Kohler GLS-1 User manual

TT-1686 3/16
INSTALLATION INSTRUCTIONS
Original Issue Date: 3/16
Model: GLS-1, GTS-1, K-1, and KB-1 Automatic Transfer Switches
Market: ATS
Subject: S340 to Decision-MakerrMPAC 1500 Controller Conversion Kit
GM99332-S1
Introduction
Use conversion kit GM99332-S1 to replace the S340
controller with a Decision-MakerrMPAC 1500 controller
on the standard-transition automatic transfer switch
models listed above. See Figure 7 to interpret the
transfer switch model designation.
Note: Do not use this conversion kit on
programmed-transition models.
See Figure 1 for an illustration of the installed kit. See
Figure 2 for controller identification, if necessary.
Note: Do not discard these instructions after kit
installation. Keep this document with the transfer
switch documentation for future reference.
GM99332
2
1. Decision MakerrMPAC 1500 controller assembly
2. Optional accessory module assembly (not provided with
controller conversion kit)
1
Figure 1 Decision-MakerrMPAC 1500 Controller
Conversion Kit, Installed
TT1686
Decision-MakerrMPAC 1500
S340
Figure 2 Controller Identification
Tools Required
DPhillipsrscrewdriver
DSmall flat tip screwdriver
DWire cutter
D7/16 nut driver
D11/32 nut driver
D5/16 nut driver
DJigsaw or reciprocating saw to cut an opening in the
enclosure door
DGray (ANSI 61) touch-up paint
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.

2TT-1686 3/16
KOHLER CO., Kohler, Wisconsin 53044 USA
Phone [phone], Fax [phone]
For the nearest sales and service outlet in the
US and Canada, phone [phone]
KOHLERPower.com
Kohler Power Systems
Asia Pacific Headquarters
7 Jurong Pier Road
Singapore 619159
Phone [phone], Fax [phone]
Current Sensing
If current sensing is required (i.e. for current [amps]
monitoring and display), obtain the appropriately rated
current sensing kit before starting the controller kit
installation procedure. If the transfer switch is equipped
with current transformers (CTs), they will need to be
replaced with the new current transformers for use with
the Decision-MakerrMPAC 1500 controller. See
Figure 3 for available 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 3 Current Sensing Kits
Controller Accessories
Many functions that required optional accessories with
the S340 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 override switches are not required.
See Figure 4 for accessory information.
S340
Decision-MakerrMPAC
1500
Time Delays Integrated
Test Switch Integrated
Override Switches Integrated
Current Meter (amps) Current sensing kit required
(see Figure 3)
Plant Exerciser Integrated
Voltage/Frequency Meters Integrated
Load Shed Contact Integrated load control
function (one output
connection required)
Phase Rotation Protection Integrated
In-Phase Monitor Integrated
Audible Alarm Alarm module required
Figure 4 Accessories
Accessory Modules
Optional accessory modules are listed in Figure 5. One
module mounting kit holds up to five accessory
modules.
Accessory Module s 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 5 Accessory Modules for Decision-Makerr
MPAC 1500
Other Accessories
Other Decision-MakerrMPAC 1500 accessories are
available. See Figure 6. 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 6 Other Accessories
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-1686 3/16 3
Model Designation
To interpret the transfer switch model designation, see
the model designation chart in Figure 7. Codes for the
model GLS, GTS, K and KB switches are combined in
the model designation chart. Some codes do not apply
to all models.
Model Designation
Model Controls Voltage and Frequency Poles Wires Enclosure Current Rating
KohlerrModel Number Key
This chart explains the Kohlerrtransfer switch model numbering code system. The sample
model number shown is for a Model K automatic transfer switch that uses a 600 volt maximum
contactor power switching device with S340 solid-state electrical controls rated at 240 volts,
60 hertz, 1 phase, 2 poles, and 3 wires in a NEMA type 1 enclosure with a current rating of 800
amps. Not all possible combinations are available.
Model (1 to 3 letters)
GLS: Model GLS 600 volt maximum, 40--400 Amp automatic transfer switch
GTS: Model GTS 250 volt maximum, 40--200 Amp automatic transfer switch
K: Model K automatic transfer switch
KN: Model KN non--automatic transfer switch
KB: Model KB bypass and isolation transfer switch
Electrical Controls (Logic Controller)
1: S340 controls, standard transition
Number of Poles and Phases
2: 2 pole, 1 phase 3: 3 pole, 3 phase 4: 3 pole, 1 phase
5: 3 pole, 3 phase with overlapping neutral contacts
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 4: NEMA type 1 CSA* 7: Open unit CSA*
* CSA versions available only up to 2000 amperes
Current Rating
Numbers indicate the current rating of switch in amperes
K-164231-0800
Voltage and Frequency (other codes are possible)
240 VAC max:
21: 110 Volts, 50 Hz
22: 120 Volts, 60 Hz
23: 220 Volts, 50 Hz
24: 240 Volts, 60 Hz
27: 190 Volts, 50 Hz
28: 208 Volts, 60 Hz
SAMPLE MODEL NUMBER
600 VAC max:
53: 220 Volts, 60 Hz
60: 600 Volts, 60 Hz
61: 110 volts, 50 Hz
62: 120 Volts, 60 Hz
63: 220 Volts, 50 Hz
64: 240 Volts, 60 Hz
65: 550 Volts, 60 Hz
66: 480 Volts, 60 Hz
67: 190 Volts, 50Hz
68: 208 Volts, 60 Hz
69: 440 Volts, 60 Hz
70: 400 Volts, 50 Hz
71: 380 Volts, 50 Hz
72: 380 Volts, 60 Hz
73: 416 Volts, 50 Hz
Note: Some codes do not apply to all models.
Figure 7 Model Designation Key

4TT-1686 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) 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.
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.
NOTICE
Foreign material contamination. Cover the transfer switch
during installation to keep dirt, grit, metal drill chips, and other
debris out of the components. Cover the solenoid mechanism
during installation. After installation, use the manual operating
handle to cycle the contactor to verify that it operates freely. Do
not use a screwdriver to force the contactor mechanism.

TT-1686 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. Place the generator set master switch in the OFF
position or press the OFF/RESET button on the
generator set controller.
2. Disconnect the power to the battery charger, if
equipped.
3. Disconnect the generator set engine starting
battery(ies), negative (--) lead first.
4. Disconnect power from the transfer switch on both
sources, Normal and Emergency.
5. If the transfer switch is equipped with current
transformers (CTs), remove all CTs from the power
lines of the ATS.
6. Disconnect and remove the TEST pushbutton.
SeeFigure8.
7. Disconnect and remove any other optional
switches. See Figure 9.
8. If the transfer switch is equipped with meters,
disconnect and remove all meters. See Figure 9.
Separate meters are not required with the MPAC
1500 controller. Voltage, frequency, and current
(amps) are shown on the controller display.
Note: For current monitoring and display, a current
sensing kit is required. See Figure 3.
9. Disconnect any other accessories mounted on the
inner panel. See Figure 8 and Figure 9.
Note: For installation of optional accessories (such as
input/output [I/O] or alarm modules), refer to the
instructions provided with the accessory kit or to
the Decision-MakerrMPAC 1500
Operation/Installation manual, TP-6883.
3
DH-295000
1. Inner panel
2. Test switch
3. S340 controller assembly
4. Optional accessories
5. Transformer assembly
6. Controller harness
6
2
5
1
4
Figure 8 Model GLS-1 ATS with S340 Controls

6TT-1686 3/16
1. Meters
2. Optional switches and lamps may be installed in this area
3. Test switch
BA-295000
1
2
3
Figure 9 S340 Controller with Optional Accessories
10. Disconnect the contactor harness from the S340
controller at plug P1. See Figure 10.
1DH-295000
1. P1 connection
Figure 10 Disconnect P1
11. Remove the mounting screws to remove the
controller and the inner panel from the enclosure
door.
12. Modify the existing enclosure door as described
below.
a. Remove the door from the enclosure. Place
the door on a bench or other work surface.
b. Use new mounting plate GM77130 as a
template to mark the opening for the
Decision-MakerrMPAC 1500 controller onto
the inside of the enclosure door. See
Figure 11.
c. Remove the mounting plate and cut out the
opening in the door.
d. Remove any burrs and use ANSI 61 gray
touch-up paint on any bare metal surfaces to
prevent rust.
e. Reinstall the door onto the enclosure.

TT-1686 3/16 7
Figure 11 Conversion Kit Assembly

8TT-1686 3/16
Note: Refer to Figure 11 during kit installation.
13. Install the conversion kit mounting plate
(GM77130). Use seven lock washers (X-22-7) and
seven nuts (X-6210-4) to install the mounting plate
as shown in Figure 11. Install three flat washers
(X-25-122) with three nuts (X-6210-2) as shown.
14. Install the switch cover plate (GM77247) on the
outside of the enclosure door. Use one washer
X-25-122 and nine nuts X-6210-4 to install the
cover plate as shown in Figure 11 and Figure 12.
1
GM99332
1. Switch cover plate mounting hardware
Figure 12 Switch Cover Plate GM77247
Note: The illustrations in the following steps may not
show the latest controller design. See Figure 13
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
(programmed- and closed-transition models only)
3. Contactor harness
4. Controller user interface
1
23
zab32174
4
Figure 13 Decision-MakerrMPAC Controller
Updated Features

TT-1686 3/16 9
15. Install the Decision-MakerrMPAC 1500 controller
assembly (GM85884-1) onto the conversion kit
mounting plate using four nuts X-6210-2. See
Figure 14.
1
GM99332
1. Controller mounting studs and nuts X-6210-2(qty. 4)
Figure 14 Controller Assembly Installation
16. See Figure 15 for ground connections. Use green
grounding lead LK-1212-1515 to connect the
ground stud on the conversion panel to the ground
lug on the door. Using lock washer X-22-12,
connect the ground wires to the ground stud on the
door. Place the grounding wires between the
washer and the nut.
Note: This photo does not show the latest controller design.
See Figure 13.
Figure 15 Ground Lead Connections
17. With the surfaces clean and dry, affix conversion kit
decals GM77248 and GM77249 over the old
decals on the outside of the enclosure door, if
present. See Figure 16.
2
GM99332
1. Decal GM77248
2. Decal 77249 (if required)
1
Note: Position decals directly over existing decals, if present.
Figure 16 Decal Installation

10 TT-1686 3/16
18. Connect P24 of the conversion kit harness
GM71472 to the contactor harness, which was
disconnected from the S340 controller in step 10.
See Figure 10 and Figure 17.
19. Connect P1 of the conversion kit harness to P1 of
the Decision-MakerrMPAC 1500 controller. See
Figure 18.
GM71472
Figure 17 Conversion Kit Harness
1
tp6883
1. Conversion kit harness connection
Figure 18 Connection to Decision-MakerrMPAC
1500 Controller

TT-1686 3/16 11
20. If current sensing is required (i.e. for current [amps]
monitoring and display), obtain the appropriately
rated current sensing kit and install according to
Figure 19.
21. Connect the current transformers as shown in
Figure 20. See Figure 3 or the Parts List for current
sensing kit numbers.
1. Connect harness GM40562 (10 ft. harness). See Figure 20 for electrical connections.
2. Current transformers. See Parts List for part numbers.
2
NOTES:
HI SIDE OF CT’S MUST ALWAYS FACE TOWARD THE CONTACTOR.
Route CT harness neatly to controller with controller/contactor harness. Use cable ties as necessary.
See wiring diagram GM47803 (Figure 20).
Decision-Makerr1500 Controller
GM89029
FROM BOTTOM SIDE
OF TERMINAL BLOCK
TO PCB CONNECTOR
X-6126-27
GM21583 (2)
GM47797 (INSULATION)
(SHOWN PHANTOMED)
ASSEMBLE UNDER SCREWS
HOLDING BRASS STRIP TO
TERMINAL BLOCK.
REMOVE BRACKETs FROM CT’S AND DISCARD BRACKETS.
ASSEMBLE CT’S ON LOAD BUS (A, B & C)
(LUGS MUST BE REMOVED FIRST AND
REASSEMBLED AFTER MOUNTING CT’S)
TIEWRAPTOVERTICAL
BUS SUPPORTS AND EACH OTHER.
1
Figure 19 Current Sensing Kit Installation

12 TT-1686 3/16
Figure 20 Current Sensing Kit Wiring Diagram, GM47803

TT-1686 3/16 13
22. Record the required information on decal
GM70205. See Figure 21. See Figure 3 for the
current sensing kit and Figure 24 for the wiring
diagram number.
23. Verify that the surface is clean and dry, and place
decal GM70205 on the mounting plate as shown in
Figure 22.
GM70205
Figure 21 Decal GM70205
1
1. Decal GM70205 (recommended location)
2. Optional accessory module mounting kit
GM99332
2
Figure 22 Decal GM70205 Location
24. If optional accessory modules are used, attach the
accessory mounting kit to the conversion kit
mounting plate (GM77130). See Figure 22. Then
refer to instruction sheet TT-1449, provided with
the accessory mounting kit, to install and connect
the modules.
25. For installation of other optional accessories, refer
to the instructions provided with the accessory kit
or see the Decision-MakerrMPAC 1500 Operation
Manual, TP-6883.
26. Reconnect power to the transfer switch.
27. Check that the generator set master switch is in the
OFF position.
28. Reconnect the generator set engine starting
battery, negative (--) lead last.
29. Reconnect power to the battery charger, if
equipped.
30. On the Decision-MakerrMPAC 1500 controller,
program the system parameters shown in
Figure 23. Refer to the transfer switch nameplate
for the ATS ratings. Also check time delays and
and other settings that affect the ATS operation.
See TP-6883, Operation Manual, for instructions.
System Parameter Factory Setting
Standard or programmed transition
Set these parameters
to match the transfer
switch [
Single/three phase
Operating voltage
Operating frequency (50 or 60 Hz)
Rated current
Phase rotation ABC
Commit to transfer (yes or no) No
Operating mode:
Generator-to-Generator,
Utility-to-Generator, or
Utility-to-Utility
Utility-to-Generator
In-phase monitor Disabled
In-phase monitor transfer angle 5_
[See the ATS nameplate.
Figure 23 System Parameters
31. Run the operation tests outlined in Operation
Manual TP-6883 to verify system operation.
32. Keep these installation instructions and wiring
diagrams with the transfer switch documentation
for future reference.

14 TT-1686 3/16
Parts Lists
S340 to Decision-MakerrMPAC 1500 Conversion
Kit
Kit: GM99332-S1
Qty. Description Part Number
1Decal, KPS MPAC-1500 GM70205
1Harness, Wiring Controller GM71472
1Plate, Mounting GM77130
1Plate, Cover Switch GM77247
1Decal ATS S340 to MPAC1500
Conversion
GM77248
1Decal ATS S340 to MPAC1500
Conversion
GM77249
1MPAC 1500 Assembly GM85884-1
1Lead LK-1212-1515
1O/M MPAC 1500 Controls , ATS TP-6883
1Installation Instructions TT-1686
1Washer, lock .262 ID x .743 in.
OD
X-22-12
10 Cable tie X-468-1
2Cable tie, nylon X-468-3
14 Nut, flange spiralock, 1/4-20 X-6210-2
9Nut, flange whiz, 8-32 X-6210-4

TT-1686 3/16 15
Current Sensing Kit Parts
Descri
p
tion
Part
Number
Part Quantity
Kit number GM89028:
-S3 -S6 -S8 -S11 -S15 -S17 -- S 2 1 -S24 -S26 -S28
200 A 400 A 1000 A 1200 A 2000 A 3000 A 200 A 400 A 1000 A 1200 A
3ph 3ph 3ph 3ph 3ph 3ph 1ph 1ph 1ph 1ph
Screw, Plastic
Tapping
GM21583 2222222222
Harness, CT 10 FT. GM40562 1111111111
Transformer, Current GM47788 3 2
Transformer, Current GM47789 3 2
Transformer, Current GM47790 3 3
Transformer, Current GM47791 3 2
Transformer, Current GM47792 3
Transformer, Current GM47793 3
Insulation, Terminal
Block
GM47797 1111111111
Bracket, CT
Mounting
GM47800 1
Diagram, Wiring CT
MPAC 1500
GM47803 1111111111
Drawing, Assembly
Current Sensing
GM89028 1111111111
Harness, CT GM89029 1111111111
Terminal Block X-6126-27 1111111111
Nut, Flange
Spirallock
X-6210-2 4
Screw, Thread
Forming
X-67-114 8

16 TT-1686 3/16
Transfer Switch Wiring Diagrams
The schematic diagrams and wiring diagrams for the
transfer switches with Decision-MakerrMPAC 1500
controls are arranged in alpha-numeric order on the
following pages. Find your model and the
corresponding drawing numbers in Figure 24.
To interpret the transfer switch model designation, see
the model designation chart in Figure 7. Codes for the
model GLS, GTS, K and KB switches are combined in
the model designation chart. Some codes do not apply
to all three models.
The schematic and wiring diagram drawing numbers for
the transfer switch with S340 controls are shown in
Figure 24 for reference only. Those drawings are not
included in this document. Refer to the original
documentation provided with the transfer switch for
S340 drawings, if necessary.
ATS Model * Poles* Amps
S340 Drawing Numbers
(for reference only) MPAC 1500 Conversion Drawings
Schematic Wiring Diagram Schematic Wiring Diagram
GTS-1 2
40--200 362114 362109 GM99391 GM99393
3
4[
GLS-1 2
40--200 362172 362164 GM100332 GM99392
Sheet 1
3
4[
2
225--400 362172 362164 GM100332 GM99392
Sheet 2
3
4[
K-1 230--800 295075 295079 GM100333 GM100334
330--4000 295074 295078 GM100335 GM100336
4[
KB-1 2150--400 294149 294263 GM100341 GM100343
3150--400 294149 294150 GM100341 GM100342
4[
2600--800 297662 297663 GM100337 GM100338
3600--800 297664 297665 GM100339 GM100340
4[
* See Figure 7 to interpret the model designation, if necessary.
[3 pole, 3 phase with overlapping neutral
Note: Drawings are arranged in alpha-numeric order on the following pages.
Figure 24 Drawing Numbers

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