the arcing contact.
Carefully work the pointed side of the insulator Then, using a 1/8 in. hex wrench, tighten the screw
under the arcing contact while pushing the to 3.6 Nm (32 in. lb.).
insulator in. Insert the thin insulator shim behind
the large insulator before pressing it all the way in. 3. Check the main contact gap. When installing a new
Position the thin insulator shim close to the arcing contact assembly, a gap of 5/32 in. between
threaded rods. the main contacts is automatically obtained when
the arcing contacts just touch. However, if a minor
3. Install the arc runner plate. Hold the thin insulator adjustment is necessary to obtain this gap, bend
shim in place close to the threaded rods while the adjustment tab on the arcing contact assembly.
sliding the arc runner plate under the arcing Refer to Figure 9-6 for instructions on tab
contact. The arc runner plate should fit snugly and adjustment.
its tab must touch the tip of the arcing contact.
Secure the arc runner plate to the large insulator Note: Recheck any adjustment by manually
piece with the small flat head screw and spring nut. operating the switch a few times and
recheck the gap between the main contacts.
9.1.4 Movable Contacts Reassembly 4. Close the bottom main contacts. Use the manual
Reassemble as shown in Figure 9-4. operator handle to remove the spacer and to put
the switch in the Normal position (bottom contacts
closed).
Movable Main Contacts and Arcing Contacts
5. Reconnect the main shunts. Attach the main shunt
1. Install the new movable main contacts. Place the
to the back of the movable main contact with the
new movable main contact behind the two finger
large hex head (SEMS) screw with flat washer. Use
blocks. Use the manual operator handle to insert
a 1/2 in. socket wrench to tighten to 15 Nm
the spacer or to open the top contacts enough to
(11 ft. lb.).
slide the new movable main contact in place.
2. Install new arcing contact assembly on the main

contact. Secure it with two socket head screws

108
1
5
4
6127-4793
3
1. Movable arcing contact 5. With 5/32 in. gap at main contacts, arcing contacts should just touch.
2. Stationary arcing contact 6. Movable main contact
3. Adjustment tab* 7. Bracket
4. Stationary main contact
* To increase gap, bend tab away from bracket. To decrease gap, bend tab toward bracket.
Figure 9-6 ArcIng Contact Adjustment (side view).

109
9.2 Transfer Switch Barrier 9.2.2 Barrier Installation
Removal and Installation 1. Install all arc chutes. Slide the arc chute (arc
splitters toward the panel) between the long
threaded rods. Place the arc chute retainer onto
the arc chute. Use a screwdriver to gently tighten
1 the two nylon retainer nuts on both sides of the arc
chute. Do not overtighten these nuts.
2. Check the clearance between the contacts and the

arc chutes. Use the manual operator handle to
slowly open and close the contacts while checking
2 that they do not hit the arc chutes.
3. Install the bottom barrier. Use the manual operator

handle to put the switch in the Emergency position
(top contacts closed). Then reinstall the bottom
barrier; make sure that the center barriers are
3 outside the movable barriers on the switch.
Tighten the two Phillips head screws.
6127-4793
4. Install the top barrier. Use the manual operator
1. Top barrier
2. Mounting screws
handle to put the switch in the NORMAL position
3. Bottom barrier (bottom contacts closed). Then reinstall the top
barrier; make sure that the center barriers are
Figure 9-7 outside the movable barriers on the switch.
Tighten the two Phillips head screws.
Note: IMPORTANT! When reinstalling barriers, make
sure they do not interfere with moving parts of the Note: Manually operate the switch to be sure there
switch. Use handle to operate switch in both is no misaligment or binding before
directions to make sure switch operates freely operating it electrically.
without interference before turning on power.
5. Return the transfer switch to service. Refer to the
bypass/isolation switch Operation and Installation
9.2.1 Barrier Removal Manual for instructions.
1. Bypass and isolate the transfer switch. Refer to the
bypass/isolation switch Operation and Installation 1
Manual for instructions.
2. Use the manual operator handle to put the switch in

the NORMAL position (top contacts open). See
Figure 9-2.
3. Use a Phillips screwdriver to loosen only two 2

screws and remove the top barrier. Slide the
barrier up and tilt outward.
4. Use the manual operator handle to put the switch in

6127-4793
the EMERGENCY position (bottom contacts 1. Rotating weight
open). 2. Manual operator handle
5. Use a Phillips screwdriver to loosen only two Figure 9-8 Manual Operator Handle
screws and remove the bottom barrier. Slide the
barrier down and tilt it outward.

110
9.3 Operator Coil Replacement two black coil leads from the square rectifier
mounted on the coil assembly. Do not remove the
blue varistor. Then remove the two hex nuts to
9.3.1 Coil Assembly Removal disconnect the two white wires from the resistor
(one on each end).
DANGER
3. Remove the retaining screw and link pin
(Figure 9-10). Use a 3/16 in. hex key wrench to
remove the hex socket head screw from the
weight. Then use a screwdriver to pry out the link
Hazardous voltage.
pin in left side of the weight.
4. Remove the coil assembly (Figure 9-11). Use a
Only authorized personnel should 7/16 in. nutdriver or wrench to remove four hex
open the enclosure. nuts from the operator frame. Then remove the coil
assembly to a work bench.
death. Bypass and isolate the transfer switch before 9.3.2 Coil Removal
The solenoid coil is held in the coil frame by the core tube
control circuit terminals. assembly. See Figure 9-12.
1. Remove the core tube assembly. Use a 1/2 in.

WARNING
nutdriver or wrench to remove the upper and lower
hex nuts and lock washers from top end of the coil
frame. Then pull out the core tube assembly.
2. Remove the coil from the coil frame. Slide the

grommet with coil leads out of the slot. Use a
Spring-loaded parts. 5/16 in. nutdriver or wrench to loosen (only) three
coil-clamping SEMS head screws (lower end of coil
or property damage.
frame), then pull out the coil and end washer.

cause severe personal injury or property damage. The
spring in the solenoid assembly exerts substantial force on the
screws.

1
The coil assembly is mounted in the operator assembly

on the left side of the panel. It must be removed to a
work bench for disassembly. See Figure 9-9,
Figure 9-10, and Figure 9-11.
1. Put the transfer switch in the EMERGENCY

position. Use the manual operator handle 6127-4793
(Figure 9-2) if necessary to close the top contacts. 1. Retaining screw
2. Disconnect the rectifier and resistor (Figure 9-9) Figure 9-9 Retaining Screw
Carefully pull off the two white power wires and the

111
6127-4793
Figure 9-12 Removal of Coil and Core Tube

6127-4793 Assembly
Figure 9-10 Link Pin
6127-4793
Figure 9-11 Removal of Coil Assembly from

Operator Frame

112
9.3.3 Core Tube and Core Disassembly
Disassembly of the core tube assembly is normally not
required. If, however, the coil has overheated and has 1
damaged the core tube assembly, rebuilding it is 12
necessary. You will need an assistant to help you 2
reassemble it, and you need to reset the stroke
11
(explained in Sections 9.4 and 9.5). See Figure 9-13
and Figure 9-14.
Note: To avoid damage, do not tighten the vise on the

core or core tube!
Note: To prevent the possibility of personal injury, hold

the core tube assembly securely away from 10
yourself when removing the center hex nut; the
spring exerts substantial outward force on the
core and link.
1. Remove the core and compression spring. See

Figure 9-13. Hold the link in a vise to secure the
assembly. Use a 3/4 in. nutdriver or wrench to
remove the center large hex nut from the threaded
stem end of the core.
9
Note: When the center hex nut is removed, the
assembly will suddenly release the core and
spring from the lower end of the core tube
assembly.
3
2. Take apart the core tube assembly. See
8
Figure 9-14. Use a 1/2 in. nutdriver or wrench to
remove the left and right hex nuts and lockwashers
7
and pull the spring retainer off the core tube
retaining plate. Then push the core tube through
the retaining plate to remove it. 4
6
9.3.4 Core Tube and Core Reassembly
Replace damaged parts (core tube and core spring) and
lubricate the core and core spring with Lubrication Kit
GM24237 before reassembly. You will need an
6127-4793
assistant to help compress the spring while you install
the hardware. See Figure 9-13 and Figure 9-14.
5
1. Stroke adjustment stop nut
1. Put together the core tube assembly Figure 9-14. 2. Flat washer*
Insert the core tube through the retaining plate 3. Lubricate surface using lubrication kit
(flared end seats on top). Then install the spring 4. Link
5. Vise
retainer (recessed hole inward) onto the retaining 6. Core
plate and use a 1/2 in. nutdriver or wrench to 7. Core and link assembly
tighten the two 5/16-18 hex nuts on 5/16 in. lock 8. Stem
washers. 9. Compression spring*
10. Core tube assembly
11. Leather washer*
2. Lubricate the core and core spring. Use the 12. Hex nut, 1/2-13 with nylon insert*
Lubrication Kit to apply a thin coating onto the core
* Indicates parts included in coil kit.
surface and onto the core spring.
Figure 9-13 Core Tube And Core Disassembly

113
1
2 2
3 3
1 4
5
6127-4793
1. Resistor
2. Snubber
3. Rectifier
4. Coil frame
Figure 9-15 Rectifier and Resistor
3
9.3.5 Coil Installation
Replace the coil before assembly if it is damaged. See
Figure 9-12.
6127-4793
1. Install the replacement coil. With coil leads up and

1. 5/16-18 hex nut
2. 5/16 in. split lock washer to the right, insert the new coil with a coil washer on
3. Nylon guide washer* the bottom into coil frame. Then run the coil leads
4. Core tube retaining plate* through the grommet and slide the grommet into
5. Core tube*
the slot (on the right side of the coil frame).
6. Spring retainer
* Indicates parts included in coil kit. 2. Install the core tube assembly. Insert the core tube
assembly down through the hole in the coil frame
Figure 9-14 Core Tube Assembly
and use a 1/2 in. nutdriver or wrench to tighten the
Note: To prevent the possibility of personal injury, upper and lower hex nuts with lock washers on the
hold the core tube assembly securely away coil frame.
from yourself when installing center hex nut;
3. Tighten the coil-clamping screws. Use a 5/16 in.
the spring exerts substantial outward force
nutdriver or wrench to tighten the three SEMS head
on the core and link.
screws on the bottom of the coil frame.
3. Assemble the core, spring, and core tube
assembly. See Figure 9-13. With the link held 9.3.6 Coil Assembly Installation
securely in a vise, set the lubricated core spring
onto the core stem. Check to see if the nylon guide The coil assembly can now be reinstalled onto the
washer is still inside the spring retainer; if it is not, operator assembly on the left side of the switch panel.
place it inside the spring retainer. See Figure 9-9, Figure 9-10, and Figure 9-11.
Have an assistant push the core tube assembly 1. Install the coil assembly onto the operator frame
onto the spring and hold it down (guide the (Figure 9-11). Place the coil assembly onto the
threaded core stem through the center hole) while four studs on the operator frame and align the link
you add the leather washer (threaded), flat washer, into the slotted weight. Use a 7/16 in. nutdriver or
and 1/2--13 hex nut onto the core stem. Use a wrench to tighten the four hex nuts.
3/4 in. nutdriver or wrench to tighten the nut (it must
be adjusted later for proper stroke of 1 1/8 in.); 2. Install the link pin and retaining screw
refer to Sections 9.4 and 9.5 . (Figure 9-10). Insert the link pin (groove side out)

114
into the left side of the weight and through the link. Tools Needed
Then install the hex socket head retaining screw
into the weight and use a 3/16 in. hex key wrench to D Voltmeter
tighten it. D Ohmmeter
D Continuity lamp
3. Reconnect the resistor/rectifier on the coil frame
D 11/32 in. open end wrench
(Figure 9-9). Replace the resistor (if necessary),
reconnect the two white wires with ring lugs to each D 1/4 in. rod or drill bit
end, and install and tighten the hex nuts. Replace
the rectifier (if necessary) and carefully reconnect Test and Adjustment Procedure
the four wires with push-on lugs to the rectifier
terminals as follows: connect the two white power DANGER
wires to the AC terminals µ, and connect the two
black coil leads to the DC terminals (red dot and no
dot, polarity does not matter). Be sure the blue
snubber is still installed between the DC terminals.
See Figure 9-15.
Hazardous voltage.
4. Use the manual operator handle to manually
operate the transfer switch. It should operate Only authorized personnel should
smoothly without any binding. If not, recheck the open the enclosure.
alignment of parts and the lubrication in the
solenoid operator. Close the bottom contacts and Removing the transfer switch from bypass/isolation
remove the manual handle. models. Hazardous voltage can cause severe injury or
5. Reinstall the transfer switch. Refer to the removing it from the enclosure. The bypass/isolation switch is
bypass/isolation switch Operation and Installation energized. Do not touch the isolation contact fingers or the
Manual for instructions. control circuit terminals.

9.4 Control Contact Test and and burns, bypass, isolate, and remove the
Adjustment bypass/isolation switch Operation and
This section explains how to test and adjust the TS coil Installation Manual for instructions.
control contacts. The TS control contacts control the
1. Bypass, isolate, and remove the transfer switch.
duration of time that power is applied to the main
solenoid operator (TS coil). To assure proper operation, 2. Locate the TS control contact assembly; see
it is important that the contacts open at the proper time Figure 9-16. The control contacts are mounted on
during the stroke of the solenoid. Improper adjustment a metal bracket below the solenoid frame, and are
will cause failure to operate at reduced voltages, failure connected with a drive link to the operator weight.
of the main contacts to properly seat, and solenoid There are other auxiliary microswitches inside,
failure. underneath the bracket, which are not part of this
control circuitry.

115
4
1. Main position indicator:

N=closed on normal,
E=closed on emergency
2. Control contact assembly
3. Miniature switch
4. Auxiliary contacts
6127-4793
Figure 9-16 Transfer Switch with Barriers Removed
3. The TS control contacts are factory set with an each direction (transfer to emergency and
adjustable power supply so that the switch can retransfer to normal). The pairs of coil clearing
operate satisfactorily over a voltage range of 80 to contacts do not have to operate
110% of the nominal system voltage. To simultaneously, but both must break the circuit
accommodate minor variances in friction and before the main solenoid operator’s core
tolerances, it is not unusual for the control contact reaches its maximum top-dead-center
settings to vary from switch to switch. position. See the table in Figure 9-17 for the
control contact position sequence.
The adjustments are factory-sealed and usually do
not require any change over the life of the switch. If Control Contacts Control Contacts
it should become necessary to check adjustments Condition 71-72 & 9-8 69-70 & 7-6
in the field, an approximation can be made by Main contacts
following the instructions in steps 4--6. The Closed Open
closed—on N
adjustments can vary to the extremes and still Main contacts
Open Closed
provide acceptable operation. However, it is closed—on E
important that the TS control contacts always open During transfer
Open before TDC Close after TDC
before top-dead-center is reached by the solenoid from N to E
core. During transfer
Close after TDC Open before TDC
from E to N
4. To verify settings and field-adjust the TS Control N=Normal position
E=Emergency position
Contacts, proceed as follows (refer to Figure 9-18): TDC=Top dead center of solenoid core or main contact shaft
a. Two sets of contacts interrupt the control Note: All contacts are open at TDC. See step 7.
current to the solenoid operator coil (TS) in Figure 9-17 Coil Control Contact Positions

116
1 2
for transfer for transfer

to normal to emergency 69 7 71 9
69 7 71 9 3
70 6 72 8
70 6 72 8
17
14
4
16
15
5
13
6127-4793
11 9 8
12 10
1. Electrical diagram (control contact positions when main TS 9. Emergency adjustment hole in weight (Step 6)
contacts are closed on the Normal source.) 10. TDC (Step 7)
2. Control contact assembly 11. Normal adjustment hole in weight (Step 5)
3. Button 12. Core
4. Drive bracket 13. Stroke adjustment nut
5. Drive link 14. Reference solenoid core stroke dimension 1.040 in.; 1 1/8 in.
6. Cams maximum stroke in TDC position (Step 7)
7. Operating button 15. Coil
8. Control contacts 69--70 (typical). Contacts open when operating 16. Weight
button is depressed by cam. 17. Operator manual handle
Figure 9-18 TS Control Contact Arrangement Below Solenoid Operator
b. With power disconnected, use an ohmmeter a. Close the main contacts of the transfer switch
(or a lamp-type continuity tester) across each on Normal. Starting from the closed-on-normal
contact to determine when the control contacts position, use the manual operator handle to
open while slowly turning the manual operator rotate the weight until a rod can be inserted into
handle. Refer to Section 9.1, Manual first hole (normal adjustment hole) in the side of
Operation, for operating handle instructions. the weight.
Note: There are three positioning holes in the side of the b. Insert a 1/4 in. diameter rod through the hole in
weight used for adjustment purposes. The center the sidewall and into the first hole in the side of
hole is used for TDC (top-dead-center) positioning. the weight. See Figure 9-20.
The other two are used for setting the control
contacts. Make sure that positioning is correct for c. Adjust the right control contact cam so that the
the task at hand. contacts just break. Use a continuity lamp or
ohmmeter across either contact for this
5. If adjustment of contacts 71--72 and 9--8 is adjustment.
necessary, proceed as follows (refer to Figure 9-18
and Figure 9-19):

117
2
1
9 3
NORMAL EMERGENCY
6127-4793
8 8 7 6
1. Adjustment, #8-32 hex locking nut 6. Control contacts typical 69, 70 contacts open when operating
2. Range of adjustment button is depressed by cam
3. 11/32 in. open end wrench 7. Cams
4. Operating button 8. Control contact sets
5. Cutaway side view 9. Drive bracket
Figure 9-19 TS Control Contact Adjustment
b. Insert a 1/4 in. diameter rod through the hole in

1
the sidewall and into the third hole in the side of
the weight. See Figure 9-20.
c. Adjust the left control contact cam so that the

contacts just break. Use a continuity lamp or
meter across either contact for this adjustment.
2
Note: IMPORTANT After final adjustment, verify
that all control contacts are open when the
3 switch is positioned at TDC.
6127-4793
1. Weight
7. Insert the 1/4 in. diameter rod into the center hole in
2. Side wall of operator frame the side of weight. Use a continuity lamp to verify
3. 1/4 in. diameter rod that all contacts are open in this position. Measure
Note: Insert rod through sidewall and into weight to lock weight 1 1/8 in. max stroke between the leather washer
at appropriate adjustment position. and coil frame (Figure 9-18). If necessary, turn the
hex nut to obtain the proper stroke (Figure 9-19).
Figure 9-20 Rod in Weight
8. After contacts have been set, remove the rod and
6. If adjustment of contacts 69-70 and 7-6 is make sure the transfer switch is fully closed on
necessary, proceed as follows. (This procedure is normal (bottom).
identical to the adjustment of contacts 71--72 and
9--8, except that the weight is positioned on the Note: Be sure to remove the rod from the weight to
other side of the top-dead-center position.) prevent coil burn out.
a. Starting from the closed-on-emergency 9. Reinstall the transfer switch. Refer to the
position, use the manual operator handle to bypass/isolation switch Operation and Installation
rotate the weight until a rod can be inserted into Manual for instructions.
the third hole (emergency adjustment hole) in
the side of the weight.

118
9.5 TS Control Contact 7. Manually operate the drive linkage with the manual
operator handle. The action should be smooth
Replacement without any binding. Be sure the cams properly
Under normal conditions the TS control contacts do not operate the pushbuttons on the control and
auxiliary contact assemblies.
replacement becomes necessary, proceed as follows: 8. Reconnect the eight labeled wires to their proper
terminals.
1. Disconnect all power to the transfer switch as
instructed in the Test and Adjustment Procedure. 9. Check the control contact adjustment. Refer to the
Test and Adjustment Procedure in Section 9.4.
2. Disconnect the drive link; refer to Figure 9-21
below. Remove the lever by removing the two
#8-32 hex head screws and nuts. Store the loose
2
pivot pin and loose hardware for safekeeping.
1 3
Note: Do not pull on the wires. Pry off connectors 4*
with a screw driver. Pulling may damage
crimped wire connections.
3. Check to verify that the wires connected to the 5*

control contact assembly are marked so that they 6
can be identified after being disconnected. Add
labels if necessary. Disconnect the labeled wires
from the control contact assembly.
8
7
4. Remove three 8-32 hex head screws from the 6127-4793
mounting feet and remove the control contact 1. TS contact assembly
2. Three hex head mounting screws
assembly. 3. Link
4. Pivot pin
5. Install the new control contact assembly and 5. Shoulder
tighten screws securely. 6. Lever
7. #8-32 hex head screws
8. Drive bracket
Note: Do not overtighten retaining screws;
excessive pressure may cause binding. * Insert stepped end of pivot pin into link so that the link rides on
the shoulder.
6. Reconnect the drive link. Install the pivot pin
between the link and lever (link must ride on Figure 9-21 TS Control Contact Assembly
shoulder of pivot pin). Then attach the lever to the
drive bracket by installing the two 8-32 hex head
screws and nuts.

119
Notes

120
Section 10 600--800 Amp Programmed-Transition
Bypass/Isolation Switches
This section explains how to replace the transfer switch

main contacts and operator coil in 600- and 800-amp
programmed-transition bypass/isolation switches.
Bypass, isolate, and remove the transfer switch from the

enclosure before working on it.
DANGER
Hazardous voltage.
open the enclosure.
1

2

A detachable manual operator handle is provided for
maintenance purposes only. The handle is stored on the
coil frame on the left side of the switch. See Figure 10-1.
Note: To prevent the possibility of personal injury or 1. Transfer switch

property damage, do not manually operate the 2. Manual operator handle (storage location) 61274797
transfer switch until it is bypassed and isolated.
Figure 10-1 Bypass Switch, typical
Install the manual handle onto the upper or lower shaft
on the left side of the transfer switch. See Figure 10-2.
Move the handle down and up to manually operate the
transfer switch, as needed, in the following maintenance 1
procedures.
NOTICE
provided on the transfer switch when service is completed. 2
1. Shafts
2. Manual operator handle 61274797
Figure 10-2 Manual Operator Handle
TP-6127 9/02 Section 10 600--800 Amp Programmed-Transition Bypass/Isolation Switches

121
10.1.1 Tools Needed DANGER
D Medium blade screwdriver
D Offset screwdriver
D Needle-nose pliers Hazardous voltage.
D Rod or drill, 1/4 in. diameter Will cause severe injury or death.
D Nutdriver, 1/4 in. Only authorized personnel should
D Nutdriver, 5/16 in. open the enclosure.
D Nutdriver, 7/16 in.
D Nutdriver, 1/2 in. Removing the transfer switch from bypass/isolation
D Nutdriver, 3/4 in. death. Bypass and isolate the transfer switch before
D Hex key wrench, 1/8 in. removing it from the enclosure. The bypass/isolation switch is
D Hex key wrench, 3/16 in. energized. Do not touch the isolation contact fingers or the
D Open-end wrench, 5/16 in.
D Socket wrench, 7/16 in. The barriers and arc chutes must be removed to gain
D Socket wrench, 1/2 in. access to the main contacts.
D Bench vise
D Voltmeter Procedure to Remove Barriers and Arc Chutes
D Ruler 1. Remove the barrier cover. Use a Phillips
D Loctiter 222 screwdriver to loosen only four screws (two on
D Thread sealant each side). Then pull the barrier cover straight out.
2. Remove all arc chutes. Use a screwdriver to
remove two nylon retainer nuts and fiber clamp
10.2 Main Contact Replacement piece on each chute. Then carefully pull the arc
chute away from the panel.
See the ATS Parts Catalog to identify the contact kits for
your transfer switch. 3. Put the switch in the center position (TDC). Use the
manual handle to open the contacts until a 1/4 in.
Note: To prevent the possibility of fatal electrical shocks diameter rod (drill) can be inserted into the center
and burns, bypass, isolate, and remove the hole in the side of the weight. It will hold the
transfer switch before working on it. Refer to the operator in the top-dead-center position and the
bypass/isolation switch Operation and contact shaft in a mid position. See Figure 10-3.
Section 10 600--800 Amp Programmed-Transition Bypass/Isolation Switches TP-6127 9/02

122
2 3
29.4 mm 1
9 (1 5/32in.)
4
8
7
6 3
1. Coil 6. Center hole
2. Manual operator handle 7. Retainer
3. Weight 8. Core stem
4. Sidewall of operator frame 9. Leather washer
5. Rod, 1/4 in. diameter. Insert rod through sidewall and into the
center hole to lock weight in TDC (center) position. 61274797
Figure 10-3 Rod Inside of Solenoid Operator Weight (shown on its side)
10.2.1 Disassembly of Movable Contacts

1 2
The movable arcing and main contacts are mounted on
the shaft assembly. The main contacts are screwed to 3*
the back side of the two finger blocks and to the shunts.
4
The arcing contact assemblies, which extend from the
ends of the main contacts, are the normal replacement 5
parts. They make first and break last to protect the main
contacts. See Figure 10-4. 8
Disassembly of Movable Arcing Contacts

7[
Remove the arcing contact assembly. Use a 1/8 in. hex
key wrench to remove the retaining screw from the base
of the arcing contact assembly. 1. Tighten to 15 Nm (11 ft. lb.)
2. Shunt
3. Movable main contact*
Disassembly of Movable Main Contacts 4. Retaining plate
5. Shaft 6[
1. Close the bottom main contacts. Remove 6. Movable arcing contact assembly[
7. Retaining screw[
the 1/4 in. rod (Figure 10-3) while using the Apply Loctiter 222; 1/8 in. hex key wrench;
manual operator handle to put the switch in the tighten to 3.6 Nm (32 in. lb.)
NORMAL position (bottom contacts closed). 8. L insulator with hex nut and shake washer
2. Disconnect the main shunts. Use a 1/2 in. socket [ Indicates parts included in arcing contact kit. 61274797
wrench to remove the large hex nut and flat washer
to disconnect the shunt from the movable main Figure 10-4 Movable Contacts
contact.
3. Remove the movable main contacts. Use a

7/16 in. nutdriver to remove the two hex nuts and
lock washers securing the movable main contact to
the shaft. Use a 7/16 in. socket wrench to hold the
nut securing the L insulator behind the main
contact while removing the screw. Then remove
the movable main contact.

123
10.2.2 Reassembly of Movable Contacts 4. Check the clearance between the contacts and the
arc chutes. Use the manual operator handle to
Reassembly of Movable Main Contacts slowly open and close the contacts while checking
that they do not hit the arc chutes.
1. Install the new movable main contacts. See
Figure 10-4. Place the new movable main contact 5. Install the barrier cover. Use the manual operator
behind the shaft and install the retaining plate. handle to put the switch in the NORMAL position
Secure the parts with two hex nuts with lock (bottom contacts closed, top contacts open). Then
washers. Install the L insulator behind the main reinstall the barrier cover and tighten the four
contact and secure it with bolt and flat washer Phillips head screws (two on each side).
(front) and lock washer and hex nut (back). Use a
7/16 in. nutdriver and socket wrench to tighten the Note: Operate the switch manually to be sure there is
hardware. no misalignment or binding before operating it
electrically.
Note: Be sure to install the L insulator behind the main
contact.
2
2. Close the bottom main contacts. Use the manual
3
operator handle to remove the spacer and to put
the switch in the NORMAL position (bottom
4 mm
contacts closed).
(5/32 in.)*
3. Reconnect the main shunts. Attach the main shunt
to the back of the movable main contact on the 1
threaded stud and secure it with the large hex nut
with flat washer. Use a 1/2 in. socket wrench to
tighten to 15 Nm (11 ft. lb.).
6
Reassembly of Movable Arcing Contacts
1. Install the new arcing contact assembly on the

main contact. Apply Loctite r 222 thread sealant to
threads of retaining screw. Install the retaining
screw through the main contact into the base of the
arcing contact and use a 1/8 in. hex wrench to
tighten to 3.6 Nm (32 in. lb.) 4
2. Check the main contact gap. When installing a new

arcing contact assembly, a gap of 4 mm (5/32 in.) 5
between the main contacts is automatically
obtained when the arcing contacts just touch.
However, if a minor adjustment is necessary to
obtain this gap, bend the adjustment tab on the 1. Stationary main contact
2. Movable main contact
arcing contact assembly. Refer to Figure 10-5 for 3. Bracket
instructions on tab adjustment. 4. Movable arcing contact*
5. Stationary arcing contact*
Note: Recheck any adjustment by manually 6. Adjustment tab:
operating the switch a few times and To increase gap, bend tab away from bracket. To decrease
gap, bend tab toward bracket.
rechecking the gap between the main
contacts. * With 4 mm (5/32 in.) gap at the main contacts, the arcing
contacts should just touch. 61274797
3. Install all arc chutes. Slide the arc chute (arc

splitters toward the panel) between the long Figure 10-5 Arcing Contact Adjustment (side view)
threaded rods. Place the arc chute retainer onto
the arc chute. Use a blade screwdriver to gently
tighten the two nylon retainer nuts on both sides of
arc chute. Do not overtighten these nuts.

124
10.2.3 Disassembly of Stationary your finger behind the plate to catch the spring nut.
Contacts Then slide the arc runner plate out from under the
arcing contact to remove it.
The stationary arcing and main contacts are mounted
on the contact pivot blocks. The main contacts are held 2. Remove the two insulator pieces. Carefully work
in the contact pivot blocks by the arc chute mounting the large insulator piece out from under the arcing
brackets. The arcing contacts, which are screwed to the contact while pulling it off the two long threaded
front of the contact pivot blocks, are the normal rods. Do not bend the insulator severely because it
replacement parts. They ‘make’ first and ‘break’ last to must be reused. Also remove the thin insulator
shim.
protect the main contacts. See Figure 10-6.
3. Remove all stationary arcing contacts. Use a
Disassembly of Stationary Arcing Contacts medium blade screwdriver to remove the flathead
screw, then remove the arcing contact.
1. Remove the arc runner plate. Use a medium blade
screwdriver to remove the flathead screw. Place
11*
10 2
9*
8 4
5
7 6[
1. Insulator tray 7. Apply conductive lubricant to main contact hinge joints

2. Right arc chute mounting bracket 8. Left arc chute mounting bracket
3. Arc runner 9. Stationary main contact segment*
4. Large insulator piece 10. Contact pivot block
5. Small insulator piece 11. Stationary main contact leaf spring*
6. Stationary arcing contact[
[ Indicates parts included in arcing contact kit. 61274797
Figure 10-6 Stationary Contacts

125
Disassembly of Stationary Main Contacts Reassembly of Stationary Main Contacts
1. Remove the insulator trays. Use a medium blade 1. Apply conductive lubricant to hinge joints. Use a
screwdriver to remove the two flathead screws cotton swab or small brush to apply conductive
from the arc chute mounting brackets, then remove lubricant (Dynaloy 495) to the inside of the contact
the insulator tray. pivot blocks. Also apply a thin film of conductive
lubricant to the curved surface of each new main
2. Remove the arc chute mounting brackets. Use a contact segment.
5/16 in. open end or box wrench and an offset
screwdriver to remove the two nuts from the Note: Failure to apply conductive lubricant to the main
screws through the contact pivot block. Then contact hinge joints will cause overheating.
remove both arc chute mounting brackets.
2. Install new contact segments and springs. Place a
3. Remove stationary main contacts and springs. new contact spring into the spring base insulator
Use a pair of needle--nose pliers to release the and hold it in place with one hand. With your other
spring leaves from the individual contact segments hand carefully install a new contact segment into
and work the main contacts out of the pivot block. the contact pivot block. Depress the contact spring
Do not damage the inside of the contact pivot block. leaves to work the contact into the center. In a
Then remove the contact spring. similar manner install the remaining contact
segments from either side of the pivot block.
Carefully use a pair of needle-nose pliers to
10.2.4 Reassembly of Stationary position the spring leaves close to the pivot block in
Contacts the notch in each contact.
Reassembly of Stationary Arcing Contacts 3. Install the arc chute mounting brackets. Place left
and right arc chute mounting brackets on either
1. Install the new stationary arcing contacts. Apply a side of the contact pivot block. Then insert two long
few drops of Loctiter 222 thread sealant to the #8--32 screws through the brackets and pivot
threads of the large flat head screw. Then attach block. Secure the brackets with lockwashers and
each new contact to the pivot block by using a nuts, and use a 5/16 in. open end or box wrench
medium blade screwdriver to install the large flat and an offset screwdriver to tighten the two nuts.
head screw. Tighten the screw.
4. Check the contact deflection. Press in on each
2. Install two insulator pieces. Slide the large stationary main contact to verify freedom of
insulator piece onto the two long threaded rods. movement and spring pressure. If there is binding
Carefully work the pointed side of the insulator check the position of the spring leaves and
under the arcing contact while pushing the conductive lubrication.
insulator in. Insert the thin insulator shim behind
the large insulator before pressing it all the way in. 5. Install the insulator trays. Place the insulator tray
Position the thin insulator shim close to the mounting tabs behind the arc chute mounting
threaded rods. brackets. Fasten the insulator tray with two #6--32
flathead screws with lockwashers and nuts. Use a
3. Install the arc runner plate. Hold the thin insulator screwdriver to tighten the screws.
shim in place close to the threaded rods while
sliding the arc runner plate under the arcing
contact. The arc runner plate should fit snugly and
its tab must touch the tip of the arcing contact.
Secure the arc runner plate to the large insulator
piece with the small flat head screw and spring nut.

126
10.3 Operator Coil Replacement Two solenoid operators are used: One drives the
normal source contact shaft, the other drives the
Refer to the ATS Parts Catalog, for instructions to obtain emergency contact shaft. The solenoid operators face
replacement parts for your switch. in opposite directions. These instructions (and
Figure 10-7 through Figure 10-13) are for the upper
solenoid operator.
10.3.1 Removal of Coil Assembly
The coil assembly is mounted in the operator assembly
DANGER on the left side of the panel. It must be removed to a
work bench for disassembly. See Figure 10-7,
Figure 10-8, and Figure 10-9.
1. Put the transfer switch in the Emergency position.

Hazardous voltage. Use the manual operator handle (Figure 10-2) if
Will cause severe injury or death. necessary to close the top contacts.
2. Disconnect the rectifier and resistor (Figure 10-7).
open the enclosure.
Carefully pull off the two white power wires and the
two black coil leads from the square rectifier
mounted on the coil assembly. Do not remove the
blue varistor. Then remove the two hex nuts to
disconnect the two white wires from the resistor
energized. Do not touch the isolation contact fingers or the (one on each end).
3. Remove the retaining screw (Figure 10-7) and link
pin (Figure 10-8). Use a 3/16 in. hex key wrench to
WARNING
remove the hex socket head screw from the
weight. Then use a screwdriver to pry out the link
pin in the left side of the weight.
4. Remove the coil assembly (Figure 10-9). Use a

7/16 in. nutdriver or wrench to remove four hex
Spring-loaded parts. nuts from the operator frame. Then remove the coil
assembly to a work bench.
or property damage.

servicing spring-loaded parts. Hold 10.3.2 Coil Removal
The solenoid coil is held in the coil frame by the core tube
assembly. See Figure 10-10.
cause severe personal injury or property damage. The 1. Remove the core tube assembly. Use a 1/2 in.
spring in the solenoid assembly exerts substantial force on the nutdriver or wrench to remove the upper and lower
hex nuts and lock washers from the end of the coil
screws.
frame. Then pull out the core tube assembly.
2. Remove the coil from the coil frame. Slide the
grommet with coil leads out of the slot. Use a
5/16 in. nutdriver or wrench to loosen (only) three
Operation and Installation Manual.
coil-clamping SEMS head screws (lower end of coil
frame), then pull out the coil and end washer.

core or core tube!

127
1
61274797
1. Retaining screw 61274797 Figure 10-9 Removal of Coil Assembly from

Operator Frame
Figure 10-7 Retaining Screw
61274797
Figure 10-10 Removal of Coil and Core Tube

61274797
Assembly
Figure 10-8 Link Pin

128
10.3.3 Core Tube and Core Disassembly
1
12
Disassembly of the core tube assembly is normally not
required. If, however, the coil has overheated and has 2
damaged the core tube assembly, rebuilding it is
11
necessary. You will need an assistant to help you
reassemble it, and you need to reset the stroke. See

the core tube assembly securely away from
yourself when removing the center hex nut; the
core and link. 10 See
Figure 10-12
core or core tube!
1. Remove the core and compression spring

(Figure 10-11). Hold the link in a vise to secure the
assembly. Use a 3/4 in. nutdriver or wrench to
remove the center large hex nut from the threaded
9
stem end of the core.
Note: When the center hex nut is removed, the

assembly will suddenly release the core and
spring from the lower end of core tube assembly.
8
2. Take apart the core tube assembly (Figure 10-12).
Use a 1/2 in. nutdriver or wrench to remove the left
and right hex nuts and lockwashers and pull the 7
3
spring retainer off the core tube retaining plate.
Then push the core tube through the retaining plate
to remove it. 6
10.3.4 Core Tube and Core Reassembly 4
Replace damaged parts (core tube and core spring) and

lubricate the core and core spring before reassembly.
Use the lubrication kit shown in the ATS parts catalog 5
listed in the Introduction to this manual.
You will need an assistant to help compress the spring

while you install the hardware. See Figure 10-11 and
Figure 10-12.
1. Stroke adjustment stop nut
2. Flat washer*
1. Put together the core tube assembly 3. Lubricate surface
(Figure 10-12)). Insert the core tube through the 4. Link
retaining plate (flared end seats on top). Then 5. Vise
install the spring retainer (recessed hole inward) 6. Core
7. Core and link assembly
onto the retaining plate and use a 1/2 in. nutdriver 8. Stem
or wrench to tighten the two 5/16-18 hex nuts on 9. Compression spring*
5/16 in. lock washers. 10. Core tube assembly
11. Leather washer*
2. Lubricate the core and core spring. Use the 12. Hex nut with nylon insert*
contents of the Lubrication Kit to apply a thin * Indicates parts included in coil kit. 61274797
coating onto the core surface and onto the core
spring. Figure 10-11 Core Tube and Core Disassembly

129
Have an assistant push the core tube assembly
1
onto the spring and hold it down (guide the
2 threaded core stem through the center hole) while
you add the threaded leather washer, flat washer,
and 1/2-13 hex nut onto the core stem. Use a
6 3/4 in. nutdriver or wrench to tighten the nut. The
nut must be adjusted later for proper stroke of 28.6
mm (1 1/8 in.).
3
10.3.5 Coil Installation

5 Replace the damaged coil before reassembly. See
Figure 10-10.
1. Install the replacement coil. With the coil leads up

and to the right, insert the new coil with a coil
washer on the bottom into coil frame Then run the
coil leads through the grommet and slide it into the
slot (right side of coil frame).
4 2. Install the core tube assembly. Insert the core tube
assembly down through the hole in the coil frame
and use a 1/2 in. nutdriver or wrench to tighten the
upper and lower hex nuts with lock washers on the
1. Split lock washer coil frame.
2. Nylon guide washer*
3. Core tube retaining plate*
4. Core tube*
3. Tighten the coil-clamping screws. Use a 5/16 in.
5. Spring retainer nutdriver or wrench to tighten the three SEMS head
6. Hex nut screws on the bottom of the coil frame.
* Indicates parts included in coil kit. 61274797
Figure 10-12 Core Tube Assembly 10.3.6 Installation of Coil Assembly

The coil assembly can now be reinstalled onto the
operator assembly on the left side of the switch panel.
the core tube assembly securely away from
yourself when installing the center hex nut; the See Figure 10-7, Figure 10-8, and Figure 10-9.
1. Install the coil assembly onto the operator frame
core and link.
(Figure 10-9). Place the coil assembly onto the
3. Assemble the core, spring, and core tube four studs on the operator frame and align the link
assembly (Figure 10-11). With the link held into the slotted weight. Use a 7/16 in. nutdriver or
securely in a vise, set the lubricated core spring wrench to tighten the four hex nuts.
onto the core stem. Check to see if the nylon guide
2. Install the link pin and retaining screw
washer is still inside the spring retainer; if it is not,
(Figure 10-8). Insert the link pin (groove side out)
place it inside the spring retainer.

130
into the left side of the weight and through the link. 4. Manually operate the transfer switch. Use the
Then install the hex socket head retaining screw manual operator handle (Figure 10-2) to manually
into the weight and use a 3/16 in. hex key wrench to operate the transfer switch. It should operate
tighten it. smoothly without any binding. If not, recheck the
alignment of parts and the lubrication of the
3. Reconnect the resistor/rectifier on the coil frame solenoid operator. Close the bottom contacts and
(Figure 10-7). Replace the resistor (if necessary) remove the manual handle.
and reconnect the two white wires with ring lugs to
each end and install and tighten the hex nuts. 5. Reinstall the transfer switch. Refer to the
Replace the rectifier (if necessary) and carefully bypass/isolation switch Operation and Installation
reconnect the four wires with push-on lugs to the Manual for instructions.
rectifier terminals as follows: connect the two white
power wires to the AC terminals (µ), and connect
the two black coil leads to the DC terminals (red dot
and no dot, polarity does not matter). Be sure the
blue snubber is still installed between the DC
terminals. See Figure 10-13.
1. Resistor
2. Snubber
3. Rectifier
4. Coil frame 61274797
Figure 10-13 Rectifier and Resistor

131
Notes

132
Section 11 1600--3000 Amp Open-Transition Switches and
1000--3000 Amp Bypass/Isolation Switches
This section explains how to replace the arcing and main D Sockets, 3/8 in. and 1/2 in.
contacts and the solenoid assemby in 1600--3000 amp D Open-end/box wrenches, 5/16 in. and 1/2 in.
automatic transfer switches and 1000--3000 amp D Torque wrench (0--50 in. lb. minimum)
bypass/isolation switches (lower assembly).
D Hex key (Allen) wrench, 5/32 in.
D Ohmmeter (or continuity tester)
DANGER
D Needle nose and regular pliers
11.1 Maintenance Handle

Hazardous voltage.
A detachable manual operator handle is provided on the
Will cause severe injury or death. frame of the transfer switch for maintenance purposes
only. After the transfer switch is isolated and pulled out
Only authorized personnel should (drawn out and totally deenergized), this handle can be
open the enclosure.
used to change the position of the contacts and operator
mechanism. The windows in the left side of the transfer
switch frame indicate which contacts are open and
death. Bypass and isolate the transfer switch before closed.
energized. Do not touch the isolation contact fingers or the 1. Bypass, isolate, and pull out the transfer switch.
control circuit terminals. Follow the procedure explained in Section 3 of the
operation manual. Verify that no electrical power is
present at the pulled-out transfer switch.
Special Tools Needed
2. Install the hub and maintenance handle. Locate
Contact your supplier of Kohler parts to order the tools
and remove the maintenance handle and hub
shown in Figure 11-1.
stored on the lower part of the transfer switch
frame. Then install the hub onto the center operator
shaft and insert the handle into the hole in the side
of the hub.
1 3. To manually operate the deenergized transfer

switch to the opposite position, grasp the
2 maintenance handle firmly and turn either
clockwise or counterclockwise. See Figure 11-3.
Then remove the handle and hub.
3
11.2 Main Contact Inspection and
Replacement
4
1. Maintenance handle GM25404 6127216
2. Adjusting pin GM25405 DANGER
3. Adjusting hub GM25406
4. Main contact shim gauge GM25407
Figure 11-1 Special Tools

Hazardous voltage.
Other Tools Needed Will cause severe injury or death.
D Small and large blade screwdrivers Only authorized personnel should

open the enclosure.
D Ratchet drive, 3/8 in., and extensions, 6 in. and 12 in.
TP-6127 9/02 Section 11 1600--3000 Amp Open-Transition Switches and 1000--3000 Amp Bypass/Isolation Switches
133
Turn counterclockwise to close top
models. Hazardous voltage can cause severe injury or (Emergency) contacts.
removing it from the enclosure. The bypass/isolation switch is Turn clockwise to close bottom
energized. Do not touch the isolation contact fingers or the (Normal) contacts.
control circuit terminals. Grasp
handle
firmly
The movable contact assemblies (two for each pole) are
slide hub onto insert
located above and below the operator mechanism. shaft handle
into hole
1. Bypass, isolate, and pull out the transfer switch.
Follow the procedure explained in the
Figure 11-3 Maintenance Handle On Operator
Bypass/Isolation Switch Operation and Installation
Shaft
Manual. See Figure 11-2. Verify that no electrical
power is present at the pulled-out transfer switch.
2. Open the contacts that will be replaced (if not

already open) by using the detachable
maintenance handle. See Figure 11-3.
3. Remove the interphase barriers (one per pole).

Use a blade screwdriver to loosen two round-head
screws holding each barrier to the arc chutes. Slide
the barrier away from the operator mechanism until
the keyholes in barrier clear the two round-head
screws, then remove the barrier. See Figure 11-4.
4. Carefully remove the arc chutes. Use a 5/8 in.

nutdriver to remove two long insulator nuts. Then
carefully pull the arc chute outward (off the long
Figure 11-4 Interphase Barriers Removed
threaded rods). Place the arc chutes in a safe
place. See Figure 11-5.
Note: The arc chutes are fragile. To prevent

breakage, avoid jarring them and do not use
any tool to pry them loose. If they become
cracked, replace them. See Figure 11-6.
Figure 11-5 Arc Chutes Removed
Figure 11-2 Isolated and Pulled-Out Transfer

Switch
Section 11 1600--3000 Amp Open-Transition Switches and 1000--3000 Amp Bypass/Isolation Switches TP-6127 9/02
134
11.2.2 Contact Replacement
Arcing Contacts only include just the arcing contacts
that make first and break last during load transfer. See
Figure 11-8.
Main and arcing contact assemblies include the entire

2 movable or stationary contact structure, including
1
6127216
contacts, springs, shunts, conductive lubricant, and
1. 1000--1200 amp arc chute hardware. See Figure 11-9.
2. 1600--2000 amp arc chute
Figure 11-6 Replacement Arc Chutes If only the arcing contacts require replacement, follow
the procedure for Arcing Contact Replacement. If the
main contacts require replacement, follow the
procedure for Main and Arcing Contact Assembly
Hole 2 Replacement.
Hole 6
1
2 6127216
1
6127216
1. Adjusting pin (with adjustment screw, thread locker Loctiter 222,
contact spring, spring retainer, washer, spring pin)
Figure 11-7 Pin the Weight to the Frame. See Step 2. Stationary arcing contact
5.
Figure 11-8 Replacement Arcing Contact Kit (One
5. Pin the weight to prevent mechanism from moving. kit includes 1 movable and 1 stationary
Fully insert the adjusting pin (see page 1) through A 3-pole switch requires 6 kits.)
the frame and into the weight. Only one of the holes
lines up with the hole in the weight. If you are
replacing the upper contacts, use the hole labeled
2; if you are replacing the lower contacts, use the
hole labeled 6. See Figure 11-7.
Note: To prevent the possibility of personal injury,

be sure to pin the weight to the weight frame
so that the mechanism cannot move. 1 2 6127216
1. Movable main and arcing contact assembly (with thread

locker Loctiter 222)
11.2.1 Contact Inspection 2. Stationary main and arcing contact assembly
The main contacts are protected by arcing contacts. The Figure 11-9 Main and Arcing Contact Assemblies
arcing contacts make first and break last to avoid arcing Kit (One kit includes 1 movable and 1
at the main contacts. Check the contact adjustments stationary. A 3-pole switch requires 6
annually (see page 6). Replace contacts when the kits.)
contact material becomes severely worn. Discoloration
is normal. Do not file contacts because it wastes
material. Instead use light emery paper to clean up the
contact surfaces. * Loctite is a registered trademark of the Loctite Corporation.
135
Arcing Contact Replacement through the arcing contact and its pivot points fit
into the two depressions (in the main contact).
1. Remove the movable arcing contact. Use Finally, install the arcing contact spring, spring
needlenose pliers and a screwdriver to remove the guide, flat washer, and spring pin. See
spring pin from the spring stud. Then remove the Figure 11-10.
flat washer, spring guide, and contact spring. Next
use a 3/8 in. socket wrench to remove two SEMS 5. Reconnect the pigtails and shunts to the contact.
screws from the pigtails attached to the main Place the arcing contact retainer over the movable
movable contact. Now remove the arcing contact arcing contact and between the shunts and
retainer and the movable arcing contact. pigtails. Install two SEMS screws through the
arcing pigtail lugs, arcing contact retainer, and
1 2 3 4 main contact shunt lugs into the main movable
contact. Use a 3/8 in. socket wrench to tighten the
two screws to 7.5 Nm (5.5 ft. lb.) torque.
6. Adjust the arcing contacts. After all arcing contacts

(both stationary and movable) have been installed,
they must be adjusted. Proceed to Section 11.3.
Note: Contact adjustment is required to prevent

contact damage. Follow the adjustment
procedures in Section 11.3.
Main and Arcing Contact Assembly Replacement
1. Remove the contact supports from both sides. Use

8 7 6 5 a 1/2 in. box or open-end wrench to remove four
6127216
1. Movable arcing contact SEMS screws (left and right, upper and lower).
2. Adjustment screw Then remove the two contact supports that run
3. Loctiter 222 service removable thread locker
4. Spring pin vertically between the Normal and Emergency
5. Washer movable contact assemblies (two for each pole). A
6. Spring guide 3 pole switch has 6 contact supports. See
7. Spring Figure 11-12.
8. Pigtails
Figure 11-10 Movable Arcing Contact and Hardware

1
2. Remove the stationary arcing contact. Use a 3/8 in.
socket wrench to remove two SEMS screws
holding the arcing contact (and arc chute support
plate) to the main contact pivot block. Then remove 2
the stationary arcing contact.
3
3. Install a new stationary arcing contact. Install a
new stationary arcing contact and the arc chute
support plate onto the main contact pivot block.
4
Use a 3/8 in. socket wrench to secure it with two
SEMS screws. Tighten both screws to 7.5 Nm
(5.5 ft. lb.) torque. See Figure 11-11.
4. Install new movable arcing contact. Put two drops

of Loctiter 222 (this service-removable
threadlocker is provided in the kit) to the lead
threads of the adjustment screw. Then install the 1. Arc chute support plate
2. SEMS screws, two
adjustment screw through the new movable arcing 3. Stationary arcing contact
contact until it protrudes 3.2 mm (1/8 in.). Now 4. Main contact pivot block 6127216
install the movable arcing contact onto the
movable main contact so that the spring stud goes Figure 11-11 Stationary Arcing Contact
136
1 2 3
1. Movable arcing assembly

2. SEMS screw 1. Nuts
3. Contact supports 6127216 2. Shaft clamp
3. Contact shaft 6127216
Figure 11-12 Contact Supports (Both Sides)
Figure 11-13 Movable Contact Shaft Clamps
2. Disconnect the crank arm from the shaft. Use a
1/2 in. socket wrench to remove the two nuts with
lock washers from each shaft clamp. Then remove
the loose clamp from the shaft. Save all hardware.
See Figure 11-13.
3. Remove the movable contact assembly. Use a

1/2 in. socket wrench with 12 in. extension to
remove two nuts with lock washers from the base of
each movable contact assembly. See
Figure 11-14.
4. Remove the stationary contact assembly. Use a

3/8 in. socket wrench to remove the two SEMS
screws from the top (or bottom) of each stationary
contact assembly. Then use a 1/2 in. socket
wrench with 12 in. extension to remove two nuts
with lock washers from the base of each main
stationary contact assembly. See Figure 11-15.
1 2
1. Mounting holes, two

Note: Crank arm attaches to the shaft 6127216
Figure 11-14 Movable Contact Assembly
137
half clamp over the front and install two bolts (from
the opposite side). Use a 1/2 in. wrench to install
two nuts with lock washers to secure each clamp.
Tighten the clamp nuts to 132 in. lb. (11 ft. lb.)
torque.
1 2
3
6127601082
1. Arc chute support plate

2. Stationary arcing contact Figure 11-16 Insulators, 2600--3000 Amp Models
3. Mounting holes, two
6127216
4. SEMS screws, two 10. Adjust the arcing and main contacts. After all
Figure 11-15 Stationary Contact Assembly movable and stationary contact assemblies have
been installed, they must be adjusted. Proceed to
5. Install the new stationary contact assembly. Section 11.3.
Position the new main stationary contact assembly
onto the two 5/16 in. studs. Use a 1/2 in. socket Note: Contact adjustment is required to prevent
wrench with 12 in. extension to install two nuts with contact damage. Follow the adjustment
lock washers to secure the assembly. Tighten to procedures in Section 11.3.
132 in. lb. (11 ft. lb.) torque.
6. Install the arc chute support plate and arcing 11.3 Main and Arcing Contact
contact. Use a 3/8 in. socket wrench to install two Adjustment
SEMS screws through the new arc chute plate and
new stationary arcing contact to the top (or bottom) DANGER
of each new stationary contact assembly. Tighten
to 66 in. lb. (5.5 ft. lb.) torque.
7. Install insulators onto the new stationary contact

assembly. See Figure 11-16.
Hazardous voltage.
8. Install the new movable contact assembly. Will cause severe injury or death.
Position the new movable contact assembly onto Only authorized personnel should
the two 5/16 in. studs. Use a 1/2 in. socket wrench open the enclosure.
with 12 in. extension to install two nuts with lock
washers to secure the assembly. Tighten to Removing the transfer switch from bypass/isolation
132 in. lb. (11 ft. lb.) torque. models. Hazardous voltage can cause severe injury or
9. Connect new movable contact assembly to shaft. removing it from the enclosure. The bypass/isolation switch is
Position the new movable contact assembly (black energized. Do not touch the isolation contact fingers or the
drive arm) under the shaft. Then position the metal control circuit terminals.
138
two SEMS screws, then move the stationary
WARNING contact left or right to approximately center it under
the movable arcing contact.
2. Retighten the stationary arcing contact screws.

Use the maintenance handle to open and close the
contacts to recheck contact alignment. Use a 3/8
Spring-loaded parts. in. socket wrench to retighten the two nuts to
Can cause severe personal injury 66 in. lb. (5.5 ft. lb.) torque.
or property damage.
Wear protective goggles when Note: To prevent arc chute breakage, be sure that the
servicing spring-loaded parts. Hold stationary arcing contact alignment is set
parts securely during disassembly. correctly.
Check the contact adjustment once a year. After

contacts are replaced contact adjustment is required
before the transfer switch can be reenergized.
Adjustment includes: A--Stationary Arcing Contact .090 in. max.
Alignment and B--Arcing Contact Lead Adjustment.
Contact Adjustment Procedure
1. Bypass, isolate, and pull out the transfer switch. 1

Follow the procedure explained in the operation
manual. Verify that no electrical power is present at
the pulled-out transfer switch. See Figure 11-2. 2
2. Use the maintenance handle (if necessary). Open 3

the contacts that will be adjusted (if not already
open) by using the detachable maintenance
handle. See Figure 11-3.
3. Remove the barriers. Use a blade screwdriver to

loosen only two round-head screws holding each
barrier to the arc chutes. Slide the barrier away
from the operator mechanism until the keyholes in
the barrier clear the two round-head screws, then
remove the barrier. See Figure 11-4.
4
4. Carefully remove the arc chutes. Use a 5/8 in.
nutdriver to remove two long insulator nuts. Then
carefully pull the arc chute outward (off the long
threaded rods). Place the arc chutes in a safe place
to prevent breakage. See Figure 11-5.
A–Stationary Arcing Contact Alignment 1. Screw 5 6127216

2. Stationary arcing contact
A maximum horizontal offset of 2.29 mm (0.090 in.) is 3. Movable arcing contact
4. Movable contact assembly
allowed between the movable and stationary arcing 5. Supports
contacts. See Figure 11-17. If adjustment is needed
follow these steps: Figure 11-17 Stationary Arcing Contact Alignment
1. Loosen the screws and move the stationary arcing

contact. Use a 3/8 in. socket wrench to loosen the
139
B--Arcing Contact Lead Adjustment
6
The arcing contacts must lead the main contacts on
closing by 2 to 3 mm (0.08 to 0.12 in.). To set this contact
gap (at the main contacts) use the adjusting hub,
adjusting pin, and maintenance handle from the contact *
adjustment handle kit. To check and/or change the
adjustment, follow these steps (see Figure 11-18 5
through Figure 11-22).
4
1. Install the adjusting hub and maintenance handle. 3 2 1
Insert the maintenance handle completely into the 1. Drive shaft 6127216
2. Adjustment hub disk
hub (compress the handle spring) and grasp it firmly. 3. Weight frame
Use the maintenance handle to close the contacts 4. AM hole; insert adjusting pin here
that you are checking or adjusting (if they are not 5. Hole at 9 o’clock
already closed). See Figure 11-2. 6. Face plate
* Shown when upper contacts are in arc-make position
be sure to fully pin the weight to the weight Figure 11-19 Pinned Weight For Upper Contacts
frame so that the mechanism cannot move (After)
while you are adjusting the contacts.
2. For closed upper contacts, pin the weight as shown

in Figure 11-19. Turn the maintenance handle
clockwise 30° until the AM hole is in the 9 o’clock
position. Fully insert the adjusting pin into hole AM
to lock the upper contact shaft in the ARC MAKE *
position. See Figure 11-18 (before) and
Figure 11-19 (after).
3. For closed lower contacts, pin the weight as shown

in Figure 11-21. Turn the maintenance handle * Shown when lower contacts are closed 6127216
counterclockwise 30° until the AM hole is in the 9
o’clock position. Fully insert the adjusting pin into Figure 11-20 Pinning Weight For Lower Contacts
hole AM to lock the lower contact shaft in the ARC (Before)
MAKE position. See Figure 11-20 (before) and
Figure 11-21 (after).
6
5
*
4 6127216
3 2 1
1. Drive shaft
2. Adjustment hub disk
3. Weight frame
* Shown when upper contacts are closed. 6127216 4. AM hole; insert adjusting pin here
5. Hole at 9 o’clock
Figure 11-18 Pinning Weight For Upper Contacts 6. Face plate
(Before) * Shown when lower contacts are in arc-make position
Figure 11-21 Pinned Weight For Lower Contacts

(After)
140
4. Measure and adjust the movable arcing contact 7. Adjust the movable arcing contact adjustment
screws. Check that all nylon adjustment screws screws. After all main contacts on the shaft are set
protrude 3 mm (1/8 in.) through the far side of all for the lead gap, adjust the arcing contacts. Turn
movable arcing contacts. If adjustment is each nylon adjustment screw until the arcing
necessary, use a blade screwdriver or 11/32 in. contacts just touch (no gap, no deflection). All
nutdriver to turn the adjustment screw. See arcing contacts on the same shaft should touch at
Figure 11-22. approximately the same time. Recheck all gaps.
Figure 11-22.
5. Check that the main contacts are open approx.
3 mm (1/8 in.). With the main contacts locked in the 8. Carefully unpin the weight as follows: After all
AM position (Figure 11-19 or Figure 11-21), verify contacts are checked and adjusted, insert the
that all main contacts are open approximately 3 maintenance handle completely into the hub
mm (1/8 in.) on the shaft being adjusted. If any main (handle spring compressed). Firmly grasp and
contact is not open at least 3 mm (1/8 in.), use a hold the maintenance handle while you remove the
5/32 in. hex key (Allen) wrench to loosen the set adjusting pin. When the adjusting pin is pulled out,
screw in the side of the crank arm. Then use a the weight releases suddenly and forcibly turns the
7/16 in. open-end wrench to turn the movable handle to the closed contact position.
contact drive rod counterclockwise until that main
contact is open 3 mm (1/8 in.). See Figure 11-22. Note: To prevent the possibility of personal injury,
fully insert the maintenance handle into the
6. Insert the main contact shim gauge (GM25407) and hub and grasp and hold it firmly when you
adjust the drive rod. With the main contacts locked remove adjusting pin. Gently allow the
in the AM position (Figure 11-19 or Figure 11-21), contacts to close.
insert the shim gauge between the movable and
stationary main contacts. The shim should fit finger Note: To prevent coil burnout in the solenoid
tight (this shim gauge is the arcing contact lead assembly, be sure to remove the adjusting
dimension). To decrease the gap, turn the drive rod pin so that the mechanism is free to operate.
clockwise; to increase the gap, turn the drive rod
counterclockwise. Recheck all gaps. See 9. Manually operate the switch and recheck
Figure 11-22. adjustments. Use the maintenance handle (see
Figure 11-2) to manually operate the transfer
switch several times. Then repeat steps 3 through
1 8. When you are finished with all contact
adjustments, remove the hub and maintenance
handle and store them on the lower frame in the
2 place provided.
3 10. Carefully reinstall the arc chutes. Carefully slide

the arc chute (with the arc splitters toward the
4 contacts and the recess for nuts outward) between
the two long threaded rods. Reinstall the two long
8 insulator nuts (round shoulder in) and use a 5/8 in.
nutdriver to GENTLY tighten until snug. Do not
overtighten these nuts. See Figure 11-4 and
Figure 11-5.
7
5 Note: Handle the arc chutes gently to prevent

breakage. Do not clamp the arc chutes too
6 tightly (hand tighten the insulator nuts only).
11. Reinstall the barriers. Install the barrier over the

1. Stationary arcing contact
arc chute and slide it toward the operator
3. Nylon stop screw protusion mechanism until the two round-head screws align
4. Nylon stop screw in the keyholes in the barrier. Then use a blade
5. Set screw screwdriver to tighten the two round-head screws
6. Drive rod
to secure the barrier to the arc chute insulator nuts.
7. Shim gage (0.001 in.)
8. Arc lead gap See Figure 11-4.
6127216
Figure 11-22 Arcing Contact Lead Alignment
141
11.4 Solenoid Assembly Solenoid Assembly Replacement Procedure
Replacement 1. Bypass, isolate, and pull out the transfer switch.
Follow the procedure explained in Section 3 of the
Solenoid assemblies include the entire solenoid with operation manual. Verify that no electrical power is
frame, coils, core tube, core spring, core and link. present at the removed transfer switch.
Solenoid assemblies must be matched to the transfer
switch voltage rating. Refer to the transfer switch Parts 2. Manually operate the switch to the EMERGENCY
Catalog for the part number for the appropriate solenoid position. After the transfer switch is pulled out
assembly for your transfer switch. completely, use the maintenance handle
(Figure 11-2) to turn the weight so that the core link
The solenoid assembly is located in the left front of the is down, as shown in Figure 11-23 (Normal
transfer switch. See Figure 11-23. contacts are in the OPEN position). Refer to
Section 2 of the operation manual.
DANGER 3. Disconnect the solenoid assembly. Squeeze the
plug latches and separate the inline wire harness
plug to the coils to disconnect them.
4. Remove both shaft indicator plates (left side). Use

Hazardous voltage. a 3/8 in. socket wrench to remove two screws.
5. Pin the weight to prevent the mechanism from
moving. Insert the adjusting pin (see page 1)
open the enclosure.
through the weight frame and into the weight. Use
the hole labeled 6 on the round label; it is the
bottom left hole adjacent to the center operator
shaft (in the 7 o’clock position). See Figure 11-24.
be sure to pin the weight to the frame so that
the mechanism cannot move while
removing the solenoid assembly.
1
7
9 2
Solenoid
8 assembly 3
4
7
6 5
1. Operator shaft 6. Shaft indicator plate

2. Hole 6 for pinning weight to weight frame 7. Mounting screw
3. Core link 8. Mounting bolts, 8 ea. Note: Two longer bolts are used in
4. Post on weight the rear
5. Weight 9. Coil harness plug 6127216
Figure 11-23 Location of the Solenoid Assembly and Related Parts in the Drawn-Out (Removed) Transfer Switch
142
1
2
5
Hole 6
3
4
adjusting pin 2
1. Coil harness plug
Figure 11-24 Pin The Weight To The Frame. See 2. Flange mounting holes
Step 5. 3. Core link
4. Rear mounting holes
5. Front mounting holes 6127216
6. Remove the solenoid assembly.
Figure 11-25 Solenoid Assembly
Note: The solenoid assembly weighs about 16 kg
(35 lb.). 10. Unpin the weight to free the mechanism. Insert the
maintenance handle completely into the hub
First use a 1/2 in. socket wrench with 6 in.
(compress the handle spring). Firmly grasp and
extension (minimum) to remove the two left rear
hold the maintenance handle while you remove the
hex-head bolts. Then use a 1/2 in. socket and/or
adjusting pin from hole 6. When the adjusting pin is
open-end wrench to remove the six other bolts (2
pulled out, the weight releases suddenly and
on the left, 4 on the right). Then carefully pull out
forceably turns the handle to the closed contact
the solenoid assembly (unhook the core link from
position.
the post on the weight) and swing out the left side
first. See Figure 11-25. Note: To prevent the possibility of personal injury,
fully insert the maintenance handle into the
7. Install the replacement solenoid assembly.
hub and grasp and hold it firmly when you
Position the solenoid assembly with the core link
remove the adjusting pin. Gently allow the
facing right and the coil wire harness plug on top.
contacts to close.
Install the new solenoid assembly (put in the right
side first) and hook the link onto the post on the Note: To prevent coil burnout in the new solenoid
weight. Use a 1/2 in. socket wrench with 6 in. assembly, be sure to remove the adjusting
extension (min.) to reinstall two longer screws in pin so that the mechanism is free to operate
the left rear. Then use a 1/2 in. socket and/or again.
open-end wrench to reinstall six hex-head bolts (4
on the right above and below the flanges, 2 on the 11. Manually operate the transfer switch. Use the
far left side front). Tighten all eight bolts to 15 Nm maintenance handle (see Figure 11-2) to operate
(11 ft. lb.) torque. the transfer switch several times. It should operate
smoothly without any binding. If it does not, check
8. Reinstall the two shaft indicator plates (on the left). to be sure that the solenoid is installed correctly.
Use a 3/8 in. socket wrench to reinstall two screws. When you are finished with all contact
adjustments, remove the hub and maintenance
9. Connect the new solenoid assembly. The inline
wire harness plug and plug from the coils are keyed
place provided.
to go together only one way. Carefully connect the
plugs and be sure that both latches click.
143
12. Check the main contact adjustments. Before 13. Return the transfer switch to service. After you
returning the transfer switch to service, the main verify that the control and main contact
contact adjustments must be checked. Refer to adjustments are correct, you can return the
Section 11.3. When you are finished with all contact transfer switch to service. Follow the procedure
adjustments, remove the hub and maintenance explained in the Operation Manual.
place provided.
Note: To prevent possible damage to the transfer

switch and interruption to the load, check the
main contact adjustments after replacing
the solenoid assembly.
144
Section 12 4000 Amp Open-Transition Transfer Switches
12.1 Purpose Note: The engine start circuit closes when the transfer
switch is operated to the emergency side. This
This section explains how to test and adjust the TS coil will cause the emergency generator set to start
control contacts in 4000-amp transfer switches. and run if not disconnected beforehand.
The TS control contacts control the duration of time that 1. Prevent the generator set from starting by moving
power is applied to the main solenoid operator (TS coil). the generator set master switch to the OFF
To assure proper operation, it is important that the position, disconnecting power to the generator
contacts open at the proper time during the stroke of the engine starting battery charger, if installed, and
solenoid. Improper adjustment will cause failure to
operate at reduced voltages, failure of the main contacts
to seat properly, and solenoid failure. 2. Disconnect all power sources before opening the
Only experienced electricians should test and adjust the circuit breakers or switches to the transfer switch.
switch. All standard safety practices must be observed.
3. Insert the manual handle into the hole in the
rotating weight (Figure 12-4). Move the handle
DANGER down and up to manually operate the switch, as
needed, in the service procedures.
NOTICE
Hazardous voltage. handle on the transfer switch for maintenance purposes only.
Will cause severe injury or death. Return the transfer switch to the normal position. Remove the
Disconnect all power sources before provided on the transfer switch when service is completed.
Servicing the transfer switch. Hazardous voltage can 12.3 Coil Control Contact Test and
before servicing. Open the main circuit breakers of all transfer Adjustment
follows: (1) Move all generator set master controller switches The TS control contacts are factory-set using an
to the OFF position. (2) Disconnect power to all battery adjustable power supply so that the switch can operate
chargers. (3) Disconnect all battery cables, negative (--) leads satisfactorily over a wide voltage range of 80 to 110% of
first. Reconnect negative (--) leads last when reconnecting the the nominal system voltage. To accommodate minor
battery cables after servicing. Follow these precautions to variances in friction and tolerances, it is not unusual for
prevent the starting of generator sets by an automatic transfer the control contact settings to vary from switch to switch.
from a remote computer. Before servicing any components The adjustments are factory-sealed and usually do not
inside the enclosure: (1) Remove all jewelry. (2) Stand on a require any change over the life of the switch. If it should
become necessary to check adjustments in the field, an
approximation can be made by following the instructions
in the following procedure. The adjustments can vary to
12.2 Manual Operation the extremes and still provide acceptable operation.
However, it is important that the TS control contacts
A detachable manual operator handle is provided for always open BEFORE top-dead-center is reached by
maintenance purposes only. The handle is stored on the the solenoid core.
transfer switch. See Figure 12-1.
Note: Do not manually operate the switch until all power

and control circuits are disconnected.
TP-6127 9/02 Section 12 4000 Amp Open-Transition Transfer Switches

145
Coil Control Contact Test and Adjustment each direction (transfer to emergency and
Procedure retransfer to normal). The pairs of coil clearing
contacts do not have to operate
DANGER simultaneously, but both must break the circuit
BEFORE the main solenoid operator core
reaches top-dead-center (TDC) position. See
the table in Figure 12-3 for control contact
positions.
Hazardous voltage. b. With the power disconnected, use a multimeter
(or a lamp-type continuity tester) across each
Disconnect all power sources before contact to determine when the control contacts
opening the enclosure. open while slowly turning the manual operator
handle (see Figure 12-4 and section on
Servicing the transfer switch. Hazardous voltage can Manual Operation for instructions).
1. Prevent the generator set from starting by moving

position; disconnecting power to the generator
engine starting battery charger, if installed; and 1
negative (--) leads first. 4

2
circuit breakers or switches to the transfer switch.
3. Use a voltmeter to verify that no voltage is present
at the switch terminal lugs on both power sources.
4. Locate the TS control contact assembly; see

Figure 12-1. 3
1. TS control contact assembly

5. To check the settings of the TS control contacts, 2. Miniature switches
proceed as follows (refer to Figure 12-2): 3. Auxiliary contacts
4. Manual operator handle (storage location) 61274789
a. Two sets of contacts interrupt the control
current to the solenoid operator coil (TS) in Figure 12-1 4000 amp transfer switch.
Section 12 4000 Amp Open-Transition Transfer Switches TP-6127 9/02

146
1
2
7
4
For transfer For transfer to

to normal emergency
side 69 7 71 9
view
5
70 6 72 8
1. Hole for insertion of manual operator handle 5. TS control contact assembly

2. Typical main solenoid operator (shown with cover removed) 6. Upper drive link
3. Solenoid core stem 7. Drive bracket
4. Electrical diagram. Control contact positions shwon when main
TS control contacts are closed on the normal side.
61274789
Figure 12-2 Typical TS Control Contact Arrangement.
Control Contacts Control

Condition 71--72 & 9--8 Contacts 1
69--70 & 7--6
Main contacts
Closed Open
closed--on N
2
Main contacts
Open Closed
closed--on E
3
During transfer Open before Close after
from N to E TDC TDC
During transfer Close after Open before
from E to N TDC TDC
N-- Normal Position E--Emergency Position
TDC-- Top Dead Center of solenoid core. 1. Rotating weight
2. Main solenoid operator
3. Manual operator handle
Figure 12-3 Control Contact Positions 61274789
Figure 12-4 Manual operator handle.

147
6. If adjustment of contacts 71--72 and 9--8 is Then tighten the locking screw. See
necessary, proceed as follows. Refer to Figure 12-6.
7. Rotate the manual handle so that the weight is over
a. Make sure the main contacts of the transfer center on the opposite side (EMERGENCY). Then
switch are closed on normal. Use the manual rotate the weight to the same core position in
operator handle to change the contact position, Figure 12-5 except coming from the emergency
if necessary. side. Perform the adjustment described in step 6
on the two opposite control contacts, 69--70 and
b. Starting from the closed-on-normal position, 7--6.
use the manual operator handle to rotate the
weight until the core has moved up to the 8. Reconnect power supplies to the transfer switch.
indicated dimensions. See Figure 12-5. 9. Reconnect the generator engine starting battery
cables, negative (--) leads last; reconnect power to
c. At this point adjust the right side control contact
the generator engine starting battery charger, if
cam adjusting arm so that the contacts just
installed; and move the generator set master
break: Use a 1/4 in. nutdriver to loosen the
switch to the AUTO (automatic) position. The
hex-head locking screw. Move the cam
generator set may start and run until the ATS time
adjusting arm so that the contacts just break.
2
1
5.6 mm
(7/32 in.)
1. Manual operator handle

2. Solenoid core extension
5.6 mm (7/32 in.)
3. Typical main solenoid operator
(shown with cover removed)
61274789
Figure 12-5 Establishing Solenoid Stroke Position for Control Contact Actuation.
Top View
2
69 7 71 9
70 6 72 8
1 3
4
5
1. 1/4 in. nutdriver
2. Control contact cam adjusting arms (shown in midpoint position)
6 3. #8-32 hex head locking screw
4. Drive bracket
5. Cams
6. Operating button
7. Control contacts 71--72 (typical). Contacts open when the operating
7 button is depressed by the cam.
61274789
Figure 12-6 TS Control Contact Adjustment

148
12.4 TS Control Contact 1. Prevent the generator set from starting by moving
Replacement position; disconnecting power to the generator
Under normal conditions the TS control contacts do not engine starting battery charger, if installed; and
replacement becomes necessary, use the following
procedure. 2. Disconnect all power sources before opening the
Control Contact Replacement Procedure circuit breakers or switches to the transfer switch.
3. Use a voltmeter to verify that no voltage is present
DANGER at the switch terminal lugs on both power sources.
4. Refer to Figure 12-7. Disconnect the upper drive

link between the weight and the control contact
assembly by prying the link off the ball joint with a
Hazardous voltage. screwdriver.
5. Label the wires connected to the control contact
Disconnect all power sources before assembly so they can be identified after being
opening the enclosure. disconnected.
Servicing the transfer switch. Hazardous voltage can 6. Disconnect the labeled wires from the control
cause severe injury or death. Deenergize all power sources contact assembly.
switch power sources and disable all generator sets as 7. Disconnect the lower drive link connected to the
follows: (1) Move all generator set master controller switches auxiliary contact assembly by removing the
to the OFF position. (2) Disconnect power to all battery #10--32 shoulder screw, lockwasher, and hex nut
chargers. (3) Disconnect all battery cables, negative (--) leads from the left side of the drive bracket. Then reinstall
first. Reconnect negative (--) leads last when reconnecting the the hardware into the loose link for safekeeping.
prevent the starting of generator sets by an automatic transfer 8. Remove three #8–32 screws from the mounting
switch, remote start/stop switch, or engine start command feet and remove the control contact assembly.
inside the enclosure: (1) Remove all jewelry. (2) Stand on a 9. Install the new control contact assembly onto
mounting plate and secure it with three #8–32
screws.
10. Reconnect the lower drive link to the drive bracket.

When assembled properly there will be free play
between the drive bracket and the head of the
shoulder screw.
11. Manually operate the drive linkage. The action

should be smooth without any binding. Be sure the
cams properly operate the pushbuttons on the
control and auxiliary contact assemblies.
12. Reconnect the eight labeled wires to the proper

terminals.
13. Connect the upper drive link to the left side of the
drive bracket on the control contact assembly.
Recheck for binding and interference.
14. Check the control contact adjustment. See Section

12.3.

149
1
3
1. TS control contact assembly
2. Upper drive link.
Pry the link off the ball joint with a screwdriver.
4 3. #8-32 mounting screws
4. Lockwasher and nut
5 5. Lower drive link. Disconnect if provided.
6 6. #10-32 shoulder screw
61274789
Figure 12-7 Replacing TS Control Contacts

150
Appendix A Abbreviations
The following list contains abbreviations that may appear in this publication.
A, amp ampere cfm cubic feet per minute exh. exhaust
ABDC after bottom dead center CG center of gravity ext. external
AC alternating current CID cubic inch displacement F Fahrenheit, female
A/D analog to digital CL centerline fglass. fiberglass
ADC analog to digital converter cm centimeter FHM flat head machine (screw)
adj. adjust, adjustment CMOS complementary metal oxide fl. oz. fluid ounce
ADV advertising dimensional substrate (semiconductor) flex. flexible
drawing cogen. cogeneration freq. frequency
AHWT anticipatory high water com communications (port) FS full scale
temperature coml commercial ft. foot, feet
AISI American Iron and Steel Coml/Rec Commercial/Recreational
Institute ft. lbs. foot pounds (torque)
conn. connection ft./min. feet per minute
ALOP anticipatory low oil pressure
cont. continued g gram
alt. alternator
CPVC chlorinated polyvinyl chloride ga. gauge (meters, wire size)
Al aluminum
crit. critical gal. gallon
ANSI American National Standards
Institute CRT cathode ray tube gen. generator
(formerly American Standards CSA Canadian Standards genset generator set
Association, ASA) Association
GFI ground fault interrupter
AO anticipatory only CT current transformer
Cu copper GND, ground
API American Petroleum Institute
cu. in. cubic inch gov. governor
approx. approximate, approximately
cw. clockwise gph gallons per hour
AR as required, as requested
CWC city water-cooled gpm gallons per minute
AS as supplied, as stated, as
suggested cyl. cylinder gr. grade, gross
ASE American Society of Engineers D/A digital to analog GRD equipment ground
ASME American Society of DAC digital to analog converter gr. wt. gross weight
Mechanical Engineers dB decibel HxWxD height by width by depth
assy. assembly dBA decibel (A weighted) HC hex cap
ASTM American Society for Testing DC direct current HCHT high cylinder head temperature
Materials HD heavy duty
DCR direct current resistance
ATDC after top dead center deg., ° degree HET high exhaust temperature,
ATS automatic transfer switch high engine temperature
dept. department
auto. automatic hex hexagon
dia. diameter
aux. auxiliary Hg mercury (element)
DI/EO dual inlet/end outlet
A/V audiovisual HH hex head
DIN Deutsches Institut fur Normung
avg. average e. V. HHC hex head cap
AVR automatic voltage regulator (also Deutsche Industrie HP horsepower
AWG American Wire Gauge Normenausschuss) hr. hour
AWM appliance wiring material DIP dual inline package HS heat shrink
bat. battery DPDT double-pole, double-throw hsg. housing
BBDC before bottom dead center DPST double-pole, single-throw HVAC heating, ventilation, and air
BC battery charger, battery DS disconnect switch conditioning
charging DVR digital voltage regulator HWT high water temperature
BCA battery charging alternator E, emer. emergency (power source) Hz hertz (cycles per second)
BCI Battery Council International EDI electronic data interchange IC integrated circuit
BDC before dead center EFR emergency frequency relay ID inside diameter, identification
BHP brake horsepower e.g. for example (exempli gratia) IEC International Electrotechnical
blk. black (paint color), block EG electronic governor Commission
(engine) EGSA Electrical Generating Systems IEEE Institute of Electrical and
blk. htr. block heater Association Electronics Engineers
BMEP brake mean effective pressure EIA Electronic Industries IMS improved motor starting
bps bits per second Association in. inch
br. brass EI/EO end inlet/end outlet in. H2O inches of water
BTDC before top dead center EMI electromagnetic interference in. Hg inches of mercury
Btu British thermal unit emiss. emission in. lbs. inch pounds
Btu/min. British thermal units per minute eng. engine Inc. incorporated
C Celsius, centigrade EPA Environmental Protection ind. industrial
cal. calorie Agency int. internal
CARB California Air Resources Board EPS emergency power system int./ext. internal/external
CB circuit breaker ER emergency relay I/O input/output
cc cubic centimeter ES engineering special, IP iron pipe
engineered special ISO International Organization for
CCA cold cranking amps
ESD electrostatic discharge Standardization
ccw. counterclockwise
est. estimated J joule
CEC Canadian Electrical Code
E-Stop emergency stop JIS Japanese Industry Standard
cert. certificate, certification, certified
etc. et cetera (and so forth)
cfh cubic feet per hour
TP-6127 9/02 Appendix A-1

k kilo (1000) MTBF mean time between failure RHM round head machine (screw)
K kelvin MTBO mean time between overhauls rly. relay
kA kiloampere mtg. mounting rms root mean square
KB kilobyte (210 bytes) MW megawatt rnd. round
kg kilogram mW milliwatt ROM read only memory
kg/cm2 kilograms per square mF microfarad rot. rotate, rotating
centimeter N, norm. normal (power source) rpm revolutions per minute
kgm kilogram-meter NA not available, not applicable RS right side
kg/m3 kilograms per cubic meter nat. gas natural gas RTV room temperature vulcanization
kHz kilohertz NBS National Bureau of Standards SAE Society of Automotive
kJ kilojoule NC normally closed Engineers
km kilometer NEC National Electrical Code scfm standard cubic feet per minute
kOhm, kW kilo-ohm NEMA National Electrical SCR silicon controlled rectifier
kPa kilopascal Manufacturers Association s, sec. second
kph kilometers per hour NFPA National Fire Protection SI Systeme international d’unites,
kV kilovolt Association International System of Units
kVA kilovolt ampere Nm newton meter SI/EO side in/end out
kVAR kilovolt ampere reactive NO normally open sil. silencer
kW kilowatt no., nos. number, numbers SN serial number
kWh kilowatt-hour NPS National Pipe, Straight SPDT single--pole, double--throw
kWm kilowatt mechanical NPSC National Pipe, Straight-coupling SPST single--pole, single--throw
L liter NPT National Standard taper pipe spec, specs
LAN local area network thread per general use specification(s)
L x W x H length by width by height NPTF National Pipe, Taper-Fine sq. square
lb. pound, pounds NR not required, normal relay sq. cm square centimeter
lbm/ft3 pounds mass per cubic feet ns nanosecond sq. in. square inch
LCB line circuit breaker OC overcrank SS stainless steel
LCD liquid crystal display OD outside diameter std. standard
ld. shd. load shed OEM original equipment stl. steel
manufacturer tach. tachometer
LED light emitting diode
OF overfrequency TD time delay
Lph liters per hour
opt. option, optional TDC top dead center
Lpm liters per minute
OS oversize, overspeed TDEC time delay engine cooldown
LOP low oil pressure
OSHA Occupational Safety and Health TDEN time delay emergency to
LP liquefied petroleum Administration normal
LPG liquefied petroleum gas OV overvoltage TDES time delay engine start
LS left side oz. ounce TDNE time delay normal to
Lwa sound power level, A weighted p., pp. page, pages emergency
LWL low water level PC personal computer TDOE time delay off to emergency
LWT low water temperature PCB printed circuit board TDON time delay off to normal
m meter, milli (1/1000) pF picofarad temp. temperature
M mega (106 when used with SI PF power factor term. terminal
units), male
ph., Æ phase TIF telephone influence factor
m3 cubic meter
PHC Phillips head crimptite (screw) TIR total indicator reading
m3/min. cubic meters per minute
PHH Phillips hex head (screw) tol. tolerance
mA milliampere
PHM pan head machine (screw) turbo. turbocharger
man. manual
PLC programmable logic control typ. typical (same in multiple
max. maximum locations)
PMG permanent-magnet generator
MB megabyte (220 bytes) UF underfrequency
pot potentiometer, potential
MCM one thousand circular mils UHF ultrahigh frequency
ppm parts per million
MCCB molded-case circuit breaker UL Underwriter’s Laboratories, Inc.
PROM programmable read-only
meggar megohmmeter memory UNC unified coarse thread (was NC)
MHz megahertz psi pounds per square inch UNF unified fine thread (was NF)
mi. mile pt. pint univ. universal
mil one one-thousandth of an inch PTC positive temperature coefficient US undersize, underspeed
min. minimum, minute PTO power takeoff UV ultraviolet, undervoltage
misc. miscellaneous PVC polyvinyl chloride V volt
MJ megajoule qt. quart, quarts VAC volts alternating current
mJ millijoule qty. quantity VAR voltampere reactive
mm millimeter R replacement (emergency) VDC volts direct current
mOhm, mW power source VFD vacuum fluorescent display
milliohm rad. radiator, radius VGA video graphics adapter
MOhm, MW RAM random access memory
megohm VHF very high frequency
RDO relay driver output W watt
MOV metal oxide varistor
ref. reference WCR withstand and closing rating
MPa megapascal
rem. remote w/ with
mpg miles per gallon
Res/Coml Residential/Commercial w/o without
mph miles per hour
RFI radio frequency interference wt. weight
MS military standard
RH round head xfmr transformer
m/sec. meters per second
A-2 Appendix TP-6127 9/02

Appendix B Common Hardware Application Guidelines
Use the information below and on the following pages to Steps for common hardware application:
identify proper fastening techniques when no specific
reference for reassembly is made. 1. Determine entry hole type: round or slotted.
Bolt/Screw Length: When bolt/screw length is not given, 2. Determine exit hole type: fixed female thread
use Figure 1 as a guide. As a general rule, a minimum (weld nut), round, or slotted.
length of one thread beyond the nut and a maximum
length of 1/2 the bolt/screw diameter beyond the nut is For round and slotted exit holes, determine if
hardware is greater than 1/2 inch in diameter, or
the preferred method.
1/2 inch in diameter or less. Hardware that is
Washers and Nuts: Use split lock washers as a bolt greater than 1/2 inch in diameter takes a standard
locking device where specified. Use SAE flat washers nut and SAE washer. Hardware 1/2 inch or less in
with whiz nuts, spiralock nuts, or standard nuts and diameter can take a properly torqued whiz nut or
spiralock nut. See Figure 2.
preloading (torque) of the bolt in all other applications.
3. Follow these SAE washer rules after determining
See Appendix C, General Torque Specifications, and
exit hole type:
other torque specifications in the service literature.
a. Always use a washer between hardware and a
slot.
Preferred Nut/Bolt Clearance
1 2 b. Always use a washer under a nut (see 2 above
for exception).
c. Use a washer under a bolt when the female

thread is fixed (weld nut).
4. Refer to Figure 2, which depicts the preceding

hardware configuration possibilities.
Unacceptable Nut/Bolt Clearance
2
3 1
G-585
1. 1/2 of bolt diameter

2. Min. 1 full thread beyond top of nut
3. Below top of nut
Figure 1 Acceptable Bolt Lengths

5
4
6
G-585
1. Cap screw
2. Entry hole types
3. Standard nut and SAE washer
4. Whiz nut or spiralock: up to 1/2 in. dia. hardware
5. Weld nuts: above 1/2 in. dia. hardware
6. Exit hole types
Figure 2 Acceptable Hardware Combinations

Appendix C General Torque Specifications
Use the following torque specifications when service oiled threads. Increase values by 15% for nonplated
literature instructions give no specific torque values. threads. All torque values are +0%/--10%.
The charts list values for new plated, zinc phosphate, or
American Standard Fasteners Torque Specifications

Assembled into Cast Iron or Steel Assembled into
Torque Aluminum
Size Measurement Grade 2 Grade 5 Grade 8 Grade 2 or 5
8-32 Nm (in. lb.) 1.8 (16) 2.3 (20) — 1.8 (16)
10-24 Nm (in. lb.) 2.9 (26) 3.6 (32) — 2.9 (26)
10-32 Nm (in. lb.) 2.9 (26) 3.6 (32) — 2.9 (26)
1/4-20 Nm (in. lb.) 6.8 (60) 10.8 (96) 14.9 (132) 6.8 (60)
1/4-28 Nm (in. lb.) 8.1 (72) 12.2 (108) 16.3 (144) 8.1 (72)
5/16-18 Nm (in. lb.) 13.6 (120) 21.7 (192) 29.8 (264) 13.6 (120)
5/16-24 Nm (in. lb.) 14.9 (132) 23.1 (204) 32.5 (288) 14.9 (132)
3/8-16 Nm (ft. lb.) 24.0 (18) 38.0 (28) 53.0 (39) 24.0 (18)
3/8-24 Nm (ft. lb.) 27.0 (20) 42.0 (31) 60.0 (44) 27.0 (20)
7/16-14 Nm (ft. lb.) 39.0 (29) 60.0 (44) 85.0 (63) —
7/16-20 Nm (ft. lb.) 43.0 (32) 68.0 (50) 95.0 (70) —
1/2-13 Nm (ft. lb.) 60.0 (44) 92.0 (68) 130.0 (96) —
1/2-20 Nm (ft. lb.) 66.0 (49) 103.0 (76) 146.0 (108) —
9/16-12 Nm (ft. lb.) 81.0 (60) 133.0 (98) 187.0 (138) —
9/16-18 Nm (ft. lb.) 91.0 (67) 148.0 (109) 209.0 (154) —
5/8-11 Nm (ft. lb.) 113.0 (83) 183.0 (135) 259.0 (191) —
5/8-18 Nm (ft. lb.) 128.0 (94) 208.0 (153) 293.0 (216) —
3/4-10 Nm (ft. lb.) 199.0 (147) 325.0 (240) 458.0 (338) —
3/4-16 Nm (ft. lb.) 222.0 (164) 363.0 (268) 513.0 (378) —
1-8 Nm (ft. lb.) 259.0 (191) 721.0 (532) 1109.0 (818) —
1-12 Nm (ft. lb.) 283.0 (209) 789.0 (582) 1214.0 (895) —
Metric Fasteners Torque Specifications, Measured in Nm (ft. lb.)

Assembled into Cast Iron or Steel Assembled into
Aluminum
Size (mm) Grade 5.8 Grade 8.8 Grade 10.9 Grade 5.8 or 8.8
M6 x 1.00 5.6 (4) 9.9 (7) 14.0 (10) 5.6 (4)
M8 x 1.25 13.6 (10) 25.0 (18) 35.0 (26) 13.6 (10)
M8 x 1.00 21.0 (16) 25.0 (18) 35.0 (26) 21.0 (16)
M10 x 1.50 27.0 (20) 49.0 (35) 68.0 (50) 27.0 (20)
M10 x 1.25 39.0 (29) 49.0 (35) 68.0 (50) 39.0 (29)
M12 x 1.75 47.0 (35) 83.0 (61) 117.0 (86) —
M12 x 1.50 65.0 (48) 88.0 (65) 125.0 (92) —
M14 x 2.00 74.0 (55) 132.0 (97) 185.0 (136) —
M14 x 1.50 100.0 (74) 140.0 (103) 192.0 (142) —
M16 x 2.00 115.0 (85) 200.0 (148) 285.0 (210) —
M16 x 1.50 141.0 (104) 210.0 (155) 295.0 (218) —
M18 x 2.50 155.0 (114) 275.0 (203) 390.0 (288) —
M18 x 1.50 196.0 (145) 305.0 (225) 425.0 (315) —

Appendix D Common Hardware Identification
Screw/Bolts/Studs Nuts Hardness Grades

Head Styles Nut Styles American Standard
Hex Head or Machine Head Hex Head Grade 2
Hex Head or Machine Head

Lock or Elastic Grade 5
with Washer
Flat Head (FHM) Square Grade 8
Grade 8/9 (Hex Socket

Round Head (RHM) Cap or Acorn
Head)
Metric
Pan Head Wing
Number stamped on 5.8
Hex Socket Head Cap or Washers hardware; 5.8 shown
Allent Head Cap
Washer Styles
Hex Socket Head or Allent
Head Shoulder Bolt Plain
Sheet Metal Screw Split Lock or Spring
Stud Spring or Wave
Drive Styles
External Tooth Lock
Hex
Internal Tooth Lock
Hex and Slotted
Internal-External Tooth Lock
Phillipsr
Slotted
Hex Socket
Allent head screw is a trademark of Holo-Krome Co.

Phillipsr screw is a registered trademark of Phillips Screw Company.
Sample Dimensions
American Standard (Screws, Bolts, Studs, and Nuts) Plain Washers
1/4-20 x 1 9/32 x 5/8 x 1/16
Length In Inches (Screws and Bolts) Thickness
Threads Per Inch External Dimension
Major Thread Diameter In Fractional Inches Or Screw Number Size Internal Dimension
Metric (Screws, Bolts, Studs, and Nuts)
M8-1.25 x 20 Lock Washers
Length In Millimeters (Screws and Bolts) 5/8
Distance Between Threads In Millimeters Internal Dimension
Major Thread Diameter In Millimeters

Appendix E Common Hardware List
The Common Hardware List lists part numbers and dimensions for common hardware items.
American Standard
Part No. Dimensions Part No. Dimensions Part No. Dimensions Type
Hex Head Bolts (Grade 5) Hex Head Bolts, cont. Hex Nuts
X-465-17 1/4-20 x .38 X-6024-5 7/16-14 x .75 X-6009-1 1-8 Standard
X-465-6 1/4-20 x .50 X-6024-2 7/16-14 x 1.00
X-465-2 1/4-20 x .62 X-6024-8 7/16-14 x 1.25 X-6210-3 6-32 Whiz
X-465-16 1/4-20 x .75 X-6024-3 7/16-14 x 1.50 X-6210-4 8-32 Whiz
X-465-18 1/4-20 x .88 X-6024-4 7/16-14 x 2.00 X-6210-5 10-24 Whiz
X-465-7 1/4-20 x 1.00 X-6024-11 7/16-14 x 2.75 X-6210-1 10-32 Whiz
X-465-8 1/4-20 x 1.25 X-6024-12 7/16-14 x 6.50
X-465-9 1/4-20 x 1.50 X-6210-2 1/4-20 Spiralock
X-129-15 1/2-13 x .75 X-6210-6 1/4-28 Spiralock
X-465-10 1/4-20 x 1.75 X-129-17 1/2-13 x 1.00
X-465-11 1/4-20 x 2.00 X-6210-7 5/16-18 Spiralock
X-129-18 1/2-13 x 1.25 X-6210-8 5/16-24 Spiralock
X-465-12 1/4-20 x 2.25 X-129-19 1/2-13 x 1.50
X-465-14 1/4-20 x 2.75 X-6210-9 3/8-16 Spiralock
X-129-20 1/2-13 x 1.75 X-6210-10 3/8-24 Spiralock
X-465-21 1/4-20 x 5.00 X-129-21 1/2-13 x 2.00
X-465-25 1/4-28 x .38 X-6210-11 7/16-14 Spiralock
X-129-22 1/2-13 x 2.25
X-465-20 1/4-28 x 1.00 X-6210-12 1/2-13 Spiralock
X-129-23 1/2-13 x 2.50
X-125-33 5/16-18 x .50 X-129-24 1/2-13 x 2.75 X-6210-15 7/16-20 Spiralock
X-125-23 5/16-18 x .62 X-129-25 1/2-13 x 3.00 X-6210-14 1/2-20 Spiralock
X-125-3 5/16-18 x .75 X-129-27 1/2-13 x 3.50 X-85-3 5/8-11 Standard
X-125-31 5/16-18 x .88 X-129-29 1/2-13 x 4.00 X-88-12 3/4-10 Standard
X-125-5 5/16-18 x 1.00 X-129-30 1/2-13 x 4.50 X-89-2 1/2-20 Standard
X-125-24 5/16-18 x 1.25 X-463-9 1/2-13 x 5.50
X-125-34 5/16-18 x 1.50 X-129-44 1/2-13 x 6.00
X-125-25 5/16-18 x 1.75 X-129-51 1/2-20 x .75 Washers
X-125-26 5/16-18 x 2.00 X-129-45 1/2-20 x 1.25
230578 5/16-18 x 2.25 Bolt/
X-129-52 1/2-20 x 1.50
X-125-29 5/16-18 x 2.50 Part No. ID OD Thick. Screw
X-125-27 5/16-18 x 2.75 X-6021-3 5/8-11 x 1.00
X-6021-4 5/8-11 x 1.25 X-25-46 .125 .250 .022 #4
X-125-28 5/16-18 x 3.00 X-25-9 .156 .375 .049 #6
X-125-22 5/16-18 x 4.50 X-6021-2 5/8-11 x 1.50
X-6021-1 5/8-11 x 1.75 X-25-48 .188 .438 .049 #8
X-125-32 5/16-18 x 5.00
273049 5/8-11 x 2.00 X-25-36 .219 .500 .049 #10
X-125-35 5/16-18 x 5.50
X-125-36 5/16-18 x 6.00 X-6021-5 5/8-11 x 2.25 X-25-40 .281 .625 .065 1/4
X-125-40 5/16-18 x 6.50 X-6021-6 5/8-11 x 2.50 X-25-85 .344 .687 .065 5/16
X-6021-7 5/8-11 x 2.75 X-25-37 .406 .812 .065 3/8
X-125-43 5/16-24 x 1.75 X-6021-12 5/8-11 x 3.75 X-25-34 .469 .922 .065 7/16
X-125-44 5/16-24 x 2.50 X-6021-11 5/8-11 x 4.50 X-25-26 .531 1.062 .095 1/2
X-125-30 5/16-24 x .75 X-6021-10 5/8-11 x 6.00 X-25-15 .656 1.312 .095 5/8
X-125-39 5/16-24 x 2.00 X-25-29 .812 1.469 .134 3/4
X-125-38 5/16-24 x 2.75 X-6021-9 5/8-18 x 2.50
X-25-127 1.062 2.000 .134 1
X-6238-2 3/8-16 x .62 X-6239-1 3/4-10 x 1.00
X-6238-10 3/8-16 x .75 X-6239-8 3/4-10 x 1.25
X-6238-3 3/8-16 x .88 X-6239-2 3/4-10 x 1.50
X-6238-11 3/8-16 x 1.00 X-6239-3 3/4-10 x 2.00
X-6238-4 3/8-16 x 1.25 X-6239-4 3/4-10 x 2.50
X-6238-5 3/8-16 x 1.50 X-6239-5 3/4-10 x 3.00
X-6238-1 3/8-16 x 1.75 X-6239-6 3/4-10 x 3.50
X-6238-6 3/8-16 x 2.00 X-792-1 1-8 x 2.25
X-6238-17 3/8-16 x 2.25 X-792-5 1-8 x 3.00
X-6238-7 3/8-16 x 2.50 X-792-8 1-8 x 5.00
X-6238-8 3/8-16 x 2.75
X-6238-9 3/8-16 x 3.00
X-6238-19 3/8-16 x 3.25
X-6238-12 3/8-16 x 3.50
X-6238-20 3/8-16 x 3.75
X-6238-13 3/8-16 x 4.50
X-6238-18 3/8-16 x 5.50
X-6238-25 3/8-16 x 6.50
X-6238-14 3/8-24 x .75
X-6238-16 3/8-24 x 1.25
X-6238-21 3/8-24 x 4.00
X-6238-22 3/8-24 x 4.50

Metric
Hex head bolts are hardness grade 8.8 unless noted.
Part No. Dimensions Part No. Dimensions Part No. Dimensions Type
Hex Head Bolts (partial thread) Hex Head Bolts (full thread) Hex Nuts
M931-05055-60 M5-0.80 x 55 M933-04006-60 M4-0.70 x 6 M934-03-50 M3-0.50 Standard
M931-06040-60 M6-1.00 x 40 M933-05035-60 M5-0.80 x 35 M934-035-50 M3.5-0.50 Standard
M931-06060-60 M6-1.00 x 60 M933-06010-60 M6-1.00 x 10
M931-06070-60 M6-1.00 x 70 M934-05-50 M5-0.80 Standard
M933-06014-60 M6-1.00 x 14 M982-05-80 M5-0.80 Elastic Stop
M931-06070-SS M6-1.00 x 70 M933-06016-60 M6-1.00 x 16
M931-06090-60 M6-1.00 x 90 M933-06025-60 M6-1.00 x 25 M934-06-64 M6-1.00 Std. (green)
M931-06150-60 M6-1.00 x 150 M933-06040-60 M6-1.00 x 40 M6923-06-80 M6-1.00 Spiralock
M931-08035-60 M8-1.25 x 35 M933-06050-60 M6-1.00 x 50 M982-06-80 M6-1.00 Elastic Stop
M931-08040-82 M8-1.25 x 40* M933-08016-60 M8-1.25 x 16 M6923-08-80 M8-1.25 Spiralock
M931-08050-60 M8-1.25 x 50 M933-08025-60 M8-1.25 x 25
M931-08055-60 M8-1.25 x 55 M934-10-60 M10-1.50 Standard
M933-08030-60 M8-1.25 x 30 M934-10-60F M10-1.25 Standard
M931-08055-82 M8-1.25 x 55* M933-08030-82 M8-1.25 x 30*
M931-08060-60 M8-1.25 x 60 M6923-10-80 M10-1.50 Spiralock
M931-08070-60 M8-1.25 x 70 M933-10012-60 M10-1.50 x 12 M6923-10-62 M10-1.50 Spiralock[
M931-08070-82 M8-1.25 x 70* M961-10020-60 M10-1.25 x 20 M982-10-80 M10-1.50 Elastic Stop
M931-08080-60 M8-1.25 x 80 M933-10025-60 M10-1.50 x 25 M934-12-60F M12-1.25 Standard
M931-08100-60 M8-1.25 x 100 M933-10030-82 M10-1.50 x 30*
M931-10040-82 M10-1.25 x 40* M933-12020-60 M12-1.75 x 20 M934-18-80 M18-2.5 Standard
M931-10045-60 M10-1.50 x 45 M933-12025-82 M12-1.75 x 25*
M961-12030-60 M12-1.25 x 30 M934-20-80 M20-2.50 Standard
M931-10050-60 M10-1.50 x 50 M982-20-80 M20-2.50 Elastic Stop
M931-10055-60 M10-1.50 x 55 M933-12030-60 M12-1.75 x 30
M931-10065-60 M10-1.50 x 65 M961-12040-82 M12-1.25 x 40* M934-24-80 M24-3.00 Standard
M931-10080-60 M10-1.50 x 80 M933-12040-82 M12-1.75 x 40*
M931-10090-60 M10-1.50 x 90 M934-30-80 M30-3.50 Standard
M961-14025-60 M14-1.50 x 25
M931-10090-82 M10-1.50 x 90* M933-14025-60 M14-2.00 x 25
M931-10100-60 M10-1.50 x 100 Washers
M931-10110-60 M10-1.50 x 110 M961-16025-60 M16-1.50 x 25 Bolt/
M931-10120-60 M10-1.50 x 120 M933-16025-60 M16-2.00 x 25
M961-16030-82 M16-1.50 x 30* Part No. ID OD Thick. Screw
M931-10130-60 M10-1.50 x 130
M931-10140-60 M10-1.50 x 140 M933-16030-82 M16-2.00 x 30* M125A-03-80 3.2 7.0 0.5 M3
M931-10180-60 M10-1.50 x 180 M933-16035-60 M16-2.00 x 35 M125A-04-80 4.3 9.0 0.8 M4
M961-16040-60 M16-1.50 x 40 M125A-05-80 5.3 10.0 1.0 M5
M931-12045-60 M12-1.75 x 45 M933-16040-60 M16-2.00 x 40 M125A-06-80 6.4 12.0 1.6 M6
M960-12050-60 M12-1.25 x 50 M933-16050-60 M16-2.00 x 50 M125A-08-80 8.4 16.0 1.6 M8
M960-12050-82 M12-1.25 x 50* M933-16050-82 M16-2.00 x 50* M125A-10-80 10.5 20.0 2.0 M10
M931-12050-60 M12-1.75 x 50 M933-16060-60 M16-2.00 x 60 M125A-12-80 13.0 24.0 2.5 M12
M931-12055-60 M12-1.75 x 55 M125A-14-80 15.0 28.0 2.5 M14
M931-12060-60 M12-1.75 x 60 M933-18035-60 M18-2.50 x 35
M933-18050-60 M18-2.50 x 50 M125A-16-80 17.0 30.0 3.0 M16
M931-12065-60 M12-1.75 x 65 M125A-18-80 19.0 34.0 3.0 M18
M931-12075-60 M12-1.75 x 75 M933-18060-60 M18-2.50 x 60
M125A-20-80 21.0 37.0 3.0 M20
M931-12080-60 M12-1.75 x 80 M933-20050-60 M20-2.50 x 50 M125A-24-80 25.0 44.0 4.0 M24
M931-12090-60 M12-1.75 x 90 M933-20055-60 M20-2.50 x 55
M931-12100-60 M12-1.75 x 100
M931-12110-60 M12-1.75 x 110 Pan Head Machine Screws * This metric hex bolt’s hardness is grade 10.9.
M960-16090-60 M16-1.50 x 90 M7985A-03010-20 M3-0.50 x 10 [ This metric hex nut’s hardness is grade 8.
M931-16090-60 M16-2.00 x 90 M7985A-03012-20 M3-0.50 x 12
M931-16100-60 M16-2.00 x 100 M7985A-04010-20 M4-0.70 x 10
M931-20065-60 M20-2.50 x 65 M7985A-04020-20 M4-0.70 x 20
M931-20120-60 M20-2.50 x 120 M7985A-04100-20 M4-0.70 x 100
M931-20160-60 M20-2.50 x 160 M7985A-05010-20 M5-0.80 x 10
M931-22090-60 M22-2.50 x 90 M7985A-05012-20 M5-0.80 x 12
M931-22120-60 M22-2.50 x 120 M7985A-05016-20 M5-0.80 x 16
M931-22160-60 M22-2.50 x 160 M7985A-05100-20 M5-0.80 x 100
M931-24090-60 M24-3.00 x 90 M7985A-06100-20 M6-1.00 x 100
M931-24120-60 M24-3.00 x 120 Flat Head Machine Screws
M931-24160-60 M24-3.00 x 160
M965A-04012-SS M4-0.70 x 12
M965A-05012-SS M5-0.80 x 12
M965A-05016-20 M5-0.80 x 16

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
TP-6127 9/02 7 Jurong Pier Road
Singapore 619159
E 2002 by Kohler Co. All rights reserved. Phone (65)264-6422, Fax (65)264-6455

Tp6127 - MPAC 1000 Controller & Service Manual

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Service

Automatic Transfer Switches

Product identification numbers determine service parts.

Transfer Switch Identification Numbers

Accessory Number Accessory Description

Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside front cover

TP-6127 9/02 Table of Contents

Section 4 Transfer Switch Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Table of Contents TP-6127 9/02

Section 8 600--1200 Amp Transfer Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

TP-6127 9/02 Table of Contents

Section 11 1600--3000 Amp Open-Transition Switches and 1000--3000 Amp Bypass/Isolation

Table of Contents TP-6127 9/02

IMPORTANT SAFETY Safety decals affixed to the equipment Battery

Disabling the generator set. Locate the battery in a well-ventilated

TP-6127 9/02 Safety Precautions and Instructions I

II Safety Precautions and Instructions TP-6127 9/02

TP-6127 9/02 Safety Precautions and Instructions III

IV Safety Precautions and Instructions TP-6127 9/02

TP-6127 9/02 Introduction i

For professional advice on generator power China

Fax: (65) 264-6455

ii Service Assistance TP-6127 9/02

1.1 Introduction WARNING

Keep records of all maintenance or service.

TP-6127 9/02 Section 1 Scheduled Maintenance 1

(600 volts and under) NOTICE

2 Section 1 Scheduled Maintenance TP-6127 9/02

D Worn, missing, or broken components SUITABLE FOR CONTROL OF MOTORS, ELEC

42 480 GE SGL4,SGP4,TB4, 400

D Other evidence of wear, damage, deterioration, or 42 480 I--T--E CJD6,HHJD6, 400

42 480 WESTH HKD,KDC,LCL, 400

42 480 ABB S5 400

Periodically oil the enclosure door locks and screws.

TP-6127 9/02 Section 1 Scheduled Maintenance 3

Wire Repair or Replacement. Replace wiring when

Power Circuit Wiring. Have damage to line voltage

Transfer Switch Inspection. Remove the arc chute

4 Section 1 Scheduled Maintenance TP-6127 9/02

Every Year Note: To obtain accurate readings, keep the meter

TP-6127 9/02 Section 1 Scheduled Maintenance 5

Compare the calculated values for resistance (R) to the

4. If the hi-pot tester indicates wire insulation

Every Five Years

6 Section 1 Scheduled Maintenance TP-6127 9/02

TP-6127 9/02 Section 1 Scheduled Maintenance 7

8 Section 1 Scheduled Maintenance TP-6127 9/02

2.1 Introduction to DANGER

Disconnect power to the transfer switch before opening

Servicing the transfer switch. Hazardous voltage can

TP-6127 9/02 Section 2 Controller Troubleshooting 9

2.3 Event History

10 Section 2 Controller Troubleshooting TP-6127 9/02

TP-6127 9/02 Section 2 Controller Troubleshooting 11

12 Section 2 Controller Troubleshooting TP-6127 9/02

TP-6127 9/02 Section 2 Controller Troubleshooting 13

14 Section 2 Controller Troubleshooting TP-6127 9/02

TP-6127 9/02 Section 2 Controller Troubleshooting 15

16 Section 2 Controller Troubleshooting TP-6127 9/02