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KPEC Series ATS Cabinet

Operation Manual

www.kipor.com

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Content

Safety instructions

1. ATS general introduction

1.1 Definition and working principle

1.2 Applications

1.3 ATS switching mode

1.4 ATS switching control

1.5 ATS

2. Brief introduction for KPEC series ATS cabinet

2.1 Brief introduction for KPEC series ATS cabinet

2.2 Brief introduction for automatic transfer switching (ATS)

2.3 Model definition for KPEC series ATS cabinet

3. Operation manual for KPEC series ATS cabinet

3.1 Introduction for KPEC series ATS cabinet

3.2 Cabinet

3.3 Electrical component

Standard component

Optional component

3.4 Installation

3.4.1 Overview

3.4.2 Safety concerns

3.4.3 Mounting method

3.4.4 Wiring

3.5 Operation

3.5.1 KPD100 controller

3.6 Trial run of ATS cabinet

Trial run at manual mode

Trial run at automatic mode

Normal operation of ATS cabinet

Periodical maintenance

How to obtain maintenance service

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4. Trouble shooting

5. Vendor list (options and accessories)

Vendor list

Options

6. Attachment

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1. SAFTY INSTRUCTIONS

Please pay special attention to the material in this manual when preceded with the

following symbols:

Indicates a strong possibility of severe personal injury or death if

instructions are not followed.

Indicates a possibility of personal injury or equipment damage if

instructions are not followed

Indicates a minor to moderate possibility of personal injury or

equipment damage if instructions are not followed Electric shock may cause serious personal injuries or even death.

There is possible electric shock that may cause serious personal injury or even death upon

the high voltage of transfer switch components. Please read and observe the following

advices.

Keep the transfer switch cabinet closed and locked. Make sure only the authorized

personnel can have the key.

High voltage in the cabinet may cause serious shock injury, so all the maintenance and

repair concerning the transfer switch should only be done by electrician or authorized

personnel.

If it is necessary to open the cabinet:

1. Turn the operation selection switch of generator set to “OFF”.

2. Power off the battery charger.

3. Power off the generator or its starting battery. (Remove the negative grounding lead

firstly.)

4. Power off the ATS AC power supply. If it is required by operation guide to switch off AC

power on ATS, special caution for electric shock should be exercised.

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General precautions

When operating electrical equipment, place a rubber insulation mat upon the dry wooden

platform on the metal or cement base.

Forbid wet dress (especially wet shoes) or wet skin surface exposed in electrical

equipment operation.

Jewelries are good conductors of electricity. Remove them when operating the electrical

equipment.

Do wear the safety glasses when maintaining the ATS. Forbid smoking around the battery.

Do not operate the machine with mental or physical fatigue, or after drinking or taking

medicine.

Warn that incorrect maintain or parts replacing may cause death,

serious personal injury or equipment damage. Electrical parts

and machine service should be carried out by qualified

technicians.

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1. ATS GENERAL INTRODUCTION

1. Definition and working principle

ATS is short for automatic transfer switch. It is mostly used in emergency power supply system,

automatically switching the load circuit from one power supply to another (standby power supply)

and insuring the continuous and reliable running of important load.

2. Applications

(1) Switch between the grid and standby power supply (i.e. generator set)

Applicable to the system of standby power supply (i.e. generator set) or one-way power grid. The

transfer switch can automatically detect power fault of the grid, send start signal to standby

generator set and switch the load.

(2) Switch between generators

Applicable to the system with several generator sets as the main power supply. If the main

generator set goes wrong, the transfer switch will send start signal to the second generator set and

switch the load.

(3) Switch between the grids

Applicable to the multiple power grids without a standby generator set. If one grid goes wrong, the

transfer switch will automatically connect the load to the second one.

(4) Triplicate power supply

A. Applicable to the single standby power supply and dual grid system.

The grid transfer switch controls the power supplied by dual grid according to the predetermined

order. If power supply of both the grids goes wrong, the transfer switch will send start signal to

standby generator set and switch the load.

B. Applicable to the single grid and dual standby power supply system.

If the grid goes wrong, the transfer switch will send start signal to the main standby generator set

and switch the load. If the main standby generator set goes wrong, the transfer switch will send

start signal to the second standby generator set and switch the load.

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3. ATS switching mode

(1) Open-loop switching (in-phase switching, power-off switching)

Off after On is the basic switching mode: Firstly switch off the first power supply, and then switch on

the second power supply. Users can monitor both the power supplies and start switch with the

in-phase monitor (or sync check function) in the controller, so as to avoid the problem of

out-of-phase.

Application: emergency power system, regulation specified power system and optional standby

power system; resistive load; small motor load.

(2) Delayed switching (program controlled switching)

Similar to the open-loop switching. Firstly switch off the first power supply, and then switch on the

second power supply after an adjustable delayed period. This adjustable period is enough for the

residual voltage to attenuate before connecting to the second power supply.

Application: Inductive (motor) load, recommendation of some UPS and VFD manufacturer.

(3) Closed-loop switching (parallel switching)

Off after On switching can make continuous power supply. Through the instant parallel of power

supply (<100ms) during the switching period, Seamless load switching from one power supply to

another is achieved.

Application: especially important load power supply, including hospitals and data centers.

(4) Isolated bypass switching

Automatic maintenance for main ATS. No need for cutting off the load power supply. Through the

parallel of two switches, the main ATS can be drew and maintained after switching to bypass

supply. The bypass switch increases redundancy to the system.

Application: especially important load power supply and maintenance, including hospitals and data

centers.

4. ATS switching control

ATS switching is controlled by ATS controller. The controller is generally used for inspecting the

work condition of monitored power supply (double lines). When the monitored power supply goes

wrong (e.g. phase failure, under voltage, loss of voltage or frequency deviation), the controller

sends operation signal and ATS automatically switches from one power supply to another. This

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digital and intelligent ATS controller features the advantages of excellent performance, adjustable

parameter, close accuracy, high reliability and convenient in use.

ATS controller can be installed at following positions:

(1) At the ATS cabinet;

(2) On the generator set* or other user specified installation position;

* = Generator set controller has the ATS controlling function.

5. ATS

ATS is classified into two types: PC grade (integrated type) and CB grade (breaker type).

(1) PC grade: integrated type. It is the special switch for dual power switching, features the benefits

of compact structure, self interlock, rapid switching speed (within 0.3s), safety and reliability, but

requires a short circuit to protect the electric appliance.

(2) CB grade: equipped with over-current tripper. The main contact can be connected and used for

breaking the short circuit current, featuring the function of overload and short circuit protection.

(3) Contactor-type: applies reversible contactor with mechanical interlocking, more economical,

without short circuit protection.

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2. BRIEF INTRODUCTION FOR KPEC SERIES ATS CABINET

KIPOR KPEC series ATS cabinet applies intelligent controller KPD100 and automatic transfer

switching (ATS), and shells with cabinet of IP32 and IP54 protection grade. It can realize the

manual/auto switching on multi power supply system at various switching modes according to the

various customer requirements.

2.1 Brief introduction for KPEC series ATS cabinet

KPEC series ATS cabinet is the KPD100 intelligent controller and ATS control system researched

and developed by KIPOR, which integrates the digital, intellectual and networking technology,

realizes manual/auto switching control between standby and main power, and obtains the data

measuring, alarm protection and 3 remote functions. It features compact design, convenient wiring,

simple handling and reliable operation.

2.2 Brief introduction for automatic transfer switching (ATS)

Automatic transfer switching (ATS) features:

(1) Conform to the international standard.

There is standard from International Electrotechnical Commission especially for ATS, i.e.

IEC60947-6-1. Automatic transfer switching (ATS) accords with this standard and has passed the

certificate of KEMA testing institute.

(2) Integrated design.

(3) Dual interlock of mechanical and electrical. ATS has reliable mechanical interlock and will never

power on two supply lines simultaneously. This is controlled by the ATS controller through the

control over electromagnetic drive coil.

(4) Electromagnetic drive switch, with high speed.

Depend upon the unique electromagnetic coil driving, with the switching time within 0.2s (open-loop

switching mode). As electrical switching on both the two power lines may generate electric arc

conduction (about 0.12s), the actual time of load power off will not exceed 0.5s.

(5) Internal mechanical state remaining mechanism

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ATS is driven by electromagnetic power. The coil only works during switching, therefore greatly

increase the lifespan of the actuating element.

(6) High withstanding capability to short circuit

ATS is to switch between two power supplies, bearing no protection function. When short circuit or

overload occurs, ATS only can withstand but not trip. So it is not until the breaker trips will not the

ATS stop withstanding the high current. This withstanding capability may equal or exceed the short

circuit breaking capability of ATS front-end circuit breaker.

2.3 Model definition for KPEC series ATS cabinet:

Rules for the serial number of KPEC series ATS cabinet are as following:

(1) KPEC= general purpose ATS cabinet of open-loop or delayed switching (option) mode:

(2) Pole number: 2, 3 or 4

2 poles: single-phase generator set

3 poles: single-phase dual voltage or three-phase three-line generator set

4 poles: three-phase four-line generator set

(3) Current ratings:

26A, 50A, 75A, 100A, 125A, 160A, 200A, 250A, 320A, 400A, 630A, 800A, 1000A, 1250A, 1600A,

2000A, 2500A, 3000A, 3200A

The types of 26A、50A、75A are equipped with ABB contactor.

(4) Voltage code:

A: single-phase 110V~120V

B: single-phase 220V~240V

C: three-phase three-line 110/190V、115/200V、120/208V、127/220V、133/230V、139/240V

D: three-phase four-line 220/380V，230/400V，240/415V

E: single-phase dual voltage 110/220V，115/230V，120/240V

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(5) Control type

P：DC12V

Q：DC24V

(6) Frequency

5：50Hz

6：60Hz

(7) Structure type

2：IP32 indoor use (wall mounted type)

3：IP54 outdoor weatherproof cabinet (floor type)

(8) Options for surge protector (lightning protector):

A: without surge protector (lightning protector)

B: with surge protector

Voltage rating of the battery charger DC output is the same to the option in “control type”, with the

maximum output of 6A.

(9) Distributed by the factory.

Remark:

KPEC series ATS cabinet can obtain the optimal power switching effect when using together with

the generator set of KIPOR.

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3. OPERATION MANUAL FOR KPEC SERIES ATS CABINET

This manual covers the KPEC series ATS cabinet produced by KIPOR.

This manual contains the operation, installation and maintaining information of KPEC series ATS

cabinet.

3.1 Introduction for KPEC series ATS cabinet

This is an open-loop (or delayed switching, optional) general purpose ATS cabinet (see fig.3-1,

ATS control function is inbuilt at the KPD100 intelligent controller). It will never power on two supply

lines simultaneously. The grid line works with a generator set (emergency power supply) as

standby power and loads connect to the ATS common terminal (see fig.3-2). The controller

monitors voltage and frequency range tolerable to the power supply and controls the transfer switch

to switch between power supplies automatically. Normally, the loads are supplied by grid (see fig.

3-3). When the grid supply is off, the loads will be switched to be supplied by generator set (see

fig.3-4). As the grid supply recovers, the loads will be switched back to grid.

Fig.3-1 Open state of KPEC series ATS cabinet: 200A, 4-pole transfer switch

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Fig.3-2 Wiring diagram for 200A 4-pole transfer switch

Fig.3-3 ATS power supply diagram: grid power – load

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Fig.3-4 ATS power supply diagram: generator power – load

3.2 Cabinet

There are two types of cabinets for KPEC series ATS use: IP32 and IP54. IP32 cabinet is designed

to prevent the foreign matters with diameter over 2.5mm and the water with 15°incidence angle

from entering, while IP54 cabinet is designed to prevent dust and water from all directions.

(1) Cabinet

Refer to fig. 3-5 and fig.3-1 for dimension and outline drawing for IP32 cabinet

Refer to fig. 3-6 and fig.3-2 for dimension and outline drawing for IP54 cabinet

Fig.3-5 IP32 cabinet outline drawing

Fig.3-1 Approximate dimension of IP32 cabinet

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Switch current

grade Height（H） Width（W） Thickness（D） Thickness（D1）

26、100、200

（Single phase）

26、50、75（Three

phase）

500mm 450mm 230mm 45mm

26、50、75、100、

125、160、200

（Three phase）

650mm 500mm 230mm 45mm

250、320、400

（Three phase） 800mm 600mm 230mm 45mm

500、630（Three

phase） 1000mm 800mm 310mm 45mm

Fig.3-6 IP54 cabinet outline drawing

Fig.3-2 Approximate dimension of IP54 cabinet

Specification Switching current grade Height（H） Width（W） Thickness（D）

Three-phase 26、50、75、100、125、160、 863mm 500mm 285mm

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200

Three-phase 250、320、400 1163mm 600mm 285mm

Three-phase 630、800、1000、1250、1600 1500mm 760mm 660mm

From fig.3-7 to fig.3-10 some examples of cabinet are displayed

Fig.3-7-1 Floor type internal components: 40-200A, 4-pole switch

Fig.3-7-2 Floor type internal components: 40-200A, 4-pole switch

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Fig.3-8 Wall-mounted type internal components: 100A and 200A, 2-pole switch

Fig.3-9-1 Wall-mounted type internal components: 250A-400A, 4-pole switch

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Fig.3-9-2 Floor type internal components: 250-400A, 4-pole switch

Fig.3-10 Floor type internal components: 630-1600A, 4-pole switch

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3.3 Electrical components

This part explains the standard and optional parts of ATS cabinet electrical controlling system (refer

to figures from 3-7 to 3-10).

Incorrect calibration or regulation may cause death, serious personal injury and/or equipment

damage. The one who calibrates or regulates must be qualified technicians.

There is electric shock hazard in the cabinet and behind the door. Opening the door may cause

serious personal injury. So special attention must be paid that body, tools, jewelries, clothes, hair

etc. should be away from the electric contactor.

Standard components:

A. KPD100 intelligent controller

KPD100 intelligent controller (fig.3-11) is installed on the ATS cabinet. ATS switching is controlled

by KPD100 intelligent controller obtaining the built-in ATS controlling function (with default

installation on the generator set). Green light on the display panel indicates the state of transfer

switch as following:

Grid power indicator – it turns light when the grid voltage is normal and turns red when abnormal.

Grid power supply indicator – it turns light when the grid is supplying power to load.

Generator power indicator– it turns light when the generator is normal and turns red when

abnormal.

Generator power supply indicator - it turns light when the generator is supplying power to load.

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Fig.3-11 ATS display panel on the cabinet door

Details about KPD100 intelligent controller please see Part 5 of this chapter.

B. ATS transfer switch:

The transfer switch (refer to fig.3-7 - 3-10), which avoids powering on two power supplies

simultaneously through a mechanical interlock mechanism, completes load transfer between two

power supplies by opening and closing the contactor. It may have 2 poles, 3 poles or 4 poles. The

electromagnetic mechanical actuating part may be controlled by the transfer switch controller or

manually switched by hand operation.

Hand operation on the transfer switch can be explained as following, taken the 4-pole 200A transfer

switch as an instance:

Make use of the spare operating handle and insert the manual operated axle, then the manual

switching on transfer switch is ready. It should be operated with zero load by qualified personnel as

following procedure:

There is electric shock hazard if operate at load bearing state, which may cause serious personal

injury or even death. Do not try to manually operate switches when there is load. Cut off both the

power supplies before manual operation.

1. Make sure there is no load on the transfer switch.

2. Open the door of ATS cabinet.

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3. Remove fuse F2, F5 to cut off the power supply (fig.3-14).。

Switch to A side

a. Place the handle on converting axle.

b. Rotate the axle until the switch is locked.

c. Status window on the transfer switch indicates “ON”

(Fig.3-12). Fig.3-12

Switch to B side

a. Place the handle on converting axle.

b. Rotate the axle until the switch is locked.

c. Status window B on the transfer switch indicates “ON”

(Fig.3-13). Fig.3-13

Attentions: Remember to convert the load of transfer switch to effective power supply (if both the

power supplies are effective, convert to grid).

Remove the hand operated handle before switching to auto mode, otherwise the operation of ATS

may make the handle throw away at high speed, which may cause serious personal injury. Place

the hand operated handle at safe position (e.g. at the bottom of the cabinet).

1. Make sure the hand operated handle has been removed and placed at safe positon.

2. To return to auto mode, relay the fuse F2, F5 to recover power supply.

3. Close the door of cabinet.

C. Terminal block X1

Control cable between the generator set and ATS cabinet needs to be connected through the

terminal block. Arrange of the terminal block is displayed in Fig.3-14.

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Fig.3-14 Terminal block X1

D. Battery charger

When the grid supplies power and the generator set is idle, battery charger will charge the battery

of generator set to ensure ample power of the battery.

BAC series automatic battery charger works according to the charge characteristics of battery. Its

charging mode is “constant variable current”, i.e., when the battery terminal voltage is below the

default value, the charge current is constant; when the battery terminal voltage is above the default

value, the charge current gradually decreases with the increase of battery terminal voltage. As the

voltage reaches threshold value, the charging turns to be floating charge. Then the charging current

only compensates the self discharge of battery and longtime charge will not harm the battery. In

other words, this charger not only can maintain the full charge state of battery, but also can ensure

its service life. It has the functions of output short circuit protection and battery reverse protection.

The charger output voltage and max output current can be regulated（increase in clockwise,

decrease in counterclockwise）. The regulating range for 12V charger is 10-16V (default set is

13.8V), for 24V charger is 20-31V (default set is 27.6V), and for current is 2-4A (default set is 4A).

Optional components:

Surge protector (SPD)

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Surge protecting system applies combined SPD, which is composed of voltage switching type

component and voltage limiting type component. The protection mode can be optional differential

mode (phase to phase and phase to midline) and common mode (phase to grounding and midline

to grounding) according the customer’s need. It complies with:

Lightning protection and grounding design standard of mobile communication base (YD5068-98)

Lightning protection technology standard of communication program power system (YD5078-98)

Thunder and lightning overvoltage protection program design standard of communication bureau

(YD5098-2001)

3.4. Installation

3.4.1 Overview

These installation suggestions apply for typical installation. They contain almost all the options or

adjustable options of the factory design. However, as there are various installation methods, it is

impossible to provide suggestion for all the situations. If you can not find solution in this manual,

please contact the nearest KIPOR distributor for support.

3.4.2 Safety concerns

With correct installation, maintenance and operation, the well-designed ATS cabinet can provide

safe and effective service. The safety and reliability of the whole system lie on a lot of other factors

that can be controlled by non-manufactures. To avoid the potential hazard, please carry through the

mechanical and electrical wiring strictly in strict accordance with requirement of the manual. All the

external system of transfer switch should accord with the operation requirement. It can start work

only after all the required inspection and test have been fulfilled and all the instruction has been

reached to finish the installation.

Make sure voltage of the grid power and generator set power correspond with the rated value on

nameplate.

Position of the ATS cabinet is adjustable according to wiring type and application.

Position and wiring of ATS cabinet should be in accordance with requirement of contract drawing.

A switch for maintenance must be configured on the line before ATS cabinet is connected to grid.

Place the ATS cabinet on vibrationless fixed surface. Keep far away from the place with flammable

liquid or gas, heat source, damp or dust.

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The electric arc generated from converting may ignite flammable gas and lead serious personal

injury or even death. Do not place ATS cabinet at positions closed to battery, fuel tank, solvent,

other flammable liquid or gas or the relevant ventilation area for emission.

3.4.3 Mounting method

ATS cabinet can be mounted vertical or on the wall.

Wall mounting

Small or medium-sized ATS cabinet (40A-400A) can be mounted on the wall.

A. Check the location. Make sure there is no wire, water conduit, gas pipe or exhaust duct behind

the wall.

B. Set two bolts on the wall to fix the fixing keyhole on the cabinet.

C. Cabinet is vertical in the packing case. Remove the top and side packing carefully.

D. Lift the cabinet and fix it on the wall with the two fixing bolts.

Incorrect lifting may cause serious personal injury, so there should be sufficient manpower to lift and

mount the cabinet.

E. Fix the two bolts at the bottom without screwing them down.

F. Have the cabinet closed to the wall. If it is not close enough, adjust with shim.

G. Screwing down all the fixing bolts.

Discretional vertical mounting

Large-sized (630A-1600A) and outdoor (IP54) ATS cabinets apply the ground mounting way.

A. Please observe the local law and regulation.

B. Make sure there is enough room for wiring under and behind the cabinet.

C. Keep the cabinet stable through having the four corners of cabinet fixed on the mounting bracket.

Apply cabinet that totally complies with the local law and regulation. The cabinet door should be

reliably locked and marked with safety warnings up to all the specifications. Minimum size of the

cabinet depends upon the rated current grade of transfer switch. Please refer to the relevant outline

drawing (Fig.3-5, Fig. 3-6) to obtain the minimum size.

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3.4.4 Wiring

Locate the parts according to figure 3-7 ~ 3-10.

AC voltage and current may bring hazard of electric shock and cause serious personal injury or

even death. Only well-trained and experienced person can exercise the following operation.

While mounting the wiring conduit, pay attention to the following precautions:

A. Cover the transfer switch to avoid unexpected enter of metal chips before mounting the

conduit.

B. If rigid tube is applied to connect the generator set and transfer switch, it is suggested to mount

flexible pipe between the rigid pipe and generator set to absorb vibration. Waste generated from

mounting may cause the equipment failure or damage.

Pay special attention not to have the drilling debris or filings into ATS, connection terminal block,

contactor or other parts. Additionally, pay attention not to damage the parts when using a

screwdriver.

Connection of AC main circuit

Please wire according to the following order:

A. Test the operation of generator set with generator set controller.

B. Shut off the generator set and cut off the negative terminal to avoid start.

Do cut off the battery of generator set (first cut off the negative wire) before wiring to prevent electric

shock caused by the start of generator which may cause serious personal injury or even death..

C. Current carrying capacity of the connection lead should be wide enough to bear the rated current

required by connection between transfer switch terminal and gird, load and generator set. Phase of

the grid and the generator set should be exactly the same (refer to Fig.3-15~3-18).

D. Connect the power cord to load output terminal.

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AC voltage and current may bring electric shock hazard and cause serious personal injury or even

death. Please make sure both the AC power supply have been cut off.

E. Make sure both the AC power supply have been cut off.

Fig.3-15 Terminal arrangement of 200A two-pole transfer switch

(inc. 100A transfer switch)

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Fig.3-16 Terminal arrangement of 40-200A four-pole transfer switch

(inc. 63A, 100A, 125A, 160A transfer switch, similar for three-pole)

Fig.3-17 Terminal arrangement of 250-400A four-pole transfer switch

(inc. 320A transfer switch, similar for three-pole)

Fig.3-18 Terminal arrangement of 630-1600A four-pole transfer switch

(inc. 800A, 1250A transfer switch)

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Control wiring connection of ATS cabinet and generator set

AC voltage and current may bring electric shock hazard and cause serious personal injury or even

death. Please make sure both the AC power supplies have been cut off.

KPEC series ATS cabinet can start and monitor the operation of generator set, so it is necessary to

connect the control cable of ATS cabinet and generator set.

Note：Control wires between ATS cabinet and genset are both optional parts!

There are 2 kinds of connection mean for control cable: connection terminal type and quick

connector type. Control cable is different from each other according to the various model of

generator set.

Connection terminal type (terminals) control cable is marked with wire number (section area: 1.0m

㎡. The length can be optional according to the onsite installation location, with recommended value

10m). During operation, users need to connect one cable terminal to relevant same-line terminal

block on generator set (refer to “Electrical principle diagram of generator set” for connection

terminal size), and the other terminal to same-line terminal block X1 on ATS cabinet (refer to

“Electrical principle diagram of ATS” for connection terminal size).Wiring diagram of ATS cabinet

please see the attachment of Part 6.

Both the terminals of quick connection type (quick connector) control cable ( section area: 1.0m㎡.

The length can be optional according to the onsite installation location, with recommended value

15m) are ready made quick connect plugs with their sockets on the generator set and the ATS.

When using it, users only need to plug the terminals of control cable and quick connectors of

generator set and ATS cabinet into their sockets and screw them down.

Check and clean

·Check all the circuit, make sure:

- The circuit and the switch do not interfere in each other.

- There is no broken wire at the switch of cabinet door.

- The circuit is not exposed to keen-edged or abrasive surface.

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- There is no line loosen or disconnection.

·After mounting and wiring the cabinet, clean the internal cabinet and remove all the debris, filings

and filth inside the cabinet and on the parts.

·Recheck the power voltage, make sure it coincide with the ratings on nameplate.

·Recheck the power phase, make sure the grid phase identical with that of generator set.

·Make sure control cable of ATS cabinet is correctly connected to that of generator set.

·Cut off power and operate ATS, make sure the operation is stable and free of cumber. If it is not,

check if there is damage caused by transportation or mounting, or if any chips are generated in

installation.

3.5 Operation

Transfer switch of KPEC series ATS cabinet is controlled by KPD100 intelligent controller installed

on ATS cabinet, so the following explanation gives a operation process of KPEC series ATS

cabinet.

3.5.1 KPD100 controller

Summary

KPD100 controller is mainly used to monitor the power grid. It will start the generator set and switch

to load power supply when the power grid is abnormal and automatically return to grid power supply

when the grid restores.

KPD100 controller monitors the power grid and indicates its status by light –emitting diode LED.

Features

1: control protection function:

Realize the function of generator manual or automatic starting, stopping, ATS transfer and alarm

protection;

2: 12/24VDC power supply;

3: manual and automatic working modes to choose;

4: AMF grid fault automatic start/stop control function;

5: RMS voltage detection functions of generator and power grid;

6: ATS manual and automatic mode to choose;

7: regular automatic maintenance can be set;

8: light –emitting diode LED fault display function;

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9: low-speed and over-speed protection of engine;

10: configurable input/output terminal and condition display function;

11: battery voltage and charge detection function;

12: working hour counting function;

13: RS232 communication function. It can monitor and set the parameters by upper machine.

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KPD100 control panel

Fig.3-21 KPD100 control panel

1. Key functions

Stop/param

eter－ key

Press the key to stop the running generator at running state and

reset the alarm at alarming state.

Press this key to choose －for parameters when at “Parameter set”

mode.

Manual

startup/para

meter+ key

Press the key to start the still generator under manual mode.

Press this key to choose +for parameters when at “Parameter set”

mode.

Auto/param

eter

increase

key

Press the key to set the generator to be under “AUTO mode”.

Press this key to increase parameters when at “Parameter set” mode,

equal to “+”

Manual/par

ameter

saving key

The key is to set the generator to be under “MAN mode”.

Press it to switch the load between power when at manual mode.

Press it under parameter configuration mode can save the parameter

value. It equals to “ok”.

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The operating mode is automatically turned into “MAN mode ” after KPD100 controller

initialized.

KPD100 controller has the function of protection.

When fault occurs:

· System outputs alarm signals, the corresponding LED indicator turns on or winks.

The relative data of KPD100 controller and ATS switching data:

2. Engine

Data Unit Pre-setting value Description

Failure start Sec 10 Fixed parameter, unchangeable

3. Generator

Data Unit Setting Range Pre-setting value Description

Freq Low 1Hz -20% 50Hz:400;60Hz:480

Freq High 1Hz +14% 50Hz:570;60Hz:684

Vol Low 0.1V 80％~90％ -10%Ue Includes disengage and return value

Vol High 0.1V 105％~130％ +10%Ue Includes disengage and return value

4. Main

Data Unit Setting Range Pre-setting

value

Description

Freq Low 1Hz (-24%)/ (-14%) 50Hz:380/430;60Hz:456/516

Freq High 1Hz (+24%)/ (+14%) 50Hz:620/570;60Hz:744/684

Vol Low 0.1V 80％~90％ -10%Ue Includes disengage and return value

Vol High 0.1V 105％~130％ +10%Ue Includes disengage and return value

5. ATS

Data Unit Pre-setti

ng ValueDescription

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ReStart Cnt Time(s) 3 Fixed parameter, unchangeable

Time lag of grid returning to be

normal Sec 30

Can be set as 0s, 5s, 10s, 20s, 30s, 60s,

180s

Time lag of generator

preheating Sec 5 Can be set as 0s, 1s, 2s, 3s, 4s, 5s, 6s, 8s

Time lag of generator warming Sec 30 Can be set as 0s, 1s, 2s, 3s, 5s, 30s,

120s, 300s

Time lag of voltage transfer Sec 2 Can be set as 0s, 1s, 2s, 3s, 4s, 5s, 8s,

10s

Time lag of generator cooling Min 2 Can be set as 0m, 0.1m, 2m, 5m, 10m,

15m, 25m, 30m

Data has been set up before delivery, adjustment is unnecessary. Users can't modify the data

under default mode! Please contact nearest dealer first if you would like to modify the data.

Maintenance personnel will service you at any moment.

As to details of KPD100 controller, please refer to operation manual of KPD100 controller.

3.6 Trial run of ATS cabinet

Take four-pole 200 ampere ATS cabinet as a sample to make a brief introduction of ATS test run：

Ensure correct wiring, no load to ATS cabinet and generator set normal

Trial run at manual mode：

A. Turn on the power switch of KPD100 controller on generator set, it enters into "Manual mode"

automatically.

B. Press the key on the panel. After generator set start, "Generator set power indicator lamp"

on ATS panel (Fig. 3-10），press the key ， ATS will switch to generator set, then the status

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window B of transfer switch will display “ON” （Fig. 3-13），"Generator set power supply indicator

lamp " on controller panel will be light.（Fig3-11）。

C. Close the grid power switch（User supply）， the "Grid power indicator lamp " on controller panel

will be light（Fig. 3-10），press the key , ATS switch to grid power, the state window A of

transfer switch will display “ON” （Fig. 3-12）, "Grid power supply indicator "on controller panel will

on（Fig. 3-11） “Generator power indicator lamp“ will go out.

D. Continuously press the key “Manual mode ”，ATS will repeat the action of B .C items

E：Press the key , generator set stops running. Disconnect the grid power, “test run under

manual mode" has been finished

Trial run at automatic mode:

A. Turn on the power switch, it enters into "Manual mode " automatically. Press the key . It

enter into “auto mode ”，the "auto indicator lamp" on control panel will be light. The controller will

realize the abnormality of grid power, then start the generator set automatically. After that,

"Generator power indicator lamp" will be light （Fig. 3-11），ATS will switch to generator set power,

the state window B of transfer switch displays “ON” （Fig.3-13），"Generator power indicator lamp"

on controller panel will be light(Fig. 3-11）。

B. Close the switch of grid power (User supply). "Grid power indicator lamp" on controller panel will

be light（Fig. 3-11），KDP100 controller controls ATS to switch to grid power. The status window A

of transfer switch will display “ON” （Fig3-12），"Generator power supply indicator lamp" will be on

(Fig. 3-11）and "Generator power indicator lamp" will go out. Generator set will stop automatically

after cooling delay, and keep in standby state.

C. Open the switch of grid power (User supply), KPD100 controller will realize abnormality of grid

power, then start the generator set automatically. ATS will repeat the action above.

D. Press the key , generator set stops running. Disconnect the grid power, "trial run under

manual mode" has been finished

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Under “AUTO mode ”, press the key can not start the set.

Normal operation of ATS cabinet

It is necessary to ensure the normal installation and set of ATS cabinet and generator set, correct

wiring of ATS AC circuit and control cables.

Turn on the power switch of KPD100 controller on generator set, press the key , it will enter into

"auto mode ”，"Auto indicator lamp" on control panel will be light. Controller will monitor the grid

data( See the following table)

When the data goes to be continuously abnormal, controller will start the generator set and make

ATS cabinet switch to generator set power. KPD100 controller still monitor data of generator set

and grid as well as engine water temperature, oil pressure, oil level to keep generator set work in

normal state. After grid is restored to be normal, controller will work again to connect load to grid

power. Generator set will stop automatically after cooling delay, and keep in standby state.

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Periodical maintenance

Periodic maintenance can make the transfer switch more reliable

Maintenance should be carried out by professional person. Ask for the dealer to repair or replace

the parts.

AC power may cause electric shock even death. Incorrect installation will cause personal injury and

equipment damage, so all maintenance should be carried out by professional person.

If not all AC power supply are cut off, transfer switch will cause injury .Ensure the switch control

button in the "stop" position. If a battery charge is equipped with, please disconnect the charger and

the starting battery (Disconnect - pole first) before maintenance

The gas generated by battery will burn which has injury hazard. Forbid smoking, electric arcs and

flame during battery maintenance.

1. Cut off all AC power supply

A. Cut off the AC power supply before continuing operation. Turn the generator operation switch

to stop position.

B. Disconnect the battery charge with AC power supply if it is equipped with.

C. Then disconnect the starting battery( Disconnect - pole first)

2. Clean

A．Clean all controller, gages, switches and inner bus and connection chips by a vacuum cleaner

B．Close the case door and clean the external surface by sponge ( mild detergent and water)

Do not let water flow into the case, especially gages, lamps and switches

3. Check

A．Check bus and supporting parts if there are burns, cracks, corrosion as well as any worn

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element. Contact dealer to replace these worn parts.

B．Check static contactor and movable contactor. Replace them if worn

C．Check all control wires and cables (especially the wires near door hinge)if they are worn

D．Check all control wires and cables. Fasten them if loose.

E．Check inner parts. Fasten them if loose.

1. Daily maintenance

A．If necessary, fasten the bus, control lines, power cables and terminals as well as all cable

connection chips

2. Connect AC power and check operation

A. Connect starting battery (connect - pole at last), common AC power and activate the power of

generator set controller is equipped with.

B. Check the battery charge and ensure correct operation

C. Close and lock the door according to this chapter

How to obtain maintenance service

Please contact nearest KIPOR dealer if maintenance is required. Maintenance personnel will

service you at any moment.

For Chinese customers, please contact:

Tel: xxxxxxxxx

Fax:xxxxxxxxx

Service support：

Please offer the specification and type of ATS when contacting the dealer.

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4.TROUBLE SHOOTING

This chapter consists of basic means of trouble shooting for operator and service agent.

These means depends on normative principle figures and phenomena.

AC power in generator or behind door is the existence of electric shock hazard. Personal injury will

occur when door opening, pay special attention to your body, clothes and hair not touching the

contactor. Remove the power of transfer switch by F2, F5 fuse. Operation as follow should be

carried out by professional technicians.

Inappropriate operation will lead to electric shock and personal injury. Please read the operation

manual carefully.

Abnormality Possible reasons Solution

Crank works,

but generator

cannot start

1. Fuel pipes fault

2. Electronic speed regulator or

line fault

3. Electronic speed regulator's

abnormal signal lead to no

output

4. Actuator fault

1. Check the fuel level and ensure no air in the fuel

pipes, filter and pipes without jam (Refer to

maintenance manual).

2. Check Electronic speed regulator and circuit,

replace broken elements.

3. Check speed sensor and ensure it no loose,

suitable clearance and normal signal into

electronic speed regulator.

4. Repair and replace the actuator.

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Crank doesn't

work

1. Fault alarm showed on

control panel.

2. Wiring fault

3. Start motor fault

4. Battery or cable fault

5. Generator controller

abnormal

1. Send the fault signals depending on fault

alarms

2 a．Check start circuit wiring.

2 b．Check controller wiring between ATS and

generator.

3. Repair and replace start motor

4. Check and ensure correct wiring of battery and

cable

5. Check controller and replace it if broken

Generator

works, but ATS

doesn't transfer

the load to

connect with

generator

1. Controller is not under "auto

mode ”

2. Voltage of generator power

output terminal is abnormal

3. Wiring fault

4. F5 fuse on the terminal strip

X1 melts down.

5. Inner contactors of KPD100

controller terminal 30、31 are

open.

6. Transfer switch broken

1．Choose "auto mode "

2．Check voltage of output terminal

3．Check wiring between ATS and generator

4．Check F5 fuse，Replace it if broken after trouble

shooting

5．Check closed contactor. Replace KPD100

controller if it is abnormal.

6. If there is rated voltage on two ends of transfer

switch, please replace the switch

Grid restores

but ATS

doesn't transfer

the load to

connect with

grid.

1. Wiring fault

2. F2 fuse on the terminal strip

X1 melts down.

3. Inner contactors of KPD100

controller terminal 34、35

are open.。

1. Check wiring between ATS and generator

2. Check F2 fuse，Replace it if broken after trouble

shooting

3. Check closed contactor. Replace KPD100

controller if it is abnormal.

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4. Transfer switch broken 4. If there is rated voltage on two ends of transfer

switch, please replace the switch

Switch

transfers the

load but

generator still

works

1. Cooling delay time of

generator

2.Circuit fault

3.Controller abnormal

1. Wait until the delay time finishes（≤30 minuets）

2. Check wiring between ATS and generator

3. Check controller, replace it if broken.

Charger does

not work (if

equipped)

1. F1 fuse melt down

2. Wiring fault

3. Battery charger broken

4. Battery worn or broken

1. Replace fuse after troubleshooting

2. Check wiring between ATS and generator

3. Replace battery charger.

4. Replace battery.

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5. VENDOR LIST (OPTIONS AND ACCESSORIES)

Vendor list

Controller

□ KPD100 intelligent controller

Rated current

□ 26（Transfer switch is ABB contact）

□ 50（Transfer switch is ABB contact）

□ 75（Transfer switch is ABB contact）

□ 100

□ 125

□ 160

□ 200

□ 250

□ 320

□ 400

□ 630

□ 800

□ 1000

□ 1250

□ 1600

□ 2000

□ 2500

□ 3000

□ 3200

□ 4000

Rated voltage（Phase voltage/line voltage）

□ Single phase 110V～120V

□ Single phase 220V～240V

□ Three-phase three-wire 190V

□ Three-phase three-wire 200V

□ Three-phase three-wire 208V

□ Three-phase three-wire 127/220V

□ Three-phase three-wire 133/230V

□ Three-phase three-wire 240V

□ Three-phase four-wire 220/380V

□ Three-phase three-wire 230/400V

□ Three-phase three-wire 240/416V

□ Single phase dual voltage 110/220V

□ Single phase dual voltage115/230V

□ Single phase dual voltage120/240V

Pole No. of transfer switch

□ 2 poles

□ 3 poles

□ 4 poles

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Frequency

□ 50Hz □ 60Hz

□ 50/60Hz

Application

□ Utility power to generator

ATS cabinet

□ IP32 Indoor

□ IP54 Outdoor cabinet

Control type (Battery voltage)

□ 12V □ 24V

Battery charger

□ 12V/4A

□ 24V/4A

Options：

Surge protection device (SPD)

□ Surge protection device

□ Remote control plug(socket) of ATS cabinet

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6. ATTACHMENT

44

45

WUXI KIPOR POWER CO., LTD. Jingyi Road Beside, Three Period, Industry Kit Park Wangzhuang, National High and New

Technique Industry Development Area, Wuxi

Tel: 0510-85205100 0510-85203799

Fax: 0510-85205026 0510-85203795

E-MAIL: kipor@kipor.com nxkipor@kipor.com