Kohler ZCS-6 User manual
TT-1685 3/16
INSTALLATION INSTRUCTIONS
Original Issue Date: 3/16
Model: ZCS-6 Programmed-Transition Transfer Switches
Market: ATS
Subject: M340+ to Decision-MakerrMPAC 1500 Controller Conversion Kit
GM99316-S6
Introduction
The conversion kit allows the replacement of the M340+
controller with a Decision-MakerrMPAC 1500
controller on model ZCS-6 programmed-transition
automatic transfer switches.
See Figure 1 for an illustration of the installed kit. See
Figure 2 for controller identification, if necessary.
Note: The optional accessory board (I/O) assembly
shown in the figures is available separately.
GM99316-S6
2
1. MPAC 1500 controller assembly
2. Optional accessory board (I/O) assembly
1
Figure 1 Decision-MakerrMPAC 1500 Controller
Conversion Kit, Installed
Tools and Materials Required:
DPhillipsrscrewdriver
DSmall flat tip screwdriver
DWire cutter
D7/16 nut driver
D11/32 nut driver
D5/16 nut driver
Read the entire installation procedure and compare the
kit parts with the parts list in this publication before
beginning installation. Refer to the wiring diagrams at
the end of this publication as needed during the
installation. Perform the steps in the order shown.
Decision-MakerrMPAC 1500 Controller
TT1685
M340+ Controller
Figure 2 Controller Identification
2TT-1685 3/16
KOHLER CO., Kohler, Wisconsin 53044 USA
Phone 920-457-4441, Fax 920-459-1646
For the nearest sales and service outlet in the
US and Canada, phone 1-800-544-2444
KOHLERPower.com
Kohler Power Systems
Asia Pacific Headquarters
7 Jurong Pier Road
Singapore 619159
Phone (65) 6264-6422, Fax (65) 6264-6455
Controller Accessories
Many functions that required optional accessories with
the M340+ controller are integrated into the
Decision-MakerrMPAC 1500 controller operation. For
example, an active time delay can be ended by pressing
a button on the Decision-MakerrMPAC 1500 controller.
Separate time delay bypass switches are not required.
See Figure 3 for accessory information.
M340+
Decision-MakerrMPAC
1500
Bypass (end) Time Delay
Switches Integrated
Source Monitor Integrated
Test Switch Integrated
Override Switches Integrated
Preferred Source Switch Alarm Module required
(see Figure 4)
Current Meter (amps) Current Sensing Kit required
(see Figure 6)
Plant Exerciser Integrated
Manual Switch Operation Supervised Transfer Control
Switch (see Figure 5)
Voltage/Frequency Meters Integrated
Load Shed Contact Integrated Load Control
Function (one output
connection required)
Figure 3 Accessories
Accessory Modules
Optional accessory modules are listed in Figure 4. One
module mounting kit holds up to five accessory
modules.
Accessory Modules Part Number
Module Mounting Assembly * GM46258-S
Standard I/O Module GM46888-S
High Voltage/Current I/O Module GM46890-S
Alarm Module GM40808-S
External Battery Supply Module GM46889-S
* One mounting assembly holds up to 5 modules.
Figure 4 Accessory Modules for Decision-Makerr
MPAC 1500
Other Accessories
Other Decision-MakerrMPAC 1500 accessories are
available. See Figure 5. Contact your local
distributor/dealer for more information.
Other MPAC 1500 Accessories Part Number
Controller Disconnect Switch GM46770-S3
Supervised Transfer Control
Switch [GM40807-S1
[Includes alarm module GM40808-S.
Figure 5 Other Accessories
Current Sensing
If current sensing is required (i.e. for current [amps]
monitoring and display), obtain the appropriately rated
current sensing kit (with 3 m [10 ft.] harness) before
starting the conversion procedure. If the transfer switch
is equipped with current transformers (CTs), they will
need to be replaced with the new current transformers
during the controller conversion procedure. See
Figure 6 for current sensing kit numbers. Check the
amp rating and number of phases of the transfer switch
and select the closest current sensing kit with an equal
or higher amp rating.
Kit Description Current Sensing
Kit Number
Amps Phases
200 3GM89028-S3
200 1GM89028-S21
400 3GM89028-S6
400 1GM89028-S24
1000 3GM89028-S8
1000 1GM89028-S26
1200 3GM89028-S11
1200 1GM89028-S28
2000 3GM89028-S15
3000 3GM89028-S17
Figure 6 Current Sensing Kits
Availability is subject to change without notice. Kohler Co. reserves
the right to change the design or specifications without notice and
without any obligation or liability whatsoever. Contact your local
Kohlerrgenerator set distributor for availability. 2016 by Kohler Co. All rights reserved.
TT-1685 3/16 3
Model Designation
To interpret the transfer switch model designation, see the model designation chart in Figure 7.
Record the transfer switch model number in the boxes below. The transfer switch model number defines characteristics and
ratings as explained in the accompanying chart.
Model Controls Voltage and Frequency Poles Wires Enclosure Current Rating
KohlerrTransfer Switch Model Designation
This chart explains the Kohlerrtransfer switch model numbering system. The sample model
number shown is for a Model ZCS programmed-transition transfer switch with M340+
microprocessor electrical controls rated at 600 volts, 60 hertz, 3 phase, 3 poles, and 4 wires in a
NEMA type 1 enclosure with a current rating of 1000 amperes. Not all possible combinations
are available.
Transfer Switch Model
ZCS: Model ZCS 600 volt maximum contactor automatic transfer switch
Electrical Controls
5: M340+ microprocessor
6: M340+ microprocessor with programmed transition
Number of Poles and Phases
2: 2 pole, 1 phase 3: 3 pole, 3 phase 4: 3 pole, 1 phase
6: 4 pole, 3 phase
Number of Wires
3: 3 wire 4: 4 wire
Enclosure
0: Open unit* 1: NEMA type 1* 2: NEMA type 12[
3: NEMA type 3R
* CSA certified
[Available only as an engineering special.
Current Rating
Numbers indicate the current rating of the switch in amperes
ZCS-660341-1000
Voltage Code (other codes possible)
53: 220 Volts, 60 Hz 60: 600 Volts, 60 Hz 63: 220 Volts, 50 Hz
64: 240 Volts, 60 Hz 66: 480 Volts, 60 Hz 68: 208 Volts, 60 Hz
71: 380 Volts, 50 Hz 72: 380 Volts, 60 Hz 73: 416 Volts, 50 Hz
Sample Model Number
Figure 7 Model Designation Key
4TT-1685 3/16
Safety Precautions
Observe the following safety precautions while
installing the kit.
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery.
WARNING
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.
DANGER
Servicing the transfer switch. Hazardous voltage can
cause severe injury or death. Deenergize all power sources
before servicing. Turn off the main circuit breakers of all
transfer switch power sources and disable all generator sets
as follows: (1) Move all generator set master controller
switches to the OFF position. (2) Disconnect power to all
battery chargers. (3) Disconnect all battery cables, negative
(--) leads first. Reconnect negative (--) leads last when
reconnecting the battery cables after servicing. Follow these
precautions to prevent the starting of generator sets by an
automatic transfer switch, remote start/stop switch, or engine
start command from a remote computer. Before servicing any
components inside the enclosure: (1) Remove all jewelry. (2)
Stand on a dry, approved electrically insulated mat. (3) Test
circuits with a voltmeter to verify that they are deenergized.
Servicing the transfer switch. Hazardous voltage can
cause severe injury or death. Deenergize all power sources
before servicing. Turn off the main circuit breakers of all
transfer switch power sources and disable all generator sets
as follows: (1) Press the generator set off/reset button to shut
down the generator set. (2) Disconnect power to all battery
chargers. (3) Disconnect all battery cables, negative (--) leads
first. Reconnect negative (--) leads last when reconnecting the
battery cables after servicing. Follow these precautions to
prevent the starting of generator sets by an automatic transfer
switch, remote start/stop switch, or engine start command
from a remote computer. Before servicing any components
inside the enclosure: (1) Remove all jewelry. (2) Stand on a
dry, approved electrically insulated mat. (3) Test circuits with a
voltmeter to verify that they are deenergized.
TT-1685 3/16 5
Installation Procedure
Note: The photos and diagrams shown in this
procedure represent a typical transfer switch.
They may not be an exact match for your ATS
model.
1. Bypass the ATS to normal. Then rack the ATS out
to the isolate position. See the bypass/isolation
switch manual for instructions to bypass and
isolate the transfer switch.
2. Place the generator set master switch in the OFF
position or press the OFF/RESET button on the
generator set controller.
3. Disconnect the power to the battery charger, if
equipped.
4. Disconnect the generator set engine starting
battery(ies), negative (--) lead first.
5. Disconnect power from the transfer switch on both
sources, Normal and Emergency.
Remove M340+ Controller and Accessories
6. Remove the plastic protective panel that covers
the electronic components on the inside of the
enclosure door. See Figure 8.
7. Disconnect plug P9. See Figure 9.
Figure 8 Remove Plastic Panel
1
1. P9 connection
Figure 9 Plug P9 Disconnected
8. If the transfer switch is equipped with current
transformers (CTs), remove all CTs from the power
lines of the ATS.
9. Disconnect the Auto/Inhibit ATS disconnect
switch. See Figure 10 and Figure 11. Do not
remove the individual leads from the plug.
Figure 10 Auto/Inhibit ATS Disconnect Switch
6TT-1685 3/16
AUTO/INHIBIT SWITCH
Figure 11 Auto/Inhibit Switch Disconnected
10. Disconnect the AUTO/TEST switch and the
bypass time delay pushbutton. See Figure 12.
Figure 12 Disconnect the AUTO/TEST Switch and
Bypass Time Delay Button
11. Remove the AUTO/TEST switch, the BYPASS
TIME DELAY pushbutton, the ATS
(AUTO/INHIBIT) disconnect switch, and any other
optional switches in this area. See Figure 13.
Keep the ATS (AUTO/INHIBIT) disconnect switch
for reinstallation later in this procedure. Other
switch functions are integrated into the new
Decision-MakerrMPAC 1500 controller.
SWITCHES
REMOVED
Figure 13 Switches and Pushbutton Removed
TT-1685 3/16 7
12. If the transfer switch is equipped with meters,
disconnect and remove all meters and the selector
switch. See Figure 14 and Figure 15.
Note: Separate meters are not required with the
MPAC 1500 controller. Voltage, frequency,
and current (amps)* are shown on the
controller display.
* For current monitoring and display, a current sensing kit is
required. See Figure 6.
METERS
Figure 14 Disconnect the Meters and Selector Switch
Figure 15 Meters and Selector Switch Removed
13. Disconnect plug P24 and the ground connection.
See Figure 16.
Figure 16 Disconnect P24 and Ground
14. Without disconnecting the leads, remove the
mounting screws that secure transformers NCPT
and ECPT and the terminal block to the lower
panel. See Figure 17 and Figure 18.
Note: Transformers NCPT and ECPT and the
terminal block will be mounted onto the new
mounting plate later.
Figure 17 Transformers and Terminal Block on Lower
Panel (do not disconnect electrical
connections)
8TT-1685 3/16
Figure 18 Transformers and Terminal Block
Removed from Lower Panel but Not
Disconnected
15. Remove the metal cover over the optional
communication module, if present. See Figure 19.
Figure 19 Remove Cover Screws
16. Remove the controller and the lower panel from the
lower door of the enclosure. See Figure 20.
Figure 20 Controller and Lower Panel Removed
Mounting Plate and Cover Plate
Note: Refer to the notes in Figure 22 before installing
the mounting plate and switch cover plate. Some
door studs may need to be cut off and some
mounting holes enlarged in the field, depending
on the specific application.
17. Install conversion kit mounting plate GM99317.
Use seven lock washers X-22-7 and seven nuts
X-6210-4 to install the mounting plate as shown in
Figure 21 and Figure 22. Install three flat washers
X-25-122 with three nuts X-6210-2 as shown.
18. Install DIN rail GM47488 using two nuts X-6210-4.
Install panel retainer GM70051. See Figure 21.
SCREW LOCATIONS TO
INSTALL CONVERSION
KIT MOUNTING PLATE
Figure 21 Mounting Plate Installation
TT-1685 3/16 9
Figure 22 Conversion Kit Assembly
10 TT-1685 3/16
19. Install switch cover plate GM69929. Use one
washer X-25-122 and five nuts X-6210-4 to install
the cover plate as shown in Figure 22 and
Figure 23.
The installed plates are shown in Figure 24.
Figure 23 Switch Cover Plate GM69929
Figure 24 Door with Mounting Plate and Switch
Cover Plate
Note: The illustrations in the following steps may not
show the latest controller design. See Figure 25
for the updated current sensing kit terminal block,
harness connection, and programmed-transition
interface board connection.
1. Current sensing terminal block with insulation and harness
(optional)
2. Programmed-transition interface board connection
3. Contactor harness
4. Controller user interface
1
23
zab32174
4
Figure 25 Decision-MakerrMPAC Controller
Updated Features
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