Kohler ZCM-6 User manual

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
The conversion kit allows the replacement of the M340+
controller with a Decision-MakerrMPAC 1500 controller
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.
GM99316
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
TT1684
M340+ Controller
Figure 2 Controller Identification

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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]
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-1684 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
KohlerrPart Number Key
This chart explains the Kohlerrtransfer switch model numbering system. The sample model
number shown is for a Model ZCB 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.
Switch Classification or Family
ZCM: 150--400 amp automatic transfer and bypass isolation switch
ZCB: 150--4000 amp automatic transfer and bypass isolation switch
Electrical Controls
5: M340+ microprocessor
6: M340+ microprocessor with programmed transition
Number of Poles and Phase
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*
* Contact the factory.
Current Rating
Numbers indicate the current rating of the switch in amperes
ZCB-660341-1000
Voltage and Frequency (other codes possible)
53: 220 Volts, 60 Hz 60: 600 Volts, 60 Hz 62: 120 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 Volt, 60 Hz
73: 416 Volts, 50 Hz
SAMPLE MODEL NUMBER
Figure 7 Model Designation Key

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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-1684 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 bottom door of
the enclosure. See Figure 8.
Figure 8 Plastic Panel on Bottom Door
7. Disconnect plug P9. See Figure 9.
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

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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-1684 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 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)

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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.
Figure 21 Mounting Plate Installation

TT-1684 3/16 9
Figure 22 Conversion Kit Assembly

10 TT-1684 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

TT-1684 3/16 11
Decision-MakerrMPAC 1500 Controller Assembly
20. Install Decision-MakerrMPAC 1500 controller
assembly GM85884-4 onto the conversion kit
mounting plate using four nuts X-6210-2. See
Figure 26.
Note: This photo does not show the latest controller design.
See Figure 25.
Figure 26 Controller Assembly Installation
21. See Figure 27 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 25.
Figure 27 Ground Lead Connections
Transformers and Terminal Block
22. Reinstall the transformers and terminal block that
were removed in step 14. See Figure 28 and
Figure 29.
a. Use four lock washers X-22-6 and four nuts
X-71-2 to re-install transformers NCPT and
ECPT onto the conversion kit mounting plate.
b. Mount the terminal block onto the DIN rail,
which was installed in step 18.
Figure 28 Transformer and Terminal Block
Installation
Note: This photo does not show the latest controller design.
See Figure 25.
Figure 29 Transformers and Terminal Block Installed

12 TT-1684 3/16
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. See Figure 30
and Figure 31.
REMOVE DECAL,
IF NECESSARY
Figure 30 Before Decal Installation
Figure 31 After Decal Installation
Disconnect Switch
24. Re-install the (AUTO/INHIBIT) disconnect switch
through the conversion kit mounting plate. See
Figure 32 and Figure 33.
Figure 32 Disconnect Switch Re-Installed
Figure 33 Disconnect Switch (inside door)
25. Connect the AUTO/INHIBIT disconnect switch to
the existing plug that was disconnected in step 9.
See Figure 34.
Figure 34 AUTO/INHIBIT Switch Connection

TT-1684 3/16 13
Conversion Kit Wiring Harness
26. At this point in the procedure, you will start to
connect the conversion kit wiring harness.
DModel ZCM switches use conversion kit harness
GM77518, included in kit GM99316-S4. See
Figure 36.
DModel ZCB switches use conversion kit harness
GM77826, included in kit GM99316-S5. See
Figure 37.
27. Connect plug P24 of the conversion kit harness to
contactor harness plug P24, which was
disconnected from the M340+ controller in step 13.
See Figure 35.
28. Connect plug P1 of the conversion kit wire harness
to the MPAC 1500 controller. See Figure 35.
P1
PLUG
P24
PLUG
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)
GM77518
Figure 36 Conversion Kit Harness GM77518 for Model ZCM-6

14 TT-1684 3/16
GM77826
Figure 37 Conversion Kit Harness GM77826 for Model ZCB-6

TT-1684 3/16 15
Interface Panel
29. Remove the plastic cover from the interface panel
components on the upper door. See Figure 38.
Figure 38 Remove Plastic Cover on Interface Panel
30. On the interface panel assembly, disconnect
lead 20 from terminal 1 on the four relays CCN,
CCE, CCEO, and CCNO. See Figure 39 and
Figure 40. Also see the wiring diagrams at the end
of this document.
Note: Relays CCEO and CCNO are not shown in
Figure 39.
31. On Model ZCM switches, also disconnect lead 20
from terminal 1 on the two relays SLN and SLE.
See Figure 40.
Terminals
CCE-1 and
CCN-1
Figure 39 Disconnect Lead 20 from CCN-1 ,CCE-1,
CCEO-1 (not shown) and CCNO-1 (not
shown)
1
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1. SLN and SLE relays (Model ZCM only)
2. CCN and CCE relays
3. CCEO and CCNO relays
2
3
Figure 40 Interface Panel Assembly Relays
32. Find the longer lead 20 that routes through the
harness from connector P1. Cut the forked
terminal from the end of the lead near the relay.
See Figure 41.
Note: Lead 20 from connector P1 will be
connected to the MPAC 1500 controller later
in this procedure.
33. Separate the leads labeled 20 from the harness
and discard the short jumper leads that were
connected between the relays.
Leads 20
Cut off
Figure 41 Cut Off Terminal

16 TT-1684 3/16
34. Disconnect plug P8 from the upper board. See
Figure 42.
Figure 42 Disconnect Plug P8
35. Cut lead 33 (pin location: 15 on plug P8). See
Figure 43. Lead 33 will be connected to the MPAC
1500 controller later in this procedure.
Figure 43 Cut Lead 33 at Pin 15 on Plug P8
36. Connect the conversion kit wire harness
(GM77518 or GM77826) connector P8 to plug P8
that was disconnected from the upper board in the
previous step. See Figure 44.
Figure 44 Connect Conversion Kit Wire Harness
Connector P8 to Plug P8
37. Disconnect plug P9 from the upper board. See
Figure 45. Cut the cable ties to separate the
harness from the other wiring and discard the P9
harness. (The other end of this harness was
disconnected in step 7.)
Disconnect
P9
P8 connected
to conversion
kit harness.
Figure 45 Disconnect P9

TT-1684 3/16 17
38. Cut the cable ties to release leads 33 and 20. See
Figure 46.
Figure 46 Leads 20 and 33
39. Re-route leads 33 and 20 and connect them to the
MPAC1500 Programmable Input 1. Connect lead
33 to MPAC 1500 TB1-1. Connect lead 20 to
MPAC 1500 TB1-2. See Figure 47.
Figure 47 Connect Leads 20 and 33 to
Programmable Input 1 on New Controller
40. Connect the conversion kit harness to the interface
panel assembly relays as follows. See Figure 48
through Figure 50 and refer to the wiring diagram
for your transfer switch. See Figure 59 for the
drawing number.
DFor Model ZCM switches, proceed to step 41.
DFor Model ZCB switches, proceed to step 42.
41. For Model ZCM switches, use conversion kit
harness GM77518 (shown in Figure 36).
a. Connect leads CN and J2 from the conversion
kit wire harness to terminal 1 on relay CCN.
b. Connect leads CE and J3 from the conversion
kit wire harness to terminal 1 on relay CCE.
c. Connect leads J1 and J2 to terminal 1 on relay
CCEO.
d. Connect leads J3 and J4 to terminal 1 on relay
CCNO.
e. Connect single lead J1 to terminal 10 on relay
SLN.
f. Connect single lead J4 to terminal 10 on relay
SLE.
g. Proceed to step 43.
42. For Model ZCB switches, use conversion kit
harness GM77826 (shown in Figure 37).
a. Connect leads CN and J2 from the conversion
kit wire harness to terminal 1 on relay CCN.
b. Connect leads CE and J3 from the conversion
kit wire harness to terminal 1 on relay CCE.
c. Connect Single lead J2 to terminal 1 on relay
CCEO.
d. Connect single lead J3 to terminal 1 on relay
CCNO.
e. Proceed to step 43.

18 TT-1684 3/16
Figure 48 CCN and CCE Relay Location (see
Figure 49 for other relays)
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1. SLN and SLE relays (Model ZCM only)
2. CCN and CCE relays
3. CCEO and CCNO relays
23
Figure 49 Relay Locations
Figure 50 Connections to CCN and CCE Relays
(other relays not shown)

TT-1684 3/16 19
43. Route the conversion kit wire harness
appropriately using the cable ties provided. See
Figure 51.
Note: This photo does not show the latest controller design.
See Figure 25.
Figure 51 Harness Routing
44. Remove the circuit board from the upper panel.
See Figure 52.
Figure 52 Remove the Upper Panel Circuit Board
45. Re-install the upper plastic cover, and finish routing
the conversion kit wire harness neatly using the
cable ties provided. See Figure 53.
Figure 53 Re-Install Plastic Cover

20 TT-1684 3/16
Current Sensing Kit Installation
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.
47. Connect the current transformers as shown in
Figure 55.
1. Connect harness GM40562 (10 ft. harness). See Figure 55 for electrical connections.
2. Current transformers. See Parts List for part numbers.
1
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 55).
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.
Figure 54 Current Sensing Kit Installation