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Kohler ZCM-6 Installation Instructions Manual
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Kohler ZCM-6 Installation Instructions Manual

Kohler ZCM-6 Installation Instructions Manual

Programmed-transition bypass/isolation switches
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Original Issue Date: 3/16
Model: ZCM-6 and ZCB-6 Programmed-Transition Bypass/Isolation Switches
Market: ATS
Subject: Controller Conversion Kits GM99316-S4 and -S5
Introduction
The conversion kit allows the replacement of the M340+
controller with a Decision-Maker
on model ZCM-6 and ZCB-6 programmed-transition
bypass/ isolation 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
r
MPAC 1500 controller
2
GM99316
r
MPAC 1500 Controller
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
r
Figure 2 Controller Identification
TT-1684 3/16
MPAC 1500 Controller
TT1684

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Summary of Contents for Kohler ZCM-6

  • Page 1 TT-1684 3/16 INSTALLATION INSTRUCTIONS Original Issue Date: 3/16 Model: ZCM-6 and ZCB-6 Programmed-Transition Bypass/Isolation Switches Market: ATS Subject: Controller Conversion Kits GM99316-S4 and -S5 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 7. Disconnect plug P9. See Figure 9. 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.
  • 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 ground connection. See disconnect and remove all meters and the selector 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-1684 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 Decision-Maker MPAC 1500 Controller Assembly Transformers and Terminal Block 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: The photos on this page do not show the latest controller design. See Figure 25. 23. Remove the existing 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 28. Connect plug P1 of the conversion kit wire harness Figure 35 Conversion Kit Harness Connection to to the MPAC 1500 controller. See Figure 35. Controller Assembly (PTIB not shown) GM77518 Figure 36 Conversion Kit Harness GM77518 for Model ZCM-6 TT-1684 3/16...
  • Page 14 GM77826 Figure 37 Conversion Kit Harness GM77826 for Model ZCB-6 TT-1684 3/16...
  • Page 15 Interface Panel 29. Remove the plastic cover from the interface panel components on the upper door. See Figure 38. tp5668 1. SLN and SLE relays (Model ZCM only) 2. CCN and CCE relays 3. CCEO and CCNO relays Figure 40 Interface Panel Assembly Relays Figure 38 Remove Plastic Cover on Interface Panel 32.
  • Page 16 34. Disconnect plug P8 from the upper board. See 36. Connect conversion wire harness Figure 42. (GM77518 or GM77826) connector P8 to plug P8 that was disconnected from the upper board in the previous step. See Figure 44. Figure 42 Disconnect Plug P8 35.
  • Page 17 38. Cut the cable ties to release leads 33 and 20. See 40. Connect the conversion kit harness to the interface Figure 46. panel assembly relays as follows. See Figure 48 through Figure 50 and refer to the wiring diagram for your transfer switch.
  • Page 18 Figure 48 CCN and CCE Relay Location (see Figure 50 Connections to CCN and CCE Relays Figure 49 for other relays) (other relays not shown) tp5668 1. SLN and SLE relays (Model ZCM only) 2. CCN and CCE relays 3. CCEO and CCNO relays Figure 49 Relay Locations TT-1684 3/16...
  • Page 19 43. Route conversion wire harness 45. Re-install the upper plastic cover, and finish routing appropriately using the cable ties provided. See the conversion kit wire harness neatly using the Figure 51. cable ties provided. See Figure 53. Figure 53 Re-Install Plastic Cover Note: This photo does not show the latest controller design.
  • Page 20 Current Sensing Kit Installation 47. Connect the current transformers as shown in Figure 55. 46. 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 54. See Figure 6 or the Parts Lists for current sensing kit numbers.
  • Page 21 Figure 55 Current Sensing Kit Wiring Diagram, GM47803 TT-1684 3/16...
  • Page 22 48. Record the required information on decal the accessory mounting kit, to install and connect GM70205 (see Figure 56). See Figure 6 or the the modules. Parts Lists for the current sensing kit number. See 51. For installation of other optional accessories, refer Figure 59 for the wiring diagram number.

  • Page 23: Parts Lists

    Parts Lists ZCM-6 M340+ to Decision-Maker MPAC 1500 ZCB-6 M340+ to Decision-Maker MPAC 1500 Conversion Kit Conversion Kit GM99316 GM99316 Kit: Kit: Qty. Description Part Number Qty. Description Part Number Rail, din GM47488 Rail, din GM47488 Decal, conversion GM67498 Decal, conversion...
  • Page 24 ATS Wiring Diagrams and Schematics Use the table below to identify the drawings for your ZCB-6 or ZCM-6 bypass/isolation switch. The M340+ and bypass schematic 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.

This manual is also suitable for:

Zcb-6