Controls: Decision-Makerr MPAC 750 - KOHLER · 5.2.1 Weekly Generator Set Exercise 32 ... the...

Automatic Transfer Switches

Controls:

Decision-Makerr MPAC 750

Transfer Switch Model:KSS

TP-6865 4/14a

Operation

Table of Contents

TP-6865 4/14 Table of Contents 3

Safety Precautions and Instructions 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .List of Related Materials 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Assistance 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 1 Operation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1 Introduction 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2 Source Names 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3 User Interface Panel 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.1 Pushbuttons 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3.2 LED Indicators 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 Test 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4.1 Unloaded System Test 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4.2 Loaded System Test 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 Automatic Operation Test 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6 Exercise 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6.1 Exercise Schedule 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6.2 Unloaded Exercise 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6.3 Loaded Exercise 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6.4 Stopping an Exercise 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6.5 Optional Programmable Exerciser 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7 Warnings and Faults 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.7.1 Fault Reset 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.8 Controller Reset 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.8.1 Reboot 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.8.2 Reset to Default Settings 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2 Sequence of Operation 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1 Controller Power--up/Reset 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2 Sequence of Operation 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.1 Source N Loss and Return 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2.2 Exerciser Operation 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2.3 Test Sequence 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 3 Settings 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1 Introduction 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2 System Setup 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3 System Parameters 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.1 Transition Type, Standard 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.2 Commit to Transfer: No 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.3 In-Phase Monitor 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 Voltage Pickup and Dropout Settings 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.5 Time Delays 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.6 Programmable Inputs and Outputs 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.1 Input Functions 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.6.2 Output Functions 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7 Common Alarms 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8 Communications 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 4 Communications 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1 Introduction 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2 Connections 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.1 USB Port SiteTech Connection 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2.2 Modbus Connection 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2.3 Ethernet Connection (Optional) 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents, continued

TP-6865 4/14Table of Contents4

4.3 Communications Setup 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3.1 Modbus Serial Communication Setup 26. . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3.2 Network Communication Setup 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3.3 Setup Using SiteTech 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 Parameter Files 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5 Controller Firmware Updates 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 5 Scheduled Maintenance 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1 Introduction 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2 Testing 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.1 Weekly Generator Set Exercise 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2.2 Monthly Automatic Control System Test 32. . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Inspection and Service 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3.1 General Inspection 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3.2 SPD Inspection 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3.3 Other Inspections and Service 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 Service Schedule 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 6 Accessories 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1 Introduction 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.2 Controller Disconnect Switch 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.3 Ethernet Board 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.4 Programmable Exerciser 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.5 Heater 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.6 Surge Protection (SPD) 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6.1 SPD Status Indicators 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.6.2 SPD Remote Status Indicator 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.6.3 SPD Replacement 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7 User Interface Cover 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A Abbreviations 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TP-6865 4/14 5Safety Precautions and Instructions

Safety Precautions and Instructions

IMPORTANTSAFETY INSTRUCTIONS.Electromechanical equipment,including generator sets, transferswitches, switchgear, and accessories,can cause bodily harm and poselife-threatening danger whenimproperly installed, operated, ormaintained. To prevent accidents beaware of potential dangers and actsafely. Read and follow all safetyprecautions and instructions. SAVETHESE INSTRUCTIONS.

Thismanual has several types of safetyprecautions and instructions: Danger,Warning, Caution, and Notice.

DANGER

Danger indicates the presence of ahazard that will cause severepersonal injury, death, orsubstantialproperty damage.

WARNING

Warning indicates the presence of ahazard that can cause severepersonal injury, death, orsubstantialproperty damage.

CAUTION

Caution indicates the presence of ahazard that will or can cause minorpersonal injury or property damage.

NOTICENotice communicates installation,operation, or maintenance informationthat is safety related but not hazardrelated.

Safety decals affixed to the equipmentin prominent places alert the operatoror service technician to potentialhazards and explain how to act safely.The decals are shown throughout thispublication to improve operatorrecognition. Replace missing ordamaged decals.

Accidental Starting

Accidental starting.Can cause severe injury or death.

Disconnect the battery cables beforeworking on the generator set.Remove the negative (--) lead firstwhen disconnecting the battery.Reconnect the negative (--) lead lastwhen reconnecting the battery.

WARNING

Disabling the generator set.Accidental starting can causesevere injury or death. Beforeworking on the generator set orconnected equipment, disable thegenerator set as follows: (1) Move thegenerator set master switch to the OFFposition. (2) Disconnect the power tothe battery charger. (3) Remove thebattery cables, negative (--) lead first.Reconnect the negative (--) lead lastwhen reconnecting the battery. Followthese precautions to prevent starting ofthe generator set by an automatictransfer switch, remote start/stopswitch, or engine start command fromaremote computer.

(Decision-Makerr 3+ and 550Generator Set Controllers)

Disabling the generator set.Accidental starting can causesevere injury or death. Beforeworking on the generator set orequipment connected to the set,disable the generator set as follows:(1) Press the generator set off/resetbutton to shut down the generator set.(2) Disconnect the power to the batterycharger, if equipped. (3) Remove thebattery cables, negative (--) lead first.Reconnect the negative (--) lead lastwhen reconnecting the battery. Followthese precautions to prevent thestarting of the generator set by theremote start/stop switch.

(Decision-Makerr 3000 and 6000Generator Set Controllers)

Hazardous Voltage/Moving Parts

Hazardous voltage.Will cause severe injury or death.

Disconnect all power sources beforeopening the enclosure.

DANGER


Only authorized personnel shouldopen the enclosure.

DANGER


Disconnect all power sources beforeservicing. Install the barrier afteradjustments, maintenance, orservicing.

DANGER

Hazardous voltage.Can cause severe injury or death.

Operate the generator set only whenall guards and electrical enclosuresare in place.

Moving parts.

WARNING

TP-6865 4/146 Safety Precautions and Instructions

WARNING


Close and secure the enclosure doorbefore energizing the transfer switch.

Grounding electrical equipment.Hazardous voltage can causesevere injury or death. Electrocutionis possible whenever electricity ispresent. Ensure you comply with allapplicable codes and standards.Electrically ground the generator set,transfer switch, and related equipmentand electrical circuits. Turn off themaincircuit breakers of all power sourcesbefore servicing the equipment. Nevercontact electrical leads or applianceswhen standing in water or on wetground because these conditionsincrease the risk of electrocution.

Short circuits. Hazardousvoltage/current can cause severeinjury or death. Short circuits cancause bodily injury and/or equipmentdamage. Do not contact electricalconnections with tools or jewelry whilemaking adjustments or repairs.Remove all jewelry before servicing theequipment.

Servicing the transfer switch.Hazardous voltage can causesevere injuryor death. Deenergizeallpower sources before servicing. Turnoff the main circuit breakers of alltransfer switch power sources anddisable all generator sets as follows:(1) Move all generator set mastercontroller switches to theOFFposition.(2) Disconnect power to all batterychargers. (3) Disconnect all batterycables, negative (--) leads first.Reconnect negative (--) leads lastwhenreconnecting the battery cables afterservicing. Follow these precautions toprevent the starting of generator setsby an automatic transfer switch, remotestart/stop switch, or engine startcommand from a remote computer.Before servicing any componentsinside the enclosure: (1) Remove alljewelry. (2) Stand on a dry, approvedelectrically insulated mat. (3) Testcircuits with a voltmeter to verify thatthey are deenergized.

Making line or auxiliaryconnections. Hazardous voltagecan cause severe injury or death. Toprevent electrical shock deenergize thenormal power source before makingany line or auxiliary connections.

Servicing the transfer switchcontrols and accessories within theenclosure. Hazardous voltage cancause severe injury or death.Disconnect the transfer switch controlsat the inline connector to deenergizethe circuit boards and logic circuitry butallow the transfer switch to continue tosupply power to the load. Disconnectall power sources to accessories thatare mounted within the enclosure butare not wired through the controls anddeenergized by inline connectorseparation. Test circuits with avoltmeter to verify that they aredeenergized before servicing.

Testing live electrical circuits.Hazardous voltage or current cancause severe injury or death. Havetrained and qualified personnel takediagnostic measurements of livecircuits. Use adequately rated testequipment with electrically insulatedprobes and follow the instructions of thetest equipment manufacturer whenperforming voltage tests. Observe thefollowing precautions when performingvoltage tests: (1) Remove all jewelry.(2) Standonadry, approvedelectricallyinsulated mat. (3) Do not touch theenclosure or components inside theenclosure. (4) Be prepared for thesystem to operate automatically.(600 volts and under)

Heavy Equipment

Unbalanced weight.Improper lifting can cause severeinjury or death and equipmentdamage.

Use adequate lifting capacity.Never leave the transfer switchstanding upright unless it is securelybolted in place or stabilized.

WARNING

NoticeNOTICE

Improper operator handle usage.Use the manual operator handle on thetransfer switch for maintenancepurposes only. Return the transferswitch to the normal position. Removethe manual operator handle, if used,and store it in the place provided on thetransfer switch when service iscompleted.

NOTICEElectrostatic discharge damage.Electrostatic discharge (ESD)damages electronic circuit boards.Prevent electrostatic dischargedamage by wearing an approvedgrounding wrist strap when handlingelectronic circuit boards or integratedcircuits. An approved grounding wriststrap provides a high resistance (about1 megohm), not a direct short, toground.

TP-6865 4/14 7Introduction

Introduction

Thismanual provides operation instructions for KohlerrDecision-Makerr MPAC 750 automatic transfer switchcontrols and related accessories.

Information in this publication represents data availableat the time of print. Kohler Co. reserves the right tochange this literature and the products representedwithout notice and without any obligation or liabilitywhatsoever.

The equipment service requirements are very importantto safe and efficient operation. Inspect parts often andperform required service at the prescribed intervals.Obtain service from an authorized service distributor/dealer to keep equipment in top condition.

Read this manual and carefully follow all proceduresand safety precautions to ensure proper equipment

operation and to avoid bodily injury. Readand follow theSafety Precautions and Instructions section at thebeginning of this manual. Keep this manual with theequipment for future reference.

List of Related Materials

A separate transfer switch installation manual providedwith the unit contains instructions for transfer switchinstallation and manual operation procedures.

Literature Item Part Number

Specification Sheet, MPAC 750 Controller G11-126

Specification Sheet, Model KSS/KSP G11-130

Installation Manual, Model KSS/KSP TP-6834

Operation Manual, Modbus Protocol TP-6113

TP-6865 4/148 Service Assistance

Service Assistance

For professional advice on generator powerrequirementsandconscientiousservice, pleasecontactyour nearest Kohler distributor or dealer.

D Consult the Yellow Pages under the headingGenerators—Electric.

D Visit the Kohler Power Systems website atKOHLERPower.com.

D Lookat the labels and stickers on yourKohler productor review the appropriate literature or documentsincluded with the product.

D Call toll free in the US and Canada 1-800-544-2444.

D Outside theUSandCanada, call the nearest regionaloffice.

Headquarters Europe, Middle East, Africa(EMEA)Kohler Power Systems Netherlands B.V.Kristallaan 14761 ZC ZevenbergenThe NetherlandsPhone: (31) 168 331630Fax: (31) 168 331631

Asia PacificPower Systems Asia Pacific Regional OfficeSingapore, Republic of SingaporePhone: (65) 6264-6422Fax: (65) 6264-6455

ChinaNorth China Regional Office, BeijingPhone: (86) 10 6518 7950

(86) 10 6518 7951(86) 10 6518 7952

Fax: (86) 10 6518 7955

East China Regional Office, ShanghaiPhone: (86) 21 6288 0500Fax: (86) 21 6288 0550

India, Bangladesh, Sri LankaIndia Regional OfficeBangalore, IndiaPhone: (91) 80 3366208

(91) 80 3366231Fax: (91) 80 3315972

Japan, KoreaNorth Asia Regional OfficeTokyo, JapanPhone: (813) 3440-4515Fax: (813) 3440-2727

Latin AmericaLatin America Regional OfficeLakeland, Florida, USAPhone: (863) 619-7568Fax: (863) 701-7131

TP-6865 4/14 9Section 1 Operation

Section 1 Operation

1.1 Introduction

This section contains operation instructions, including:

D User interface panel, with pushbuttons and LEDindicators

D Warnings and faultsD TestD ExerciseD Controller Reset

1.2 Source Names

Throughout this manual, the sources are referred tousing the following names:

D Source N

D Source E

D Preferred Source

D Standby Source

SourceN is connected to theNormal side of the transferswitch. SourceE is connected to theEmergency side of

the transfer switch. Inmost applications,SourceN is theutility source, andSourceE is thestandbygenerator set.The engine start contacts are associatedwith SourceE.

The Preferred Source is the source that will be used ifboth sources are available. With the MPAC 750controller, the preferred source is Source N. Thestandby source is Source E.

1.3 User Interface Panel

Theuser interfacepanel is locatedon the transfer switchdoor. Figure 1-1 shows the user interface pushbuttonsand LED indicators.

1.3.1 Pushbuttons

The user interface panel has two pushbuttons:

D Test (see Section 1.4)

D Exercise (see Section 1.6)

1. Source N Available LED2. Source N Position LED3. Source E Position LED

4. Source E Available LED5. USB port location

6. System Alert LED7. Not in Auto LED

8. Exercise button9. Test button

GM85888

6

1 2 3 4

7

9

5

8

Figure 1-1 User Interface Panel

TP-6865 4/1410 Section 1 Operation

1.3.2 LED Indicators

LEDs on the user interface indicate contactor position,source availability, faults, and other conditions. Thetable in Figure 1-2 describes the functions of the LEDindicators. Source N is connected to the normal side ofthe ATS and is typically the utility source. Source E isconnected to the emergency side of the ATS and istypically the generator set.

The Source E Available and Source E Position LEDsalso indicate test and exercise runs as described inFigure 1-3. See Sections 1.4 and 1.6 for moreinformation.

See Section 1.7 for more information about warningsand faults.

Some programmable inputs will trigger the LEDs to lightor flash. See Section 3.6.

LED Indicator Condition

Source N Available,Green

Source N is available.

Source E Available, Red Source E is available.

Position N, Green Contactor is in Normal position.

Position E, Red Contactor is in Emergency position.

System Alert, Red Fault. Identify and correct the causeof the fault condition, then reset faultsat the controller. See Section 1.7.

Input active: Low Battery Voltage orRemote Common Alarm. SeeSection 3.6.

Not in Auto, Red ATS is not set for automaticoperation.

Flashes for manual transfer waiting.

Inhibit Transfer input is active. SeeSection 3.6.

Figure 1-2 User Interface LED Indicators

ConditionSource E

Available (RED)Source E

Position (RED)

Unloaded Test Flash 1sec/1sec OFF

Loaded Test Flash 1sec/1sec Flash 1sec/1sec

Unloaded Exercise Flash 0.5 sec/2 sec OFF

Loaded Exercise Flash 0.5 sec/2 sec Flash 0.5 sec/2 sec

Figure 1-3 Test and Exercise Indication

1.4 Test

Use the Test button to:

D Start and run the generator set (unloaded test).

D Simulate a Source N failure, resulting in a transfer toSource E (loaded test).

If the emergency source is lost during a system test, thetest is terminated. If the contactor is in the standbyposition, it transfers immediately to the preferredposition.

For remote test information, also see Section 3.6.1.

1.4.1 Unloaded System Test

Press and hold the Test button for 3--5 seconds to startan unloaded test. The generator set will start withoutwaiting for the engine start time delay. The load is nottransferred to the generator set. The generator runsuntil the test is ended.

During an unloaded test, the Source E available LEDflashes, 1 second on and 1 second off.

Press and hold the Test pushbutton for about 2 secondstoend the test. Timedelayswill executeasprogrammedwhen the test is ended. The Source E available LEDlights during the time delays. The generator set shutsdown.

If the normal source fails during the test, the contactortransfers to the emergency source. The ATS thenmonitors the sources and operates automatically whenthe normal source returns.

1.4.2 Loaded System Test

A loaded test simulates a failure of source N. Press andhold the Test button for 6 seconds or longer to start aloaded test. The generator set will start without waitingfor the engine start time delay. The ATS then transfersthe load to the generator set.

Since the loaded test transfer will be between two livesources, the in-phasemonitor feature will be activated ifit is enabled.

During a loaded test, theSourceEavailable andSourceE position LEDs flash, 1 second on and 1 second off.


Press and hold the Test pushbutton for about 2 secondsto end the test. The retransfer sequence operates asthough Source N has been restored after a failure. Theload is transferred back to source N. All time delays areexecuted and an in-phase transfer will occur if enabled.The Source E LEDs light during the time delays. Thegenerator set shuts down.

If Source E is lost during the test and Source N isavailable, the transfer switchwill immediately transfer tothe Source N position, bypassing all time delays. IfsourceN is lost during a loaded test with the contactor inthe standby position, the test will continue to run.

1.5 Automatic Operation TestCheck the transfer switch’s automatic control systemimmediately after the voltage check. Review theoperation instructions in Section 1 before proceeding.

Note: Close and lock the enclosure door before startingthe test procedure.

Follow the procedure below to start a loaded test. Verifythat the ATS starts the generator set and transfers theload to the emergency source, executing all time delaysthat are set up to operate during a loss of the normalsource. End the test and verify that the transfer switchtransfers the load back to the normal source andremoves the engine start signal, executing allappropriate programmed time delays. Refer to Section2.2.3 for a more detailed description of the testsequence of operation.

Note: If the standby source fails during a loaded test,theATSwill immediately attempt to transfer to thepreferred source.

Automatic Operation Test Procedure

1. Check the controller LED indicators to verify thatthe Source N Position and Source N Availableindicators are lit.

2. Verify that the generator set master switch is in theAUTO position.

3. Press and hold the Test button for 6 seconds orlonger to start a loaded test.

4. Verify that the generator set starts and the SourceE Available LED lights.

5. Verify that the switch transfers the load toSourceE.Observe the controller LEDs and display as thetime delays execute and the load is transferred.

After the preferred-to-standby transfer time delay,verify that the Source N Position LED turns off andtheSourceEPositionLED lights, indicating that theswitch has transferred the load to Source E.

6. Press and hold the Test pushbutton for about 2seconds to end the test.

7. Verify that the switch transfers the load back toSource N. After the standby-to-preferred timedelay, verify that the Source E Position LED goesout and the Source N Position LED lights,indicating that theswitchhas transferred the load toSource N.

8. After the engine cooldown time delay expires, theengine start signal is removed. Verify that thegenerator set stops.

Note: The generator setmay have an engine cooldowntime delay that causes the generator set engineto run after the transfer switch engine start signalis removed.


1.6 Exercise

Set the exerciser after theATS is installed. Theexerciseautomatically runs thegenerator set for 20minuteseachweek.

If a system test is active when the exercise is scheduledto occur, the exercise is skipped. A preferred-sourcefailure during an exerciser period causes the exercise tobe terminated and normal ATS operation to resume.

1.6.1 Exercise Schedule

Pressing the exercise button to start a loaded orunloaded exercise as described in the followingsections sets the exercise time andday. The systemwillexercise at the same time and day each week.

To change the schedule, simply start a new exercise onthe desired day and time.

To start and stop the generator set without changing theexercise schedule, use the Test button. SeeSection 1.4for instructions.

1.6.2 Unloaded Exercise

An unloaded exercise starts and runs the generator setfor 20 minutes without transferring the load. Press andhold the exercise button for 3--5 seconds to start an

unloaded exercise. During an unloaded exercise, theSource E available LED flashes, 0.5 seconds on and 2seconds off.

1.6.3 Loaded Exercise

A loaded exercise starts the generator set and transfersthe load from the normal source to Source E. Press andhold the Exercise button for 6 seconds or longer to starta loaded exercise. During a loaded exercise, theSource E available and Source E position LEDs flash,0.5 seconds on and 2 seconds off. After 20minutes, theload transfers back to the normal source and thegenerator set shuts down.

1.6.4 Stopping an Exercise

If it is necessary to stop an exercise while it is running,press and hold the exercise button for 2 seconds.Stopping an exercise does not affect the weeklyexercise schedule.

1.6.5 Optional Programmable Exerciser

A programmable exercise timer is available. Theoptional exerciser allows scheduling of additionalloadedor unloadedexercises. SeeSection 6.4 formoreinformation.


1.7 Warnings and Faults

Whena fault exists, theSystemAlert indicator LED turnson and the related output is activated. If the output isassigned to the common fault, the common fault outputis also activated. See Figure 1-4 for the location of theSystem Alert indicator.

GM468921. System Alert LED

1

Figure 1-4 Fault Indication

ATS warnings and faults are shown in Figure 1-5.There are three types of warning/fault conditions:

Warning. Warnings automatically reset with a sourceavailability change or a transfer request.

Fault Requiring Manual Reset. Under theseconditions, normal ATS operation is halted. Activemodes are turned off. If the contactor is in the Source Nposition, the engine cooldown time delay executes andthe engine start contacts open, allowing the generatorset to shut down. See Section 1.7.1 for instructions toreset faults.

Self Resetting Faults. Under these conditions, activemodes are turned off. If the contactor is in the Source Nposition, the engine cooldown time delay executes andthe engine start contacts open, allowing the generatorset to shut down. When the fault condition is corrected,the fault is automatically cleared from the controller andnormal ATS operation continues.

Condition Type Description

Failure to Acquire Standby Source Warning The source voltage did not reach the acceptable range within a settime (see Time Delays). For example, the Source E generator setdid not start.

IPM Synching(In-Phase Monitor Synching)

Warning (status) The two sources did not come into phase within the Fail toSynchronize time delay.Note: If the sources do come into phase after the time delayexpires, the warning is automatically cleared and normal ATSoperation continues.

Failure to Transfer Warning The signal to transfer is sent to the contactor and the main shaftauxiliary switch fails to indicate a complete ATS position change.The controller will attempt to transfer the unit three times before thefault is indicated.

Src N (or Src E) Rotation Err Self-Resetting Fault The detected phase rotation of one or both sources does not matchthe preselected setting.

Auxiliary Switch Fault Manual Reset Fault The main shaft auxiliary switches indicate that the ATS is in morethan one position, or the position changed when no signal was sentto initiate the change.

Auxiliary Switch Open Manual Reset Fault The main shaft auxiliary switches indicate that the ATS is in neitherposition (all inputs are open).

External Fault Self-Resetting Fault The external input dedicated to this condition is closed.

Figure 1-5 Warnings and Faults


1.7.1 Fault Reset

To clear a fault or warning condition and reset theSystem Alert LED, press the Test and Exercise buttonsat the same time and hold for 2 seconds. SeeFigure 1-6.

1GM85888

1. Test button2. Exercise button

Press andhold theTest andExercise buttons for 2 seconds to clear afault condition.

2

Figure 1-6 Fault Reset

1.8 Controller Reset

1.8.1 Reboot

To reboot the controller processor while retaining allparameter settings, press the Test andExercise buttonsat the same time and hold for 15 seconds.

1.8.2 Reset to Default Settings

A personal computer with Kohlerr SiteTecht softwarecan be used to reset the controller to factory defaults, ifnecessary. SiteTech software is only available toKohlerauthorized distributors or dealers.

Note: Resetting to the default parameters will reset allparameters, including the system voltage andfrequency, to a factory default setting. Thedefault system voltage and frequency settingsmay not match the settings for your application.

The transfer switch will not operate correctly if thesystem voltage and frequency do not match thesources. Use SiteTech software to set the systemvoltage and frequency after resetting to the defaultparameters.

Check the system operation to verify the settings afterresetting.

TP-6865 4/14 15Section 2 Sequence of Operation

Section 2 Sequence of Operation

2.1 Controller Power--up/Reset

Following isanexplanationof the sequenceof operationwhen power is initially applied to the controller or acontroller reset occurs.

1. Controller self test is executed.

2. System parameters are downloaded fromnonvolatile memory.

3. Contactor position and source availability aredetermined.

4. If neither source is acceptable, the contactor doesnot change position.

5. If both sources are available, the controllerimmediately transfers the contactor to thepreferred source.

6. If only one source is available, the controllerimmediately transfers the contactor to that source,executing only the off-position and load controltime delays.

If the available source is the preferred source, andthe contactor is in the standby position, thecontactor transfers to preferred, the enginecooldown time delay runs, and then the enginestart contacts open.

If the available source is the preferred source andthe contactor is already in the preferred position,the engine start contacts open immediately,bypassing the engine cooldown time delay.

2.2 Sequence of Operation

The Sequence of Operation describes the transferswitch normal operation. The MPAC 750 controlleroperates using standard transition only (noprogrammed- or closed-transition operation).

Operation can be affected by faults such as the normalor emergency contacts failing to open or close whensignaled to do so.

2.2.1 Source N Loss and Return

Following is an explanation of the transfer switchsequence of operation when Source N failure isdetected.

Source N Fails

1. Engine start time delay expires.

2. The generator is signaled to start.

3. The generator starts and Source E becomesavailable.

4. Preferred-to-standby time delay expires.

5. Contactor transfers to Source E.

Source N Returns

1. Standby-to-preferred time delay expires.

2. Contactor transfers to Source N.

3. Engine cooldown time delay expires.

4. The engine start contacts open, signaling thegenerator to stop.

2.2.2 Exerciser Operation

Unloaded Exercise Sequence Starts

1. Exerciser timer begins.



TP-6865 4/1416 Section 2 Sequence of Operation

Unloaded Exercise Sequence Ends



Loaded Exercise Sequence Starts

1. Exerciser timer begins.



4. Preferred-to-standby time delay and pre-transferload control sequences run.


Source E Fails (Source N is available)

1. Exerciser is deactivated.

2. Contactor immediately transfers to Source N.

3. Immediate failure to acquire standby alarm.


5. Engine start contacts open.

Loaded Exercise Sequence Ends

1. Contactor transfers to preferred.



2.2.3 Test Sequence

Unloaded Test Function is Initiated

1. The generator set is signaled to start.


Unloaded Test Function is Ended


2. The generator is signaled to stop.

Loaded Test Function is Initiated

1. The generator is signaled to start (engine startcontacts close).


3. Preferred-to-standby time delay expires.


Source E Fails (Source N is available)

1. Test function is deactivated.

2. Contactor immediately transfers to Source N.

3. Immediate failure to acquire standby alarm.


5. Engine start contacts open.

Loaded Test Function is Ended

1. Standby-to-preferred time delay sequence runs.

2. Contactor transfers to Source N.



TP-6865 4/14 17Section 3 Settings

Section 3 Settings

3.1 Introduction

TheDecision-MakerrMPAC750controller is factorysetfor your transfer switch. This section lists factorysettings and adjustment ranges.

If necessary, some settings can be changed using apersonal computer and Kohlerr SiteTechr software orover Modbusr. SiteTech software is only available toKohler authorized distributors and dealers.

Use a USB cable with a male mini-B connector toconnect the controller to a laptop computer. The USBconnector is located on the front of the controller. SeeFigure 1-1.

Using Modbus

Commercially available programs can be used to readand change some settings over Modbus. For otherModbus applications, the Modbus master must beprogrammed to read the Modbus registers. Modbusregisters are published in TP-6113, Modbus ProtocolOperation Manual. A system designer trained in theapplication of Modbus protocol must write andthoroughly test the program before implementation.

3.2 System Setup

The transfer switch is factory-setwith default settings fortime delays and other parameters. SeeSection 1 for thedefault settings. Settings can be adjusted, if necessaryusing a personal computer and Kohlerr SiteTechtsoftwareor overModbus. SiteTechsoftware isavailableto Kohler authorized distributors and dealers.

Note: Use caution when changing transfer switchsettings. The source voltage and frequencysettings must match the values shown on thetransfer switch nameplate.

3.3 System ParametersThe transfer switch is factory-set for the transfer switchmodel and rating. System parameters should notrequire adjustment.

The system parameter factory settings are shown inFigure 3-1. Note that some settings are not adjustable.

System Parameter Factory Setting

Transition type, standard

See the ATSnameplate

Single/three phase

Operating voltage

Operating frequency (50 or 60 Hz)

Rated current

Transfer mode(automatic or non-automatic)*

Phase rotation* ABC

Commit to transfer* No

Operating mode* Utility-to-Generator

In-phase monitor Disabled

In-phase monitor transfer angle 5_

* Not adjustable.

Figure 3-1 System Parameters

3.3.1 Transition Type, Standard

The MPAC 750 controller is only available forstandard-transition model transfer switches.Standard-transition models (also referred to as opentransition) use a break-before-make transfer that doesnot require source synchronization for transfer betweenavailable sources.

Note: The transition type is determined by the ATSmodel. Do not change the transition type.

3.3.2 Commit to Transfer: No

This setting is factory set to No and is not adjustable. Ifthe preferred source returns returns during thetransfer-to-standby time delay, the transfer sequence iscancelled and the load is not transferred to the standbysource.

3.3.3 In-Phase Monitor

The in-phase monitor can be enabled or disabled forstandard-transition models. The in-phase monitoroperates prior to transfer when both sources areavailable. Transfer is inhibited while both sources aregreater than2 cyclesapart. If the connected source fallsbelow the undervoltage dropout setting, the in-phasemonitor terminates and allows transfer.

TP-6865 4/1418 Section 3 Settings

The synchronism window has a default value of 5_ andis adjustable from 15_ to 5_ before synchronism only.Settings can be changed using a personal computerand Kohler SiteTech software or over Modbus. Contactyour distributor or dealer for service.

The In-Phase Monitor Sync Output is activated if thesources do not synchronize within 60 seconds.

3.4 Voltage Pickup and DropoutSettings

The controller senses the voltage on both sources withan accuracy of ±0.5%. A source is consideredavailable when its voltage is within the range of dropoutsettings. If the voltage of the active source is outside theacceptable range for a length of time longer than thedebounce time, the system attempts to transfer the loadto the alternate source. The debounce time preventsnuisance transfers caused by brief voltage spikes anddips.

See Figure 3-2 for default settings and adjustmentranges.

SettingsDefaultSetting Adjustment Range [

Under voltagedropout

90% of pickup 75% to 98% of Pickup

Under voltagepickup

90% of nominal 85% to 100% of Nominal

Over voltagedropout

115% 106% to 135% ofNominal

Over voltagepickup

95% of dropout 95 to 100% of Dropout

Debounce time 0.5 seconds 0.1 to 9.9 seconds

[ Settings can be changed using a PC with SiteTech softwareor over Modbus.

Figure 3-2 Normal Source Pickup and DropoutSettings

3.5 Time Delays

The factory settings and adjustment ranges for the timedelays are shown in Figure 3-3.

The engine start time delay and transfer time delays canprevent nuisance transfers caused by brief voltage dipsor surges.

The engine cooldown time delay holds the engine startcontacts closed for a designated time after transfer toallow the generator set to run without load beforeshutting down.

If the standby source does not reach acceptable voltageand stabilize within the allowed time, the Fail to AcquireStandby Source fault is activated.

Time Delay DescriptionFactorySetting

AdjustmentRange [

Engine Start 3 sec 0--6 sec

Engine Cooldown 5 min.

0--60 minTransfer, preferred to standby 3 sec

Transfer, standby to preferred 15 min

Fail to Acquire Stby 1 min

Fail to Synch 1 min NA

[ PC with SiteTech software required.

Figure 3-3 Time Delay Settings

3.6 Programmable Inputs andOutputs

The controller includes connections for twoprogrammable inputs and two programmable outputs.Inputs and outputs are unassigned until the installerassigns a function to the I/O.

The programmable inputs and outputs can be assignedto the functions shown in Figure 3-4 and Figure 3-5.Programmable inputs and outputs can be assigned intwo ways:

D Using a PC with Kohlerr SiteTecht software.SiteTech software is available only to Kohlerauthorized distributors and dealers.

D Over Modbus; see TP-6113, Modbus ProtocolManual, for Modbus registers.

Programmable input functions correspond to theconnections to the transfer switch controller. Do notchange the programmable input assignments withoutverifying the input connections to the transfer switch.

See the transfer switch installation manual forconnection information for controller inputs andoutputs.

TP-6865 4/14 19Section 3 Settings

3.6.1 Input Functions

Available input functionsareshown inFigure 3-4. Someinputs will trigger an indicator LED on the user interfaceand/or display amessage on the LCDscreenwhen theyare activated.

All of the inputsmay be assigned to either one or both ofthe common alarms.

Remote Test Input. Activating the input starts a test,and deactivating the input stops the test. Tests followthe sequence described in Sections 1.4 and 2.2.3.

If a local test is already running, activating the remotetest input will stop the local test. A remote test can bestopped locally, if necessary, by pressing and holdingthe TEST button on the controller for about 2 seconds.

The default type for a remote test is “unloaded.” Tochange the remote test type, use a computer andKohlerr SiteTecht Software to set the Remote TestLoaded parameter. Alternatively, set the remote testtype over Modbus.

The optional programmable exerciser uses the remotetest input. See the instructions provided with theexerciser for more information.

ProgrammableInputs LED

«

LED

Inhibit Transfer(maintenance mode)

None Flashing

Remote Common Alarm Steady None

Remote Test None None

Figure 3-4 Available Programmable Inputs

3.6.2 Output Functions

Output functions are shown in Figure 3-5. Informationabout selected output functions is shown below. Referto the section number shown in Figure 3-5 for moreinformation about the output function.

Programmable Output TypeSee

SectionAux Switch Fault Fault 1.7

Aux Switch Open Fault 1.7

Common Alarm Active (1 and 2) Fault 3.7

Contactor in Preferred Position Monitor —

Contactor in Source E Position Monitor —

Contactor in Source N Position Monitor —

Contactor in Standby Position Monitor —

Exerciser Active Monitor 2.2.2

Fail to Acquire Standby Fault 1.7

Fail to Transfer Fault 1.7

In-Phase Monitor Sync Control 3.3.3

Not in Auto Monitor 1.3.2

Source E (Phase) Rotation Error Fault —

Source N (Phase) Rotation Error Fault —

Test Mode Active Monitor 1.4

Figure 3-5 Available Programmable Outputs

TP-6865 4/1420 Section 3 Settings

3.7 Common Alarms

Functions can be assigned to two alarm groups. Thegroups can then be assigned to programmable outputs,if desired. Any function assigned to the Common Alarmtriggers theCommonAlarm programmable output. SeeSection 3.6, Programmable Inputs and Outputs, formore information about programmable outputs.

Use Kohlerr SiteTecht software or Modbus to assignevents to the controller’s common alarm groups. SeeFigure 3-6 for a list of functions that can be assigned tothe common alarm.

Alarm Descriptions

Auxiliary Switch Fault

Auxiliary Switch Open

Contactor in Preferred

Contactor in Source E Position

Contactor in Source N Position

Contactor in Standby Position

Exerciser Active

Fail to Acquire Standby Source

Fail to Transfer

In Phase Monitor Synching

Not in Auto

Remote Common Alarm

Source E Available

Source N Available

Source N Rotation Error

Source E Rotation Error

System Ready

Test Mode Active

Figure 3-6 Alarm Descriptions

3.8 Communications

Use a personal computer with Kohler SiteTech softwareor Modbus to set the communication parameters forserial or Ethernet connections. See Section 4,Communications, for instructions.

TP-6865 4/14 21Section 4 Communications

Section 4 Communications

4.1 Introduction

The Decision-MakerrMPAC 750 controller is equippedwith a USB port and a Modbus port with an RS-485connector. An optional Ethernet accessory board isavailable.

Kohler authorized distributors and dealers can use apersonal (laptop) computer with Kohlerr SiteTechtsoftware to view and adjust controller parameters, viewevent history, import and export parameter files, andupdate controller firmware. See TP-6701, SiteTechSoftware Operation manual, for instructions.

Controller settings can also be viewed and adjustedusing Modbus. The Modbus registers are available inthe Modbus Protocol Manual, TP-6113.

The controller can send encapsulated Modbusmessages over the network connection. Only oneModbus address can be assigned to the controller,regardless of the communication port or protocol beingused.

Note: Modbusr applications require a Modbussoftware driver written by a trained and qualifiedsystems programmer.

4.2 Connections

4.2.1 USB Port SiteTech Connection

A personal computer and Kohler SiteTech software canbe used for changing controller settings. Use a USBcable to connect the controller to a personal computer.

See Figure 4-1 for the USB port location on the front ofthe controller assembly. Remove the small port coverand use aUSBcable with amini-B connector to connectthe controller’s USB port to the computer.

See TP-6701, SiteTech Software OperationManual, forinstructions to use the software.

1

GM85888

1. USB connection (below port cover)

Figure 4-1 USB Connection (for SiteTech)

TP-6865 4/1422 Section 4 Communications

4.2.2 Modbus Connection

See Figure 4-2 and Figure 4-3 for the RS-485 Modbusconnector location. The Modbus port on the controllercircuit board is Port 0.

Use serial connections to TB2 on the controller board toconnect the transfer switch to a personal computer forsystem monitoring, the optional remote annunciator, ora Modbus network. See Figure 4-5.

A 121 ohm terminating resistor is recommended on thelast device in a network. If there is only one device, aterminating resistor may be required depending on thecable distance and communication speed. Long cablesand high speedswill increase the need for a terminatingresistor.

The serial port is an isolated RS-485 port withconnection speeds of 9.6, 19.2, and 57.6 kbps. Useshielded twisted-pair cable to connect to the RS-485connectors on controller terminal strip TB2 for serialconnections. For connection to a PC, use a USB toRS-485 converter.

Connect the Modbus input and output to the terminalsshown in Figure 4-4. Use #12-24 AWG shielded,twisted-pair wire. Belden cable #9841 or equivalent isrecommended. Connect one end of the shield toground. Leave the other end of the shield disconnected.Tighten the connections to 0.5 Nm (4.4 in. lb.).

Use Modbusr RTU (remote terminal unit) protocol forcommunication over the serial port. The Modbusregisters are available in the Modbus Protocol Manual,TP-6113.


1. RS-485 Modbus connections2. Access opening for RS-485 cables

GM85884

1

2

Figure 4-2 Modbus Connections (controller coverremoved for illustration only)

1. Modbus communication RS-485 connectorGM89713

1

Figure 4-3 Modbus Connector on the ControllerCircuit Board


TB2

A1(--)

B1(+)

GND1

3

6

1

4

A1(--)

B1(+)

GND1

Customer connections

Input

Output

Cable shield

Cable shield

Figure 4-4 Modbus RS-485 Connections

USB to RS-485 portconverter ]

RS-485 *USB port

Device

USB port

Device

LastDevice

RS-485

*

RS-485 *

Device

Terminating resistor [,(121 Ohms)

USB to RS-485port converter ]

Terminating resistormay be required [

(121 Ohms)

In

Out

In

In

In

Out

Out

Out

PCPC

PC

* Use Belden #9841 or equivalent shielded, twisted-paircommunication cable for RS-485 connections. Groundone end of the cable shield. Leave the other end of thecable shield disconnected.

[ Long cables and high communication speeds will requirea terminating resistor. Use 121 ohm resistor X-6058-27.

] Customer-provided

RS-485

*Figure 4-5 Serial Connections


4.2.3 Ethernet Connection (Optional)

The Ethernet communication accessory board isrequired for connection to the Ethernet. The Ethernetcommunication board is an optional accessory for theMPAC 750 controller. The communication boardconnects to the controller board as shown in Figure 4-6.

1. Ethernet communication board with RJ-45 connector2. Access opening for Ethernet cable

GM85884

1

12

Figure 4-6 Ethernet Board (controller coverremoved for illustration only)

The Ethernet communication accessory board allowsthe transfer switch to be connected to a building’sEthernet network to communicate with personalcomputers connected to the same subnet.

Note: For an ethernet connection, obtain an IP addressand subnet mask number from the local systemadministrator.

Ethernet Port. The ethernet port is a standard RJ-45jack. SeeFigure 4-6 for the locationof theEthernet port.UseCategory5eorbetter cable toconnect thecontrollerto the building’s network.

Use the Setup menus or a personal computerconnected to the controller’s USB port and KohlerSiteTech software to set the communicationparameters. The Ethernet communication board mayhave a default IP address assigned at the factory for testpurposes. See Figure 4-7. Change the IP address toan address owned by the user. See Section 3.8 forinstructions to set the communication parameters.

The transfer switch controller does not operate as aModbus-to-Ethernet converter for other devices in anetwork. Formultiple device networks connected to thepersonal computer through the Ethernet, use aModbus-to-Ethernet converter for the other devices inthe network. See Figure 4-8 and instruction sheetTT-1405, provided with the converter, for connectioninstructions.

The controller can communicate with up to five (5)simultaneous TCP/IP (ethernet) connections. Thesefive connections do not include the RS-485 serial port.In the extreme case, five users may be communicatingwith the controller via TCP/IP network connections andanother may be communicating through the serial port,for a total of six (6) communication channels. As thecontroller is asked to communicate with more andmoreoutside devices, the communication will slow down.

PCIP xx.xx.xx.02

EthernetNetwork

Modbusr TCP/IPCategory 5e


Note: ThePCand theATSmust be on the samesubnet.

Note: A crossover cable can be used to connect the PCto the ATS controller through the Ethernet port.

MPACController withEthernet comm.

boardIP xx.xx.xx.03

Figure 4-7 Remote Network (Ethernet) Connection


MPACController withEthernet comm.

boardIP xx.xx.xx.03

PCIP xx.xx.xx.02

Device

Last device

RS-485

Converter,Modbusr/EthernetIP xx.xx.xx.05 RS-485

ModbusrTCP/IP

ModbusrTCP/IP

EthernetNetwork

PCIP xx.xx.xx.01

Terminating resistor(121 Ohms)

Device

Device

RS-485

Device

ModbusrRTU

RS-485



Figure 4-8 Ethernet Connections to Multiple-Device Network


4.3 Communications Setup

Use a personal computer with Kohlerr SiteTechtsoftware connected to the USB port to set thecommunication parameters for serial or Ethernetconnections. For serial communications, the controlleruses Modbusr communication protocol.

4.3.1 Modbus Serial CommunicationSetup

Set the following communication parameters for serialcommunication. Also see Figure 4-9 for a summary ofthese settings.


Modbus Enabled. Set to True to allow Modbuscommunication.

Modbus Baud Rate. Required for serial connections.The baud rate must match the baud rate of theconnected PC.

Modbus Slave Addr. Assign a unique addressbetween 001 and 247 to the serial port.

4.3.2 Network Communication Setup

Work with your local network administrator to set thefollowing communication parameters for Ethernetcommunication.

See Figure 4-9 for a summary of the following settings.

DHCP Enabled. Factory set to False. Setting thisparameter to True enables dynamic host configurationprotocol (DHCP), which allows a DHCP server toautomatically assign a dynamic IP address, subnetmask, and default gateway to the MPAC controller.Workwith your local network administrator to determinewhether DHCP is required.

Static IP Address. The transfer switch may have adefault IP address assigned at the factory. Change the

IP address to a static IP address owned by the user.Obtain an IP address, subnet mask, and defaultgateway information from the local networkadministrator.

Static Subnet Mask. Obtain subnet mask informationfrom the local network administrator. All devices thatcommunicatewith eachother on the same local networkmust use the same subnet mask.

Static Default Gateway. Obtain gateway informationfrom the local network administrator.

DHCP Server. Displayed for information only. Providethis value to the network administrator if there areproblems with DHCP.

Modbus TCP Unit ID. The unit ID is required forModbus over TCP communication. The unit ID for TCPcommunication is analogous to theModbus address forserial communication through the RS-485 ports. Thefactory default setting is 2.

Modbus TCP Server Enabled. Enable (set to True) toenable TCP if the transfer switch is connected to anetwork for TCP/IP communication (for example,ethernet communication).

MAC address. The MAC hardware address isfactory-set. It canbeseen in theView>CommunicationsSetup screens but not viewed or changed in the setupmenus.

4.3.3 Setup Using SiteTech

Use a USB cable, male USB A to male USB mini-B, toconnect the MPAC controller to a personal computer.Then use Kohler SiteTech software to set thecommunication parameters for serial or Ethernetconnections. See Figure 4-10 and TP--6701, SiteTechSoftware Operation Manual.

SiteTech software is available only to Kohler authorizeddistributor and dealers.


Setting Range Default Notes

Modbus Enabled True or False True Enable for network communication through the ethernet port.

Modbus Baud Rate 9600, 19200, 57600 19200 Baud rate in bits per second for serial communication between thecontroller and a personal computer’s COM port.

Modbus Slave Address 001-247 0 Address for the RS-485 serial port (on the controller board).

Modbus Parity Read only None Not adjustable.

Modbus Stop Bits Read only 1 Not adjustable.

DHCP Enabled True or False False Dynamic host communication protocol. Enable if required; checkwith your local network administrator.

Static IP Address See notes. * Obtain from your local network administrator. Every device on thenetwork must have a unique IP address.

Static Subnet Mask See notes. * Obtain from your local network administrator.All devices that communicate with each other on the same localnetwork must use the same subnet mask.

Static Default Gateway See notes. * Obtain from your local network administrator.

DHCP Server Read only — Displayed for information only.

Modbus TCP Unit ID 001-247 002 The unit ID is required for Modbus over TCP communication.

Modbus TCP Server Enabled True or False True Enable (set to True) to enable TCP/IP communication (for example,Ethernet communication).

MAC Address Not Adjustable Factory-set

Hardware address, entered at the factory. Not adjustable.

* Do not use the factory settings for IP address, subnet mask, or default gateway. Obtain these settings from your local networkadministrator.

Figure 4-9 Communication Parameters


***

* Obtain from the local network administrator

*

Figure 4-10 Communications Parameters in Kohler SiteTech Software


4.4 Parameter Files

The parameter setting files can be exported to apersonal computer (PC) using Kohlerr SiteTechtsoftware. Use a USB cable to connect the PC to thecontroller. The resulting file can be opened usingspreadsheet softwareonyour computer. Modificationofthe settings in the file is not recommended.

Parameter settings can be loaded onto theMPAC controller fromasaved file. This canbeuseful forservice or controller replacement. See the SiteTechOperation Manual for instructions to export and importfiles.

4.5 Controller Firmware Updates

Kohler may release updated versions of the controllerfirmware. A personal (laptop) computer connected tothe USB port and Kohlerr SiteTecht software arerequired for updating the firmware on the controller.Have an authorized distributor/dealer load an updatedversion of the controller firmware, if necessary. SeeTP-6701 for instructions to update the firmware.


Notes

TP-6865 4/14 31Section 5 Scheduled Maintenance

Section 5 Scheduled Maintenance

5.1 Introduction

Regular preventive maintenance ensures safe andreliable operation and extends the life of the transferswitch. Preventive maintenance includes periodictesting, cleaning, inspection, and replacement of wornor missing components. Section 5.4 contains a serviceschedule for recommended maintenance tasks.

A local authorized distributor/dealer can providecomplete preventive maintenance and service to keepthe transfer switch in top condition. Unless otherwisespecified, havemaintenanceor serviceperformedbyanauthorized distributor/dealer in accordance with allapplicable codes and standards. See the ServiceAssistance section in this manual for how to locate alocal distributor/dealer.

Keep records of all maintenance or service.

Replace all barriers and close and lock the enclosuredooraftermaintenanceor serviceandbefore reapplyingpower.



WARNING

Disabling the generator set. Accidental starting cancause severe injury or death. Before working on thegenerator set or connected equipment, disable the generatorset as follows: (1) Move the generator setmaster switch to theOFFposition. (2) Disconnect the power to the battery charger.(3) Remove the battery cables, negative (--) lead first.Reconnect the negative (--) lead last when reconnecting thebattery. Follow these precautions to prevent starting of thegenerator set by an automatic transfer switch, remotestart/stop switch, or engine start command from a remotecomputer.

Disabling the generator set. Accidental starting cancause severe injury or death. Before working on thegenerator set or equipment connected to the set, disable thegenerator set as follows: (1) Press the generator set off/resetbutton to shut down the generator set. (2) Disconnect thepower to the battery charger, if equipped. (3) Remove thebattery cables, negative (--) lead first. Reconnect the negative(--) lead last when reconnecting the battery. Follow theseprecautions to prevent the starting of the generator set by theremote start/stop switch.


Disconnect all power sources beforeopening the enclosure.

DANGER



DANGER


Operate the generator set only whenall guards and electrical enclosuresare in place.

Moving parts.

WARNING

TP-6865 4/1432 Section 5 Scheduled Maintenance

Grounding electrical equipment. Hazardous voltage cancause severe injury or death. Electrocution is possiblewhenever electricity is present. Ensure you comply with allapplicable codes and standards. Electrically ground thegenerator set, transfer switch, and related equipment andelectrical circuits. Turn off the main circuit breakers of allpower sources before servicing the equipment. Never contactelectrical leads or appliances when standing inwater or onwetground because these conditions increase the risk ofelectrocution.

Servicing the transfer switch. Hazardous voltage cancause severe injury or death. Deenergize all power sourcesbefore servicing. Turn off the main circuit breakers of alltransfer switch power sources and disable all generator setsas follows: (1) Move all generator set master controllerswitches to the OFF position. (2) Disconnect power to allbattery chargers. (3) Disconnect all battery cables, negative(--) leads first. Reconnect negative (--) leads last whenreconnecting the battery cables after servicing. Follow theseprecautions to prevent the starting of generator sets by anautomatic transfer switch, remote start/stop switch, or enginestart command from a remote computer. Before servicing anycomponents inside the enclosure: (1) Remove all jewelry. (2)Stand on a dry, approved electrically insulated mat. (3) Testcircuits with a voltmeter to verify that they are deenergized.

Short circuits. Hazardous voltage/current can causesevere injury or death. Short circuits can cause bodily injuryand/or equipment damage. Do not contact electricalconnections with tools or jewelry while making adjustments orrepairs. Remove all jewelry before servicing the equipment.

NOTICEElectrostatic discharge damage. Electrostatic discharge(ESD) damages electronic circuit boards. Preventelectrostatic discharge damage by wearing an approvedgrounding wrist strap when handling electronic circuit boardsor integrated circuits. An approved grounding wrist strapprovides a high resistance (about 1 megohm), not a directshort, to ground.

5.2 Testing

5.2.1 Weekly Generator Set ExerciseUse the exerciser to start and run the generator setunder load once aweek tomaximize the reliability of theemergency power system. See Section 1.6 forinstructions to program the exerciser.

5.2.2 Monthly Automatic ControlSystem Test

Test the transfer switch’s automatic control systemmonthly. See Section 1.5 for the test procedure.

D Verify that the expected sequence of operationsoccurs as the switch transfers the load to theemergency source when a preferred source failureoccurs or is simulated.

D Observe the indicator LEDs included on the transferswitch to check their operation.

D Watch and listen for signs of excessive noise orvibration during operation.

D After the switch transfers the load to the standbysource, end the test and verify that the expectedsequence of operations occurs as the transfer switchretransfers to the preferred source and signals thegenerator set to shut down after a cooldown period.

TP-6865 4/14 33Section 5 Scheduled Maintenance

5.3 Inspection and Service

Contact an authorized distributor/dealer to inspect andservice the transfer switch annually and also when anywear, damage, deterioration, or malfunction of thetransfer switch or its components is evident orsuspected.

5.3.1 General InspectionExternal Inspection. Keep the transfer switch cleanand in good condition by performing a weekly generalexternal inspection of the transfer switch for anycondition of vibration, leakage, excessive temperature,contamination, or deterioration. Removeaccumulations of dirt, dust, and other contaminantsfrom the transfer switch’s external components orenclosure with a vacuum cleaner or by wiping with a drycloth or brush.

Note: Do not use compressed air to clean the transferswitch because it can cause debris to lodge in thecomponents and damage the switch.

Tighten loose external hardware. Replace any worn,missing, or broken external components withmanufacturer-recommended replacement parts.Contact a local authorized distributor/dealer for specificpart information and ordering.

Internal Inspection. Disconnect all power sources,open the transfer switch enclosure door, and inspectinternal components monthly or when any conditionnoticed during anexternal inspectionmayhaveaffectedinternal components.

Contact an authorized distributor/dealer to inspect andservice the transfer switch if any of the followingconditions are found inside the transfer switch.

D Accumulations of dirt, dust, moisture, or othercontaminants

D Signs of corrosion

D Worn, missing, or broken components

D Loose hardware

D Wire or cable insulation deterioration, cuts, orabrasion

D Signs of overheating or loose connections:discoloration of metal, melted plastic, or a burningodor

D Other evidence of wear, damage, deterioration, ormalfunction of the transfer switch or its components.

If the application does not allow a power interruption forthe time required for the internal inspection, have anauthorized distributor/dealer perform the internalinspection.

5.3.2 SPD InspectionOn transfer switches equipped with optional surgeprotective devices (SPDs), check the following itemsevery two months:

D SPD status indicators

D Condition of SPD connecting leads

5.3.3 Other Inspections and ServiceHave an authorized distributor/dealer performscheduled maintenance, service, and othermaintenance that ensures the safe and reliableoperation of the transfer switch. See Section 5.4,Service Schedule, for the recommended maintenanceitems and service intervals.

Have an authorized distributor/dealer repair or replacedamaged or worn internal components withmanufacturer-recommended replacement parts.

TP-6865 4/1434 Section 5 Scheduled Maintenance

5.4 Service Schedule

Follow the service schedule below for therecommended service intervals. Have all service

performedbyanauthorized distributor/dealer except foractivities designated by an X, which may be performedby the switch operator.

System Component or ProcedureSee

SectionVisuallyInspect Check

Adjust,Repair,Replace Clean Test Frequency

Electrical SystemCheck for signs of overheating or loose connections:discoloration of metal, melted plastic, or a burning odor 5.3.1 X X Y

Check the contactor’s external operating mechanismfor cleanliness; clean and relubricate if dirty * 5.3.1 X

D (cleanand lube) Y

Inspect wiring insulation for deterioration, cuts, orabrasion. Repair or replace deteriorated or damagedwiring

5.3.1 X D D Y

Tighten control and power wiring connections tospecifications 2 D D Y

Check the transfer switch’s main power switchingcontacts’ condition; clean or replace the main contactsor replace the contactor assembly as necessary

S/M D D D Y

Control SystemExercise the generator set under load 5.2.1 X W

Test the transfer switch’s automatic control system 5.2.21.5

X X M

General Equipment ConditionInspect the outside of the transfer switch for any signsof excessive vibration, leakage, high temperature,contamination, or deterioration *

5.3.1 X X M

Check that all external hardware is in place, tightened,and not badly worn 5.3.1 X X X M

Inspect the inside of transfer switch for any signs ofexcessive vibration, leakage, high temperature,contamination, or deterioration*

5.3.3 D D D Y

Check that all internal hardware is in place, tightened,and not badly worn 5.3.3 X D D Y

SPD Modules (if equipped)

Check status indicators 6.6 X D Every2 monthsCheck condition of connecting leads 6.6 X D

* Service more frequently if the transfer switch is operated in dusty or dirty areas.

See Section: Read these sections carefully for additional information before attempting maintenance or service.Visually Inspect: Examine these items visually.Check: Requires physical contact with or movement of system components, or the use of nonvisual indications.Adjust, Repair, Replace: Includes tightening hardware and lubricating the mechanism. May require replacement of components dependingupon the severity of the problem.Clean: Remove accumulations of dirt and contaminants from external transfer switch’s components or enclosure with a vacuum cleaner or bywiping with a dry cloth or brush. Do not use compressed air to clean the switch because it can cause debris to lodge in the components andcause damage.Test: May require tools, equipment, or training available only through an authorized distributor/dealer.

Symbols used in the chart:X=The transfer switch operator can perform these tasks.D=An authorized distributor/dealer must perform these tasks.S/M=ServiceManual. An authorized distributor/dealermust performthese tasks.

W=WeeklyM=MonthlyQ=QuarterlyS=Semiannually (every six months)Y=Yearly (annually)

TP-6865 4/14 35Section 6 Accessories

Section 6 Accessories

6.1 Introduction

This section describes the hardware options that areavailable for transfer switches equipped withDecision-Makerr MPAC 750 controls.

6.2 Controller Disconnect Switch



WARNING

Disabling the generator set. Accidental starting cancause severe injury or death. Before working on thegenerator set or connected equipment, disable the generatorset as follows: (1) Move the generator setmaster switch to theOFFposition. (2) Disconnect the power to the battery charger.(3) Remove the battery cables, negative (--) lead first.Reconnect the negative (--) lead last when reconnecting thebattery. Follow these precautions to prevent starting of thegenerator set by an automatic transfer switch, remotestart/stop switch, or engine start command from a remotecomputer.



DANGER

The controller disconnect switch allows disconnectionof the power to the controller during maintenance andservice. See Figure 6-1.

Note: Disable the generator set before using thecontroller disconnect switch to disconnect powerto the ATS controls.

Disconnecting power to the controls can cause the ATSto signal the generator set to start. Prevent thegenerator set from starting by moving the generator setmaster switch to OFF and disconnecting the batterycharger and battery. Refer to the generator setoperation manual for specific instructions.

The switch has two positions, auto (I) and disconnect(0). Move the controller disconnect switch to the 0position to disconnect power to the ATS controller. Aftermaintenanceor service,move theswitch to the Ipositionto reconnect power. Follow the instructions in thegenerator set documentation to reenable the generatorset.

#

I = Connect

0 = Disconnect

Figure 6-1 Controller Disconnect Switch

TP-6865 4/1436 Section 6 Accessories

6.3 Ethernet Board

Ethernet communication is provided by an optionalcircuit board that connects to the MPAC controllerboard. See Figure 6-2. The Ethernet board includes anRJ-45 connector for an Ethernet cable.

The Ethernet board may have a default IP addressassigned at the factory for test purposes. Change theIP address to an address owned by the user. UseKohler SiteTech software to assign a new IP addressand port number.

See Section 4.2.3 for more information about Ethernetcommunications.

1. Ethernet communication board with RJ-45 connector

GM85884

1

Figure 6-2 Ethernet Communication Board

6.4 Programmable Exerciser

The optional programmable exerciser is a 7-day timerthat allowsprogrammingof up to 8 on/off events per day.See Figure 6-3. Use the exercise timer to programweekly loaded or unloaded exercise periods in additionto the exercise time set through the ATS controller. Thetimer is installed inside the ATS enclosure.

Programmable exerciser features include:

D Seven-day programmable timer allows schedulingup to 56 on/off events.

D LCDdisplay indicates day, time, program/runmodes,on/off status, and skip cycle status.

D Skip next cycle button.

D 5-year lithium backup battery.

The programmable exerciser uses the Remote Testinput. See Section 3.6.1. If necessary, a remote teststarted by the programmable exerciser can be stoppedlocally by pressing and holding the TEST button on theMPAC 750 controller for about two seconds.

Refer to the instruction sheet providedwith theexerciserfor installation, connection, loaded/unloaded selection,and programming instructions. A personal computerand Kohlerr SiteTecht software are required to set upthe remote exerciser. SiteTech software is available toKohler-authorized distributors and dealers.

Figure 6-3 Programmable Exerciser


6.5 Heater

An anti-condensation heater kit is available. The stripheater is controlled by a hygrostat to raise thetemperature inside theenclosureabove thedewpoint toprevent condensation. Figure 6-4 shows typicallocations of the heater kit components inside theenclosure.

The installer must connect 120 VAC power to theterminal block near the hygrostat. See Figure 6-5 andFigure 6-6. The heater and hygrostat are connected topower through a 15-amp circuit breaker.

The relative humidity setting on the hygrostat isadjustable from 35% to 95%. A setting of 65% isrecommended.

Because of space limitations in the smaller enclosures,40--225 Amp Model KSS transfer switches can includeeither an enclosure heater or a surge protection device(SPD), but not both.

1. Hygrostat assembly, see Figure 6-52. Strip heater with guard

1

GM69824

2

Right Side View

Figure 6-4 Heater Location, Typical

1. 120 VAC power connection terminal block2. Circuit breaker3. Relative humidity adjustment control

GM71056

3

2

1

Figure 6-5 Hygrostat Assembly, Typical

GM71278

HYGROSTAT

HEATER

CIRCUITBREAKER

TERMINALBLOCK

120 VAC ONLYCUSTOMER SUPPLIED

Figure 6-6 Heater Connections


6.6 Surge Protection (SPD)

A surge protection device (SPD) is available for thetransfer switch. Installed on theNormal source side, theSPD protects the system from voltage surges,preventing damage to household loads. The SPDresets automatically. See Figure 6-7 for the typical SPDassembly location inside the ATS enclosure. SeeFigure 6-8 for SPD specifications.

Because of space limitations in the smaller enclosures,40--225 Amp Model KSS transfer switches can includeeither an enclosure heater or a surge protectiondevice(SPD), but not both.

1

GM49947

1. SPD assembly is typically located on the side of theenclosure. Location varies for different models.

Figure 6-7 SPD Location, Typical

SPD Specifications

NominalVoltage(V±15%)

Max.DischargeCurrent(kA) Phase Poles

UL VPR 3rd Ed(L-N/N-G/L-G)

(kV)

Limiting Voltage, (L-N/N-G/L-G)(kV)

Short CircuitWithstandCurrent (kA)

MaximumContinuou

sOperatingVoltage(VAC)at 3kAmps at 10kAmp

120 /240 40 Split 3 0.6 / 1.2 / 0.7 0.6 / 0.4 / 0.6 0.8 / 0.7 / 0.8 200 175 / 350

120 /208 40 Wye 4 0.6 / 1.2 / 0.7 0.6 / 0.4 / 0.6 0.8 / 0.7 / 0.8 200 175 / 350

277 /480 40 Wye 4 1.0 / 1.2 / 1.1 1.0 / 0.4 / 1.0 1.2 / 0.7 / 1.2 200 320 / 460

120 /240 40 HLD 4 1.0 / 1.2 / 1.1 1.0 / 0.4 / 1.0 1.2 / 0.7 / 1.2 200 320 / 460

347 /600 40 Wye 4 1.3 / 1.2 / 1.4 1.3 / 0.4 / 1.3 1.5 / 0.7 / 1.5 200 440 / 880

Figure 6-8 SPD Specifications


Figure 6-9 SPD Wiring Diagram, GM89992


6.6.1 SPD Status Indicators

A status indicator on each Surge Protection Device(SPD) module indicates the SPD condition. SeeFigure 6-10. A green indicator shows that the SPD isproviding protection. When the status indicator is red,the SPD no longer provides protection. Replace theSPD cartridge. See Section 6.6.3 for replacementinstructions.

GM89934

1. Decal, remote status indicator wiring2. Fuse blocks3. Surge suppressors4. SPD status indicator location5. Remote status indicator connections

5

1

4

3

2

Figure 6-10 SPD Assembly, Typical

6.6.2 SPD Remote Status Indicator

A customer-supplied indicator for the SPD can beconnected to provide remote indication when the SPDneeds to be replaced. The contact changes state whenthe SPD module needs replacement.

Connect customer-provided indicators or alarms to thenormally open (NO) or normally closed (NC) auxiliarycontact terminals on terminal block TB1. SeeFigure 6-11 for the contact rating andFigure 6-10 for theterminal block location. See the decal on the SPDassembly or the transfer switch wiring diagram forconnections.

SPD Remote Status Indication Specification

Contact rating 1 A @ 250 VAC

Wire Size 16 AWG

Figure 6-11 Remote Status Indicator ContactSpecifications

6.6.3 SPD Replacement

Replace the module when the SPD indicator turns red.Follow the replacement procedure in this section.


This equipment must be installed andserviced by qualified electricalpersonnel.

DANGER

Servicing the transfer switch. Hazardous voltage cancause severe injury or death. Deenergize all power sourcesbefore servicing. Turn off the main circuit breakers of alltransfer switch power sources and disable all generator setsas follows: (1) Move all generator set master controllerswitches to the OFF position. (2) Disconnect power to allbattery chargers. (3) Disconnect all battery cables, negative(--) leads first. Reconnect negative (--) leads last whenreconnecting the battery cables after servicing. Follow theseprecautions to prevent the starting of generator sets by anautomatic transfer switch, remote start/stop switch, or enginestart command from a remote computer. Before servicing anycomponents inside the enclosure: (1) Remove all jewelry. (2)Stand on a dry, approved electrically insulated mat. (3) Testcircuits with a voltmeter to verify that they are deenergized.


SPD Replacement Procedure

Note: The cartridges are keyed for the phases or theneutral. Be sure to obtain the correct service partfor each cartridge. See the transfer switch partscatalog for service part numbers.

1. Disable the generator set to prevent starting asfollows:

a. Move the generator set master switch to theOFF position.

b. Disconnect power to the battery charger.

c. Disconnect the generator set engine startingbattery, negative (--) lead first.

2. Disconnect power to the transfer switch: Open thenormal and emergency source circuit breakersupstream of the transfer switch.

3. Remove the enclosure’s inner panel , if equipped.

4. Open the fuse holder.

5. Remove the cartridge by pulling straight out.

6. Replace the SPD cartridge with the appropriateservice part.

7. Close the fuse holder.

8. Replace the enclosure’s inner panel, if equipped.

9. Reconnect power to the transfer switch by closingthenormal andemergencysource circuit breakers.

10. Check the SPD status indicators.

11. Reconnect the generator set engine startingbattery, negative (--) lead last.

12. Reconnect power to the battery charger.

13. Close and lock the ATS enclosure door.

14. Move the generator setmaster switch to the AUTOposition.

6.7 User Interface Cover

The gasket-sealed, hinged user interface coverprevents unauthorized access to the transfer switchcontrols and protects the user interface from harshenvironmental conditions. Use a customer-suppliedpadlock to lock the cover.

NEMA 3R enclosures include a cover as standardequipment.


Notes

TP-6865 4/14 Appendix 43

Appendix A Abbreviations

The following list contains abbreviations that may appear in this publication.

A, amp ampereABDC after bottom dead centerAC alternating currentA/D analog to digitalADC advanced digital control;

analog to digital converteradj. adjust, adjustmentADV advertising dimensional

drawingAh amp-hourAHWT anticipatory high water

temperatureAISI American Iron and Steel

InstituteALOP anticipatory low oil pressurealt. alternatorAl aluminumANSI American National Standards

Institute (formerly AmericanStandards Association, ASA)

AO anticipatory onlyAPDC Air Pollution Control DistrictAPI American Petroleum Instituteapprox. approximate, approximatelyAPU Auxiliary Power UnitAQMD Air Quality Management DistrictAR as required, as requestedAS as supplied, as stated, as

suggestedASE American Society of EngineersASME American Society of

Mechanical Engineersassy. assemblyASTM American Society for Testing

MaterialsATDC after top dead centerATS automatic transfer switchauto. automaticaux. auxiliaryavg. averageAVR automatic voltage regulatorAWG American Wire GaugeAWM appliance wiring materialbat. batteryBBDC before bottom dead centerBC battery charger, battery

chargingBCA battery charging alternatorBCI Battery Council InternationalBDC before dead centerBHP brake horsepowerblk. black (paint color), block

(engine)blk. htr. block heaterBMEP brake mean effective pressurebps bits per secondbr. brassBTDC before top dead centerBtu British thermal unitBtu/min. British thermal units per minuteC Celsius, centigradecal. calorieCAN controller area networkCARB California Air Resources BoardCAT5 Category 5 (network cable)CB circuit breakerCC crank cyclecc cubic centimeterCCA cold cranking ampsccw. counterclockwiseCEC Canadian Electrical Codecert. certificate, certification, certifiedcfh cubic feet per hour

cfm cubic feet per minuteCG center of gravityCID cubic inch displacementCL centerlinecm centimeterCMOS complementary metal oxide

substrate (semiconductor)com communications (port)coml commercialComl/Rec Commercial/Recreationalconn. connectioncont. continuedCPVC chlorinated polyvinyl chloridecrit. criticalCSA Canadian Standards

AssociationCT current transformerCu coppercUL Canadian Underwriter’s

LaboratoriesCUL Canadian Underwriter’s

Laboratoriescu. in. cubic inchcw. clockwiseCWC city water-cooledcyl. cylinderD/A digital to analogDAC digital to analog converterdB decibeldB(A) decibel (A weighted)DC direct currentDCR direct current resistancedeg., degreedept. departmentdia. diameterDI/EO dual inlet/end outletDIN Deutsches Institut fur Normung

e. V. (also Deutsche IndustrieNormenausschuss)

DIP dual inline packageDPDT double-pole, double-throwDPST double-pole, single-throwDS disconnect switchDVR digital voltage regulatorE2PROM, EEPROM

electrically-erasableprogrammable read-onlymemory

E, emer. emergency (power source)ECM electronic control module,

engine control moduleEDI electronic data interchangeEFR emergency frequency relaye.g. for example (exempli gratia)EG electronic governorEGSA Electrical Generating Systems

AssociationEIA Electronic Industries

AssociationEI/EO end inlet/end outletEMI electromagnetic interferenceemiss. emissioneng. engineEPA Environmental Protection

AgencyEPS emergency power systemER emergency relayES engineering special,

engineered specialESD electrostatic dischargeest. estimatedE-Stop emergency stopetc. et cetera (and so forth)

exh. exhaustext. externalF Fahrenheit, femaleFHM flat head machine (screw)fl. oz. fluid ounceflex. flexiblefreq. frequencyFS full scaleft. foot, feetft. lb. foot pounds (torque)ft./min. feet per minuteftp file transfer protocolg gramga. gauge (meters, wire size)gal. gallongen. generatorgenset generator setGFI ground fault interrupter

GND, groundgov. governorgph gallons per hourgpm gallons per minutegr. grade, grossGRD equipment groundgr. wt. gross weightH x W x D height by width by depthHC hex capHCHT high cylinder head temperatureHD heavy dutyHET high exhaust temp., high

engine temp.hex hexagonHg mercury (element)HH hex headHHC hex head capHP horsepowerhr. hourHS heat shrinkhsg. housingHVAC heating, ventilation, and air

conditioningHWT high water temperatureHz hertz (cycles per second)IBC International Building CodeIC integrated circuitID inside diameter, identificationIEC International Electrotechnical

CommissionIEEE Institute of Electrical and

Electronics EngineersIMS improved motor startingin. inchin. H2O inches of waterin. Hg inches of mercuryin. lb. inch poundsInc. incorporatedind. industrialint. internalint./ext. internal/externalI/O input/outputIP internet protocolISO International Organization for

StandardizationJ jouleJIS Japanese Industry Standardk kilo (1000)K kelvinkA kiloampereKB kilobyte (210 bytes)KBus Kohler communication protocolkg kilogram

TP-6865 4/1444 Appendix

kg/cm2 kilograms per squarecentimeter

kgm kilogram-meterkg/m3 kilograms per cubic meterkHz kilohertzkJ kilojoulekm kilometerkOhm, k kilo-ohmkPa kilopascalkph kilometers per hourkV kilovoltkVA kilovolt amperekVAR kilovolt ampere reactivekW kilowattkWh kilowatt-hourkWm kilowatt mechanicalkWth kilowatt-thermalL literLAN local area networkL x W x H length by width by heightlb. pound, poundslbm/ft3 pounds mass per cubic feetLCB line circuit breakerLCD liquid crystal displayLED light emitting diodeLph liters per hourLpm liters per minuteLOP low oil pressureLP liquefied petroleumLPG liquefied petroleum gasLS left sideLwa sound power level, A weightedLWL low water levelLWT low water temperaturem meter, milli (1/1000)M mega (106 when used with SI

units), malem3 cubic meterm3/hr. cubic meters per hourm3/min. cubic meters per minutemA milliampereman. manualmax. maximumMB megabyte (220 bytes)MCCB molded-case circuit breakerMCM one thousand circular milsmeggar megohmmeterMHz megahertzmi. milemil one one-thousandth of an inchmin. minimum, minutemisc. miscellaneousMJ megajoulemJ millijoulemm millimetermOhm, mmilliohmMOhm, MmegohmMOV metal oxide varistorMPa megapascalmpg miles per gallonmph miles per hourMS military standardms millisecondm/sec. meters per secondmtg. mountingMTU Motoren-und Turbinen-UnionMW megawattmW milliwattF microfaradN, norm. normal (power source)NA not available, not applicablenat. gas natural gas

NBS National Bureau of StandardsNC normally closedNEC National Electrical CodeNEMA National Electrical

Manufacturers AssociationNFPA National Fire Protection

AssociationNm newton meterNO normally openno., nos. number, numbersNPS National Pipe, StraightNPSC National Pipe, Straight-couplingNPT National Standard taper pipe

thread per general useNPTF National Pipe, Taper-FineNR not required, normal relayns nanosecondOC overcrankOD outside diameterOEM original equipment

manufacturerOF overfrequencyopt. option, optionalOS oversize, overspeedOSHA Occupational Safety and Health

AdministrationOV overvoltageoz. ouncep., pp. page, pagesPC personal computerPCB printed circuit boardpF picofaradPF power factorph., phasePHC Phillipsr head Crimptiter

(screw)PHH Phillipsr hex head (screw)PHM pan head machine (screw)PLC programmable logic controlPMG permanent magnet generatorpot potentiometer, potentialppm parts per millionPROM programmable read-only

memorypsi pounds per square inchpsig pounds per square inch gaugept. pintPTC positive temperature coefficientPTO power takeoffPVC polyvinyl chlorideqt. quart, quartsqty. quantityR replacement (emergency)

power sourcerad. radiator, radiusRAM random access memoryRDO relay driver outputref. referencerem. remoteRes/Coml Residential/CommercialRFI radio frequency interferenceRH round headRHM round head machine (screw)rly. relayrms root mean squarernd. roundRO read onlyROM read only memoryrot. rotate, rotatingrpm revolutions per minuteRS right sideRTDs Resistance Temperature

Detectors

RTU remote terminal unitRTV room temperature vulcanizationRW read/writeSAE Society of Automotive

Engineersscfm standard cubic feet per minuteSCR silicon controlled rectifiers, sec. secondSI Systeme international d’unites,

International System of UnitsSI/EO side in/end outsil. silencerSMTP simple mail transfer protocolSN serial numberSNMP simple network management

protocolSPDT single-pole, double-throwSPST single-pole, single-throwspec specificationspecs specification(s)sq. squaresq. cm square centimetersq. in. square inchSMS short message serviceSS stainless steelstd. standardstl. steeltach. tachometerTB terminal blockTCP transmission control protocolTD time delayTDC top dead centerTDEC time delay engine cooldownTDEN time delay emergency to

normalTDES time delay engine startTDNE time delay normal to

emergencyTDOE time delay off to emergencyTDON time delay off to normaltemp. temperatureterm. terminalTHD total harmonic distortionTIF telephone influence factortol. toleranceturbo. turbochargertyp. typical (same in multiple

locations)UF underfrequencyUHF ultrahigh frequencyUIF user interfaceUL Underwriter’s Laboratories, Inc.UNC unified coarse thread (was NC)UNF unified fine thread (was NF)univ. universalURL uniform resource locator

(web address)US undersize, underspeedUV ultraviolet, undervoltageV voltVAC volts alternating currentVAR voltampere reactiveVDC volts direct currentVFD vacuum fluorescent displayVGA video graphics adapterVHF very high frequencyW wattWCR withstand and closing ratingw/ withWO write onlyw/o withoutwt. weightxfmr transformer

TPMPFP-6865 4/14 45

Notes

TPMPFP-6865 4/1446

Notes

E 2014 by Kohler Co. All rights reserved.

TP-6865 4/14a

KOHLER CO. Kohler, Wisconsin 53044Phone 920-457-4441 Fax 920-459-1646For the nearest sales/service outlet in theUS and Canada, phone 1-800-544-2444KOHLERPower.com

Kohler Power SystemsAsia Pacific Headquarters7 Jurong Pier RoadSingapore 619159Phone (65) 6264-6422, Fax (65) 6264-6455

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