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Original Issue Date: 3/16
Model: ZCS-6 Programmed-Transition Transfer Switches
Market: ATS
Subject: M340+ to Decision-Maker
Introduction
The conversion kit allows the replacement of the M340+
controller
with
a
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.
1
1. MPAC 1500 controller assembly
2. Optional accessory board (I/O) assembly
Figure 1 Decision-Maker
Conversion Kit, Installed
INSTALLATION INSTRUCTIONS
GM99316-S6
Decision-Maker
r
MPAC 1500
2
GM99316-S6
r
MPAC 1500 Controller
r
MPAC 1500 Controller Conversion Kit
Tools and Materials Required:
Phillipsr screwdriver
D
Small flat tip screwdriver
D
Wire cutter
D
7/16 nut driver
D
11/32 nut driver
D
5/16 nut driver
D
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.
M340+ Controller
Decision-Maker
Figure 2 Controller Identification
TT-1685 3/16
r
MPAC 1500 Controller
TT1685
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Related Manuals for Kohler ZCS-6
Summary of Contents for Kohler ZCS-6
- Page 1 TT-1685 3/16 INSTALLATION INSTRUCTIONS Original Issue Date: 3/16 Model: ZCS-6 Programmed-Transition Transfer Switches Market: ATS Subject: M340+ to Decision-Maker MPAC 1500 Controller Conversion Kit GM99316-S6 Introduction Tools and Materials Required: Phillipsr screwdriver The conversion kit allows the replacement of the M340+...
-
Page 2: Controller Accessories
* One mounting assembly holds up to 5 modules. Figure 4 Accessory Modules for Decision-Maker MPAC 1500 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 ... -
Page 3: Model Designation
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... -
Page 4: Safety Precautions
Safety Precautions 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 Observe the following safety precautions while transfer switch power sources and disable all generator sets installing the kit. -
Page 5: Installation Procedure
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. - Page 6 11. Remove the AUTO/TEST switch, the BYPASS TIME DELAY pushbutton, (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-Maker MPAC 1500 controller.
- Page 7 12. If the transfer switch is equipped with meters, 13. Disconnect plug P24 and the ground connection. disconnect and remove all meters and the selector See Figure 16. switch. See Figure 14 and Figure 15. Note: Separate meters are not required with the MPAC 1500 controller.
- Page 8 16. Remove the controller and the lower panel from the lower door of the enclosure. See Figure 20. Figure 18 Transformers and Terminal Block Removed from Lower Panel but Not Disconnected Figure 20 Controller and Lower Panel Removed 15. Remove the metal cover over the optional communication module, if present.
- Page 9 Figure 22 Conversion Kit Assembly TT-1685 3/16...
- Page 10 19. Install switch cover plate GM69929. Use one Note: The illustrations in the following steps may not washer X-25-122 and five nuts X-6210-4 to install show the latest controller design. See Figure 25 the cover plate as shown in Figure 22 and for the updated current sensing kit terminal block, Figure 23.
- Page 11 1500 Controller Assembly Transformers and Terminal Block Decision-Maker MPAC 20. Install Decision-Maker MPAC 1500 controller 22. Reinstall the transformers and terminal block that assembly GM85884-4 onto the conversion kit were removed in step 14. See Figure 28 and mounting plate using four nuts X-6210-2. See Figure 29.
- Page 12 Decals Note: Photos on this page do not show the latest controller design. See Figure 25. 23. Remove the existing Auto/Inhibit switch decal, if necessary. Verify that the surface is clean and dry, and affix conversion kit decal GM67498 over the old decal on the outside of the bottom door.
- Page 13 MPAC 1500 controller. See Figure 35. Note: This photo does not show the latest controller design. See Figure 25. Figure 35 Conversion Kit Harness Connection to Controller Assembly (PTIB not shown) GM77827 Figure 36 Conversion Kit Harness GM77827 for Model ZCS-6 TT-1685 3/16...
- Page 14 Interface Panel 28. Remove the plastic cover from the interface panel components on the upper door. See Figure 37. tp5668 1. SLN and SLE relays 2. CCN and CCE relays Figure 39 Interface Panel Assembly Relays, typical Figure 37 Remove Plastic Cover on Interface Panel (relays vary by model) 29.
- Page 15 32. Disconnect plug P8 from the upper board. See Figure 41. Disconnect P9 P8 connected to conversion kit har- ness. Figure 43 Disconnect P9 35. Connect leads CN, CE, J2, and J3 of the Figure 41 Disconnect Plug P8 conversion kit harness GM77827 to the interface panel assembly relays.
- Page 16 40- -260 Amps Dashed lines show new conversion kit harness leads. New customer-provided 18AWG leads. See steps 39--44. GM99386- Figure 45 Interface Panel Relay Connections, 40--260 Amps 400 Amps Dashed lines show new conversion kit harness leads. GM99390- Figure 46 Interface Panel Relay Connections, 400 Amps TT-1685 3/16...
- Page 17 600- -3000 Amps Dashed lines show new conversion kit harness leads. GM99388- Figure 47 Interface Panel Relay Connections, 600--3000 Amps 37. Remove the circuit board from the upper panel. 38. Re-install the upper plastic cover, and finish routing See Figure 48. the conversion kit wire harness neatly using the cable ties provided.
- Page 18 For 40- -260 Amp 2, 3, and 4-pole models only: Steps 39--44 apply to 40--260 Amp 2, 3, and 4-pole models only. For other models, proceed to step 45. The following steps require two customer-provided 18 AWG leads. 39. Find switches SOL-1, SOL-2, and SNO-1, located on the left side of the contactor assembly.
- Page 19 Current Sensing Kit Installation 46. Connect the current transformers as shown in Figure 54. 45. If current sensing is required (i.e. for current [amps] monitoring and display), obtain the appropriately rated current sensing kit with 10 foot harness, and install according to Figure 53. See Figure 6 or the Parts Lists for current sensing kit numbers.
- Page 20 Figure 54 Current Sensing Kit Wiring Diagram, GM47803 TT-1685 3/16...
- Page 21 47. Record the required information on decal refer to instruction sheet TT-1449, provided with GM70205 (see Figure 55). See Figure 6 or the the accessory mounting kit, to install and connect Parts Lists for the current sensing kit number. See the modules.
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Page 22: Parts Lists
Parts Lists ZCS-6 M340+ to Decision-Maker MPAC 1500 Conversion Kit Kit: GM99316-S6 Qty. Description Part Number Rail, din GM47488 Decal, conversion GM67498 Plate, cover switch GM69929 Retainer, panel GM70051 Decal, KPS MPAC 1500 GM70205 Harness, wiring controller GM77827 MPAC1500 assembly... - Page 23 ATS Wiring Diagrams and Schematics Use the table below to identify the drawings for your Model ZCS-6 programmed-transition transfer switch. The M340+ drawing numbers are shown for reference only. The MPAC 1500 conversion drawings are arranged in alpha-numeric order by drawing number on the following pages.
- Page 24 Notes TT-1685 3/16...
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