Service

Automatic Transfer Switches

Models:
KSS/KSP
KGS/KGP
Power Switching Device:
Standard and Bypass/Isolation

Electrical Controls:
Decision-Makerr MPAC 1500
Decision-Makerr MPAC 1200
Decision-Makerr MPAC 750

TP-6921 10/14
 Table of Contents

Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
List of Related Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Section 1 Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1 Controller Power-up/Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 Sequence of Operation, MPAC 750 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2.1 Source N Loss and Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2.2 Exerciser Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2.3 Test Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3 Sequence of Operation, MPAC 1200 and 1500, Standard Transition . . . . . . . . . . 15
1.3.1 Preferred Source Loss and Return, Standard Transition . . . . . . . . . . . . . 15
1.3.2 Exerciser Operation, Standard Transition . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.3 Test Sequence, Standard Transition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4 Sequence of Operation, MPAC 1200 and 1500, Programmed-Transition . . . . . . 17
1.4.1 Preferred Source Loss and Return, Programmed Transition . . . . . . . . . 17
1.4.2 Exerciser Operation, Programmed Transition . . . . . . . . . . . . . . . . . . . . . . 17
1.4.3 Test Sequence, Programmed Transition . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Section 2 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2 Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.2.1 General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.2.2 Internal Inspections and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.2.3 Model KGS/KGP Bypass/Isolation Switches . . . . . . . . . . . . . . . . . . . . . . . 22
2.3 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.3.1 Weekly Generator Set Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.3.2 Monthly Automatic Operation Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.3.3 Other Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.4 View Maintenance Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.5 Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Section 3 SiteTech Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.1 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.2 Using SiteTech . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.2.1 Changing Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.2.2 Update Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.3 Exporting and Importing Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.3.1 Export Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.3.2 Editing Parameter Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.3.3 Import Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.4 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.5 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Section 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.1 Initial Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.2 Check for Loose Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.3 View Event History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.4 System Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.4.1 Controller Display is OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.4.2 Generator is Not Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.4.3 Source Voltage, Frequency, and Phase Rotation Checks . . . . . . . . . . . . 44
4.5 System Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.5.1 Controller Source Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.5.2 Voltage and Frequency Pickup and Dropout Settings . . . . . . . . . . . . . . . 46

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4.6 Time Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4.7 Reset Data, MPAC 1200 and 1500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.7.1 Reset Maintenance Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.7.2 Reset Event History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.7.3 Reset Default Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.7.4 Reset and Disable Test Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.7.5 Reset Data Procedure, MPAC 1200 and MPAC 1500 . . . . . . . . . . . . . . . 49
4.8 Controller Reset, MPAC 750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.9 Warnings and Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.9.1 Fault Reset, MPAC 1200 and 1500 Controllers . . . . . . . . . . . . . . . . . . . . 51
4.9.2 Fault Reset, MPAC 750 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.10 Accessory Module Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.10.1 Module Status Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.10.2 Module Status Conflict . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.11 Common Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.12 Events and Faults Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.13 Transfer Switch Operation Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.14 MPAC Controller Troubleshooting Flowcharts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.14.1 MPAC 750 and 1200 Controllers for Models KSS/KSP . . . . . . . . . . . . . . 63
4.14.2 MPAC 1500 Controller for Models KGS/KGP . . . . . . . . . . . . . . . . . . . . . . 69
Section 5 Transfer Switch Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.1 Initial Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.2 Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.3 Rectifier Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.4 Solenoid Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.4.1 Solenoid Coil Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.4.2 Solenoid Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.4.3 Solenoid Operation Diagrams, 40--225 Amp Model KSS Standard
Transition Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5.4.4 Solenoid Operation Diagrams, 400--600 Amp Model KSS Standard
Transition Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.4.5 Solenoid Operation Diagrams, 800--1000 Amp Model KSS Standard
Transition Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.4.6 Solenoid Operation Diagrams, Model KSP Programmed-Transition
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.4.7 Solenoid Operation Diagrams, Model KGS Open Transition
Bypass/Isolation Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.4.8 Solenoid Operation Diagrams, 150--400 Amp Model KGP
Programmed-Transition Bypass/Isolation Switches . . . . . . . . . . . . . . . . . 86
Solenoid Operation Diagrams, 150--400 Amp Model KGP
Programmed-Transition Bypass/Isolation Switches, continued . . . . . . . 87
5.4.9 Solenoid Operation Diagrams, 600--3000 Amp Model KGP
Programmed-Transition Bypass/Isolation Switches . . . . . . . . . . . . . . . . . 88
Solenoid Operation Diagrams, 600--3000 Amp Model KGP
Programmed-Transition Bypass/Isolation Switches, Continued . . . . . . . 89
Section 6 Controller Test and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
6.1 User Interface Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
6.1.1 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
6.1.2 LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6.1.3 Pushbuttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
6.1.4 Lamp Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
6.2 Controller Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
6.3 Controller Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6.3.1 Controller Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6.3.2 Controller Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

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6.4 System Test, MPAC 1200 and 1500 Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

6.4.1 Unloaded System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
6.4.2 Loaded System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
6.4.3 Auto-Loaded System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
6.4.4 Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
6.5 Test, MPAC 750 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
6.5.1 Unloaded System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
6.5.2 Loaded System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
6.5.3 Automatic Operation Test, MPAC 750 Controller . . . . . . . . . . . . . . . . . . . 101
6.6 Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
6.7 Engine Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
6.8 Controller DIP Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
6.9 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
6.10 Position Microswitch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
6.11 Programmed-Transition Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
6.12 Controller Application Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
6.13 Controller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
6.13.1 Controller Configuration (Settings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
6.13.2 Circuit Board and Electronic Component Handling . . . . . . . . . . . . . . . . . 110
6.13.3 Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Section 7 Component Replacement, 40--600 Amp KSS and KGS/KGP . . . . . . . . . . . . . . . . . . . . . . . . . . 115
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
7.2 Microswitch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
7.2.1 40--260 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
7.2.2 400--600 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
7.3 Power Panel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
7.4 Arc Chute Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
7.5 Limit Switch Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
7.6 Solenoid and Rectifier Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
7.6.1 Solenoid and Rectifier Replacement, 40--225 Amp Models . . . . . . . . . . 126
7.6.2 Solenoid and Rectifier Replacement, 400--600 Amp Models . . . . . . . . . 129
Section 8 Component Replacement, 100--600 Amp KSP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
8.2 Disconnect Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
8.3 Component Replacement, 100--400 Amp Model KSP . . . . . . . . . . . . . . . . . . . . . . . 136
8.3.1 Disassembly, 100--400 Amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
8.3.2 Reassembly, 100--400 Amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
8.3.3 Printed Circuit Board Replacement, 100--400 Amps . . . . . . . . . . . . . . . . 139
8.3.4 Closing Coil Replacement, 100--400 Amps . . . . . . . . . . . . . . . . . . . . . . . . 140
8.3.5 Select Coil Replacement, 100--400 Amps . . . . . . . . . . . . . . . . . . . . . . . . . 141
8.3.6 Trip Coil Replacement, 100--400 Amps . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
8.3.7 Arc Chute Replacement, 100--400 Amps . . . . . . . . . . . . . . . . . . . . . . . . . . 144
8.4 Component Replacement, 600 Amp Model KSP . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
8.4.1 Closing Coil Replacement, 600 Amp Model KSP . . . . . . . . . . . . . . . . . . . 145
8.4.2 Shaft Adjustment, 600 Amp Model KSP . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
8.4.3 Trip Coil Replacement, 600 Amp Models . . . . . . . . . . . . . . . . . . . . . . . . . . 146
8.4.4 Select Coil Replacement, 600 Amp Models . . . . . . . . . . . . . . . . . . . . . . . . 147
8.4.5 Printed Circuit Board Replacement, 600 Amp Models . . . . . . . . . . . . . . . 148
8.4.6 Auxiliary Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
8.4.7 Arc Chute Replacement, 600 Amp Models . . . . . . . . . . . . . . . . . . . . . . . . 149
8.4.8 Contact Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
8.4.9 Replacement of the Mechanical Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

TP-6921 10/14 Table of Contents

Table of Contents, continued

Section 9 Component Replacement, 800-1000 Amp Model KSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
9.2 Disconnect Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
9.3 Remove the Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
9.4 Rectifier Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
9.5 Closing Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
9.6 Auxiliary Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
9.7 Arc Chute Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
9.8 Contact Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
9.8.1 Source A Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
9.8.2 Source B Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
9.8.3 Replacement of the Mechanical Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
9.9 Reconnect Power and Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Section 10 Component Replacement, 800--3000 Amp KGS/KGP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
10.2 Disconnect Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
10.3 Contact Assembly Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
10.3.1 800--1200 Amp Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
10.3.2 1600--2000 Amp Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
10.3.3 3000 Amp Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
10.4 Auxiliary Switch Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
10.5 Reconnect Power and Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Appendix B Screen Summaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Appendix C Noise and Wiring Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Appendix D Common Hardware Application Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Appendix E General Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Appendix F Common Hardware Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Appendix G Common Hardware List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

Table of Contents TP-6921 10/14

 Safety Precautions and Instructions

IMPORTANT SAFETY INSTRUCTIONS.

Electromechanical equipment,
Accidental Starting Hazardous Voltage/
including generator sets, transfer Moving Parts
switches, switchgear, and accessories, WARNING
can cause bodily harm and pose DANGER
life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be
aware of potential dangers and act
safely. Read and follow all safety
precautions and instructions. SAVE Accidental starting.
Can cause severe injury or death. Hazardous voltage.
THESE INSTRUCTIONS. Will cause severe injury or death.
Disconnect the battery cables before
This manual has several types of safety working on the generator set. Disconnect all power sources before
precautions and instructions: Danger, Remove the negative (--) lead first opening the enclosure.
Warning, Caution, and Notice. when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery. DANGER
DANGER
Disabling the generator set.
Danger indicates the presence of a
Accidental starting can cause
hazard that will cause severe
severe injury or death. Before
personal injury, death, or substantial
working on the generator set or Hazardous voltage.
property damage.
connected equipment, disable the Will cause severe injury or death.
generator set as follows: (1) Move the
generator set master switch to the OFF Disconnect all power sources before
WARNING position. (2) Disconnect the power to servicing. Install the barrier after
the battery charger. (3) Remove the adjustments, maintenance, or
Warning indicates the presence of a battery cables, negative (--) lead first. servicing.
hazard that can cause severe Reconnect the negative (--) lead last
personal injury, death, or substantial when reconnecting the battery. Follow
property damage. these precautions to prevent starting of DANGER
the generator set by an automatic
transfer switch, remote start/stop
CAUTION switch, or engine start command from a
remote computer.
Caution indicates the presence of a (Decision-Makerr 3+ and 550
hazard that will or can cause minor Generator Controllers) Hazardous voltage.
personal injury or property damage. Will cause severe injury or death.
Disabling the generator set.
NOTICE Only authorized personnel should
Accidental starting can cause
Notice communicates installation, open the enclosure.
severe injury or death. Before
operation, or maintenance information working on the generator set or
that is safety related but not hazard equipment connected to the set,
related. disable the generator set as follows: WARNING
(1) Press the generator set off/reset
Safety decals affixed to the equipment button to shut down the generator set.
in prominent places alert the operator (2) Disconnect the power to the battery
or service technician to potential charger, if equipped. (3) Remove the
hazards and explain how to act safely. battery cables, negative (--) lead first.
The decals are shown throughout this Reconnect the negative (--) lead last Hazardous voltage. Moving parts.
publication to improve operator when reconnecting the battery. Follow Can cause severe injury or death.
recognition. Replace missing or these precautions to prevent the
damaged decals. Operate the generator set only when
starting of the generator set by the all guards and electrical enclosures
remote start/stop switch. are in place.
(RDC, DC, RDC2, DC2,
Decision-Makerr 3000, 3500 and
6000 Controllers)

TP-6921 10/14 Safety Precautions and Instructions 7

 Servicing the transfer switch. Testing live electrical circuits.
WARNING Hazardous voltage can cause Hazardous voltage or current can
severe injury or death. Deenergize all cause severe injury or death. Have
power sources before servicing. Turn trained and qualified personnel take
off the main circuit breakers of all diagnostic measurements of live
transfer switch power sources and circuits. Use adequately rated test
disable all generator sets as follows: equipment with electrically insulated
Hazardous voltage.
(1) Move all generator set master probes and follow the instructions of the
Backfeed to the utility system can
controller switches to the OFF position. test equipment manufacturer when
cause severe injury, death, or
(2) Disconnect power to all battery performing voltage tests. Observe the
property damage.
chargers. (3) Disconnect all battery following precautions when performing
Before energizing the transfer switch, cables, negative (--) leads first. voltage tests: (1) Remove all jewelry.
verify that both the normal and Reconnect negative (--) leads last when (2) Stand on a dry, approved electrically
emergency contacts are not left in the reconnecting the battery cables after insulated mat. (3) Do not touch the
closed position. servicing. Follow these precautions to enclosure or components inside the
prevent the starting of generator sets enclosure. (4) Be prepared for the
by an automatic transfer switch, remote system to operate automatically.
Grounding electrical equipment. start/stop switch, or engine start (600 volts and under)
Hazardous voltage can cause command from a remote computer.
severe injury or death. Electrocution Before servicing any components Removing the transfer switch from
is possible whenever electricity is inside the enclosure: (1) Remove all bypass/isolation models.
present. Ensure you comply with all jewelry. (2) Stand on a dry, approved Hazardous voltage can cause
applicable codes and standards. electrically insulated mat. (3) Test severe injury or death. Bypass and
Electrically ground the generator set, circuits with a voltmeter to verify that isolate the transfer switch before
transfer switch, and related equipment they are deenergized. removing it from the enclosure. The
and electrical circuits. Turn off the main bypass/isolation switch is energized.
circuit breakers of all power sources (Decision-Makerr 3+ and 550
Generator Controllers) Do not touch the isolation contact
before servicing the equipment. Never fingers or the control circuit terminals.
contact electrical leads or appliances
when standing in water or on wet Servicing the transfer switch.
ground because these conditions Hazardous voltage can cause WARNING
increase the risk of electrocution. severe injury or death. Deenergize all
power sources before servicing. Turn
Short circuits. Hazardous off the main circuit breakers of all
voltage/current can cause severe transfer switch power sources and
injury or death. Short circuits can disable all generator sets as follows:
cause bodily injury and/or equipment (1) Press the generator set off/reset
damage. Do not contact electrical button to shut down the generator set. Spring-loaded parts.
connections with tools or jewelry while (2) Disconnect power to all battery Can cause severe personal injury
making adjustments or repairs. chargers. (3) Disconnect all battery or property damage.
Remove all jewelry before servicing the cables, negative (--) leads first.
equipment. Wear protective goggles when
Reconnect negative (--) leads last when
reconnecting the battery cables after servicing spring-loaded parts. Hold
Making line or auxiliary servicing. Follow these precautions to parts securely during disassembly.
connections. Hazardous voltage prevent the starting of generator sets
can cause severe injury or death. To by an automatic transfer switch, remote Disassembling the solenoid.
prevent electrical shock deenergize the start/stop switch, or engine start Spring-loaded parts can cause
normal power source before making command from a remote computer. severe personal injury or property
any line or auxiliary connections. Before servicing any components damage. The spring in the solenoid
Connecting the battery and the inside the enclosure: (1) Remove all assembly exerts substantial force on
battery charger. Hazardous voltage jewelry. (2) Stand on a dry, approved the coil. Hold the coil assembly
can cause severe injury or death. electrically insulated mat. (3) Test securely when removing the screws.
Reconnect the battery correctly, circuits with a voltmeter to verify that
positive to positive and negative to they are deenergized.
negative, to avoid electrical shock and (RDC, DC, RDC2, DC2,
damage to the battery charger and Decision-Makerr 3000, 3500 and
battery(ies). Have a qualified 6000 Generator Controllers)
electrician install the battery(ies).

8 Safety Precautions and Instructions TP-6921 10/14

Heavy Equipment Notice
NOTICE
WARNING
Improper operator handle usage.
Use the manual operator handle on the
transfer switch for maintenance
purposes only. Return the transfer
switch to the normal position. Remove
the manual operator handle, if used,
and store it in the place provided on the
Unbalanced weight. transfer switch when service is
Improper lifting can cause severe completed.
injury or death and equipment
damage. NOTICE
Use adequate lifting capacity. Foreign material contamination.
Never leave the transfer switch Cover the transfer switch during
standing upright unless it is securely installation to keep dirt, grit, metal drill
bolted in place or stabilized. chips, and other debris out of the
components. Cover the solenoid
mechanism during installation. After
installation, use the manual operating
handle to cycle the contactor to verify
that it operates freely. Do not use a
screwdriver to force the contactor
mechanism.

NOTICE
Electrostatic discharge damage.
Electrostatic discharge (ESD)
damages electronic circuit boards.
Prevent electrostatic discharge
damage by wearing an approved
grounding wrist strap when handling
electronic circuit boards or integrated
circuits. An approved grounding wrist
strap provides a high resistance (about
1 megohm), not a direct short, to
ground.

TP-6921 10/14 Safety Precautions and Instructions 9

 Notes

10 Safety Precautions and Instructions TP-6921 10/14

 Introduction

This manual provides service information for Kohlerr List of Related Materials
Model KSS/KSP and KGS/KGP transfer switches
equipped with the following Decision-Makerr MPAC Figure 1 lists the part numbers for related literature.
electrical controls. Separate operation and installation manuals contain
operation and installation information not provided in
D Decision-Makerr MPAC 750 (Model KSS) this manual. Refer to the parts catalog for instructions to
obtain replacement parts.
D Decision-Makerr MPAC 1200 (Model KSS or KSP)

D Decision-Makerr MPAC 1500 (Model KGS or KGP) Document Part

Document Number
This manual includes troubleshooting, repair, and Specification Sheet, KSS/KSP ATS G11-130
maintenance procedures for the transfer switches and Specification Sheet KGS/KGP ATS G11-132
electrical controls. Specification Sheet,
Decision-Makerr MPAC 750 Controller G11-126

The information included in this manual is intended Specification Sheet,

G11-127
solely for use by trained and qualified service personnel Decision-Makerr MPAC 1200 Controller

of authorized service distributors/dealers. Specification Sheet,

Decision-Makerr MPAC 1500 Controller G11-128

Information in this publication represents data available Operation and Installation Manual,
Model KSS/KSP ATS TP-6834
at the time of print. Kohler Co. reserves the right to
Operation and Installation Manual,
change this literature and the products represented Model KGS/KGP Bypass/Isolation Switch TP-6836
without notice and without any obligation or liability Operation Manual,
whatsoever. Decision-Makerr MPAC 750 Controller TP-6865

Operation Manual,
TP-6866
Read this manual and carefully follow all procedures Decision-Makerr MPAC 1200 Controller
and safety precautions to ensure proper equipment Operation Manual,
Decision-Makerr MPAC 1500 Controller TP-6883
operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section at the Operation Manual, Modbus Protocol TP-6113
beginning of this manual. Operation Manual, SiteTech Software TP-6701
Parts Catalog, Transfer Switch TP-6433
The equipment service requirements are very important Wiring Diagram Manual,
TP-6918
to safe and efficient operation. Inspect parts often and Models KSS/KSP/KGS/KGP ATS
perform required service at the prescribed intervals. Figure 1 Related Materials
Obtain service from an authorized service distributor/
dealer to keep equipment in top condition.

TP-6921 10/14 Introduction 11

Service Assistance

For professional advice on generator set power China

requirements and conscientious service, please contact North China Regional Office, Beijing
your nearest Kohler distributor or dealer. Phone: (86) 10 6518 7950
(86) 10 6518 7951
D Consult the Yellow Pages under the heading (86) 10 6518 7952
Generators—Electric. Fax: (86) 10 6518 7955

D Visit
the Kohler Power Systems website at East China Regional Office, Shanghai
KOHLERPower.com. Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
D Look at the labels and stickers on your Kohler product India, Bangladesh, Sri Lanka
or review the appropriate literature or documents India Regional Office
included with the product. Bangalore, India
Phone: (91) 80 3366208
D Call toll free in the US and Canada 1-800-544-2444.
(91) 80 3366231
Fax: (91) 80 3315972
D Outside the US and Canada, call the nearest regional
office. Japan, Korea
North Asia Regional Office
Headquarters Europe, Middle East, Africa Tokyo, Japan
(EMEA) Phone: (813) 3440-4515
Kohler Power Systems Netherlands B.V. Fax: (813) 3440-2727
Kristallaan 1
Latin America
4761 ZC Zevenbergen
Latin America Regional Office
The Netherlands
Lakeland, Florida, USA
Phone: (31) 168 331630
Phone: (863) 619-7568
Fax: (31) 168 331631
Fax: (863) 701-7131
Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: (65) 6264-6422
Fax: (65) 6264-6455

12 Service Assistance TP-6921 10/14

 Section 1 Sequence of Operation

This section explains the transfer switch sequence of 1.2 Sequence of Operation,
operation during the following events:
MPAC 750 Controller
D Controller powerup or reset
The Sequence of Operation describes the transfer
D Preferred source loss and return switch normal operation. The MPAC 750 controller
operates using standard transition only (no
D Test programmed- or closed-transition operation).

D Exercise Operation can be affected by faults such as the normal

or emergency contacts failing to open or close when
D Emergency source loss and return signaled to do so.
The Sequence of Operation descriptions in the following
sections explain the transfer switch normal operation for 1.2.1 Source N Loss and Return
standard and programmed transition models.
Following is an explanation of the transfer switch
Operation can be affected by faults such as the normal
sequence of operation when Source N failure is
or emergency contacts failing to open or close when
detected.
signaled to do so.

Source N Fails
1.1 Controller Power-up/Reset
1. Engine start time delay expires.
Following is an explanation of the sequence of operation
when power is initially applied to the controller or a 2. The generator is signaled to start.
controller reset occurs.
3. The generator starts and Source E becomes
1. Controller self test is executed. available.

2. System parameters are downloaded from 4. Preferred-to-standby time delay expires.

nonvolatile memory.
5. Contactor transfers to Source E.
3. Contactor position and source availability are
determined. Source N Returns

4. If neither source is acceptable, the contactor does 1. Standby-to-preferred time delay expires.
not change position.
2. Contactor transfers to Source N.
5. If both sources are available, the controller
3. Engine cooldown time delay expires.
immediately transfers the contactor to the
preferred source. 4. The engine start contacts open, signaling the
generator to stop.
6. If only one source is available, the controller
immediately transfers the contactor to that source,
executing only the off-position and load control 1.2.2 Exerciser Operation
time delays.
Unloaded Exercise Sequence Starts
If the available source is the preferred source, and
the contactor is in the standby position, the 1. Exerciser timer begins.
contactor transfers to preferred, the engine
cooldown time delay runs, and then the engine 2. The generator is signaled to start.
start contacts open.
3. The generator starts and Source E becomes
If the available source is the preferred source and available.
the contactor is already in the preferred position,
the engine start contacts open immediately,
bypassing the engine cooldown time delay.

TP-6921 10/14 Section 1 Sequence of Operation 13

Unloaded Exercise Sequence Ends 1.2.3 Test Sequence
1. Engine cooldown time delay expires.
Unloaded Test Function is Initiated
2. The engine start contacts open, signaling the 1. The generator set is signaled to start.
generator to stop.
2. The generator starts and Source E becomes
Loaded Exercise Sequence Starts available.
1. Exerciser timer begins.
Unloaded Test Function is Ended
2. The generator is signaled to start. 1. Engine cooldown time delay expires.
3. The generator starts and Source E becomes 2. The generator is signaled to stop.
available.

4. Preferred-to-standby time delay and pre-transfer Loaded Test Function is Initiated

load control sequences run.
1. The generator is signaled to start (engine start
5. Contactor transfers to Source E. contacts close).

2. The generator starts and Source E becomes

Source E Fails (Source N is available) available.
1. Exerciser is deactivated. 3. Preferred-to-standby time delay expires.
2. Contactor immediately transfers to Source N. 4. Contactor transfers to Source E.
3. Immediate failure to acquire standby alarm.
Source E Fails (Source N is available)
4. Engine cooldown time delay expires.
1. Test function is deactivated.
5. Engine start contacts open.
2. Contactor immediately transfers to Source N.
Loaded Exercise Sequence Ends 3. Immediate failure to acquire standby alarm.
1. Contactor transfers to preferred. 4. Engine cooldown time delay expires.
2. Engine cooldown time delay expires. 5. Engine start contacts open.
3. The engine start contacts open, signaling the
generator to stop. Loaded Test Function is Ended
1. Standby-to-preferred time delay sequence runs.

2. Contactor transfers to Source N.

3. Engine cooldown time delay expires.

4. The engine start contacts open, signaling the

generator to stop.

14 Section 1 Sequence of Operation TP-6921 10/14

1.3 Sequence of Operation, 1.3.2 Exerciser Operation, Standard
MPAC 1200 and 1500, Transition
Standard Transition Unloaded Exercise Sequence Starts
Operation can be affected by faults such as the normal 1. Exerciser timer begins.
or emergency contacts failing to open or close when
signaled to do so. 2. The generator is signaled to start (engine start
contacts close).
Pre-transfer signals can overlap the
preferred-to-standby and standby-to-preferred time 3. The generator starts and the standby source
delays. The longest time delay will control the time becomes available.
before transfer.
4. The load bank control is activated (as
programmed).
1.3.1 Preferred Source Loss and
Return, Standard Transition Unloaded Exercise Sequence Ends
Following is an explanation of the transfer switch 1. The load bank control is deactivated (as
sequence of operation when Preferred Source failure is programmed).
detected.
2. Engine cooldown time delay expires.
Preferred Source Fails
3. The engine start contacts open, signaling the
1. Load control contacts open. generator to stop.

2. Engine start time delay expires. Loaded Exercise Sequence Starts

3. The generator is signaled to start. 1. Exerciser timer begins.

4. The generator starts and the standby source 2. The generator is signaled to start (engine start
becomes available. contacts close).

5. Preferred-to-standby time delay expires. 3. The generator starts and the standby source
becomes available.
6. Contactor transfers to standby.
4. Preferred-to-standby time delay and pre-transfer
7. Post-transfer load control sequences run. load control sequences run (as programmed).
8. Load control contacts close. 5. Load control contacts open.

Preferred Source Returns 6. In-phase monitor or transfer to OFF (as

programmed).
1. Standby-to-preferred and pre-transfer load control
time delays expire. 7. Contactor transfers to standby.

2. Load control contacts open. 8. Post-transfer load control sequences run (as
programmed).
3. Contactor transfers to preferred source.
9. Load control contacts close.
4. Post-transfer load control sequences and engine
cooldown time delay expire. Emergency Source Fails (Normal Source is
available)
5. Load control contacts close.
1. Exerciser is deactivated.
6. The engine start contacts open, signaling the
generator to stop. 2. Load control contacts open.

3. Contactor immediately transfers to preferred.

4. Immediate failure to acquire standby alarm.

TP-6921 10/14 Section 1 Sequence of Operation 15

 5. Post-transfer load control sequences and engine 3. Preferred-to-standby time delay and pre-transfer
cooldown time delay expire. load control time delays expire.

6. Load control contacts close. 4. Load control contacts open.

7. Engine start contacts open. 5. In-phase monitor or transfer to OFF operates as

programmed.
Loaded Exercise Sequence Ends
6. Contactor transfers to standby.
1. Exercise time period ends or the END button is
pressed. 7. Post-transfer load control time delays expire and
load control contacts close.
2. Time delay standby-to-preferred and pre-transfer
load control sequences run as programmed. Emergency Source Fails (Normal Source is
available)
3. Load control contacts open.
1. Test function is deactivated.
4. In-phase monitor or transfer to OFF as
programmed. 2. Load control contacts open.

5. Contactor transfers to preferred. 3. Contactor immediately transfers to preferred.

6. Post-transfer load control sequences and engine 4. Immediate failure to acquire standby alarm.
cooldown time delay expire.
5. Post-transfer load control sequences and engine
7. Load control contacts close. cooldown time delay expire.

8. Engine start contacts open, signaling the generator 6. Load control contacts close.
to stop.
7. Engine start contacts open.

1.3.3 Test Sequence, Standard

Loaded Test Function is Ended
Transition
1. The END button is pressed.
Unloaded Test Function is Initiated
2. Standby-to-preferred time delay and pre-transfer
1. The generator set is signaled to start (engine start load control sequences run.
contacts close).
3. Load control contacts open.
2. The generator starts and the standby source
becomes available. 4. In-phase monitor or transfer to OFF operates as
programmed.
3. The load bank control is activated.
5. Contactor transfers to preferred.
Unloaded Test Function is Ended
6. Post-transfer load control sequences operate as
1. The END button is pressed. programmed.

2. The load bank control is deactivated. 7. Load control contacts close.

3. Engine cooldown time delay expires. 8. Engine cooldown time delay expires.

4. The generator is signaled to stop (engine start 9. The engine start contacts open, signaling the
contacts open). generator to stop.

Loaded Test Function is Initiated

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

2. The generator starts and the standby source

becomes available.
16 Section 1 Sequence of Operation TP-6921 10/14
1.4 Sequence of Operation, 1.4.2 Exerciser Operation, Programmed
MPAC 1200 and 1500, Transition
Programmed-Transition Unloaded Exercise
Programmed-transition models operate with a pause in The unloaded exercise sequence is the same as for
the off position during transfer. The time in the off standard transition. See Section 1.2.2.
position is set through the off-to-standby and
off-to-preferred time delays.
Loaded Exercise Sequence Starts
Operation can be affected by faults such as the normal 1. Exerciser timer begins.
or emergency contacts failing to open or close when
signaled to do so. 2. The engine start contacts close, signaling the
generator set to start.
1.4.1 Preferred Source Loss and 3. The generator starts and the standby source
Return, Programmed Transition becomes available.

Preferred Source Fails 4. Preferred-to-standby time delay and pre-transfer

load control sequences run.
1. Load control contacts open.
5. Load control contacts open.
2. Engine start time delay expires.
6. Contactor transfers to OFF position.
3. The generator is signaled to start (engine start
contacts close). 7. Off-to-standby time delay expires.

4. The generator starts and the standby source 8. Contactor transfers to standby source.
becomes available.
9. Post-transfer load control sequences run.
5. Preferred-to-standby time delay expires.
10. Load control contacts close.
6. Contactor transfers to OFF position.
Emergency Source Fails (Normal Source is
7. Off-to-standby time delay expires. available)
8. Contactor transfers to standby source. 1. Exerciser is deactivated.
9. Post-transfer load control sequences run. 2. Immediate failure to acquire standby alarm.
10. Load control contacts close. 3. Load control contacts open.

Preferred Source Returns 4. Contactor transfers to OFF position.

1. Standby-to-preferred and pre-transfer load control 5. Off-to-preferred time delay expires.

time delays expire.
6. Contactor transfers to preferred source.
2. Load control contacts open.
7. Post-transfer load control sequences and engine
3. Contactor transfers to OFF position. cooldown time delay expire.

4. Off-to-preferred time delay expires. 8. Load control contacts close.

5. Contactor transfers to preferred source. 9. Engine start contacts open.

6. Post-transfer load control sequences and engine

cooldown time delay expire.

7. Load control contacts close.

8. The generator is signaled to stop (engine start

contacts open).
TP-6921 10/14 Section 1 Sequence of Operation 17
Loaded Exercise Sequence Ends Emergency Source Fails (Normal Source is
available)
1. Pre-transfer load control sequences run.
1. Test function is deactivated.
2. Load control contacts open.
2. Immediate failure to acquire standby alarm.
3. Contactor transfers to OFF position.
3. Load control contacts open.
4. Off-to-preferred time delay expires.
4. Contactor moves to the OFF position.
5. Contactor transfers to preferred source.
5. Off-to-preferred time delay expires.
6. Post-transfer load control sequences and engine
cooldown time delay expire. 6. Contactor transfers to preferred.

7. Load control contacts close. 7. Post-transfer load control sequences and engine
cooldown time delay expire.
8. The engine start contacts open, signaling the
generator to stop. 8. Load control contacts close.

9. Engine start contacts open.

1.4.3 Test Sequence, Programmed
Transition Loaded Test Sequence is Ended

Unloaded Test Sequence 1. Standby-to-preferred time delay and pre-transfer

load control sequences run.
The unloaded test sequence is the same as for standard
transition. See Section 1.2.3. 2. Load control contacts open.

3. Contactor moves to the OFF position.

Loaded Test Sequence is Initiated
1. The generator is signaled to start (engine start 4. Off-to-preferred time delay expires.
contacts close).
5. Contactor transfers to preferred.
2. The generator starts and the standby source
6. Post-transfer load control sequences and engine
becomes available.
cooldown time delay expire.
3. Pre-transfer load control time delays expire and
7. Load control contacts close.
load control contacts open.
8. The engine start contacts open, signaling the
4. Preferred-to-standby time delay expires.
generator to stop.
5. Contactor transfers to the OFF position.

6. Off-to-standby time delay expires.

7. Contactor transfers to standby.

8. Post-transfer load control time delays expire and

load control contacts close.

18 Section 1 Sequence of Operation TP-6921 10/14

 Section 2 Scheduled Maintenance

2.1 Introduction Disabling the generator set. Accidental starting can

cause severe injury or death. Before working on the
Regular preventive maintenance ensures safe and generator set or equipment connected to the set, disable the
generator set as follows: (1) Press the generator set off/reset
reliable operation and extends the life of the transfer
button to shut down the generator set. (2) Disconnect the
switch. Preventive maintenance includes periodic power to the battery charger, if equipped. (3) Remove the
testing, cleaning, inspecting, and replacing of worn or battery cables, negative (--) lead first. Reconnect the negative
missing components. Section 2.5 contains a service (--) lead last when reconnecting the battery. Follow these
schedule of recommended maintenance tasks. precautions to prevent the starting of the generator set by the
remote start/stop switch.
Maintenance or service must be performed in (RDC, DC, RDC2, DC2, Decision-Makerr 3000, 3500 and
accordance with all applicable codes and standards. 6000 Generator Controllers)

Keep records of all maintenance or service.

DANGER
Replace all barriers and close and lock the enclosure
door after maintenance or service and before reapplying
power.

Hazardous voltage.
WARNING Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.

Testing live electrical circuits. Hazardous voltage or

Accidental starting. current can cause severe injury or death. Have trained and
Can cause severe injury or death. qualified personnel take diagnostic measurements of live
circuits. Use adequately rated test equipment with electrically
Disconnect the battery cables before insulated probes and follow the instructions of the test
working on the generator set. equipment manufacturer when performing voltage tests.
Remove the negative (--) lead first Observe the following precautions when performing voltage
when disconnecting the battery. tests: (1) Remove all jewelry. (2) Stand on a dry, approved
Reconnect the negative (--) lead last electrically insulated mat. (3) Do not touch the enclosure or
when reconnecting the battery. components inside the enclosure. (4) Be prepared for the
system to operate automatically.
(600 volts and under)
Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on the Short circuits. Hazardous voltage/current can cause
generator set or connected equipment, disable the generator severe injury or death. Short circuits can cause bodily injury
set as follows: (1) Move the generator set master switch to the and/or equipment damage. Do not contact electrical
OFF position. (2) Disconnect the power to the battery charger. connections with tools or jewelry while making adjustments or
(3) Remove the battery cables, negative (--) lead first. repairs. Remove all jewelry before servicing the equipment.
Reconnect the negative (--) lead last when reconnecting the
battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote
start/stop switch, or engine start command from a remote
computer.
(Decision-Makerr 3+ and 550 Generator Controllers)

TP-6921 10/14 Section 2 Scheduled Maintenance 19

Servicing the transfer switch. Hazardous voltage can
cause severe injury or death. Deenergize all power sources
2.2 Inspection and Service
before servicing. Turn off the main circuit breakers of all
transfer switch power sources and disable all generator sets 2.2.1 General Inspection
as follows: (1) Move all generator set master controller
switches to the OFF position. (2) Disconnect power to all External Inspection. Inspect the transfer switch
battery chargers. (3) Disconnect all battery cables, negative weekly.
(--) leads first. Reconnect negative (--) leads last when
reconnecting the battery cables after servicing. Follow these D Look for signs of vibration, leakage, excessive noise,
precautions to prevent the starting of generator sets by an
high temperature, contamination, or deterioration.
automatic transfer switch, remote start/stop switch, or engine
start command from a remote computer. Before servicing any
D Remove accumulations of dirt, dust, and other
components inside the enclosure: (1) Remove all jewelry. (2)
Stand on a dry, approved electrically insulated mat. (3) Test contaminants from the transfer switch’s exterior with
circuits with a voltmeter to verify that they are deenergized. a vacuum cleaner or by wiping with a dry cloth or
(Decision-Makerr 3+ and 550 Generator Controllers)
brush. Do not use compressed air to clean the switch
because it can cause debris to lodge in the
Servicing the transfer switch. Hazardous voltage can components and damage the switch.
cause severe injury or death. Deenergize all power sources
before servicing. Turn off the main circuit breakers of all D Replace any worn, missing, or broken external
transfer switch power sources and disable all generator sets components with manufacturer-recommended
as follows: (1) Press the generator set off/reset button to shut replacement parts. Contact a local authorized
down the generator set. (2) Disconnect power to all battery distributor/dealer for part information and ordering.
chargers. (3) Disconnect all battery cables, negative (--) leads
first. Reconnect negative (--) leads last when reconnecting the D Tighten loose external hardware.
battery cables after servicing. Follow these precautions to
prevent the starting of generator sets by an automatic transfer
Contact an authorized distributor/dealer to inspect and
switch, remote start/stop switch, or engine start command
from a remote computer. Before servicing any components service the transfer switch when any wear, damage,
inside the enclosure: (1) Remove all jewelry. (2) Stand on a deterioration, or malfunction of the transfer switch or its
dry, approved electrically insulated mat. (3) Test circuits with a components is evident or suspected.
voltmeter to verify that they are deenergized.
(RDC, DC, RDC2, DC2, Decision-Makerr 3000, 3500 and
6000 Generator Controllers)
2.2.2 Internal Inspections and
Maintenance
Servicing the transfer switch controls and accessories
within the enclosure. Hazardous voltage can cause Internal Inspection. Have an authorized distributor/
severe injury or death. Disconnect the transfer switch dealer perform an annual inspection of the transfer
controls at the inline connector to deenergize the circuit switch. Inspect the switch more frequently if it is located
boards and logic circuitry but allow the transfer switch to in a dusty or dirty area or when any condition noticed
continue to supply power to the load. Disconnect all power
sources to accessories that are mounted within the enclosure during an external inspection may have affected internal
but are not wired through the controls and deenergized by components. Disconnect all power sources, open the
inline connector separation. Test circuits with a voltmeter to transfer switch enclosure, and inspect internal
verify that they are deenergized before servicing. components. Look for:
NOTICE D Accumulations of dirt, dust, moisture, or other
Electrostatic discharge damage. Electrostatic discharge contaminants
(ESD) damages electronic circuit boards. Prevent
electrostatic discharge damage by wearing an approved D Signs of corrosion
grounding wrist strap when handling electronic circuit boards
or integrated circuits. An approved grounding wrist strap D Worn, missing, or broken components
provides a high resistance (about 1 megohm), not a direct
short, to ground. D Loose hardware
The transfer switch may use both American Standard D Wire or cable insulation deterioration, cuts, or
and metric hardware. Use the correct size tools to abrasions
prevent rounding of the bolt heads and nuts.
D Signs of overheating or loose connections:
Screws and nuts are available in different hardness discoloration of metal, melted plastic, or a burning
ratings. To indicate hardness, American Standard odor
hardware uses a series of markings and metric
hardware uses a numeric system. Check the markings D Other evidence of wear, damage, deterioration, or
on the bolt heads and nuts for identification. malfunction of the transfer switch or its components

20 Section 2 Scheduled Maintenance TP-6921 10/14

Cleaning. Use a vacuum cleaner or a dry cloth or brush Control Circuit Leads. Repair minor damage to leads
to remove contaminants from internal components. Do in low power and control circuits operating up to
not use compressed air to clean the switch because it 250 volts. Carefully splice and insulate the connections.
can cause debris to lodge in the components and Tape minor control circuit wire insulation cuts or
damage the switch. abrasions. Repair moderately damaged leads, where
conductors are cut or insulation is damaged over
Lubrication. Maintain the transfer switch lubrication. If sections shorter than about 100 mm (4 in.) or less than
the transfer switch is subject to extremely dusty or about 25% of the length of the wire, by cutting out the
abnormal operating conditions, lubricate all movements damaged section and splicing in wire of the same type.
and linkages yearly. Lubricate the solenoid operator if Use UL-listed insulated (250 V minimum) connectors
the TS coil is replaced. Do not use oil; order the and follow the connector manufacturer’s instructions.
lubrication kit shown in the Parts Catalog. Fabricate new leads using the same type of wire and
UL-listed insulated (250 V minimum) connectors and
Disconnect power and manually operate the transfer follow the connector manufacturer’s instructions.
switch mechanism to verify that it operates smoothly
without binding. If lubricating the outer mechanism of Transfer Switch Inspection. Remove the arc chute
the transfer switch does not eliminate binding, replace assemblies or covers at the front of the transfer switch
the transfer switch assembly. and inspect the main contacts inside the transfer switch.
See Figure 2-1 or Figure 2-2.
Periodically oil the enclosure door locks and screws.
Note: A clamp or fixture must be attached before
Part Replacement and Tightening. Replace worn, removing the arc chutes on 600-amp Model KSP
missing, broken, deteriorated, or corroded internal programmed-transition switches. See
components with manufacturer-recommended Section 8.4.7 for complete instructions.
replacement parts. Tighten loose internal hardware.
Remove surface deposits with a clean cloth. Do not use
Terminal Tightening. Loose connections on the an emery cloth or a file. Discoloration of the contact
power circuits can lead to overheating or explosion. surface does not affect performance. If the contacts are
Tighten all lugs to the torque values shown on the label pitted, show signs of overheating, or are worn, replace
on the switch. Tighten engine start, input/output, and the contacts. The contacts are worn if the contact
auxiliary connections to the torque indicated on the surface material, a layer of silvery-colored metal, is worn
decals affixed to the unit. through to the metal below. Check the condition of the
arc chutes. If arc chutes show signs of disintegration,
Signs of Overheating. Replace components damaged
replace the arc chute assembly.
by overheating and locate the cause of the overheating.
Overheating could be caused by loose power
connections, overloading, or a short circuit in system.
After tightening the power terminals, perform a millivolt
drop test to locate areas with high contact resistance.
See Section 2.3.3. Check the line circuit breakers in the
system to be sure that they do not allow the load to
exceed the switch rating. Use the controller
troubleshooting and schematics to locate a control
circuit short.

Wire Repair or Replacement. Replace wiring when

there is any doubt about its condition or when there is
extensive damage or deterioration. If the damaged or
deteriorated wires are part of a wiring harness, replace
the entire wiring harness.

Power Circuit Wiring. Have damage to line voltage

and power circuit wiring evaluated and repaired or
replaced by a qualified electrician.

TP-6921 10/14 Section 2 Scheduled Maintenance 21

 2.2.3 Model KGS/KGP Bypass/Isolation
Switches
For Model KGS/KGP bypass/isolation switches,
perform the following additional maintenance checks
every year.

D Apply dielectric grease to movable finger assemblies,

if possible.

D Take thermal readings of each socket after the socket

has been energized for at least 3 hours. Any readings
on the socket surface that exceed 65_C (149_F)
indicate a need to replace the socket. Record the
amperage levels when taking the thermal readings.

D With the transfer switch removed, locate the bolt that

1 6226
retains the pin for each power connector and ensure
1. Arc chute assemblies that it is properly torqued.
Figure 2-1 Typical Arc Chute Assemblies, 40--600 D With the bypass de-energized, locate the bolt that
Amp Model KSS retains the socket for each power connector (where
accessible) and verify that it is properly torqued.

6226
1. Arc chute retainer clips

Figure 2-2 Typical Arc Chute Assemblies,

800--1000 Amp Model KSS and All
Model KSP

22 Section 2 Scheduled Maintenance TP-6921 10/14

2.3 Testing DANGER
Periodic testing is important in any transfer switch
application. It helps to ensure that the generator set will
start and the transfer switch mechanisms and control
circuits will operate when needed.
Hazardous voltage.
Will cause severe injury or death.
2.3.1 Weekly Generator Set Exercise Only authorized personnel should
Use the exerciser to start and run the generator set once open the enclosure.
a week to maximize the reliability of the emergency
Testing live electrical circuits. Hazardous voltage or
power system. See the transfer switch operation and
current can cause severe injury or death. Have trained and
installation manual for additional information about the qualified personnel take diagnostic measurements of live
exerciser. circuits. Use adequately rated test equipment with electrically
insulated probes and follow the instructions of the test
equipment manufacturer when performing voltage tests.
2.3.2 Monthly Automatic Operation Test Observe the following precautions when performing voltage
tests: (1) Remove all jewelry. (2) Stand on a dry, approved
Test the transfer switch’s automatic control system electrically insulated mat. (3) Do not touch the enclosure or
monthly. See Section 6.4.4 or the transfer switch components inside the enclosure. (4) Be prepared for the
operation and installation manual for the test procedure. system to operate automatically.
Verify that the expected sequence of operations occurs (600 volts and under)
as the switch transfers the load to the emergency source
when a normal source failure occurs or is simulated. Millivolt Drop Test Procedure
After the switch transfers the load to the emergency
1. Apply a balanced load of at least 10% of the switch
source, end the test and verify that the expected
rating. (Currents of 10 amps or greater will give
sequence of operations occurs as the transfer switch
more accurate results than lower currents.)
retransfers to the available normal source and signals
the generator set to shut down after a cooldown period. 2. Carefully measure the voltage on each phase of
both sources from the source lug to the load lug.
Note: The ATS will not transfer the load during the test Take several readings to ensure accuracy. The
sequence if the test DIP switch is set to the readings may be erratic because of the small
unloaded position. voltage measured, load fluctuations, and meter
circuit contact resistances.
2.3.3 Other Tests
Note: To obtain accurate readings, keep the meter
as far as possible from current-carrying
Every Year conductors and the meter leads as short,
Measure the voltage drop to help locate high-resistance direct, and at right angles to current-carrying
contacts in the ATS. The test procedure measures the conductors as possible. This minimizes the
effect of induced voltages (transformer
voltage drop across a contact and the current in the
effect) in the vicinity of the current-carrying
circuit, then uses those measured values to find the
conductors.
contact resistance.
3. Use an ammeter to measure the current flow
The purpose of the test is to locate any contact that has
through the circuit.
significantly higher resistance than others. An
unusually high voltage across one set of contacts may
signal unacceptably high resistance in the contacts.

Run the test with the ATS under a moderate and

balanced load. Use the following procedure to take
voltage measurements and calculate resistances for
each phase of both Source N and Source E.

TP-6921 10/14 Section 2 Scheduled Maintenance 23

 4. Calculate the contact resistance using the Servicing the transfer switch. Hazardous voltage can
following formula: cause severe injury or death. Deenergize all power sources
before servicing. Turn off the main circuit breakers of all
R=V÷I transfer switch power sources and disable all generator sets
as follows: (1) Move all generator set master controller
Where: switches to the OFF position. (2) Disconnect power to all
battery chargers. (3) Disconnect all battery cables, negative
V = measured voltage in millivolts (--) leads first. Reconnect negative (--) leads last when
I = measured current in amps reconnecting the battery cables after servicing. Follow these
R = calculated resistance in milliohms precautions to prevent the starting of generator sets by an
automatic transfer switch, remote start/stop switch, or engine
Compare the calculated values for resistance (R) to the start command from a remote computer. Before servicing any
values in the table in Figure 2-3. If the calculated components inside the enclosure: (1) Remove all jewelry. (2)
resistance is significantly higher (2 times larger or more) Stand on a dry, approved electrically insulated mat. (3) Test
than the value shown in the table, disconnect power, circuits with a voltmeter to verify that they are deenergized.
check the connections and lug torques, and repeat the (Decision-Makerr 3+ and 550 Generator Controllers)
test. If the second measurement also indicates that the
Servicing the transfer switch. Hazardous voltage can
resistance is too high, replace the contact. See the ATS cause severe injury or death. Deenergize all power sources
parts catalog for replacement part ordering information. before servicing. Turn off the main circuit breakers of all
Refer to the table of contents in the front of this manual to transfer switch power sources and disable all generator sets
locate the contact replacement procedure for your as follows: (1) Press the generator set off/reset button to shut
switch. 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
Transfer Switch Maximum Contact Resistance, battery cables after servicing. Follow these precautions to
Rating, Amps milliohms (m) prevent the starting of generator sets by an automatic transfer
30--200 0.250 switch, remote start/stop switch, or engine start command
225--400 0.200 from a remote computer. Before servicing any components
inside the enclosure: (1) Remove all jewelry. (2) Stand on a
600--800 0.175
dry, approved electrically insulated mat. (3) Test circuits with a
1000--1200 0.085 voltmeter to verify that they are deenergized.
1600--3000 0.050 (RDC, DC, RDC2, DC2, Decision-Makerr 3000, 3500 and
Figure 2-3 Maximum Contact Resistance 6000 Generator Controllers)

Every Three Years Wire Insulation Breakdown Test Procedure

Test the wire insulation. Use the following procedure to 1. Disconnect all power sources by opening
check for insulation breakdown and replace any faulty upstream circuit breakers or switches to the
components. transfer switch. Disconnect the load from the
transfer switch by opening circuit breakers or
switches leading from the transfer switch.
DANGER Disconnect the transfer switch wiring harness from
the controller at connector P1.

2. Use a hi-pot tester or meggar to check the

insulation resistance phase-to-phase and phase-
Hazardous voltage. to-neutral, and phase-to-ground if neutral and
Will cause severe injury or death. ground are isolated. For a hi-pot tester, the
maximum potential is 500 VAC and the maximum
Disconnect all power sources before
opening the enclosure.
test time is 1 second.

24 Section 2 Scheduled Maintenance TP-6921 10/14

 3. Verify that the measured insulation resistance arrow button to enter the maintenance records menu,
exceeds 1.24 megohms (M and then use the down arrow button to step through the
maintenance records.
4. If the hi-pot tester indicates wire insulation
breakdown or if the measured resistance is less See Section 4.7 and Figure 4-9 for instructions to reset
than 1.24 M, isolate the leakage current using an the maintenance records.
instrument designed for this purpose. Replace the
faulty components.
View View Maintenance
Note: You may need to disconnect power Maintenance Records Maintenance Item
conductors from the lugs to isolate the #######
problem. If you disconnect the power B Y " Main B Y Back
conductors, see transfer switch operation
and installation manual for reconnection Press the right arrow Press the down arrow
instructions. (") button to view (B) button to step to the
maintenance items. next maintenance item.
Every Five Years
Maintenance Items
Check the normal and emergency source setpoint
Total Min Not in Pref Reset Fail Transfer
calibration according to the procedures in Section 4.5,
Reset Min Not Pref Total Loss Pref Tran
System Settings.
Total Min in Standby Reset Loss Pref Tran
Reset Min in Standby Transfer Time N>E
2.4 View Maintenance Records Total Min Operation Transfer Time E>N

Maintenance records can be viewed on any of the Reset Min Operation System Start Date
Decision-Makerr MPAC controllers using a personal Total Transfers Last Maint Date
computer and Kohler SiteTech software. In the Reset Transfers Last Loss Date/Time
Parameters screen in SiteTech, click on ATS Run Time Total Fail Transfer Last Loss Duration
to view operation and maintenance records. See
Section 3 and the SiteTech Operation Manual for more
information about SiteTech. 2.5 Service Schedule
Follow the service schedule in Figure 2-4 for the
The Decision-Makerr MPAC 1200 and 1500 controllers
recommended service intervals. The transfer switch
also allow viewing the maintenance records using the
operator can perform tasks marked by an X. An
controller display and pushbuttons. From the main
authorized distributor/dealer should inspect the switch
screen, press the down arrow button until View
annually and perform all service marked by a D.
Maintenance Records is displayed. Press the right

TP-6921 10/14 Section 2 Scheduled Maintenance 25

 Adjust,
See Visually Repair, or
System Component or Procedure Section Inspect Check Replace Clean Test Interval
Electrical System
Check for signs of overheating or loose connections:
2.2.2 X X Y
discoloration of metal, melted plastic, or a burning odor.
Check the transfer switch’s external operating
mechanism for cleanliness. Clean and relubricate if 2.2.2 X D D Y
dirty.*
Check wiring insulation for deterioration, cuts, or X Y
abrasion. Repair or replace wiring to regain the 2.2.2
properties of the original wiring. D D D Y
Check the transfer switch’s main power switching
2.2.2 D D D Y
mechanisms’ mechanical operation and integrity.
Tighten control and power wiring connections to
2.2.2 D D Y
specifications.
Check the transfer switch’s main power switching
contacts’ condition. Clean or replace the main contacts 2.2.2 D D D Y
or replace the transfer switch assembly as necessary.
Perform a millivolt drop test to check for high contact
resistances on power circuits. Tighten connections,
clean main contacts, or adjust or replace main contacts 2.3.3 D D D D Y
or transfer switch assembly to eliminate high contact
resistances.
Test wire and cable insulation for electrical breakdown. 2.3.3 D Every 3 Years
Check calibration of voltage-sensing circuitry and
2.3.3 D D Every 5 Years
setpoints, and recalibrate circuitry as necessary.
Control System
Test the transfer switch’s automatic control system. O/I/M X X M
Test all LED indicators, time delays, and remote control
O/I/M D D D D Y
systems for operation.
General Equipment Condition
Inspect the outside of the transfer switch for any signs
of excessive vibration, leakage, high temperature, 2.2.1 X X M
contamination, or deterioration.*
Check that all external hardware is in place, tightened,
2.2.1 X X X M
and not badly worn.
Inspect the inside of the transfer switch for any signs of X M
vibration, leakage, noise, high temperature,
2.2.2
contamination, or deterioration. Check for metal
D D D Y
discoloration, melted plastic, or a burning odor.*
Check that all internal hardware is in place, tightened, X M
2.2.2
and not badly worn. D D Y
* Service more frequently if the ATS operates in extremely 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, or Replace: Includes tightening hardware and lubricating the mechanism. May require replacement of components depending
upon 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 by
wiping 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 and cause
damage.
Test: May require tools, equipment, or training available only through an authorized distributor/dealer.
Symbols used in the chart:
O/I/M=See the transfer switch operation/installation manual. M=Monthly
X= The transfer switch operator can perform these tasks. Q=Quarterly
D=An authorized distributor/dealer must perform these tasks. S=Semiannually (every six months)
W=Weekly Y=Yearly (annually)

Figure 2-4 Service Schedule

26 Section 2 Scheduled Maintenance TP-6921 10/14

 Section 3 SiteTech Software

3.1 Connection D Prog Inputs. View and adjust programmable inputs

on the controller and optional input/output modules.
Kohlerr SiteTechr software can be used with
Decision-Makerr MPAC controllers to check the D Prog Outputs. View and adjust programmable
transfer switch status, change adjustable controller outputs on the controller and optional input/output
settings, and update the application code on the modules.
controller. SiteTech software is available to Kohler
authorized distributor and dealers.
1
SiteTech can be used with Decision-Makerr MPAC 750,
1200, and 1500 controllers. For the MPAC 750
controller, which has no display or navigation buttons,
SiteTech is required for viewing and changing controller
settings.

The controller must have power to communicate with

SiteTech. Use a USB cable to connect a laptop
computer to the the MPAC controller’s USB port. The
cable should have a male mini-B connector on one end GM85884
for the controller and the appropriate connector for your Decision-Makerr
computer’s USB port on the other end. The USB port is MPAC 1200 and 1500
located on the front of the controller. See Figure 3-1 for
1
the USB port location on the controller. It is not
necessary to open the ATS enclosure to connect your
computer.

3.2 Using SiteTech

Start the SiteTech program. The Kohler SiteTech icon
and then a screen similar to the one shown in Figure 3-2
appear. The program takes a few moments to read the
data from the controller. GM85888
Decision-Makerr
MPAC 750
The following tabs appear in the blue field near the top of
the screen. 1. USB port (behind cover)

D Parameters. View and adjust transfer switch settings Figure 3-1 Decision-Makerr MPAC Controllers
from this view. See Section 3.4 for a list of parameters
that can be viewed and adjusted using SiteTech. 3.2.1 Changing Settings
D Common Alarms. View and adjust events assigned Not all settings are adjustable. Settings that cannot be
to common alarms 1 and 2. changed have a gray background. Scroll up and down
to see the parameter groups. Click on the down arrow
D Time-Based Load Control. See the controller
next to each group to reveal the individual settings in that
operation manual for information about load control
group.
settings. (MPAC 1200 and 1500 only)
Type in the new value for the setting. New settings
D Current-Based Load Control. See the controller
appear in bold on the screen. New settings for more
operation manual for information about load control
than one parameter can be entered. Then click Apply
settings. (MPAC 1500 only)
Changes near the top of the screen. If the setting is
D Exercise Setup. View and adjust the exercise accepted by the controller, the new setting appears in
schedule. (MPAC 1200 and 1500 only) normal (non-bold) text. If the setting is not accepted, the

TP-6921 10/14 Section 3 SiteTech Software 27

old setting reappears in the cell. Refer to the controller 3.2.2 Update Firmware
operation manual for default settings and adjustment
ranges. See Section 6.12 for instructions to update the controller
firmware.
See TP-6701, SiteTech Software Operation Manual, for
more detailed instructions.

1 5

1. Select Device Details View

2. Select desired group (Parameters shown in this sample screen)
3. Scroll to find desired menu and click on the arrow to open the menu
4. Enter new settings if necessary
5. Click Apply Changes to save new settings
6. Event history
7. Update Firmware command (see Section 6.12)

Figure 3-2 Sample SiteTech Screen for Decision-Makerr MPAC 1200 Controllers

28 Section 3 SiteTech Software TP-6921 10/14

3.3 Exporting and Importing
Parameter Settings
SiteTech software allows the generator set installer or
service technician to save the device settings in a file
and use that file to reload those settings later.

After the device has been installed and set up for the
application, save the settings to a file on the computer.
Setting files are saved as spreadsheets with the file
extension .xls. Give the file a suitable name that
identifies the specific device, and store it in a secure
location.

Note: Saving the settings to a file is strongly Figure 3-4 Import and Export Commands
recommended.
2. Click on Export. The Save As dialog window will
Saving the device settings to a file immediately after open. See Figure 3-5.
system startup creates a file that can be used to restore
the device to the desired settings in the event of a 3. The default location to save the file is shown at the
system problem. The file can also be used to quickly set top of the dialog box. Use the down arrow to select
up a new controller if the device must be replaced in the a different file location on the PC, if necessary.
future.
4. In the File Name box, type in a suitable name for the
The settings and events are saved in a spreadsheet file file. Use a name that clearly identifies the device
that can be opened using Microsoftr Excel software. for future reference.
Open the file to view the settings and events, if desired.
Some settings can be modified in the file using Excel. 5. Click Save to save the file to the selected directory
See Section 3.3.2 for important information about on the PC. The settings and events will be saved in
editing the file. a spreadsheet file that can be viewed on a PC,
edited, and used to import the settings to another
device.
3.3.1 Export Parameters
Note: When more than one device is connected, the file
The Export command saves the parameter settings to a export command will export all the settings for
spreadsheet file. each device into the spreadsheet.

File Export Procedure

1. Click on the File tab in the upper left corner of the
screen to open the file import and export
commands screen. See Figure 3-3 and Figure 3-4. 1

1. File tab 2 3

Figure 3-3 Click the File Tab 1. File will be saved to this location on the PC. Use the down
arrow to change the location, if necessary.
2. Type in a suitable file name.
3. Click Save.

Figure 3-5 Save As Dialog Box for File Export

TP-6921 10/14 Section 3 SiteTech Software 29

3.3.2 Editing Parameter Files 3.3.3 Import Parameters
The parameter files created by the Export command can The Import command allows the operator to import
be opened using Excel software and reviewed for device settings from a file. Use setting files created by
service or troubleshooting purposes. Some parameter the Export command in SiteTech. (See Section 3.3.1.)
settings can be changed in the Excel file and then Setting files are saved as spreadsheets with the file
reloaded onto the device using the Import Parameters extension .xls. Parameters not included in the files are
command. not changed.

Note: Do not modify any settings that are not labeled Use the Import Parameters command to set up more
“Write” in the Access column of the spreadsheet. than one controller to the same settings, or to import the
device settings to a new controller after the controller
Only settings that are labeled “Write” in the Access has been replaced.
column and have simple numerical values or True or
False in the last column of the spreadsheet should be The parameter file can contain settings for more than
modified. See Figure 3-6. Change only the values one device. Select the device you want to use as the
shown in the device column of the spreadsheet. source device and then select the target device.
SiteTech may select the connected device as the target
Use this feature with caution. Be sure that the new device for you. See Figure 3-7 and Figure 3-8.
values are within the acceptable range for each
parameter. Refer to the documentation provided with File Import Procedure
the controller or device for default settings and
adjustment ranges. 1. Click on the File tab in the upper left corner of the
screen to reveal the file import and export
Change commands. See Figure 3-4.
Sample Allowed in
Access Value Values Spreadsheet? 2. Click on Import. A dialog window will open. See
Simple 0 Figure 3-7.
Write YES
numerical values 57.5
True
Write True or False YES
False
Numbers in
Write (0) NO
parentheses
Mixed text and Off(0)
Write NO
numbers 12 V (12)
Read Any — NO
Locked Any — NO

Figure 3-6 Parameter Changes Allowed in

Spreadsheet

Figure 3-7 Import Parameters Window

30 Section 3 SiteTech Software TP-6921 10/14

 3. Click on the Browse button. A window will open. 4. The default location to find the file is shown at the
See Figure 3-8. top of the dialog box. Use the down arrow to select
a different file location on the PC, if necessary.
1
5. Click on the name of the file to select it. Check that
the selected file name appears in the File Name
box near the bottom of the window.

6. Click Open.

7. The selected file now appears in the Source File

2
box. See Figure 3-7.

8. Click on Import Unlocked Parameters. See

Figure 3-7.

9. Check that the Source Device and the Target

Device windows both show MPAC Dm 1500.

10. Click the Import button to load the new parameters

onto the controller. See Figure 3-7.
3 4
1. File location. Click down arrow to change, if necessary.
11. New settings will appear in bold face on the
2. Select the desired file from the list. SiteTech screen. Click on Apply Changes to load
3. Name of selected parameter file should appear here. the new settings onto the device. Click Discard
4. Click Open. Changes if you decide not to load the new settings
onto the device.
Figure 3-8 Open Dialog Box for File Import

TP-6921 10/14 Section 3 SiteTech Software 31

3.4 Parameters See Section 3.1 for instructions to connect a computer to
the controller’s USB port and Section 3.2 for an
The following table lists the parameters that are illustration of a sample screen from SiteTech. See
available using a personal computer and Kohler TP--6701, SiteTech Software Operation Manual, for
SiteTech software. The parameters are divided into more detailed instructions to use the software.
groups as shown. The access column indicates which
parameters can be adjusted using SiteTech. For adjustable parameters and time delays, see the
Parameters marked “Write” can be adjusted; applicable controller operation manual for default
parameters marked “Read” are for monitoring only and settings and adjustment ranges.
cannot be adjusted using SiteTech.

Group Parameter Access Units

Identity Vendor Read
Product Read
Firmware Version Read
Sub MPAC Firmware Version Read
ATS Metering MPAC ATS Contactor Position Read
Summary Key Switch Press Status Read
Preferred Source Read
Preferred Source Available Read
Standby Source Available Read
Exercise In Progress Read
In Phase Monitor Active Read
Load Control In Progress Read
Peak Shave In Progress Read
Loaded Test Occurring Read
Unloaded Test Occurring Read
Auto Loaded Test Occurring Read
Synchronous Check Occurring Read
User Forcing To Off Read
Dip Switch Status Read
Closed Transition In Phase Delta * Read degrees
ATS Information ATS Serial Number Write
Controller Serial Number Write
Contactor Serial Number Write
Fpga Firmware Version Read
ATS Designation Write
ATS Load Write
ATS Branch Write
ATS Location Write
Source 1 Metering MPAC Source 1 Rotation Actual Read
Source 1 Voltage L1-L2 Read Volts
Source 1 Voltage L2-L3 Read Volts
Source 1 Voltage L3-L1 Read Volts
Source 1 Voltage L1-N * Read Volts
Source 1 Voltage L2-N * Read Volts
Source 1 Voltage L3-N * Read Volts
Source 1 Frequency Read Hz
* Not applicable to the Decision-Makerr MPAC 750 controller.
ms = milliseconds

32 Section 3 SiteTech Software TP-6921 10/14

Group Parameter Access Units
Source 2 Metering MPAC Source 2 Rotation Actual Read
Source 2 Voltage L1-L2 Read Volts
Source 2 Voltage L2-L3 Read Volts
Source 2 Voltage L3-L1 Read Volts
Source 2 Voltage L1-N * Read Volts
Source 2 Voltage L2-N * Read Volts
Source 2 Voltage L3-N * Read Volts
Source 2 Frequency Read Hz
ATS Load Metering Load Current L1 * Read Amps
Load Current L2 * Read Amps
Load Current L3 * Read Amps
ATS Load Metering Calibration Factor Load Current L1 * Write
Calibration Calibration Factor Load Current L2 * Write
Calibration Factor Load Current L3 * Write
ATS Run Time ATS Controller Clock Date Time Write
ATS Total Hours Of Operation Read hours
ATS Total Hours Not In Preferred Read hours
ATS Total Hours In Standby Read hours
ATS Total Switch Transfers Read
ATS Total Failure To Transfers Read
ATS Total Loss Of Preferred Transfers Read
Transfer Time Source 1 To Source 2 Read ms
Transfer Time Source 2 To Source 1 Read ms
MPAC ATS Date Of Last Maintenance Write
ATS Hours Of Operation Since Maintenance Read hours
ATS Hours Not In Preferred Since Maintenance Read hours
ATS Hours In Standby Since Maintenance Read hours
ATS Switch Transfers Since Maintenance Read
ATS Failure To Transfers Since Maintenance Read
ATS Loss Of Preferred Transfers Since Maintenance Read
Last Outage Date Time Read
Last Outage Duration Read hours
System Start Date Write
Daylight Saving Adjust Enabled * Write
Move Forward Date Day Of Week Write
Move Forward Date Week Of Month Write
Move Forward Date Month Of Year Write
Move Backward Day Of Week Write
Move Backward Week Of Month Write
Move Backward Month Of Year Write
Closed Transition Dual Source Connected Time * Read ms
Source 1 To Open Time * Read ms
Source 1 To Close Time * Read ms
Source 2 To Open Time * Read ms
Source 2 To Close Time * Read ms
* Not applicable to the Decision-Makerr MPAC 750 controller.
ms = milliseconds

TP-6921 10/14 Section 3 SiteTech Software 33

Group Parameter Access Units
ATS Connection MPAC ATS Phase Rotation Setting Write
Configuration ATS Contactor Rating Write Amps
Fail To Synchronize Enabled Write
Manual Transfer Mode * Write
Transition Mode Write
Mode Of Operation Write
Manual Transfer Switch Position * Write
Closed Programmed Transition Override Mode * Write
Synchronous Voltage Phase Angle * Write degrees
Synchronous Voltage Differential * Write %
Synchronous Frequency Differential * Write Hz
Service Entrance Configuration * Write
Save Configuration Parameters Write
MPAC Dm ATS Preferred Source Write
Accessory Setup A1 Accessory Setup A1 Extended Engine Start Timer Enabled Write
Accessory Setup A1 Inphase Monitor Enabled Write
Accessory Setup A1 Remote Test Loaded Write
Accessory Setup A1 Commit To Transfer Write
Accessory Setup A1 Peak Shave Retransfer Delay Bypass Write
Accessory Setup A1 Three Source Simultaneous Engine Start Mode Write
Accessory Setup A1 Three Source Preferred Source Toggle Write
Accessory Setup A1 Inphase Monitor Transfer Angle Write
Source 1 System Source 1 System Voltage Write Volts
Configuration Source 1 System Frequency Write Hz
Source 1 Number Of Phases Write
Source 1 Voltage Debounce Delay Write sec.
Source 1 Unbalance Enabled * Write
Source 1 Unbalance Voltage Dropout * Write %
Source 1 Unbalance Voltage Pickup * Write %
Source 1 High Voltage Pickup Write %
Source 1 High Voltage Dropout Write %
Source 1 Low Voltage Pickup Write %
Source 1 Low Voltage Dropout Write %
MPAC Source 1 MPAC Source 1 Calibration Factor Voltage L1-L2 Write Volts
Calibration MPAC Source 1 Calibration Factor Voltage L2-L3 Write Volts
MPAC Source 1 Calibration Factor Voltage L3-L1 Write Volts
MPAC Source 1 Calibration Factor Voltage L1-N * Write Volts
MPAC Source 1 Calibration Factor Voltage L2-N * Write Volts
MPAC Source 1 Calibration Factor Voltage L3-N * Write Volts
* Not applicable to the Decision-Makerr MPAC 750 controller.
ms = milliseconds

34 Section 3 SiteTech Software TP-6921 10/14

Group Parameter Access Units
Source 2 System Source 2 System Voltage Write Volts
Configuration Source 2 System Frequency Write Hz
Source 2 Number Of Phases Write
Source 2 Voltage Debounce Delay Write sec.
Source 2 Unbalance Enabled * Write
Source 2 Unbalance Voltage Dropout * Write %
Source 2 Unbalance Voltage Pickup * Write %
Source 2 High Voltage Pickup Write %
Source 2 High Voltage Dropout Write %
Source 2 Low Voltage Pickup Write %
Source 2 Low Voltage Dropout Write %
Source 2 Frequency Debounce Delay Write s
Source 2 High Frequency Pickup Write %
Source 2 High Frequency Dropout Write %
Source 2 Low Frequency Pickup Write %
Source 2 Low Frequency Dropout Write %
MPAC Source 2 MPAC Source 2 Calibration Factor Voltage L1-L2 Write Volts
Calibration MPAC Source 2 Calibration Factor Voltage L2-L3 Write Volts
MPAC Source 2 Calibration Factor Voltage L3-L1 Write Volts
MPAC Source 2 Calibration Factor Voltage L1-N * Write Volts
MPAC Source 2 Calibration Factor Voltage L2-N * Write Volts
MPAC Source 2 Calibration Factor Voltage L3-N * Write Volts
ATS Delays ATS Transfer From Preferred Delay Write sec.
ATS Transfer From Standby Delay Write sec.
ATS Transfer Off To Preferred Delay * Write sec.
ATS Transfer Off To Standby Delay * Write sec.
ATS Source 2 Engine Start Delay Write sec.
ATS Source 2 Engine Cool Down Delay Write sec.
ATS Fail To Acquire Standby Delay Write sec.
ATS Source 2 Extended Engine Start Delay Write sec.
ATS Fail To Synchronize Delay Write sec.
Active Time Delay Read
Active Delay Time Remaining Read sec.
Active Delay Time Delay Preset Read sec.
* Not applicable to the Decision-Makerr MPAC 750 controller.
ms = milliseconds

TP-6921 10/14 Section 3 SiteTech Software 35

Group Parameter Access Units
ATS Timed Load Timed Disconnect LCR 1 From Source 1 * Write sec.
Control Timed Disconnect LCR 2 From Source 1 * Write sec.
Timed Disconnect LCR 3 From Source 1 * Write sec.
Timed Disconnect LCR 4 From Source 1 * Write sec.
Timed Disconnect LCR 5 From Source 1 * Write sec.
Timed Disconnect LCR 6 From Source 1 * Write sec.
Timed Disconnect LCR 7 From Source 1 * Write sec.
Timed Disconnect LCR 8 From Source 1 * Write sec.
Timed Disconnect LCR 9 From Source 1 * Write sec.
Timed Connect LCR 1 From Source 2 * Write sec.
Timed Connect LCR 2 From Source 2 * Write sec.
Timed Connect LCR 3 From Source 2 * Write sec.
Timed Connect LCR 4 From Source 2 * Write sec.
Timed Connect LCR 5 From Source 2 * Write sec.
Timed Connect LCR 6 From Source 2 * Write sec.
Timed Connect LCR 7 From Source 2 * Write sec.
Timed Connect LCR 8 From Source 2 * Write sec.
Timed Connect LCR 9 From Source 2 * Write sec.
Timed Disconnect LCR 1 From Source 2 * Write sec.
Timed Disconnect LCR 2 From Source 2 * Write sec.
Timed Disconnect LCR 3 From Source 2 * Write sec.
Timed Disconnect LCR 4 From Source 2 * Write sec.
Timed Disconnect LCR 5 From Source 2 * Write sec.
Timed Disconnect LCR 6 From Source 2 * Write sec.
Timed Disconnect LCR 7 From Source 2 * Write sec.
Timed Disconnect LCR 8 From Source 2 * Write sec.
Timed Disconnect LCR 9 From Source 2 * Write sec.
Timed Connect LCR 1 From Source 1 * Write sec.
Timed Connect LCR 2 From Source 1 * Write sec.
Timed Connect LCR 3 From Source 1 * Write sec.
Timed Connect LCR 4 From Source 1 * Write sec.
Timed Connect LCR 5 From Source 1 * Write sec.
Timed Connect LCR 6 From Source 1 * Write sec.
Timed Connect LCR 7 From Source 1 * Write sec.
Timed Connect LCR 8 From Source 1 * Write sec.
Timed Connect LCR 9 From Source 1 * Write sec.
Number Of Source 2 Timed Lcrs * Write
Number Of Source 1 Timed Lcrs * Write
ATS Current Based Source 1 Load Control Mode * Write
Load Control Source 2 Load Control Mode * Write
Modbus Modbus Enabled Write
MPAC Modbus Baud Rate Write b/sec
Modbus Slave Address Write
Modbus Parity Read
Modbus Stop Bits Read
* Not applicable to the Decision-Makerr MPAC 750 controller.
ms = milliseconds

36 Section 3 SiteTech Software TP-6921 10/14

Group Parameter Access Units
Network DHCP Enabled Write
Configuration Static IP Address Write
Static Subnet Mask Write
Static Default Gateway Write
DHCP Server Write
Modbus Tcp Unit Id Write
Modbus Tcp Server Enabled Write
Network Status MAC Address Read
Digital Input Output Software Controlled Output 1 Description * Write
Descriptions Software Controlled Output 2 Description * Write
Software Controlled Output 3 Description * Write
Software Controlled Output 4 Description * Write
Remote Monitored Input 1 Description * Write
Remote Monitored Input 2 Description * Write
Remote Monitored Input 3 Description * Write
Remote Monitored Input 4 Description * Write
Installed Boards Expansion Board 1 * Read
Expansion Board 2 * Read
Expansion Board 3 * Read
Expansion Board 4 * Read
Alarm Board * Read
Battery Option Board Installed * Read
MPAC Dm Digital Main Logic Board User Outputs Read
Input Output Status Main Logic Board User Inputs Read
Expansion Board 1 User Outputs * Read
Expansion Board 2 User Outputs * Read
Expansion Board 3 User Outputs * Read
Expansion Board 4 User Outputs * Read
Expansion Board 1 User Inputs * Read
Expansion Board 2 User Inputs * Read
Expansion Board 3 User Inputs * Read
Expansion Board 4 User Inputs * Read
Software Controlled User Outputs * Write
Software Controlled User Outputs Assigned * Read
Remote Monitoring User Inputs * Read
Remote Monitoring User Inputs Assigned * Read
Main Logic Board Hardware Outputs * Read
MPAC Digital Input MPAC Digital Input A1 Event Write
A1
MPAC Digital Input MPAC Digital Input A2 Event Write
A2
MPAC Digital Input MPAC Digital Input B1 Event * Write
B1
MPAC Digital Input MPAC Digital Input B2 Event * Write
B2
MPAC Digital Input MPAC Digital Input C1 Event * Write
C1
MPAC Digital Input MPAC Digital Input C2 Event * Write
C2
* Not applicable to the Decision-Makerr MPAC 750 controller.
ms = milliseconds

TP-6921 10/14 Section 3 SiteTech Software 37

Group Parameter Access Units
MPAC Digital Input MPAC Digital Input D1 Event * Write
D1
MPAC Digital Input MPAC Digital Input D2 Event * Write
D2
MPAC Digital Input MPAC Digital Input E1 Event * Write
E1
MPAC Digital Input MPAC Digital Input E2 Event * Write
E2
MPAC Digital Output MPAC Digital Output A1 Event Write
A1
MPAC Digital Output MPAC Digital Output A2 Event Write
A2
MPAC Digital Output MPAC Digital Output B1 Event * Write
B1
MPAC Digital Output MPAC Digital Output B2 Event * Write
B2
MPAC Digital Output MPAC Digital Output B3 Event * Write
B3
MPAC Digital Output MPAC Digital Output B4 Event * Write
B4
MPAC Digital Output MPAC Digital Output B5 Event * Write
B5
MPAC Digital Output MPAC Digital Output B6 Event * Write
B6
MPAC Digital Output MPAC Digital Output C1 Event * Write
C1
MPAC Digital Output MPAC Digital Output C2 Event * Write
C2
MPAC Digital Output MPAC Digital Output C3 Event * Write
C3
MPAC Digital Output MPAC Digital Output C4 Event * Write
C4
MPAC Digital Output MPAC Digital Output C5 Event * Write
C5
MPAC Digital Output MPAC Digital Output C6 Event * Write
C6
MPAC Digital Output MPAC Digital Output D1 Event * Write
D1
MPAC Digital Output MPAC Digital Output D2 Event * Write
D2
MPAC Digital Output MPAC Digital Output D3 Event * Write
D3
MPAC Digital Output MPAC Digital Output D4 Event * Write
D4
MPAC Digital Output MPAC Digital Output D5 Event * Write
D5
MPAC Digital Output MPAC Digital Output D6 Event * Write
D6
MPAC Digital Output MPAC Digital Output E1 Event * Write
E1
MPAC Digital Output MPAC Digital Output E2 Event * Write
E2
MPAC Digital Output MPAC Digital Output E3 Event * Write
E3
* Not applicable to the Decision-Makerr MPAC 750 controller.
ms = milliseconds

38 Section 3 SiteTech Software TP-6921 10/14

Group Parameter Access Units
MPAC Digital Output MPAC Digital Output E4 Event * Write
E4
MPAC Digital Output MPAC Digital Output E5 Event * Write
E5
MPAC Digital Output MPAC Digital Output E6 Event * Write
E6
MPAC Common MPAC Common Alarm A1 Common Alarm Read
Alarm A1 MPAC Common Alarm A1 Alarm Audible Write
MPAC Common Alarm A1 Assigned To Common Alarm 2 Write
MPAC Common Alarm A1 Assigned To Common Alarm 1 Write
MPAC Common The parameters shown above for common alarm A1 also appear for common alarms A2 through
Alarms A2 through A64.
A64.
Exerciser Summary Enabled * Read
Loaded * Read
Interval * Read
Repeat Rate * Read
Start Date * Read
Start Time * Read
Event Run Duration * Read
Running * Read
Source * Read
MPAC Dm Exerciser MPAC Dm Exerciser Scheduler A1 Enabled * Write
Scheduler A1 MPAC Dm Exerciser Scheduler A1 Loaded * Write
MPAC Dm Exerciser Scheduler A1 Interval * Write
MPAC Dm Exerciser Scheduler A1 Repeat Rate * Write
MPAC Dm Exerciser Scheduler A1 Start Date * Write
MPAC Dm Exerciser Scheduler A1 Start Time * Write
MPAC Dm Exerciser Scheduler A1 Event Run Duration * Write min
MPAC Dm Exerciser Scheduler A1 Running * Read
MPAC Dm Exerciser Scheduler A1 Source * Read
MPAC Dm Exerciser The parameters shown above for exerciser schedule A1 also appear for exercises A2 through
Scheduler A2 A21. *
through A21.
Special Parameters Profile
Saved Date
File Version
Address
Password
* Not applicable to the Decision-Makerr MPAC 750 controller.
ms = milliseconds

TP-6921 10/14 Section 3 SiteTech Software 39

3.5 Calibration Current Calibration

SiteTech can be used to adjust the controller calibration. Current calibration is also possible for transfer switches
Refer to Sections 4.5 and 6.9 for instructions to measure equipped with the current sensing accessory. Current
the voltage and current (if equipped with the current calibration factors appear in the ATS Load Metering
sensing accessory) and check the controller calibration. group.

If the current measured at the ATS does not match the

Voltage Calibration current displayed on the controller, enter the measured
Voltage calibration parameters appear in the MPAC current value (in amps) into the corresponding
Source 1 Calibration and MPAC Source 2 Calibration Calibration Factor Load Current L1, L2, or L3 setting in
groups in SiteTech. Note that there are separate SiteTech. For example, enter the amps measured on
settings for line-to-line and line-to-neutral voltages on all line 1 into Calibration Factor Load Current L1. Then
phases. click on Apply Changes.

If the voltage measured at the ATS source lugs does not

match the voltage shown on the controller display, enter
the actual measured voltage into the corresponding
voltage calibration parameter. For example, enter the
measured line-to-neutral voltage into MPAC Source 1
Calibration Factor Voltage L1-N. Then click on Apply
Changes.

40 Section 3 SiteTech Software TP-6921 10/14

 Section 4 Troubleshooting

4.1 Initial Checks System settings and time delays can be viewed and
changed using the display and pushbuttons on the
Read and follow all safety precautions in this manual MPAC 1200 and MPAC 1500 controllers’ user interface.
and on labels on the switch. Only trained and qualified A personal computer connected to the controller’s USB
personnel should service the transfer switch and port and Kohler SiteTech software can also be used to
connected equipment. view and change settings on the MPAC controllers. For
the MPAC 750 controller, SiteTech is required for
Refer to the wiring diagrams provided with the switch or viewing and changing settings. See Section 3 and the
the wiring diagram manual when troubleshooting the SiteTech Operation Manual for instructions to use the
transfer switch and controller. software.

DANGER
1

Hazardous voltage.
2
Will cause severe injury or death.
Only authorized personnel should 3
open the enclosure.

Testing live electrical circuits. Hazardous voltage or GM85884

current can cause severe injury or death. Have trained and MPAC 1200 and 1500
qualified personnel take diagnostic measurements of live
circuits. Use adequately rated test equipment with electrically
insulated probes and follow the instructions of the test 1
equipment manufacturer when performing voltage tests.
Observe the following precautions when performing voltage
tests: (1) Remove all jewelry. (2) Stand on a dry, approved
electrically insulated mat. (3) Do not touch the enclosure or
components inside the enclosure. (4) Be prepared for the 2
system to operate automatically.
(600 volts and under) 3
When troubleshooting a problem, check the following
things first.
GM85888

D Check the Service Required LED and the transfer MPAC 750
switch controller display for fault or warning
indications. See Figure 4-1 for the system alert LED 1. USB port (behind cover)
location on the controller’s user interface. If a fault or 2. System Alert LED
3. Not in AUTO LED
warning is indicated, proceed to Section 4.12.
Figure 4-1 Decision-Makerr MPAC Controllers
D Check the event history log. The log lists the 100
most recent transfer switch events, including
transfers and DIP switch setting changes as well as
faults and alarms. See Section 4.3 for instructions to
view the event history log.

D Check for loose connections as described in

Section 4.2.

D Check the system settings and time delays. See

Section 4.5, System Settings.

TP-6921 10/14 Section 4 Troubleshooting 41

4.2 Check for Loose Connections Procedure to check connections
1. Disable the generator set:
DANGER
a. Move the generator set master switch to the
OFF position or press the OFF button on the
generator set controller.

b. Disconnect power to the battery charger, if

Hazardous voltage.
Will cause severe injury or death. equipped.

Disconnect all power sources before c. Disconnect the battery, negative (--) lead first.
opening the enclosure.
2. Disconnect power to the transfer switch by turning
Servicing the transfer switch. Hazardous voltage can off all main circuit breakers..
cause severe injury or death. Deenergize all power sources
before servicing. Turn off the main circuit breakers of all 3. Check for loose connections. Check the source
transfer switch power sources and disable all generator sets lugs, controller harnesses, and generator set
as follows: (1) Move all generator set master controller engine start connection.
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
4.3 View Event History
precautions to prevent the starting of generator sets by an When troubleshooting, check the event history for
automatic transfer switch, remote start/stop switch, or engine
start command from a remote computer. Before servicing any faults, transfer attempts, or other events leading to the
components inside the enclosure: (1) Remove all jewelry. (2) current condition. The history lists the 100 most recent
Stand on a dry, approved electrically insulated mat. (3) Test transfer switch events, including transfers and DIP
circuits with a voltmeter to verify that they are deenergized. switch setting changes as well as faults and alarms.
(Decision-Makerr 3+ and 550 Generator Controllers)
MPAC 1200 and 1500: From the main screen, step to
Servicing the transfer switch. Hazardous voltage can View Event History and display recent events as shown
cause severe injury or death. Deenergize all power sources in Figure 4-2. Possible event descriptions are listed in
before servicing. Turn off the main circuit breakers of all Figure 4-3. A personal computer connected to the
transfer switch power sources and disable all generator sets
as follows: (1) Press the generator set off/reset button to shut controller’s USB port and Kohler SiteTech software can
down the generator set. (2) Disconnect power to all battery also be used to view the event history. See Section 3
chargers. (3) Disconnect all battery cables, negative (--) leads and the SiteTech Software Operation Manual for more
first. Reconnect negative (--) leads last when reconnecting the information.
battery cables after servicing. Follow these precautions to
prevent the starting of generator sets by an automatic transfer MPAC 750: Use a personal computer connected to the
switch, remote start/stop switch, or engine start command controller’s USB port and Kohler SiteTech software to
from a remote computer. Before servicing any components
inside the enclosure: (1) Remove all jewelry. (2) Stand on a view the event history.
dry, approved electrically insulated mat. (3) Test circuits with a
voltmeter to verify that they are deenergized. If a fault condition or alarm is displayed, proceed to
Section 4.12.
(RDC, DC, RDC2, DC2, Decision-Makerr 3000, 3500 and
6000 Controllers)

42 Section 4 Troubleshooting TP-6921 10/14

 System Ready 4.4 System Power
LD Exer ##/## @ ##:##
Main Screen. Press
the View button to step
Norm ###V Emer ###V
to the Event History DANGER
B View Set Test
screen.

View Event Description

Event History ON / OFF MM/DD/YY HH:MM
Additional Info Hazardous voltage.
B Y " Main B Back Will cause severe injury or death.
Only authorized personnel should
Press the right arrow open the enclosure.
Press the down arrow
button to view events. button to step through
events. Testing live electrical circuits. Hazardous voltage or
current can cause severe injury or death. Have trained and
Figure 4-2 Viewing Event History qualified personnel take diagnostic measurements of live
circuits. Use adequately rated test equipment with electrically
Event Descriptions insulated probes and follow the instructions of the test
equipment manufacturer when performing voltage tests.
End Time Delay Btn Low Battery Voltage
Observe the following precautions when performing voltage
Test Btn Remote Common Alarm
tests: (1) Remove all jewelry. (2) Stand on a dry, approved
Exercise Btn Bypass Contactor Dis
electrically insulated mat. (3) Do not touch the enclosure or
Lamp Test 3 Src System Disable
components inside the enclosure. (4) Be prepared for the
Service Req’d Reset Over Frequency
system to operate automatically.
Maint DIP Switch Under Frequency
Pwd DIP Switch Phase Loss (600 volts and under)
Manual Option Switch Phase Rotation Error
New Module Over Voltage L1--L2 4.4.1 Controller Display is OFF
Contactor in Off Over Voltage L2--L3
Contactor in Src N Over Voltage L3--L1 If the transfer switch display is off, check for power to the
Contactor in Src E Under Voltage L1--L2
Low Battery Under Voltage L2--L3
controller. See Section 6.3 for instructions. Also see the
Exerciser Active Under Voltage L3--L1 troubleshooting flowcharts in Section 4.14.
Fail to Acquire Pref Voltage Imbalance
Fail to Acquire Stby Auto Loaded Test End
Fail to Sync Test Loaded Changed 4.4.2 Generator is Not Running
Fail to Transfer Pref Source Changed
I/O Module Lost Comm Reload Dflt Params If utility power is not available and the emergency
Aux Switch Fault MODBUS Peak Shave generator set is not running:
Aux Switch Open MODBUS Forced to OFF
Breaker Trip MODBUS System Test 1. Check that the generator is in AUTO mode.
Battery Backup Low Battery Control Out
Rem End Time Delay 2. Try to start the generator set by moving the master
Forced Trans to Off switch to the RUN position or pressing the RUN
Peak Shave Mode
button on the generator controller.
Inhibit Transfer
Remote Test
a. If the engine does not start, troubleshoot the
Figure 4-3 Events generator set as described in the generator set
documentation.

b. If the engine starts, check the engine start

circuit from the ATS to the generator set. See
Section 6.7.

TP-6921 10/14 Section 4 Troubleshooting 43

4.4.3 Source Voltage, Frequency, and Voltage, Frequency, and Phase Rotation
Phase Rotation Checks Measurement Procedure

Check for power to the transfer switch. Follow the Note: Perform voltage checks in the order given to
voltage check procedures below to check voltage at the avoid damaging the transfer switch.
Source N (normal) or Source E (emergency) lugs. 1. Verify that the generator set master switch is in the
OFF position and both power sources are
The voltage, frequency, and phase rotation of the
disconnected from the transfer switch.
transfer switch and the power sources must be the same
to avoid damage to loads and the transfer switch. 2. Disconnect the power switching device and
Compare the voltage and frequency ratings of the utility controller wiring harnesses at the inline disconnect
source, transfer switch, and generator set, and verify plug, if they are connected.
that the ratings are all the same. 3. Manually operate the transfer switch to position E.
The phase rotation on the MPAC 750 controller is set to See the transfer switch operation and installation
ABC and cannot be changed. manual for manual operation instructions.

Read and understand all instructions on installation 4. If Source N is a generator set, start the generator by
drawings and labels on the switch. Note any optional moving the generator set master switch to the RUN
position or pressing the RUN button on the
accessories that have been furnished with the switch
generator controller.
and review their operation.
5. Close the Source N circuit breaker or switch.
Note: Source N is the source connected to the normal
side of the transfer switch. Source E is the source 6. Use a voltmeter to check the Source N (normal)
connected to the emergency side of the transfer phase-to-phase and phase-to-neutral (if
switch. applicable) terminal voltages and frequency.

The voltage check procedure requires the following a. If Source N is the utility and the measured input
equipment: does not match the voltage and frequency
shown on the transfer switch nameplate,
D A digital voltmeter (DVM) with electrically insulated STOP! The transfer switch does not match the
probes capable of measuring the rated voltage and application—order the correct transfer switch.
frequency
b. If Source N is a generator set and the generator
D A phase rotation meter set output voltage and frequency do not match
the nominal system voltage and frequency
DANGER shown on the transfer switch nameplate, follow
the manufacturer’s instructions to adjust the
generator set. The automatic transfer switch
will only function with the rated system voltage
and frequency specified on the nameplate.
Hazardous voltage. 7. Use a phase rotation meter to check the phase
Will cause severe injury or death. rotation at the Source N (normal) terminals. Rewire
Only authorized personnel should the transfer switch Source N terminals to obtain the
open the enclosure. correct phase sequence if necessary.
The default setting for the phase rotation on the
Testing live electrical circuits. Hazardous voltage or controller is ABC. If the application uses a phase
current can cause severe injury or death. Have trained and
qualified personnel take diagnostic measurements of live
rotation of CBA, use the Set Sources screen to
circuits. Use adequately rated test equipment with electrically change the phase rotation setting on the controller.
insulated probes and follow the instructions of the test See the controller operation manual for
equipment manufacturer when performing voltage tests. instructions.
Observe the following precautions when performing voltage
tests: (1) Remove all jewelry. (2) Stand on a dry, approved Note: The phase rotation on the MPAC 750
electrically insulated mat. (3) Do not touch the enclosure or controller is set to ABC and cannot be
components inside the enclosure. (4) Be prepared for the changed.
system to operate automatically.
(600 volts and under)

44 Section 4 Troubleshooting TP-6921 10/14

 8. If the source is a generator set, stop the generator 4.5 System Settings
set by moving the master switch to the OFF
position. If the ATS does not recognize the source, check that the
source voltage and frequency settings on the controller
9. Disconnect Source N by opening upstream circuit
breakers or switches. match the actual source parameters. Compare the
controller settings to the ratings on the ATS nameplate
10. Manually operate the transfer switch to position N. and to the measured source parameters.
11. Repeat steps 4 through 8 for Source E. Then
proceed to step 12. 4.5.1 Controller Source Settings
12. Disconnect both sources to the transfer switch by
Check the controller settings for source voltage,
opening the circuit breakers or switches.
frequency, and phase. See the controller operation
13. Connect the power switching device and controller manual for instructions.
wiring harnesses together at the inline disconnect
plug. Check the controller settings and compare them to the
voltage rating, frequency rating, and number of phases
Note: Do not connect or disconnect the controller
shown on the ATS nameplate. The nameplate is
wiring harness when power is connected.
attached to the cover of the controller assembly, which is
14. Close and lock the transfer switch enclosure door. mounted on the inside of the transfer switch door. See
Figure 4-4 for an illustration of the nameplate.
15. Reconnect both power sources by closing the
circuit breakers or switches. Note: The system voltage and frequency shown on the
16. Move the generator set master switch to the AUTO ATS nameplate must match the Source N and
position or press the AUTO button on the generator Source E voltage and frequency settings. Do not
controller. enter settings that do not match the nameplate
ratings of the ATS.
Note: If the engine cooldown time delay setting is
not set to zero (default setting), the
generator set may start and run until the
Time Delay Engine Cooldown (TDEC) ends. 3
1
2

4
5
6

GM21291
1. Model designation
2. Serial number
3. Factory-installed accessory numbers
4. Voltage rating
5. Frequency rating
6. Number of phases (single or three)

Figure 4-4 Typical Transfer Switch Nameplate

TP-6921 10/14 Section 4 Troubleshooting 45

Use the procedure in Section 4.4.3 to measure the Voltage and Frequency Sensing
source voltage, frequency, and phase rotation, and
compare the measured values to the controller settings. Parameter Default Adjustment Range
Follow the instructions in the controller operation Undervoltage
90% of pickup 75%--98%
manual to change the controller settings if they do not dropout
match the measured source parameters. Undervoltage 90% of
85%--100%
pickup nominal
4.5.2 Voltage and Frequency Pickup Overvoltage 115% of
106%--135%
and Dropout Settings dropout * nominal*

Figure 4-5 illustrates the relative values of the voltage Overvoltage

95% of dropout 95%--100%
pickup
pickup and dropout settings. Typical frequency pickup
and dropout settings relate to the nominal source Voltage dropout
0.5 sec. 0.1--9.9 sec.
time
frequency in a similar way.
Unbalance
Disable Enable/Disable
enable [
276 V Overvoltage Dropout
Unbalance
20% 5%--20%
262 V dropout [
Overvoltage Pickup
Unbalance
10% 3%--18%
pickup [
240 V Nominal Voltage
* 690 volts, maximum. Default = 110% for 600 volt applications.
[ Not applicable to the MPAC 750 controller
216 V Undervoltage Pickup
Figure 4-6 Voltage Settings
194 V Undervoltage Dropout
tp6921
Parameter Default Adjustment Range
Underfrequency
Figure 4-5 Relationship Between Voltage Pickup 99% of pickup 95%--99%
dropout
and Dropout Settings (default settings
for 240-volt system shown) Underfrequency 90% of
80%--95%
pickup nominal
If the source voltage rises above the overvoltage Overfrequency 101% of
dropout setting or falls below the undervoltage dropout 101%--115%
dropout pickup
setting for a time longer than the debounce time, the
Overfrequency 110% of
controller will consider the source as failed. The source 105%--120%
pickup nominal
voltage must return to a level within the range of the
pickup values for the controller to recognize the source Frequency
3 sec. 0.1--15 sec.
as restored. dropout time

Figure 4-7 Frequency Settings(not applicable to

Choose pickup and dropout settings that allow a
the MPAC 750 controller)
tolerable variation in the source parameters to prevent
nuisance transfers caused by small changes in the
source voltage and frequency.

46 Section 4 Troubleshooting TP-6921 10/14

4.6 Time Delays through the controller’s USB port and Kohler SiteTech
software are required.
Check the time delays when troubleshooting problems
with transfer switch operation. Figure 4-8 shows the factory settings and adjustment
ranges for the adjustable time delays. See the
On the MPAC 1200 and MPAC 1500 controllers, use the Operation Manual for more information.
View Time Delays screen or a personal computer
connected through the controller’s USB port and Kohler Observe the controller’s display to identify which time
SiteTech software to check the settings for the delay is executing at any given time. Initiate a test and
adjustable time delays. To change settings on the observe as each programmed time delay executes.
MPAC 750 controller, a personal computer connected Compare the operation to the test sequence described
in Section 1.

Time Delay Description Description/Note Default Time Adjustment Range

Engine Start, Source S2 Source S2 -- Util/Gen and Gen/Gen modes 3 sec 0--6 sec*
Engine Start, Source S1 [ Source S1 -- Use for Gen/Gen mode 3 sec
Engine Cooldown, Source S2 Source S2 -- Util/Gen and Gen/Gen modes 5 sec
Engine Cooldown, Source S1 [ Source S1 -- Gen/Gen mode 2 sec
Transfer, preferred to standby Transfer delay, preferred to standby 3 sec
Transfer, standby to preferred Transfer delay, standby to preferred 15 min
Xfr Off>Stby [ Time in the OFF position (Preferred to Standby for 1 sec
programmed transition models only)
Xfr OFF>Pref [ Time in the OFF position (Standby to Preferred for 1 sec
programmed transition models only)
Fail to Acquire Pref [ If the preferred source does not reach acceptable 1 min
voltage and stabilize within the allowed time, the Fail to
Acquire Preferred Source fault is activated.
Fail to Acquire Stby If the standby source does not reach acceptable 1 min
voltage and stabilize within the allowed time, the Fail to
Acquire Standby Source fault is activated. 0--60 min
In-Phase Xfr Fail (found in the For in-phase monitoring: the time allowed for the two 30 sec
Set Sources menu) sources to come into synchronization within specified
phase angle before a Fail to Sync fault is activated.
Load # Disc N>E [ Disconnect load before-transfer to standby source. 0 sec
Used for time-based and current-based load control.
Load # Rec N>E [ Reconnect load after-transfer to standby source. Used 0 sec
for time-based load control.
Load # Disc E>N [ Disconnect load before-transfer to preferred source. 0 sec
Used for time-based and current-based load control.
Load # Rec E>N [ Reconnect load after-transfer to preferred source. 0 sec
Used for time-based load control.
Load # Add Source1/Source2 [ For current-based load control. 0 sec
Load # Remove Srce1/Srce2 [ For current-based load control.
* The optional external battery module allows extended engine start time delays from 0--60 min.
[ Not applicable to the MPAC 750 controller.

Figure 4-8 Time Delays

TP-6921 10/14 Section 4 Troubleshooting 47

4.7 Reset Data, MPAC 1200 and 4.7.3 Reset Default Parameters
1500 Resetting to the default parameters will reset all
parameters, including the system voltage and
Be sure to read and understand the information in this
frequency, to a factory default setting. The default
section before resetting.
system voltage and frequency settings may not match
This section refers to the Reset Data menu on the settings for your application.
Decision-Makerr MPAC 1200 and 1500 controllers,
The transfer switch will not operate correctly if the
shown in Figure 4-9.
system voltage and frequency do not match the
Note: See Section 4.8 for reset instructions for the sources. Use the Set Sources screen to set the system
Decision-Makerr MPAC 750 controller. voltage and frequency after resetting to the default
parameters. See the controller operation manual for
instructions.
4.7.1 Reset Maintenance Records
Reset the maintenance records after transfer switch 4.7.4 Reset and Disable Test Password
service to update the last maintenance date and totals
since reset that are displayed in the maintenance Reset the Test password to return the test password to
records screen. the default, 0000.

Disable the test password to allow the user to start a test

4.7.2 Reset Event History without entering a password.
Resetting the event history clears the events from the Note: Disable the test password only during service
event history log. unless the transfer switch is installed in a secure
location.

Reset
Reset Data Maintenance Records Press the up arrow to toggle yes or no.
Yes/No
B Y " Main B Save Back

Reset
Press the right arrow Event History
button to move to the Yes/No
Reset Data screens. B Save Back

Press the down arrow Reset Note: Resetting to the default parameters will reset all
button to step through Default Parameters parameters, including the system voltage
the screens shown Yes/No and frequency, to a factory default setting. The
here. B Save Back transfer switch will not operate correctly if the
system voltage and frequency do not match the
Reset
sources.
Test Password
Yes/No
B Save Back

Disable Note: Disable the test password only during service

Test Password unless the transfer switch is installed in a secure
Yes/No
location.
B Save Back

Figure 4-9 Reset Data, MPAC 1200 and MPAC 1500 Controllers

48 Section 4 Troubleshooting TP-6921 10/14

4.7.5 Reset Data Procedure, MPAC 1200 4.9 Warnings and Faults
and MPAC 1500
When a fault exists, the System Alert indicator lights, a
Use the Reset Data menus to set records or parameters designated output and the common fault output are
back to factory default settings. See Figure 4-9. turned on. On MPAC 1200 and 1500 controllers, an
appropriate message is displayed to indicate the fault.
1. Use the black arrow buttons to step to the desired See Figure 4-11 for the location of the System Alert
screen. See the following sections for information indicator.
about each reset screen.
ATS warnings and faults are shown in Figure 4-12.
2. Press the open up arrow button to toggle Yes or No There are three types of warning/fault conditions:
until Yes is displayed.
Warning. Warnings automatically reset with a source
3. Press Save to reset the displayed records to the availability change or a transfer request.
factory defaults. Pressing Back exits the screen
without resetting. Fault Requiring Manual Reset. Under these
conditions, normal ATS operation is halted. Active
modes are turned off. If the contactor is in the preferred
4.8 Controller Reset, MPAC 750
source position, the engine cooldown time delay
To reset the controller processor while retaining all executes and the engine start contacts open, allowing
parameter settings, press the Test and Exercise buttons the generator set to shut down. See Section 4.9.1 or
at the same time and hold for 15 seconds. 4.9.2 for instructions to reset faults.

Self Resetting Faults. Under these conditions, active

modes are turned off. If the contactor is in the preferred
source position, the engine cooldown time delay
executes and the engine start contacts open, allowing
the generator set to shut down. When the fault condition
is corrected, the fault is automatically cleared from the
controller and normal ATS operation continues.

GM85888
1 2
1
1. Test button
2. Exercise button
Press and hold the Test and Exercise buttons for 15 seconds to reset
the controller.

Figure 4-10 Controller Reset, MPAC 750

GM85884

GM85888

1. System Alert LED, MPAC 1200 and MPAC 1500

2. System Alert LED, MPAC 750

Figure 4-11 Fault Indication

TP-6921 10/14 Section 4 Troubleshooting 49

Condition Type Description
Failure to Acquire Standby Source Warning The source voltage did not reach the acceptable range within
a set time (see Time Delays). For example, the standby
Failure to Acquire Preferred Source [ Warning source generator set did not start.
IPM Synching Warning (status) The two sources did not come into phase within the Fail to
(In-Phase Monitor Synching) Synchronize time delay.
Note: If the sources do become in phase, the warning is
automatically cleared and normal ATS operation continues.
External Battery Low [ Warning The voltage of the battery connected to the external battery
supply module (EBSM) is low.
Failure to Transfer Warning The signal to transfer is sent to the contactor and the main
shaft auxiliary switch fails to indicate a complete ATS position
change. The controller will attempt to transfer the unit three
times before the fault is indicated.
Auxiliary Switch Fault Manual Reset Fault The main shaft auxiliary switches indicate that the ATS is in
more than one position, or the position changed when no
signal was sent to initiate the change.
Auxiliary Switch Open Manual Reset Fault The main shaft auxiliary switches indicate that the ATS is in
neither position (all inputs are open).
Src N (or Src E) Rotation Err [ Self-Resetting Fault The detected phase rotation of one or both sources does not
match the preselected setting.
I/O Module Lost Comm [ Self-Resetting Fault An I/O device has stopped communicating or does not have
a correct address specified. Fault resets if communication is
reestablished.
Module Status Change [ Self-Resetting Fault An accessory module has been disconnected OR a new
module is detected. See Section 4.10.1 to reset.
Module Status Conflict [ Self-Resetting Fault An accessory module has been replaced with a different type
of module. See Section 4.10.2 to correct.
External Fault Self-Resetting Fault The input contact assigned to the remote common alarm
(Remote Common Alarm) input function is closed.
[ Not applicable to the MPAC 750 controller.

Figure 4-12 Warnings and Faults

50 Section 4 Troubleshooting TP-6921 10/14

4.9.1 Fault Reset, MPAC 1200 and 1500 4.10 Accessory Module Faults
Controllers
This section explains faults related to the optional
To clear a fault or warning condition and reset the accessory modules, including I/O modules, the alarm
System Alert LED, go to the Main screen and press the module, and the extended battery supply module
down arrow button to open the Reset screen. See (EBSM).
Figure 4-11 and Figure 4-13. Then press the button
labelled Reset. A fault reset does not change the
4.10.1 Module Status Change
controller settings.
If the Module Status Change message appears on the
When a fault Fault Message controller display, first verify that the cable from the
message is displayed, LD Exer ##/## @ ##:## controller to the accessory module assembly is not
press the down arrow Norm ###V Emer ###V loose or disconnected.
(B) button on the B View Set Test
Main screen to step to The Module Status Change message automatically
the Reset Fault Reset clears if the fault condition is corrected (self-resetting
screen. Fault Description fault).
Then press the Reset
B Y Reset Main Module Connection (new or reconnected module)
button.
Installing or reconnecting one or more accessory
Figure 4-13 Fault Reset, MPAC 1200 and 1500
modules triggers the Module Status Change message.

4.9.2 Fault Reset, MPAC 750 Controller 1. If the ATS display shows Module Status Change,
press the Reset button. See Figure 4-15.
To clear a fault or warning condition and reset the
System Alert LED, press the Test and Exercise buttons Module Status Change
at the same time and hold for 2 seconds. See
Press Reset.
Figure 4-13. Norm ###V Emer ###V
Reset View Set Test

Reset
New Module Press Reset.

B Y Reset Main

Figure 4-15 Screens after Module Connection

2. The ATS display will show Reset New Module.

Press the Reset button from that screen. The
GM85888 controller recognizes the module type(s).
1 2
3. Navigate to the Set Input/Outputs>Set Aux I/O
1. Test button screen to check that the controller has recognized
2. Exercise button
the connected modules. See Figure 4-17.
Press and hold the Test and Exercise buttons for 2 seconds to clear a
fault condition.
See the transfer switch operation/installation manual for
Figure 4-14 Fault Reset, MPAC 750 instructions to assign programmable inputs and outputs
to I/O modules or assign functions to the audible alarm
for an Alarm Module.

TP-6921 10/14 Section 4 Troubleshooting 51

Disconnected Module 3. Press Set to enter setup mode.
If one or more accessory modules are disconnected 4. Enter the setup password.
from the controller, the message Module Status Change
appears. See Figure 4-16. Pressing the Reset button 5. Press the down arrow to step to the Set
displays the message Check Module Setup to Clear Inputs/Outputs screen. See Figure 4-17.
Fault.
6. Navigate to the Set Auxiliary I/O screen. See
Figure 4-17. Press the right arrow button to see the
Module Status Change status of module 1. Press the down arrow to step to
Press Reset. the next module, if necessary, until the screen
Norm ###V Emer ###V
shows Status: Lost.
Reset View Set Test
7. Press the right arrow button to move to the
Check Module Setup Press Main and follow Uninstall Module screen. Verify that the screen
to Clear Fault Module Uninstall says Uninstall Module Yes. (Press the open arrow
Procedure. button to toggle no/yes, if necessary.)
B Y Reset Main
8. When Yes is displayed, press Save to uninstall the
module.
Figure 4-16 Screens after Module Disconnection
9. Repeat the uninstall procedure for additional
When modules are physically disconnected from the
modules, if necessary.
transfer switch, they must be uninstalled through the
controller keypad. Use the following procedure to
uninstall modules after disconnection. Other Module Status Change Conditions
A Module Status Change message that cannot be
Module Uninstall Procedure cleared as described above may indicate a failure of the
controller’s real-time clock. Carefully follow the
1. If the ATS display shows Module Status Change,
procedures above to attempt to reset the fault. If the
press the button labelled Reset.
fault cannot be reset, replace the controller. See
2. If the ATS display shows Check Module Setup to Section 6.13.
Clear Fault,, press Main to return to the main
screen.

Set
Set Inputs/Outputs Main Board I/O

B Y " Main B Y " Back

Set Module 1 Module 1

Auxiliary I/O Type POB Addr 1 Uninstall Module
Status: Lost Yes

B Y " Back B Y " Back Save Back

Press the down arrow button to step to the

next module, if necessary.

Figure 4-17 Uninstall Module

52 Section 4 Troubleshooting TP-6921 10/14

4.10.2 Module Status Conflict 4.11 Common Alarms
The message Module Status Conflict appears if one Any of the functions listed in Figure 4-18 can be
type of module is replaced with another type of module assigned to Common Alarms 1 and 2. Common alarms
that has the same address. Follow the procedure below 1 and 2 can then be assigned to output functions which
to resolve the conflict. activate when any of the conditions assigned to the
common alarm are present. Common Alarms 1 and 2
Procedure to Clear a Module Status Conflict can also be set to sound the alarm horn on the optional
Alarm Module.
1. Disconnect power to the transfer switch.

2. Disconnect the module. Functions that can be Assigned to Common Alarms

Aux Switch Fault * Src E Over Freq
3. Close the enclosure door and reconnect power to Aux Switch Open * Src E Over Voltage
the ATS. The display will show Module Status Battery Backup Low * Src E Rotation Err *
Change.
Contactor in Off Src E Under Freq
4. Press the button labelled Reset. The display will Contactor in Pref Src E Under Voltage
show Check Module Setup to Clear Fault. Contactor in Src E Src E Voltage Unbal
Contactor in Src N Src N Loss of Phase
5. Follow the procedure in Section 4.10.1 to uninstall
the module through the ATS controller keypad. Contactor in Stby Src N Over Freq
Exerciser Active Src N Over Voltage
6. Disconnect power to the ATS. Fail to Acquire Pref * Src N Rotation Err *
7. Connect the new module. Fail to Acquire Stby * Src N Under Freq
Fail to Transfer * Src N Under Voltage
8. Close the enclosure door and reconnect power to IPM Synching Src N Voltage Unbal
the ATS. The display will show Module Status
Load Bank Control Stby Src Available
Change. See Figure 4-15.
Load Control Active System Ready
9. Press the button labeled Reset to display Reset Low Battery *[ Test Mode Active
New Module. Press the reset button from that Non-Emergency Trans Critical Service Required
screen. The controller will now recognize the new
Not in Auto Man Transfer Waiting
module type.
Peak Shave Active [ Module Lost Comm *
10. Navigate to the Set Auxiliary I/O screen to check Pref Src Available Non-Critical Service Req
the status and settings for the new module. See Remote Common Alarm * Source E Available
Figure 4-17. Press the right arrow button to see the
Remote Monitor In #1--4 Source N Available
status of module 1. Press the down arrow to step to
the next module, if necessary, Fail to Sync Breaker Trip
Src E Loss of Phase Modbus-Controlled RDO
See the transfer switch operation/installation manual for #1--4
instructions to assign programmable inputs and outputs * Assigned to Critical Service Required
to I/O modules or assign functions to the audible alarm [ Assigned to Non-Critical Service Required
for an Alarm Module. Figure 4-18 Common Alarm Functions

If the common alarm is activated, the specific condition

that triggered the alarm will be shown on the ATS
controller display screen. Check the display to identify
the problem and then refer to the troubleshooting tables
in Sections 4.12 and 4.13.

Use the View Common Alarms screen to identify which

functions have been assigned to each common alarm.
See the operation and installation manual for
instructions to check the view screens and to change the
settings, if necessary.

TP-6921 10/14 Section 4 Troubleshooting 53

Selected functions as noted in Figure 4-18 are grouped 4.12 Events and Faults
into the Critical Service Required and Non-Critical
Service Required functions. The Critical Service
Troubleshooting Table
Required and Non-Critical Service Required functions The following tables list the faults and alarms that may
can be assigned to activate the alarm horn on the be shown on the controller’s display screen or listed in
optional Alarm Module. If any of the conditions included the event history log. The tables also list the possible
in the Critical Service Required or Non-Critical Service causes for each problem and suggested procedures to
Required function occurs, the alarm horn will sound. identify and correct the source of the problem.
The message on the ATS display will identify which
condition (for example, Fail to Acquire Standby) The event history log also lists transfers and other
triggered the alarm and caused the horn to sound. normal events not shown in these tables. The event
history log can be saved to an electronic file. Refer to the
transfer switch operation/installation manual for
instructions to save the event log to a file.

Fault or Event See

Message Possible Cause Check Section
Overfrequency, Frequency settings Check that the system frequency setting matches the actual 4.5
Underfrequency source frequency (50 or 60 Hz).
Check the over/underfrequency pickup and dropout settings. See 4.5
Section 4.5.2 and the Setup Program Operation Manual.
Check that the frequency debounce setting is long enough to 4.5
prevent nuisance faults caused by brief frequency variations.
Source availability, Check that the source frequency matches the nominal system 4.4.3
stability frequency and stays within the range of the pickup and dropout 4.5
settings.
Source connections Check for loose connections. W/D
Check wiring.
Overvoltage, Voltage settings Check that the system voltage setting matches the actual source 4.5
Undervoltage voltage.
Check the over/undervoltage pickup and dropout settings. 4.5
4.5.2
Check that the voltage debounce setting is long enough to prevent 4.5
nuisance faults caused by brief voltage dips or spikes.
Source availability, Check that the source voltage matches the nominal system 4.5
stability voltage and stays within the range of the pickup and dropout
settings.
Source connections Check for loose connections. W/D
Check wiring.
Calibration error Check the ATS calibration. 6.9
Loss of Phase Single/three phase Check that the controller single/three phase setting matches the 4.5
setting does not source.
match source
One phase of the Check that all phases of the source are available. 4.4.3
source has been
lost
Source connections Check for loose connections.
Source Rotation Phase rotation Check that the controller phase rotation setting matches the 4.5
Error setting (ABC or source phase rotation (ABC or BAC). Check the source
BAC) does not connections to the transfer switch and verify that A,B, and C are
match source connected to the appropriate lugs. Change the controller phase
rotation setting or rewire the source connections if necessary.
Failure to Transfer Transfer switch See Section 4.13, Troubleshooting. 4.13
mechanism problem

54 Section 4 Troubleshooting TP-6921 10/14

Fault or Event See
Message Possible Cause Check Section
Auxiliary Switch Controller cannot Check wiring and connections to position microswitches. See the W/D
Fault or determine the schematic drawing for connections.
Auxiliary Switch transfer switch
Test position microswitch operation. Replace microswitch if
Open position
necessary.
Transfer switch in intermediate position. Manually operate the TOC
transfer switch, following safety precautions and instructions for
your model.
See the Table of Contents for manual operation procedures for
your unit.
Check the control contact operation. Inspect for signs of coil TOC
damage or overheating and replace coil if necessary. See the
Table of Contents for coil control contact test procedures for your
unit.
Failure to Acquire Generator set did See Failure to Start Generator Set, below.
Standby not start
Open circuit breaker Check and close ATS source and generator set circuit breakers. —
ATS does not Check source voltage, frequency, phase rotation settings and 4.4.3
recognize the compare to actual values. 4.5
standby source Check for loose source connections. Check the labels on the 2.2.2
switch for tightening torques.
Check for open switch or circuit breaker to the source. —
Check ATS calibration. 6.9
Check voltage sensing. See Figure 4-20 (KS) or Figure 4-26 (KG), 4.14
Voltage Sensing Troubleshooting flowchart.
Failure to Acquire Open circuit breaker Check and close ATS source and generator set circuit breakers.
Preferred ATS does not Check source voltage, frequency, phase rotation settings and 4.4.3
recognize the compare to actual values. 4.5
source Check for loose source connections. Check the labels on the 2.2.2
switch for tightening torques.
Check for open switch or circuit breaker. —
Check ATS calibration. 6.9
Check voltage sensing. See Figure 4-20 (KS) or Figure 4-26 (KG), 4.14
Voltage Sensing Troubleshooting flowchart.
External Battery Low generator set Check battery connections and voltage. Charge or replace battery Generator
Low engine starting if voltage is low. set
battery voltage manuals
Inphase Monitor The two sources did Adjust inphase monitor angle. ATS O/I/M
(IPM) Synching not synchronize
within the Fail to
Sync time delay. It may be necessary to adjust the generator set frequency in order Generator
The ATS will to achieve source synchronization. set
continue to monitor manuals
for synchronization.
Fail to Sync The two sources did Check the synchronization settings for voltage differential, Controller
(closed-transition not synchronize frequency differential, and phase angle. See the Controller Operation
models) within the Fail to Operation Manual. Manual
Sync time delay. The programmed-transition override function can be set to allow a
The ATS will programmed-transition transfer in the event that the sources do not
continue to monitor synchronize. See TP-6714 for instructions.
for synchronization.
The IPM Synching output can be connected to customer-supplied
equipment to boost the generator set if the sources do not
synchronize.

TP-6921 10/14 Section 4 Troubleshooting 55

Fault or Event See
Message Possible Cause Check Section
Module Status A new accessory Press the reset button to open Reset New Module screen. Then 4.10.1
Change module is detected press Reset again.
A module has been Check connections from the controller to the I/O module assembly 4.10.1
disconnected and at the top of each I/O module.
Verify that the module is securely installed.
If a module has been removed, go to Set Inputs/Outputs screen
and uninstall the module.
Communication to Check I/O module connections. 4.10.1
an installed I/O
module has been
lost
Real-time clock If the procedures in Section 4.10.1 fail to clear the error message, 4.10.1
failure on logic replace the controller’s logic board. 6.13
board
Module Status One type of module Follow the procedure in Section 4.10.2 to uninstall the old module 4.10.2
Conflict was replaced with and then install the new module.
another type of
module that has the
same address
External Fault Fault condition in Identify and correct the cause of the fault condition. Manuals
customer- supplied for
equipment connected
connected to equipment
external input
Loose or faulty Check connection to external input. ATS OIM
connection

56 Section 4 Troubleshooting TP-6921 10/14

4.13 Transfer Switch Operation Always follow the safety precautions at the beginning of
this manual when troubleshooting and servicing the
Troubleshooting Table transfer switch.

The following table lists potential problems with possible

causes and suggested remedies. Section numbers in
the last column refer to other sections of this manual.
TOC refers to the Table of Contents in this manual;
check the table of contents for service procedures for
your size (amps) and type (standard or programmed-
transition, standard or bypass/isolation) of transfer
switch in Sections 7 through 10.

See
Problem Possible Cause Check Section
Generator set Engine start time delay is running Check the controller display to see if the engine start 4.6
engine does not time delay is active. Wait for the engine start time
start delay to expire. Press End Delay button to end the
delay early, if necessary.
See the ATS controller Operation Manual for ATS O/I/M
instructions to change the engine start time delay
setting, if necessary.
Loose engine start connection Check for loose engine start connection on the ATS ATS O/I/M
and the generator set. Tighten connections and/or Generator
replace wiring if necessary. manuals
No engine start signal from the Follow the procedure in Section 6.7 to test the 6.7
ATS engine start contact operation.
Generator set master switch not in Check that the generator set is in AUTO. Refer to Generator
the AUTO position the generator manuals for instructions, if necessary. set
Generator set problem If the ATS is sending an engine start signal and the manuals
the generator set is in AUTO, troubleshoot the
generator set for failure to start. Refer to the
generator set and engine manuals for instructions.
Generator set ATS does not recognize the Is the normal (utility source available? Check the —
engine runs when it Normal source normal source available LED on the ATS controller. 4.5
should not If not lit, check for utility voltage to the transfer switch
normal lugs. Check source connections to the
transfer switch.
Check that the switches or circuit breakers between
the utility power source and the ATS are closed.
Check that the ATS settings for voltage, frequency,
and phase rotation are correct for the normal source.
Check the transfer switch voltage calibration.
ATS not in the expected position Check the ATS position LEDs to verify that the ATS 6.1
is in the normal position.
Check the position of the preferred source selector
switch, if equipped. If the preferred source selector
switch is set to Emergency, the ATS will remain in
the emergency position and generator set will run,
even if the utility source is available.
Exerciser is running Check the controller display for Exerciser Active ATS O/I/M
message. Press the END button to end an exercise
run, if necessary.
A remote switch may be signalling an exercise run.
Check for remote exercise inputs.
O/I/M= Operation and Installation Manual; O/M = Operation Manual; TOC = Table of Contents, this manual;
W/D = Wiring Diagrams

TP-6921 10/14 Section 4 Troubleshooting 57

 See
Problem Possible Cause Check Section
Generator set Test sequence is running Check the controller display for indication that a test ATS O/I/M
engine runs when it sequence is active. Press the END TEST button to
should not end a test sequence, if necessary.
(continued) A remote switch may be signalling a test run. Check
for remote test inputs.
Engine cooldown time delay Check for Engine Cooldown message on the 4.6
operating controller display. Press End Delay button to end the ATS O/I/M
cooldown delay, if necessary. Check the ATS
controller engine cooldown time delay setting.
Check the generator set controller for operation of a Generator
separate engine cooldown cycle. O/M
Engine start connection closed Check the wiring and connections to the engine start ATS O/I/M
contacts on the ATS and the generator set. Check W/D
for shorts or incorrect connections.
Disconnect the engine start leads to see if engine
stops.
Test the engine start contact operation. 6.7
Generator set master switch not in Move the generator set master switch to the AUTO Generator
AUTO position. Wait for the generator set engine cooldown set
delay, if necessary. manuals
Other generator set problem Disconnect the engine start leads from the ATS. If
the engine continues to run, troubleshoot the
generator set.
In-phase monitor Inphase monitor function not Check that the inphase monitor option in the Set O/M
does not operate enabled Sources menu on the ATS controller is enabled.
Low source voltage If voltage of the connected source falls below 70% of O/M
nominal, the in--phase monitoring is terminated and
transfer is allowed.
Inphase monitor option not Not available on programmed-transition models.
available (programmed-transition Center-OFF position makes the inphase monitor —
models) option unnecessary.
Exerciser does not Exerciser not set Use View Exercise Setup screen to check exerciser O/M
start generator set settings. See the ATS controller operation manual
for instructions to check and change the exerciser
settings.
Check that exercise run duration Use View Exercise Setup screen to check exerciser O/M
is not set to zero settings. See the ATS controller operation manual
for instructions to check and change the exerciser
settings.
Loose or open engine start Check the wiring and connections to the engine start ATS O/I/M
connection terminals on the ATS and the generator set. Engine
start terminal locations vary with transfer switch
model and size. See the ATS installation manual or
ADV drawing for the engine start terminal location, if
necessary.
Engine start problem Follow the procedure in Section 6.7 to test the 6.7
engine start operation. Also see Generator set
engine does not start in this table.
Exerciser does not Exerciser not set Use View Exercise Setup screen to check exerciser O/M
run regularly or at settings.
all Maintenance DIP switch SW1B Check for Maintenance Mode message on controller —
closed display.
Check the DIP switch setting. 6.8
O/I/M= Operation and Installation Manual; O/M = Operation Manual; TOC = Table of Contents, this manual;
W/D = Wiring Diagrams

58 Section 4 Troubleshooting TP-6921 10/14

 See
Problem Possible Cause Check Section
Exerciser does not Exercise interval different than Use View Exercise Setup screen to check exerciser O/M
run regularly or at expected settings.
all, cont’d
Failure to transfer Alternate source is not available Check that the source available LED on the ATS 2.2.2
controller is lit.
Check the source connections to the ATS normal
and/or emergency lugs.
Check that circuit breakers and/or switches between
the source and ATS are closed.
Check source voltage and frequency. 4.4.3
Check that the ATS settings for voltage, frequency, 4.5
and phase rotation are correct for the both sources.
Check the transfer switch voltage calibration. 6.9
AC voltage sensing is incorrect Perform troubleshooting procedures in Figure 4-20 4.14
(KS) or Figure 4-26 (KG), voltage sensing
troubleshooting flowchart.
Unloaded exercise selected Use View Exercise Setup screen to check exerciser O/M
settings.
Unloaded test sequence selected Press the End Test button, wait for the test sequence ATS O/M
to stop, and then select a Loaded or Auto Loaded
test sequence.
For remote tests, check the Remote Test loaded/
unloaded setting. See the ATS Operation Manual for
instructions.
Pre-transfer time delays operating Check controller display for time delay indication. ATS O/I/M
See the operation manual for information on time
delays during normal operation.
Check the time delay settings on the ATS controller. 4.6
Maintenance DIP switch enabled Check DIP switch setting. 6.8
Connected source available Check the Source Available LEDs. if the normal or 6.1
preferred source is available the ATS will not transfer
automatically.
Preferred source selection set to Check the preferred source selection and the Source —
emergency and emergency Available LEDs.
source is available
Supervised transfer control switch Check the position of the supervised transfer control ATS O/I/M
(optional) in manual position switch, if equipped. Move the switch to the
TRANSFER or AUTO position, as appropriate for the
application.
Fail to sync time delay expired If the sources do not synchronize with the fail to sync O/M
(closed-transition models) time delay, the fail to sync message is displayed on
the controller.
The programmed-transition override function
provides options for transfer after the fail to sync time
delay expires. See instructions for programmed-
transition override in the ATS controller operation
manual.
In-phase monitor transfer angle Check the transfer angle setting. A small transfer O/M
setting (if enabled) angle may prevent transfer because the two sources
may not fall within range.
Slow or no transfer Perform the troubleshooting procedures in the Transfer Troubleshooting flowcharts in 4.14
to utility Figure 4-22 and Figure 4-23 (KS) or Figure 4-28 and Figure 4-29 (KG).
O/I/M= Operation and Installation Manual; O/M = Operation Manual; TOC = Table of Contents, this manual;
W/D = Wiring Diagrams

TP-6921 10/14 Section 4 Troubleshooting 59

 See
Problem Possible Cause Check Section
Failure to transfer Jammed or damaged solenoid Inspect and test solenoid coil. 5.4.1
Transfer switch Faulty or worn core spring Inspect and replace damaged parts. TOC
mechanical binding Bent main contact shaft Inspect and replace damaged parts. TOC
Jammed main contacts Check for foreign object.
Contact lever or pushbutton Test control contacts. See the Table of Contents for TOC
jammed against solenoid test procedures for your model transfer switch.
counterweight
Loose hardware. Check for and tighten loose hardware. 2.2.2
Accumulation of dirt or other Clean. Lubricate if necessary. 2.2.2
foreign material
Failure to transfer Damaged or wrong coil Check for signs of overheating (warped or melted 5.4
Transfer switch plastic, dark stains, etc.). Measure the coil
electrical resistance to check for damaged coil.
malfunction Verify that the coil voltage rating matches the transfer
switch voltage rating and source voltage.
Replace the coil and rectifier.
Damaged or wrong rectifier Inspect for damage. Replace the rectifier and coil. 5.3
Corroded or fused contacts Inspect contacts. Clean or replace. Do not use an 2.2.2
emery cloth or file. See the Table of Contents for TOC
contact replacement procedures for your model.
Coil control contact operation Test coil control contact operation. See the Table of TOC
Contents for control contact test procedures for your
model transfer switch.
Faulty connections Check leads and harnesses for loose connections, W/D
broken leads, or incorrect connections.
Wrong voltage Check system voltage, controller system voltage and 4, 6
over/undervoltage pickup and dropout settings, and
controller meter calibration.
Chattering noise Coil control contact operation See the Table of Contacts for control contact test TOC
when attempting to procedures for your model transfer switch.
transfer Low voltage Check source voltage and connections. 4.4.3
Incorrect spring See the Table of Contents for coil replacement TOC
instructions for your model transfer switch.
Wrong coil Check coil voltage rating and verify that it matches —
the transfer switch voltage rating.
O/I/M= Operation and Installation Manual; O/M = Operation Manual; TOC = Table of Contents, this manual;
W/D = Wiring Diagrams

60 Section 4 Troubleshooting TP-6921 10/14

 See
Problem Possible Cause Check Section
No LEDs illuminated No power to the transfer switch Check that source switches or circuit breakers —
and/or display is between the sources and the transfer switch are
blank closed.
Verify that at least one source is available. Check for 4.4.3
utility or gen set voltage to the ATS.
Check source connections to the normal and
emergency lugs on the ATS.
No power to the controller Check that the transfer switch harness is connected Figure 6-9
to the controller.
Check the harness for loose connections or broken W/D
leads (continuity check).
One or more faulty LEDs Press the Lamp Test button to check the operation of 6.1.4
all LEDs.
Replace the controller if one or more LEDs do not 6.13
light during the lamp test.
If no LEDs light during the lamp test, troubleshoot 6.3
power and connections to the controller as described
above.
See Figure 4-21 (KS) or Figure 4-27(KG), Blank Display Troubleshooting. 4.14
Strange characters See Figure 4-24 (KS) or Figure 4-30 (KG), Troubleshooting Display Errors or Controller 4.14
on controller display Lockup.
or controller lockup
Source available Malfunctioning LED Press the Lamp Test button to check the operation 6.1.4
LED off when of all LEDs. Replace the controller if one or more
Source is available LEDs do not light. If no LEDs light, troubleshoot
power and connections to the controller.
Source settings do not match Check the source voltage, frequency, and phase 4.5
actual source parameters rotation settings. See the ATS Operation Manual for
instructions.
Incorrect ATS meter calibration Check calibration. 6.9
Position LED not lit Position microswitch malfunction Check the operation of the position microswitches. 6.10
Transfer switch in intermediate Manually operate the transfer switch and check the TOC
position position LED operation.
Check the control contact operation. TOC
Check for evidence of solenoid coil damage. Test 5.4
solenoid coil resistance and operation.
Replace the coil if necessary. TOC
LEDs not functioning See No LEDs illuminated in this table. —
O/I/M= Operation and Installation Manual; O/M = Operation Manual; TOC = Table of Contents, this manual;
W/D = Wiring Diagrams

TP-6921 10/14 Section 4 Troubleshooting 61

4.14 MPAC Controller Problems with the transfer switch controller can often be
traced to incorrect controller settings, faulty wiring, or a
Troubleshooting Flowcharts bad circuit board. Use the troubleshooting flowcharts in
this section to diagnose problems and identify the parts
DANGER that require service or replacement. Do not replace the
entire controller assembly.

The MPAC 750 and 1200 controllers for the Models KSS
and KSP are covered in Section 4.14.1. The MPAC
Hazardous voltage. 1500 controller for Models KGS and KGP is covered in
Will cause severe injury or death. Section 4.14.2.
Only authorized personnel should
open the enclosure.

Testing live electrical circuits. Hazardous voltage or

current can cause severe injury or death. Have trained and
qualified personnel take diagnostic measurements of live
circuits. Use adequately rated test equipment with electrically
insulated probes and follow the instructions of the test
equipment manufacturer when performing voltage tests.
Observe the following precautions when performing voltage
tests: (1) Remove all jewelry. (2) Stand on a dry, approved
electrically insulated mat. (3) Do not touch the enclosure or
components inside the enclosure. (4) Be prepared for the
system to operate automatically.
(600 volts and under)

62 Section 4 Troubleshooting TP-6921 10/14

4.14.1 MPAC 750 and 1200 Controllers D Slow or no transfer to utility
for Models KSS/KSP
D Strange characters on display or controller lockup
Use the troubleshooting flowcharts in Figure 4-20
through Figure 4-24 to diagnose and correct the Refer to the operation/installation manual and wiring
following controller problems. diagrams provided with the transfer switch during the
procedure. See Figure 4-19 for an illustration of the
D Incorrect voltage sensing controller connections referred to in the flowcharts.

D Blank display

GM89643

Figure 4-19 MPAC Controller Circuit Board P1 Connector, Models KSS/KSP

TP-6921 10/14 Section 4 Troubleshooting 63

 Controller AC voltage Note: To prevent damage to the controller and the device, NEVER
sensing is incorrect. remove or reapply devices while the controller is energized. Follow
the safety precautions during this troubleshooting procedure.
Check the system voltage
programmed into the controller.

Does the controller NO

system voltage match the Check the voltage rating
actual system voltage? on the ATS nameplate.

NO
YES Is the ATS rating correct Order a transfer switch that is
for the application? rated for the application.

Use a digital voltmeter to verify power to the YES

ATS. See 4.4.3. Check AC line voltage at
P1-12(A), P1-11(B), and P1-4(C) for the
normal source. Check AC line voltage at Reprogram the controller’s system
P1-7(A), P1-18(B), and P1-6(C) for the voltage setting to the correct system
emergency source. voltage.

NO Trace leads back to the contactor and

Line voltage found at sensing terminals. Repair or replace
all points? damaged leads or harness.

YES

Verify power directly on circuit board where

P1-12, P1-11, and P1-4 (Normal) and
P1-7, P1-6, and P1-18 (Emergency) are
soldered to the board.

NO
Line voltage found at Poor connection at P1 connector.
all points? Identify and correct.

YES

Replace the controller.

SB-697

Figure 4-20 Voltage Sensing Troubleshooting, Models KSS/KSP

64 Section 4 Troubleshooting TP-6921 10/14

 Note: To prevent damage to the controller and the device, NEVER
Controller display is remove or reapply devices while the controller is energized. Follow
blank.
the safety precautions during this troubleshooting procedure.

Verify power to the

Trace leads back to the
ATS. Check AC line voltage at
NO contactor and sensing
P1-12(A) and P1-4(C) for the normal NO
Are any LEDs on the terminals. Refer to the wiring
source. Check AC line voltage at
controller illuminated? diagrams provided with the
P1-7(A) and P1-6(C) for the
transfer switch. Repair or
emergency source. Line
replace damaged leads or
YES voltage found at all
harness.
points?

YES

Verify power directly NO Poor pin connection or broken

on circuit board P1-12 and wire at P1. Correct the pin or
P1-4 (Normal), and P1-6 and wire connection.
P1-7 (Emergency).

YES

Inspect the
ribbon cable. Is the ribbon NO Unplug the ribbon cable and reconnect it
cable connected correctly? correctly.

YES

NO YES
Is the ribbon cable Check for display operation. Complete.
damaged? Does the display operate?

YES
NO

Replace the controller.

SB-697

Figure 4-21 Blank Display Troubleshooting, MPAC 1200 Controller

TP-6921 10/14 Section 4 Troubleshooting 65

 Controller does not transfer
to utility or takes excessive
time to transfer.
Note: To prevent damage to the controller and the device, NEVER
remove or reapply devices while the controller is energized. Follow
the safety precautions during this troubleshooting procedure.

Utility Trace leads back to contactor

source available at NO sensing terminals. Repair or
P1-4, P1-11, and replace damaged leads or
P1-12? harness.

YES

Is LED1 on the Verify power NO Poor connection at P1 connector.

NO
controller circuit directly on circuit Identify and correct.
board on? board P1-4, P1-11,
and 1-12.

YES YES

Replace the controller.

NO Reprogram controller
Is the Utility Source
Available LED on? to correct AC voltage.
and recalibrate

YES

Wait for TDEN to time out.

(Verify that in--phase
monitor sequence is
complete, if enabled.)

A Go to point A in
Figure 4-23. SB-697

Figure 4-22 Transfer Troubleshooting, Models KSS/KSP, Part 1

66 Section 4 Troubleshooting TP-6921 10/14

 Continued from point
A A in Figure 4-22.

When TDEN times NO Pull relay K1 from its NO

out, can you hear or see the K1 base. Check for 12VDC at the Replace the controller.
relay move 3 times before a surface-mounted base as you
fault is issued? retry the transfer.

YES YES

Faulty K1 relay.
Replace K1. NO
Transfer? Return to point A.
and reset faults.
Reset faults.
YES

Complete.

NO Are the pin NO

Is there power connections and Identify and correct
to the transfer leads to the transfer the bad pin
coil? coil good? connections or wiring.

YES YES

Faulty transfer coil or Power down the controller and remove the controller board
rectifier. Identify and from the plastic case. Check the solder traces to the K1
replace. relay on the power board.

NO
Are the solder Faulty K1 relay, K1
traces open? contacts, or power board.

YES

Faulty transfer coil or rectifier has damaged the

controller. Identify and replace the faulty rectifier,
transfer coil, or wiring AND replace the controller.

SB-697

Figure 4-23 Transfer Troubleshooting, Models KSS/KSP, Part 2

TP-6921 10/14 Section 4 Troubleshooting 67

68
Controller has strange Note: To prevent damage to the controller and the device, NEVER
characters on the remove or reapply devices while the controller is energized.
display or the controller Follow the safety precautions during this troubleshooting
is locked up.
procedure.

Section 4 Troubleshooting
Power down the controller
and remove all external
components and
accessories, including
factory and customer
installed accessories. Then
re--power the controller.

Power down the

Check the two ribbon
Is the controller NO Is the cable seated NO controller, Is the controller NO
cables between the
operational? properly? re--seat the operational?
controller circuit board and
cable, and
the display.
re--power.
YES YES
YES

Load the latest version of the

Power down, reconnect devices controller application code. Complete.
one at a time, and power up again
to determine which device is
causing the problem.

Figure 4-24 Troubleshooting Display Errors or Controller Lockup, MPAC 1200

NO Replace the
Is the controller
operational? controller.

YES

Complete.

SB-697

TP-6921 10/14
4.14.2 MPAC 1500 Controller for Models D Slow or no transfer to utility
KGS/KGP
D Strange characters on display or controller lockup
Use the troubleshooting flowcharts in Figure 4-26
through Figure 4-30 to diagnose and correct the Refer to the operation/installation manual and wiring
following problems on the controller. diagrams provided with the transfer switch during the
procedure. See Figure 4-25 for an illustration of the
D Incorrect voltage sensing controller connections referred to in the flowcharts.

D Blank display

GM89702

Figure 4-25 MPAC Controller Circuit Board P1 Connector, Models KGS/KGP

TP-6921 10/14 Section 4 Troubleshooting 69

 Controller AC voltage Note: To prevent damage to the controller and the device, NEVER
sensing is incorrect. remove or reapply devices while the controller is energized. Follow
the safety precautions during this troubleshooting procedure.
Check the system voltage
programmed into the controller.

Does the controller NO

system voltage match the Check the voltage rating
actual system voltage? on the ATS nameplate.

NO
YES Is the ATS rating correct Order a transfer switch that is
for the application? rated for the application.

Use a digital voltmeter to verify power to the YES

ATS. See 4.4.3. Check AC line voltage at
P1-1(A), P1-2(B), and P1-3(C) for the normal
source. Check AC line voltage at P1-6(A), Reprogram the controller’s system
P1-7(B), and P1-8(C) for the emergency voltage setting to the correct system
source. voltage.

NO Trace leads back to the contactor and

Line voltage found at sensing terminals. Repair or replace
all points? damaged leads or harness.

YES

Verify power directly on circuit board where

P1-1, P1-2, and P1-3 (Normal) and P1-6,
P1-7, and P1-8 (Emergency) are soldered
to the board.

NO
Line voltage found at Poor connection at P1 connector.
all points? Identify and correct.

YES

Replace the controller.

SB-697

Figure 4-26 Voltage Sensing Troubleshooting, Models KGS/KGP

70 Section 4 Troubleshooting TP-6921 10/14

 Note: To prevent damage to the controller and the device, NEVER
Controller display is remove or reapply devices while the controller is energized. Follow
blank.
the safety precautions during this troubleshooting procedure.

Verify power to the

Trace leads back to the
ATS. Check AC line voltage at
NO contactor and sensing
P1-1(A) and P1-3(C) for the normal NO
Are any LEDs on the terminals. Refer to the wiring
source. Check AC line voltage at
controller illuminated? diagrams provided with the
P1-6(A) and P1-8(C) for the
transfer switch. Repair or
emergency source. Line
replace damaged leads or
YES voltage found at all
harness.
points?

YES

Verify power directly NO Poor pin connection or broken

on circuit board P1-1 and P1-3 wire at P1. Correct the pin or
(Normal), and P1-6 and P1-8 wire connection.
(Emergency).

YES

Inspect the
ribbon cable. Is the ribbon NO Unplug the ribbon cable and reconnect it
cable connected correctly? correctly.

YES

NO YES
Is the ribbon cable Check for display operation. Complete.
damaged? Does the display operate?

YES
NO

Replace the controller.

SB-697

Figure 4-27 Blank Display Troubleshooting, Models KGS/KGP

TP-6921 10/14 Section 4 Troubleshooting 71

 Controller does not transfer
to utility or takes excessive
time to transfer.
Note: To prevent damage to the controller and the device, NEVER
remove or reapply devices while the controller is energized. Follow
the safety precautions during this troubleshooting procedure.

Utility Trace leads back to contactor

source available at NO sensing terminals. Repair or
P1-1, P1-2, and replace damaged leads or
P1-3? harness.

YES

Is LED1 on the Verify power NO Poor connection at P1 connector.

NO
controller circuit directly on circuit Identify and correct.
board on? board P1-1, P1-2,
and P1-3.

YES YES

Replace the controller.

NO Reprogram controller
Is the Utility Source
Available LED on? to correct AC voltage.
and recalibrate

YES

Wait for TDEN to time out.

(Verify that in--phase
monitor sequence is
complete, if enabled.)

A Go to point A in
Figure 4-23. SB-697

Figure 4-28 Transfer Troubleshooting, Models KGS/KGP, Part 1

72 Section 4 Troubleshooting TP-6921 10/14

 Continued from point
A A in Figure 4-22.

NO Are the pin NO

Is there power connections and Identify and correct
to the transfer leads to the transfer the bad pin
coil? coil good? connections or wiring.

YES YES

Faulty transfer coil or Power down the controller and remove the controller board
rectifier. Identify and from the plastic case. Check the solder traces to the K1
replace. relay on the power board.

NO
Are the solder Faulty K1 relay, K1
traces open? contacts, or power board.

YES

Faulty transfer coil or rectifier has damaged the

controller. Identify and replace the faulty rectifier,
transfer coil, or wiring AND replace the controller.

SB-697

Figure 4-29 Transfer Troubleshooting, Models KGS/KGP, Part 2

TP-6921 10/14 Section 4 Troubleshooting 73

74
Controller has strange Note: To prevent damage to the controller and the device, NEVER
characters on the remove or reapply devices while the controller is energized.
display or the controller Follow the safety precautions during this troubleshooting
is locked up.
procedure.

Section 4 Troubleshooting
Power down the controller
and remove all external
components and
accessories, including
factory and customer
installed accessories. Then
re--power the controller.

Power down the

Check the two ribbon
Is the controller NO Is the cable seated NO controller, Is the controller NO
cables between the
operational? properly? re--seat the operational?
controller circuit board and
cable, and
the display.
re--power.
YES YES
YES

Load the latest version of the

Power down, reconnect devices controller application code. Complete.
one at a time, and power up again
to determine which device is
causing the problem.

NO Replace the
Is the controller

Figure 4-30 Troubleshooting Display Errors or Controller Lockup, Models KGS/KGP

operational? controller.

YES

Complete.

SB-697

TP-6921 10/14
 Section 5 Transfer Switch Testing

5.1 Initial Checks

When troubleshooting the transfer switch mechanism,
always check for simple causes first: broken or loose
wires, corroded contacts, exposure to dirt or foreign
material, etc.

Check the time delays, source settings, and other

system parameters as described in Sections 4 and 6
before concluding that there is a mechanical problem
with the transfer switch. Many transfer problems can be
traced to inappropriate controller settings.

Verify that the voltage on the nameplate matches the

actual nominal source voltage. Use the procedure in
Section 4.4.3 to measure the source voltage. Observe
safety precautions when taking voltage measurements.
Verify that the measured voltage matches the transfer
switch rated voltage.

Figure 5-1 Checking Rectifier Diode Operation

5.2 Contacts
Use the millivolt drop test in Section 2.3.3 to identify
damaged contacts. If the contacts are damaged or have
high resistance, replace the power panel assembly. See
the table of contents for service procedures for your
transfer switch. COIL

5.3 Rectifier Test Typical rectifier diode arrangement

Use an ohmmeter or a diode checker to test the rectifiers

when necessary. See Section 7.6 for instructions to test 1 2
rectifiers on Model KSS switches.

Note: The rectifiers on model KSP programmed-

transition switches are built into the solenoid coils I I
and are not accessible for testing.
 
Disconnect all leads to the bridge rectifier and test each
rectifier (diode) in the bridge individually using an
ohmmeter (R x 1 scale) or diode checker. See
Figure 5-1 and Figure 5-2. The diodes should exhibit a -- + -- +
reverse resistance of at least 100 times the forward Low  High 
6226
resistance. If the reverse resistance is low, replace the
damaged rectifier assembly. 1. Forward-biased diode—current flows from the positive
terminal of the meter to the negative terminal in the same
direction as the diode arrow, low resistance
2. Reverse-biased diode—current flows from the positive
terminal of the meter to the negative terminal in the opposite
direction of the diode arrow, high resistance

Figure 5-2 Testing Diodes

TP-6921 10/14 Section 5 Transfer Switch Testing 75

5.4 Solenoid Tests relay K2 (ER) in the controller closes, applying power to
the solenoid coil and initiating transfer.
5.4.1 Solenoid Coil Resistance When Source N (or the preferred source) is restored, the
controller starts the standby-to-preferred time delay.
Use an ohmmeter to measure the coil resistance. Most
When the time delay ends, the controller’s K1 (NR) relay
damaged coils will result in an open circuit (very high
closes, applying power to the solenoid coil and initiating
resistance) or a shorted coil (near zero resistance).
transfer back to Source N (or the preferred source).
Note: Because coils for model KSP programmed-
Note: The K1 (NR) and K2 (ER) relays are energized for
transition switches have integral rectifiers, the
only 250 milliseconds to initiate transfer.
coil resistance on those units cannot be easily
measured. Check coil operation according to the On 40--225 amp model KSS standard-transition
diagrams in Section 5.4.2. If the coil does not
switches, control contacts SCN and SCE control the
operate correctly, replace it.
amount of time that power is applied to the solenoid coil.
See Section 7.6 for instructions to test coils on Model The contacts open before the operating mechanism
KSS switches. Replace the coil if an open circuit or a reaches Top Dead Center (TDC). Inertia carries the
short circuit is found. mechanism through TDC, and a spring in the solenoid
assembly moves the mechanism into the Source E (or
standby) position.
5.4.2 Solenoid Operation
Model KSP programmed-transition models stop in the
This section contains descriptions and diagrams of the OFF position for a programmed length of time during
solenoid coil operation. For complete diagrams, refer to transfer. The transfer-to-OFF sequence is controlled by
the schematic diagrams provided with the transfer the NR1 and ER1 relays on the programmed-transition
switch. interface board (PTIB).
The ATS controller monitors the connected source and The controller K1 and K2 relays and the PTIB relays are
detects source failure, either a complete loss of the replaceable.
source or a source parameter that is outside the
acceptable range. The controller starts the engine start Note: Always check all wiring and connections before
time delay. If power is restored before the time delay replacing parts.
ends, the controller resets the time delay and continues
to monitor the source. If the source failure persists and The solenoid power circuits vary for different ATS
the time delay ends, the controller closes the engine models. The following sections describe and illustrate
start contacts to signal the Source E generator set to the transfer sequence for the different models.
start.
Figure 5-3 explains the notation used in the solenoid
When Source E (or the standby source) becomes operation diagrams in the following coil operation
available, the controller starts the preferred-to-standby diagrams.
time delay (if not set to zero). When the time delay ends,

ATS1: Trip switch, Normal * NR, ER: Controller relays. Energized for
AX: Coil clearing switch, Normal * 250 milliseconds to initiate transfer.

BTS1: Trip switch, Emergency * NR1, ER1: Programmed-transition interface

board relays. *
BX: Coil clearing switch, Emergency *
SCN, SCE: Coil control contacts (microswitches)
CC: Closing coil *
EA, EC: Emergency source SC: Select coil *
LS: Line select switch * S1: Bridge rectifier *
NA, NC: Normal source TC: Trip coil *

Power through the coil circuit. = closed = open

contacts contacts
* Used on programmed-transition switch diagrams

Figure 5-3 Legend for Solenoid Operation Diagrams

76 Section 5 Transfer Switch Testing TP-6921 10/14

5.4.3 Solenoid Operation Diagrams, 40--225 Amp Model KSS Standard Transition
Switches
K1 K1 K2
Source N position, Source N SCN NR NR ER SCE
available. The solenoid coil is not
energized. NA EA

+ -- COIL

NC EC

K1 K1 K2
NR NR ER

K1 K1 K2
Source N position, Source N lost. SCN NR NR ER SCE
The coil is energized if Source E is
available. The transfer switch is ready NA EA
to transfer to Source E.

+ -- COIL

NC EC

K1 K1 K2
NR NR ER

K1 K1 K2
Source E position, Source E available. SCN NR NR ER SCE
The solenoid coil is not energized.
NA EA

+ -- COIL

NC EC

K1 K1 K2
NR NR ER

Source E position, Source N SCN

K1 K1 K2
NR NR ER SCE
available. The controller is calling for
transfer to Source N. The coil is NA EA
energized and the transfer switch will
transfer to Source N.
+ -- COIL

NC EC

K1 K1 K2
NR NR ER

Figure 5-4 40--225 Amp Model KSS Standard-Transition Switches, Solenoid Operation

TP-6921 10/14 Section 5 Transfer Switch Testing 77

5.4.4 Solenoid Operation Diagrams, 400--600 Amp Model KSS Standard Transition
Switches
K1 K1 K2
Source N position, Source N NR NR ER
available. The solenoid coil is not
energized. NA EA

+ -- COIL

NC EC

K1 K1 K2
NR NR ER

K1 K1 K2
Source N position, Source N lost. NR NR ER
The coil is energized if Source E is
available. The transfer switch is ready NA EA
to transfer to Source E.

+ -- COIL

NC EC

K1 K1 K2
NR NR ER

K1 K1 K2
Source E position, Source E available. NR NR ER
The solenoid coil is not energized.
NA EA

+ -- COIL

NC EC

K1 K1 K2
NR NR ER

Source E position, Source N K1 K1 K2

NR NR ER
available. The controller is calling for
transfer to Source N. The coil is NA EA
energized and the transfer switch will
transfer to Source N.
+ -- COIL

NC EC

K1 K1 K2
NR NR ER

Figure 5-5 400--600 Amp Model KSS Standard-Transition Switches, Solenoid Operation

78 Section 5 Transfer Switch Testing TP-6921 10/14

5.4.5 Solenoid Operation Diagrams, 800--1000 Amp Model KSS Standard Transition
Switches

Transfer from Normal to Emergency

Contactor in Source N position; power is lost on N.
Power is available on E.
BX is closed.

NA EA

NC EC

K2 is pulsed (closed) for 250 ms. Select coil SC is energized.

Line select switch LS is energized and moves to supply closing coil solenoid CCS with current.

NA EA

NC EC
250 ms

Figure 5-6 800--1000 Amp Model KSS Standard-Transition Switches, Transfer from Normal to Emergency,
Steps 1 and 2

TP-6921 10/14 Section 5 Transfer Switch Testing 79

 Coil clearing switch BX opens when contactor is in Emergency position.
LS returns to deenergized state.
Coil clearing switch AX closes.
Contactor remains in Emergency position.

NA EA

NC EC

Figure 5-7 800--1000 Amp Model KSS Standard-Transition Switches, Transfer from Normal to Emergency,
Step 3

80 Section 5 Transfer Switch Testing TP-6921 10/14

 Transfer from Emergency to Normal
Contactor is in Emergency position.
Power is available on N.
AX is closed.

NA EA

NC EC

K1 is pulsed for 250 ms.

CCS is supplied current from the Normal source.
Contactor moves to the Normal position.

NA EA

NC EC
250 ms

Figure 5-8 800--1000 Amp Model KSS Standard-Transition Switches, Transfer from Emergency to Normal,
Steps 1 and 2

TP-6921 10/14 Section 5 Transfer Switch Testing 81

 AX Opens when contactor is in the normal position.
Emergency coil clearing switch BX closes.
Contactor remains in Normal position.

NA EA

NC EC

Figure 5-9 800--1000 Amp Model KSS Standard-Transition Switches, Transfer from Emergency to Normal,
Step 3

82 Section 5 Transfer Switch Testing TP-6921 10/14

5.4.6 Solenoid Operation Diagrams, Model KSP Programmed-Transition Models

Normal to OFF EA

Source N position
Source N is lost A1 B1 AT1 BT1
Emergency available
AX BX

ER is pulsed for 250 ms

ATS1 BTS1
to energize trip coil TC.

LS
ATS1 AND ATS2:
Closed in Normal
SI SI SI
Open in OFF AC AC AC
+ -- + -- + --
AC AC AC

CC SC TC

LS
BTS2 ATS2

A2 B2 BT2 AT2

ER NR

EC

250 ms

OFF to Emergency EA

ER1 is pulsed for 250 ms to

energize select coil SC. SC picks A1 B1 AT1 BT1
up LS, which energizes closing
coil CC AX BX

BX: ATS1 BTS1

Closed in OFF
Open in Emergency LS

SI AC SI AC SI AC
+ -- + -- + --
AC AC AC

CC SC TC

LS
BTS2 ATS2

A2 B2 BT2 AT2

ER1 NR1

EC

250 ms 6226

Figure 5-10 Model KSP Programmed-Transition Switches, Transfer from Normal to Emergency

TP-6921 10/14 Section 5 Transfer Switch Testing 83

 Emergency to OFF NR1
NC
NR1 is pulsed for
250 ms to energize A1 B1 AT1 BT1 250 ms
trip coil TC.
AX BX

BTS1 and BTS2:

Closed in Emergency ATS1 BTS1
Open in OFF
LS

SI AC SI AC SI AC
+ -- + -- + --
AC AC AC

CC SC TC

LS
BTS2 ATS2

A2 B2 BT2 AT2

NA

OFF to Normal
NA

NR is pulsed for 250 ms to A1 B1 AT1 BT1

energize closing coil CC.
AX BX
AX is closed in OFF.
ATS1 BTS1

LS

SI AC SI AC SI AC
+ -- + -- + --
AC AC AC

CC SC TC

LS
BTS2 ATS2

A2 B2 BT2 AT2

NR
NC

250 ms

Figure 5-11 Model KSP Programmed-Transition Switches, Transfer from Emergency to Normal

84 Section 5 Transfer Switch Testing TP-6921 10/14

5.4.7 Solenoid Operation Diagrams, Model KGS Open Transition Bypass/Isolation
Switches
Normal to Emergency

SCR SCR
RN RE

Central voltage C.V.

triggers SCR RE to
activate coil CE.

Emergency to Normal

Central voltage C.V. triggers SCR

RN
SCR
RE
SCR RN to activate coil CN.

GM46246

TP-6921 10/14 Section 5 Transfer Switch Testing 85

5.4.8 Solenoid Operation Diagrams, 150--400 Amp Model KGP Programmed-Transition
Bypass/Isolation Switches
Normal to Off

Off to
Emergency

GM46248

86 Section 5 Transfer Switch Testing TP-6921 10/14

Solenoid Operation Diagrams, 150--400 Amp Model KGP Programmed-Transition
Bypass/Isolation Switches, continued
Emergency to Off

Off to Normal

GM46248

TP-6921 10/14 Section 5 Transfer Switch Testing 87

5.4.9 Solenoid Operation Diagrams, 600--3000 Amp Model KGP
Programmed-Transition Bypass/Isolation Switches

Normal to Off

SCR SCR
RN RE

SCR SCR
REO RNO

Off to
Emergency

SCR SCR
RN RE

SCR SCR
REO RNO

GM46249

88 Section 5 Transfer Switch Testing TP-6921 10/14

Solenoid Operation Diagrams, 600--3000 Amp Model KGP Programmed-Transition
Bypass/Isolation Switches, Continued
Emergency to Off

SCR SCR
RN RE

SCR SCR
REO RNO

Off to Normal

SCR SCR
RN RE

SCR SCR
REO RNO

GM46249

TP-6921 10/14 Section 5 Transfer Switch Testing 89

 Notes

90 Section 5 Transfer Switch Testing TP-6921 10/14

 Section 6 Controller Test and Replacement

6.1 User Interface Panel D Active time delays

The user interface panel is located on the transfer switch D Source voltages
door. Figure 6-1 and Figure 6-2 show the user interface
panels for the Decision-Makerr MPAC 1200/1500 and D Source frequency (Hz)
MPAC 750 controllers.
D Current (amps)

6.1.1 Display D Source setup information

The Decision-Makerr MPAC 750 controller has no D Time and date

display. The four-line display on the Decision-Makerr
MPAC 1200 and MPAC 1500 controllers indicates D Time and date of next scheduled exercise
transfer switch status and setup, including the following:
The display also identifies the pushbutton functions,
D System status which can change from screen-to-screen.

D Faults and warnings

1 2 3 4
5

GM85884

1. Source N Available LED 4. Source E Available LED 6. System Alert LED 8. Pushbuttons (4)
2. Source N Position LED 5. USB port for SiteTecht 7. Not in Auto LED 9. Display
3. Source E Position LED connection

Figure 6-1 User Interface Panel, MPAC 1200/1500 Controller

TP-6921 10/14 Section 6 Controller Test and Replacement 91

 1 2 3 4
5

GM85888

9 8

1. Source N Available LED 4. Source E Available LED 6. System Alert LED 8. Exercise button
2. Source N Position LED 5. USB port location 7. Not in Auto LED 9. Test button
3. Source E Position LED

Figure 6-2 User Interface, MPAC 750 Controller

6.1.2 LED Indicators

LEDs on the user interface indicate contactor position,
source availability, faults, and other conditions.
Figure 6-3 describes the functions of the LED
indicators. See Section 4.9 for more information about
warnings and faults.

LED Indicator Condition

Source N Available, Source N is available.
Green
Source E Available, Source E is available.
Red
Position A, Green Contactor is in Normal position.
Position B, Red Contactor is in Emergency
position.
System Alert, Red Fault. Identify and correct the
cause of the fault condition, then
reset faults at the controller. See
Section 4.9.
Input active: Low Battery
Voltage or Remote Common
Alarm.
Not in Auto, Red ATS is not set for automatic
operation or a load shed (forced
transfer to OFF) sequence is
active.
Flashes for manual transfer
waiting.
Input active: Inhibit Transfer or
Forced Transfer to OFF.
Figure 6-3 User Interface LED Indicators

92 Section 6 Controller Test and Replacement TP-6921 10/14

6.1.3 Pushbuttons
B Down arrow (closed). Step down to the next
The MPAC 750 controller has Test and Exercise screen or scroll through a list.
pushbuttons. See the controller operation manual for
instructions. Y Up arrow (closed). Step back to the previous
screen.
The MPAC 1200 and MPAC 1500 controller user
interface panels have four pushbuttons below the " Right arrow (closed). Move to the next
submenu.
display. Pushbutton functions are shown above each
button in the last line of the display and can change from Up arrow (open). Increases the selected
screen-to-screen. numerical value.

The pushbutton functions are defined in Figure 6-5. Down arrow (open). Decreases the selected
See the controller operation manual for instructions to numerical value.
use the pushbuttons to navigate the controller menus Right arrow (open). Steps to the next digit in a
and change settings. selected numerical value.

6.1.4 Lamp Test Back Steps back to the previous screen or submenu.

The lamp test can be preformed on MPAC 1200 and End Ends the current time delay.
MPAC 1500 controllers. To test the LEDs on the Delay
controller’s user interface, go to the Main screen. Press
the down arrow button once, then press the Lamp Test End Ends an active test sequence. See
button and verify that all 6 LEDs on the user interface Test Section 1.2.3.
illuminate. See Figure 6-4.
OK Enters the displayed numerical value
System Ready
(password or setting).
LD Exer 12/14 @ 16:00
Press the down arrow Main Returns to the main screen.
Norm 480V Emer 480V
button.
B View Set Test Next Steps to the next parameter in an item with
multiple settings (for example, in Exerciser
Norm AB BC AC Setup).
##Hz ###V ###V ###V Press and hold the
Lamp Lamp Test button. Reset Reset the fault condition shown on the display,
B Y Test Main or reset an accessory module after connection.
Save Saves settings shown on the display.
Figure 6-4 Lamp Test
Set From the main screen, moves to the first
setup screen.

Start From the Test screen, starts the test sequence.

Test From the main screen, moves to the test

sequence screens.

View From the main screen, moves to the first

view screen.
Figure 6-5 MPAC 1200/1500 Pushbutton
Functions

TP-6921 10/14 Section 6 Controller Test and Replacement 93

6.2 Controller Connections

3 4
2 5
1

6
8 GM85884

1. Standard input/output connection 5. Access openings to optional RJ-45 connector

2. RS-485 connection TB2 6. Latch
3. Connection for optional current sensing kit 7. Ground wire
4. Optional I/O module connection P16 8. Contactor harness connection

Figure 6-6 Controller

94 Section 6 Controller Test and Replacement TP-6921 10/14

6.3 Controller Power The switch has two positions, auto (I) and disconnect
(0). Move the controller disconnect switch to the 0
position to disconnect power to the ATS controller. After
6.3.1 Controller Disconnect Switch maintenance or service, move the switch to the I position
to reconnect power. Follow the instructions in the
WARNING generator set documentation to re--enable the
generator set.

The controller disconnect switch is not available for

service entrance models, which are equipped with a
control circuit isolation switch as standard equipment.
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.

Disabling the generator set. Accidental starting can

cause severe injury or death. Before working on the
generator set or equipment connected to the set, disable the
generator set as follows: (1) Press the generator set off/reset
button to shut down the generator set. (2) Disconnect the
power to the battery charger, if equipped. (3) Remove the
battery cables, negative (--) lead first. Reconnect the negative
(--) lead last when reconnecting the battery. Follow these
precautions to prevent the starting of the generator set by the
remote start/stop switch.
(Decision-Makerr 3+ and 550 Generator Controllers)

Disabling the generator set. Accidental starting can #

cause severe injury or death. Before working on the

generator set or equipment connected to the set, disable the
generator set as follows: (1) Press the generator set off/reset I = Connect
button to shut down the generator set. (2) Disconnect the
power to the battery charger, if equipped. (3) Remove the 0 = Disconnect
battery cables, negative (--) lead first. Reconnect the negative
(--) lead last when reconnecting the battery. Follow these Figure 6-7 Controller Disconnect Switch
precautions to prevent the starting of the generator set by the
remote start/stop switch.
(RDC, DC, RDC2, DC2, Decision-Makerr 3000, 3500 and
6000 Controllers)

The controller disconnect switch allows disconnection

of the power to the controller during maintenance and
service. See Figure 6-7.

Note: Disable the generator set before using the

controller disconnect switch to disconnect power
to the ATS controls.

Disconnecting power to the controls will cause the ATS

to send an engine start signal to the generator set.
Prevent the generator set from starting by pressing the
OFF button on the generator set controller and
disconnecting the battery charger and battery. Refer to
the generator set operation manual for specific
instructions.

TP-6921 10/14 Section 6 Controller Test and Replacement 95

6.3.2 Controller Power Supply D Verify that the transfer switch wiring harness is
connected to the controller. See Figure 6-9.
DANGER
D If the transfer switch is equipped with a controller
disconnect switch. verify that the switch is in the
Connect position. See Section 6.3.1.

D If the transfer switch is equipped with an External

Hazardous voltage. Battery Supply Module (EBSM), disconnect the I/O
Will cause severe injury or death. module assembly at connector P16 on the controller
Only authorized personnel should to remove the external battery supply. Then check
open the enclosure. LED1 with the Normal or Emergency source
available.
Servicing the transfer switch. Hazardous voltage can
cause severe injury or death. Deenergize all power sources D If LED1 does not light when the Normal or Emergency
before servicing. Turn off the main circuit breakers of all source is available, check for line voltage to the
transfer switch power sources and disable all generator sets controller using the following procedure.
as follows: (1) Move all generator set master controller
switches to the OFF position. (2) Disconnect power to all
Check for Line Voltage to the Controller
battery chargers. (3) Disconnect all battery cables, negative
(--) leads first. Reconnect negative (--) leads last when 1. Disconnect power to the transfer switch by opening
reconnecting the battery cables after servicing. Follow these
circuit breakers or switches.
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
2. Disconnect the transfer switch wiring harness from
components inside the enclosure: (1) Remove all jewelry. (2) the controller at the 24-pin connector. See
Stand on a dry, approved electrically insulated mat. (3) Test Figure 6-9.
circuits with a voltmeter to verify that they are deenergized.
3. Reapply power to the transfer switch.
(Decision-Makerr 3+ and 550 Generator Controllers)

Servicing the transfer switch. Hazardous voltage can 4. Check for voltage across the wiring harness pins.
cause severe injury or death. Deenergize all power sources Observe all Safety Precautions when checking the
before servicing. Turn off the main circuit breakers of all voltage.
transfer switch power sources and disable all generator sets
as follows: (1) Press the generator set off/reset button to shut Models KSS and KSP:
down the generator set. (2) Disconnect power to all battery
chargers. (3) Disconnect all battery cables, negative (--) leads a. If Source N is available, check for line voltage
first. Reconnect negative (--) leads last when reconnecting the across pins 4 and 12 of the transfer switch
battery cables after servicing. Follow these precautions to
prevent the starting of generator sets by an automatic transfer
wiring harness connector.
switch, remote start/stop switch, or engine start command
from a remote computer. Before servicing any components b. If Source E is powering the transfer switch,
inside the enclosure: (1) Remove all jewelry. (2) Stand on a check for line voltage across pins 6 and 7 of the
dry, approved electrically insulated mat. (3) Test circuits with a connector.
voltmeter to verify that they are deenergized.
(RDC, DC, RDC2, DC2, Decision-Makerr 3000, 3500 and Models KGS and KGP:
6000 Generator Controllers)
c. If Source N is available, check for line voltage
The controller circuitry converts AC line voltage to DC across pins 1 and 3 of the transfer switch wiring
voltage. Line voltage or DC voltage from an external harness connector P1.
battery connected through an External Battery Supply
d. If Source E is powering the transfer switch,
Module (EBSM) will cause LED1 on the controller’s
check for line voltage across pins 6 and 8 of
power board to light. See Figure 6-8 for the LED connector P1.
location.
If there is no power to the pins checked in step 4, check
D If the Normal or Emergency source is available but the wiring harness continuity. Replace the harness if
the controller display is dark, check LED1 on the necessary.
controller power board. LED1 lights when voltage is
available for the controller. See Figure 6-8.

96 Section 6 Controller Test and Replacement TP-6921 10/14

If there is power to the pins checked in step 4 but LED1
on the power board does not light when power is
connected, replace the controller.

Note: Model KGS/KGP transfer switches use a different

controller than other models with MPAC 1500
controls. Refer to Parts Catalog TP-6433 for the
correct part numbers.

1 30887

1. Transfer switch harness connection to controls,

controller connector P1

Figure 6-9 Transfer Switch Harness Connection to

Control Board, Typical

Note: K1 and K2 relays are not

used on controllers for Model
KG transfer switches.
GM86131
1. LED1 Power indicator

Figure 6-8 LED1 Location on MPAC Controller

Circuit Board

TP-6921 10/14 Section 6 Controller Test and Replacement 97

6.4 System Test, MPAC 1200 and 6.4.2 Loaded System Test
1500 Controllers A loaded test actually simulates a preferred source
failure, except that the engine start time delay is
Use the system test feature to:
bypassed. The generator set is signaled to start
D Start and run the generator set, or immediately upon test activation. Load control signals
are issued prior to transfer with their associated time
D Simulate a preferred source failure, resulting in a delays. Since the loaded test transfer will be between
transfer to the standby source. two live sources, the in-phase monitor will be activated if
it is enabled. If the preferred source is lost during a
On MPAC 1200 and 1500 controllers, a password is loaded test with the contactor in the standby position,
required to activate the system test, ensuring that only the test will continue to be active, even on restoration of
authorized personnel can start a test. Pressing the Test preferred. If the standby source is lost and the preferred
pushbutton signals the controller to initiate the system source is available, the test will be terminated, and the
test sequence. transfer switch will immediately transfer to the preferred
source position, bypassing all time delays except the
An Auto-Loaded test executes for a set length of time
off-position requirements in a programmed-transition
and then ends automatically. Press the End Test
system.
pushbutton to end a Loaded or Unloaded test. Time
delays will execute as programmed after the end test When a loaded test is terminated normally, the
button is pressed. Pressing the End Delay button will retransfer sequence will be as though the preferred
end the currently displayed time delay. source has been restored after a failure. All time delays
will be executed and an in-phase transfer will occur if
To check the source voltage and frequency while a test
enabled. The loaded test feature will be available with
is running, press the Main button. Press the Test button
the Util-Genset, Util-Util and Genset-Genset modes of
to return to the test sequence screens.
operation.
During a system test, if the emergency source becomes
unavailable based on its preset operating parameters, 6.4.3 Auto-Loaded System Test
the fail to acquire standby signal is indicated
immediately, and the test is terminated. If the contactor The auto-loaded test feature is a timed loaded test. The
is in the standby position, it transfers immediately to the auto-loaded time delay determines how long after the
preferred position. transfer to standby to terminate the test and transfer
back to the preferred source. The time is defaulted to
30 minutes and can be adjusted from 1 minute to
6.4.1 Unloaded System Test 60 minutes.
When an unloaded test is initiated, the controller
immediately signals the generator to start, without 6.4.4 Test Procedure
waiting for time delay engine start to timeout. The
Use the following procedure to run a test to check the
contactor does not change position during an unloaded
test, but if the normal source should fail, the contactor transfer switch operation. Watch the LEDs on the
will transfer to the emergency source. The unloaded test controller’s user interface as the time delays run and
feature will be available only with the Util-Genset and Source E becomes available when the generator set
Genset-Genset modes of operation. starts. For a loaded test, watch the position LEDs to
verify that the ATS transfers the load.
The test sequence simulates a loss of the normal
source, starts the generator set, and transfers the load
to the emergency source (loaded test), executing all
time delays that are set up to operate during a loss of the
normal source. When the test is ended in step 8 of the
procedure, the transfer switch transfers the load back to
the normal source and removes the engine start signal,
executing all programmed time delays.
Refer to Section 1 for the test sequence of operation
without and with load.

98 Section 6 Controller Test and Replacement TP-6921 10/14

Note: If the standby source fails during a test, the ATS 6. Verify that the generator set starts and the Source
will immediately attempt to transfer to the E Available LED lights.
preferred source.
7. Verify that the switch transfers the load to Source E.
Check the preferred source selection. The test
procedure assumes that Source N is the preferred a. Open-Transition Models: After the
source. preferred-to-standby time delay, verify that the
Position N LED goes out and the Position E
If the transfer switch is equipped with a supervised LED lights, indicating that the switch has
transfer switch, verify that it is set to the Auto position. transferred the load to Source E.
Note: Close and lock the enclosure door before starting b. Programmed-Transition Models: After the
the test procedure. preferred-to-off time delay, verify that the
Position N LED goes out. After the
DANGER off-to-standby time delay, check that the
Position E LED lights, indicating that the switch
has transferred the load to Source E.

8. Press the End Test button.

Hazardous voltage. 9. Verify that the switch transfers the load back to
Will cause severe injury or death.
Source N.
Only authorized personnel should
open the enclosure. a. Open-Transition Models: After the
standby-to-preferred time delay, verify that the
Position E LED goes out and the Position N
Automatic Operation Test Procedure LED lights, indicating that the switch has
transferred the load to Source N.
1. Check the controller LED indicators to verify that
the Position N and Source N Available indicators b. Programmed-Transition Models: After the
are lit. standby-to-off time delay, verify that the
Position E LED goes out. After the
2. Verify that the generator set master switch is in the
off-to-preferred time delay, check that the
AUTO position.
Position N LED lights, indicating that the switch
3. Refer to Figure 6-10. From the main screen, press has transferred the load to Source N.
the Test button. Enter the test password when
Note: The generator set may have an engine
prompted and press OK.
cooldown time delay that causes the
4. Press the down arrow button to display Type of Test generator set engine to run after the transfer
Loaded. switch engine start signal is removed.

5. Press the Start button.

TP-6921 10/14 Section 6 Controller Test and Replacement 99

 Test Sequence Screens
System OK
LD Exer ##/## @ ##:## Engine Start in ##:##
Norm ###V Emer ###V Norm ###V Emer ###V
B View Set Test
End End
Main Delay Test
Press the Test button.
LD# Disc in ##:##
Norm ###V Emer ###V
Enter Password
Time to Enter #:## End End
>????< Main Delay Test

OK Xfr to Off in ##:##

Norm ###V Emer ###V
Use the open arrow buttons to enter the Test password.
End End
Then press the OK button. Main Delay Test
Type of Test Auto Loaded Test Xfr to Emer in ##:##
Auto Loaded Enter Time Norm ###V Emer ###V
Time :## min Time: ?? min
End End
B Main " Start Back OK Main Delay Test

For an auto loaded test, press the right arrow button Add LD# in ##:##
and enter the desired length of the test run. Press Norm ###V Emer ###V
OK and then press Start to initiate the test sequence. End End
OR: Main Delay Test
Press the down arrow button to step to
the next type of test. System on Test
Norm ###V Emer ###V
Type of Test End End
Loaded Main Delay Test

LD# Disc in ##:##

B Main Start Norm ###V Emer ###V

Press the Start button to initiate the End End

Main Delay Test
displayed type of test sequence.
Type of Test Xfr to Off in ##:##
Unloaded Norm ###V Emer ###V
End End
B Main Start Main Delay Test

Xfr to Norm in ##:##

Norm ###V Emer ###V
The displays shown to the right will appear during the test
sequence. Some displays are dependent on the system settings End End
and may not appear. Main Delay Test

During a test sequence, press the End Delay button to end the Add LD# in ##:##
current time delay, if desired. Press Main to step to the main Norm ###V Emer ###V
screen, then Test to return to the test sequence screens.
End End
Main Delay Test
Press the End Test button during the test run to end the test and
return to normal operation. An Auto-Load test will end Eng Cooldown ##:##
automatically after the set time . Norm ###V Emer ###V

End End
Main Delay Test

Figure 6-10 Test Sequence Screens, MPAC 1200/1500 controllers

100 Section 6 Controller Test and Replacement TP-6921 10/14

6.5 Test, MPAC 750 Controller Note: End the test as described below. The test will not
end automatically unless the source is lost.
Use the Test button to:
Press and hold the Test pushbutton for about 2 seconds
D Start and run the generator set (unloaded test). to end the test. The retransfer sequence operates as
though Source N has been restored after a failure. The
D Simulate a Source N failure, resulting in a transfer to load is transferred back to source N. All time delays are
Source E (loaded test). executed and an in-phase transfer will occur if enabled.
The Source E LEDs light during the time delays. The
If the emergency source is lost during a system test, the generator set shuts down.
test is terminated. If the contactor is in the standby
position, it transfers immediately to the preferred If Source E is lost during the test and Source N is
position. available, the transfer switch will immediately transfer to
the Source N position, bypassing all time delays. If
Refer to Section 1 for the test sequence of operation
source N is lost during a loaded test with the contactor in
without and with load. the standby position, the test will continue to run.

6.5.1 Unloaded System Test 6.5.3 Automatic Operation Test, MPAC

Press and hold the Test button for 3--5 seconds to start 750 Controller
an unloaded test. The generator set will start without
Check the transfer switch’s automatic control system
waiting for the engine start time delay. The load is not
immediately after the voltage check. Review the
transferred to the generator set. The generator runs
operation instructions in the controller operation manual
until the test is ended.
before proceeding.
During an unloaded test, the Source E available LED Note: Close and lock the enclosure door before starting
flashes, 1 second on and 1 second off. the test procedure.
Note: End the test as described below. The test will not Follow the procedure below to start a loaded test. Verify
end automatically unless the source is lost. that the ATS starts the generator set and transfers the
load to the emergency source, executing all time delays
Press and hold the Test pushbutton for about 2 seconds that are set up to operate during a loss of the normal
to end the test. Time delays will execute as programmed source. End the test and verify that the transfer switch
when the test is ended. The Source E available LED transfers the load back to the normal source and
lights during the time delays. The generator set shuts removes the engine start signal, executing all
down. appropriate programmed time delays. Refer to Section
1.2.3 for a more detailed description of the test
If the normal source fails during the test, the contactor
sequence of operation.
transfers to the emergency source. The ATS then
monitors the sources and operates automatically when Note: If the standby source fails during a loaded test,
the normal source returns. the ATS will immediately attempt to transfer to the
preferred source.
6.5.2 Loaded System Test
Automatic Operation Test Procedure
A loaded test simulates a failure of source N. Press and
hold the Test button for 6 seconds or longer to start a 1. Check the controller LED indicators to verify that
loaded test. The generator set will start without waiting the Source N Position and Source N Available
for the engine start time delay. The ATS then transfers indicators are lit.
the load to the generator set.
2. Verify that the generator set master switch is in the
Since the loaded test transfer will be between two live AUTO position.
sources, the in-phase monitor feature will be activated if
it is enabled. 3. Press and hold the Test button for 6 seconds or
longer to start a loaded test.
During a loaded test, the Source E available and Source
E position LEDs flash, 1 second on and 1 second off. 4. Verify that the generator set starts and the Source
E Available LED lights.

5. Verify that the switch transfers the load to Source E.

Observe the controller LEDs and display as the

TP-6921 10/14 Section 6 Controller Test and Replacement 101

 time delays execute and the load is transferred. 6.6 Exercise
After the preferred-to-standby transfer time delay, Schedule exercise runs through the Set Exercise
verify that the Source N Position LED turns off and screen or use the exercise button on the MPAC 750
the Source E Position LED lights, indicating that the controller. See the transfer switch Operation and
switch has transferred the load to Source E. Installation Manual for instructions. To run the generator
set at a time other than a scheduled exercise sequence,
6. Press and hold the Test pushbutton for about 2 use the Test function. See Section 6.4 for instructions.
seconds to end the test.
When a scheduled exercise is running, the screens
7. Verify that the switch transfers the load back to
shown in Figure 6-11 appear on the MPAC 1200 or 1500
Source N. After the standby-to-preferred time
display. Press Main to return to the main screen, if
delay, verify that the Source E Position LED goes
desired. Press the End button to end the exercise
out and the Source N Position LED lights,
sequence before the scheduled stop time, if necessary.
indicating that the switch has transferred the load to
Source N. Refer to Section 1 for the exercise sequence of
operation without and with load.
8. After the engine cooldown time delay expires, the
engine start signal is removed. Verify that the
generator set stops. Exerciser Active
Screen during
Time Remaining 00:29
exercise run.
Note: The generator set may have an engine cooldown Norm ###V Emer ###V
time delay that causes the generator set engine Main End
to run after the transfer switch engine start signal
is removed.

Exerciser Active
Display if generator
Fail to Acquire 00:59
set does not start
Norm ###V Emer ###V
immediately on
Main End exercise signal.

Figure 6-11 Exercise Sequence Screens, MPAC

1200/1500 Controllers

102 Section 6 Controller Test and Replacement TP-6921 10/14

6.7 Engine Start Testing live electrical circuits. Hazardous voltage or
current can cause severe injury or death. Have trained and
The engine start contacts close when the Normal source qualified personnel take diagnostic measurements of live
circuits. Use adequately rated test equipment with electrically
is lost and when the ATS controller starts a test or
insulated probes and follow the instructions of the test
exercise sequence. The engine start contacts are equipment manufacturer when performing voltage tests.
labeled with a decal. Check the Operation /Installation Observe the following precautions when performing voltage
Manual or the dimension drawing for the contact tests: (1) Remove all jewelry. (2) Stand on a dry, approved
location, if necessary. electrically insulated mat. (3) Do not touch the enclosure or
components inside the enclosure. (4) Be prepared for the
Use the following procedure to check for continuity system to operate automatically.
(600 volts and under)
across the engine start contacts when the Normal
source is disconnected and during a test sequence.
Allow time for the engine start and engine cooldown time Engine Start Test Procedure
delays during the test. Refer to the sequence of Start with the transfer switch in the Source N position.
operation in Sections 1 and 6.4 for the applicable time
delays. 1. Connect an ohmmeter or test lamp across the
engine start contacts at one of the following
Be sure to read and follow the safety precautions when locations:
performing the test procedure.
a. Models KSS/KSP: Pins 8 and 9 of connector
P1. See Figure 6-12.
WARNING
b. Models KGS/KGP: Pins 5 and 10 of connector
P1. See Figure 6-13.

c. The engine start contacts on the transfer switch

contactor or field-connection terminal block.
Accidental starting. See the decal on the transfer switch or the
Can cause severe injury or death.
transfer switch Operation and Installation
Disconnect the battery cables before Manual for the engine start contact location.
working on the generator set.
Remove the negative (--) lead first d. The generator set engine start leads. See the
when disconnecting the battery. generator set documentation for engine start
Reconnect the negative (--) lead last lead identification and location.
when reconnecting the battery.
2. Disconnect Normal power from the transfer switch
Disabling the generator set. Accidental starting can and verify that the engine start contacts close.
cause severe injury or death. Before working on the
generator set or connected equipment, disable the generator 3. Reconnect Normal power to the transfer switch
set as follows: (1) Move the generator set master switch to the and verify that the engine start contacts open after
OFF position. (2) Disconnect the power to the battery charger. applicable time delays.
(3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the 4. If the engine start contacts do not operate as
battery. Follow these precautions to prevent starting of the indicated in steps 2 and 3 when power is
generator set by an automatic transfer switch, remote
disconnected and reconnected, replace the ATS
start/stop switch, or engine start command from a remote
computer. controller. See Section 6.13.

5. Press the Test button to initiate a test sequence and

DANGER verify that the engine start contacts close.

6. Press the End button to end the test. Verify that the
engine start contacts open after the engine
cooldown time delay (which may be set to zero).
Hazardous voltage.
Will cause severe injury or death. 7. If the ATS engine start contacts do not close during
the Test Procedure, replace the ATS controller.
Only authorized personnel should See Section 6.13.
open the enclosure.

TP-6921 10/14 Section 6 Controller Test and Replacement 103

If the generator set engine does not start, check the
engine start connections to the generator set. Verify that
the generator set master switch is in the AUTO position.
Troubleshoot the generator set if the engine start
connections are good but the engine does not start.

GM89702

1. Engine start contacts

Figure 6-13 Connector P1 Engine Start

Connections, Models KGS/KGP

1
1. Engine start connections GM89643

Figure 6-12 Connector P1 Engine Start Connections,

Models KSS/KSP

104 Section 6 Controller Test and Replacement TP-6921 10/14

6.8 Controller DIP Switches SW1-2, Maintenance. The maintenance DIP switch
inhibits transfer. Use it to prevent transfers while
servicing the ATS. When this switch is in the closed
DANGER
position, sensing, timing, engine start and contactor
functions are disabled. A preferred source failure will be
ignored. The Not in Auto LED flashes red and the
message Maintenance Mode is indicated on the LCD
screen. In addition, a programmable digital output is
Hazardous voltage. turned on and an entry in the event log indicates that the
Will cause severe injury or death. maintenance mode has been activated. System
Disconnect all power sources before monitoring and setup are allowed while in maintenance
opening the enclosure. mode.

Switch SW1-2 should be closed only during

DANGER maintenance or service. It must be open during
normal operation.

Close and lock the enclosure door before energizing the

transfer switch.
Hazardous voltage.
Will cause severe injury or death.
Only authorized personnel should
open the enclosure.

Two DIP switches on the controller’s circuit board are

assigned functions. Switch 3 is for factory use only.
Switch 4 is not used. The DIP switches are located on
the controller’s circuit board on the inside of the
enclosure door. Figure 6-14 shows the locations of the
switches on the controller circuit board.

SW1-1, Password Disable. Closing the password

1
disable DIP switch SW1-1 disables the setup password
and resets it to the factory defaults. When the switch is
closed, system setup and programming is allowed
without the need to enter a password.

Note: Disable the setup password only during service

unless the transfer switch is installed in a secure
location.

Closing and then reopening DIP switch SW1-1 resets

the password to the default value, 0000. GM46733

1. DIP switches SW1

The test password is not affected by this DIP switch.
Use the Reset Data screen to disable the test password.
Figure 6-14 DIP Switch Location (cover removed)

TP-6921 10/14 Section 6 Controller Test and Replacement 105

6.9 Calibration A personal computer and Kohler SiteTech software are
required for calibration of the MPAC 750 controller.
DANGER SiteTech can be used to calibrate the MPAC 1200 and
1500 controllers, if desired. See Figure 6-16 for a
sample SiteTech calibration screen.

Calibration
Hazardous voltage. 1. Measure the source voltages as instructed in
Will cause severe injury or death.
Section 4.4.3. Be sure to review and follow the
Only authorized personnel should safety precautions when measuring the source
open the enclosure. voltages. Record the measured values.

Testing live electrical circuits. Hazardous voltage or 2. Use the Setup Screen--Calibration or SiteTech
current can cause severe injury or death. Have trained and software to enter the measured values. See
qualified personnel take diagnostic measurements of live Figure 6-15.
circuits. Use adequately rated test equipment with electrically
insulated probes and follow the instructions of the test
equipment manufacturer when performing voltage tests. Entering new calibration using SiteTech
Observe the following precautions when performing voltage
tests: (1) Remove all jewelry. (2) Stand on a dry, approved
1. Connect the computer to the MPAC controller and
electrically insulated mat. (3) Do not touch the enclosure or start the SiteTech program.
components inside the enclosure. (4) Be prepared for the
system to operate automatically. 2. Click on Parameters in the dark blue navigation
(600 volts and under) panel. Scroll down to find MPAC Source 1
Calibration or MPAC Source 2 Calibration as
The transfer switch controls are calibrated at the factory applicable for the source being calibrated. Click on
and should not require recalibration in the field. If the down arrow to open the calibration menu.
recalibration is necessary, follow the instructions in this
section. 3. Enter the measured voltage into the corresponding
line under MPAC Source 1 Calibration or MPAC
The current sensing accessory is required in order for Source 2 Calibration.
the transfer switch to measure and display the current
values. Use a clamp-on current sensing meter to 4. Click on Apply Changes near the top of the screen
measure the current and enter the measured values to save the new calibration settings.
through the Setup Screen--Calibration shown below or
through the calibration screens in SiteTech.

Calibrate Calibrate L1 - L0 VAC ###

Calibration L - N Voltages L1 - L0 Voltage Cal VAC ? ? ?
Source N(E)
B Y " Main B Y " Back B Y " Back Back Save

Calibrate Calibrate L1 - L2 VAC ###

L - L Voltages L1 - L2 Voltage Cal VAC ? ? ?
Source N(E)
B Y " Back B Y " Back Back Save

Calibrate Calibrate LA Amps ####

Load Current LA Current Cal Amps ? ? ? ?

B Y " Back B Y " Back Back Save

Figure 6-15 Calibration Screens, MPAC 1200/1500 Controls

106 Section 6 Controller Test and Replacement TP-6921 10/14

 4

1. Click on Parameters.
2. MPAC Source 1 Calibration (go to MPAC Source 2 Calibration if applicable). Click on arrow to open the menu.
3. Enter new values.
4. Click Apply Changes to save new settings.

Figure 6-16 Calibration Using SiteTech

TP-6921 10/14 Section 6 Controller Test and Replacement 107

6.10 Position Microswitch Test 6.11 Programmed-Transition
Interface Board
DANGER
Programmed-transition transfer switch models KSP and
KGP are equipped with the programmed-transition
interface board (PTIB). See Figure 6-17. The PTIB
contains two replaceable 10-amp relays. Refer to the
Hazardous voltage. operation sequence diagrams in Section 5.4.2 and to
Will cause severe injury or death. the schematic diagram provided with the transfer switch
to troubleshoot the relays.
Disconnect all power sources before
opening the enclosure.

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 1
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.
(Decision-Makerr 3+ and 550 Generator Controllers)

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.
(RDC, DC, RDC2, DC2, Decision-Makerr 3000, 3500 and
6000 Generator Controllers)
1. Programmed-Transition Interface Board (PTIB) GM85884

Test Procedure Note: The controller’s main circuit board and user
interface are not replaceable.
Disconnect power to the transfer switch and use an
ohmmeter or test lamp to check the operation of the Figure 6-17 Programmed-Transition Interface
position microswitches. Manually operate the switch Board
and check for continuity across pins 10 and 13 of the
connector P1 for Source E and pins 10 and 14 for
Source N.

108 Section 6 Controller Test and Replacement TP-6921 10/14

6.12 Controller Application After loading new code, run a loaded test to verify that
the system operates correctly. See Section 6.4, System
Program Test.
The manufacturer occasionally releases new versions
of the controller application code. The new code can be 1
downloaded from TechTools and loaded onto the
controller using Kohler SiteTech software.

Program Loader software is not used for loading code

onto the Decision-Makerr MPAC controllers.

To download the latest version of the controller

application code:

1. On your computer, go to Kohler TechTools.

2. Click on Software and then ATS Controllers.

3. Click on the ATS controller and then click on the link

to download the latest software version. The file
name will be of the form MpacDmAppV###.zip, 1. Update Firmware
where V### indicates the version number.
Figure 6-18 SiteTech Update Firmware Command
Note: All three Decision-Makerr MPAC controllers
use the same application code file.

4. Save the file onto your laptop computer.

5. Connect the computer to the ATS controller using a

USB cable. See Figure 3-1 and Section 3 if
necessary. Start Kohler SiteTech software.

6. Select UpdateFirmware near the top of the screen.

See Figure 6-18. 1

7. In the Update Firmware dialog box, click on Browse

and navigate to the location of the firmware file on
your computer. Click on the firmware zip file and
click Open.

Note: Select the entire zip file. Do not attempt to

load individual files contained within the zip
file.

8. Click on the Update Firmware button in the dialog

box to start loading the new firmware onto the
controller.

9. SiteTech will indicate that the firmware was 2

successfully updated. Close the program and
disconnect the computer from the controller. 1. Click and find the firmware file stored on your computer.
2. Click to start loading the new firmware onto the controller.
See the SiteTech Operation Manual, TP-6701, for more
information, if necessary. Figure 6-19 Firmware Update Dialog Boxes

Loading new code does not change the system settings.

After loading a new version of code, check the system
settings, input/output assignments, time delays, and
other parameters to verify that they are correct for the
application.

TP-6921 10/14 Section 6 Controller Test and Replacement 109

6.13 Controller Replacement 6.13.2 Circuit Board and Electronic
Component Handling
Always check for open switches or circuit breakers,
loose connections, or faulty wiring before replacing any Improper removal, installation, transportation, storage,
parts. Replace the controller only if the troubleshooting or service can damage sensitive electronic
and test procedures in this manual indicate conclusively components. Observe the following guidelines to
that the controller is damaged or inoperative. prevent damage when working with circuit boards or
electronic components.
Relays on the controller circuit board can be replaced if
necessary. NOTICE
Electrostatic discharge damage. Electrostatic discharge
The user interface and the controller circuit board (ESD) damages electronic circuit boards. Prevent
cannot be replaced separately. If necessary, replace the electrostatic discharge damage by wearing an approved
entire controller and plastic housing assembly. Save the grounding wrist strap when handling electronic circuit boards
old controller’s plastic cover, which includes the transfer or integrated circuits. An approved grounding wrist strap
provides a high resistance (about 1 megohm), not a direct
switch nameplate, for use with the new controller. short, to ground.

6.13.1 Controller Configuration Circuit Board and Electronic Component Handling

(Settings) D Keep circuit boards or electronic components inside
New controllers are shipped with the factory default the antistatic, cushioned factory packaging until
settings for the system settings, including voltage, installation.
frequency, number of phases, phase rotation, and other
D Store circuit boards or electronic components in a
user-adjustable settings. After installation, the system clean environment away from moisture, vibration,
parameters must be set for the application. static electricity, corrosive chemicals, and solvents.
If the old controller is operable, it may be possible to D Disconnect all power sources before removing or
save the controller settings to a file before removing the installing circuit boards or electronic components.
controller from the transfer switch. The settings file
contains the system parameter settings, including D Wear an approved, grounded, antistatic wrist strap
system setup, source setup, time delays, input and when handling circuit boards or electronic
output assignments, and communications settings. The components.
configuration file can be loaded onto the new controller
using SiteTech. D Carefully hold the circuit board by its edges and not by
any of its components or electrical contacts.
Note: Operation problems can be caused by incorrect
controller settings. Do not load the old D Do not drop the circuit board or electronic
configuration file onto the new controller unless components.
you are certain that all the settings in the file are
D Do not bend the circuit board, electronic components,
correct.
or electronic component leads.
If the configuration settings file is not available, use the
D Do not strike the circuit board or electronic
controller user interface or a computer with Kohler
components using or against a hard object.
SiteTech software to check and adjust the system
settings for the application. Refer to the Transfer Switch D Clean dusty or dirty circuit boards with a vacuum
Operation and Installation Manual for instructions. cleaner or soft, dry brush.

D Never attempt circuit board repairs, adjustments, or

modifications other than replacing plug-in service
parts or performing manufacturer-approved
installation or service procedures.

110 Section 6 Controller Test and Replacement TP-6921 10/14

6.13.3 Replacement Procedure Servicing the transfer switch. Hazardous voltage can
cause severe injury or death. Deenergize all power sources
Before removing the old controller, refer to Section before servicing. Turn off the main circuit breakers of all
6.13.1. It may be possible to download the system transfer switch power sources and disable all generator sets
as follows: (1) Press the generator set off/reset button to shut
settings from the controller to a file that can later be
down the generator set. (2) Disconnect power to all battery
loaded onto the new controller for more efficient system chargers. (3) Disconnect all battery cables, negative (--) leads
setup. first. Reconnect negative (--) leads last when reconnecting the
battery cables after servicing. Follow these precautions to
Disconnect power to the transfer switch before starting prevent the starting of generator sets by an automatic transfer
to disconnect the controller. Observe the following switch, remote start/stop switch, or engine start command
safety precautions to avoid injury or equipment damage. 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
Note: Model KGS/KGP transfer switches use a different
voltmeter to verify that they are deenergized.
controller part number than other models with
MPAC 1500 controls. Refer to Parts Catalog (RDC, DC, RDC2, DC2, Decision-Makerr 3000, 3500 and
TP-6433 for the correct part numbers. 6000 Controllers)

DANGER

Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.

DANGER

Hazardous voltage.
Will cause severe injury or death.
Only authorized personnel should
open the enclosure.

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

TP-6921 10/14 Section 6 Controller Test and Replacement 111

Controller Replacement Procedure 10. Remove the plastic cover from the old controller
and save it to install on the new controller
1. Move the generator set master switch to the OFF assembly.
position.
Note: The cover includes the transfer switch
2. Disconnect the generator set engine starting nameplate, which must remain with the
battery, negative (--) lead first. transfer switch.
3. Disconnect power to the transfer switch by opening To remove the cover, depress the latch at the
switches or circuit breakers to the switch. bottom of the cover. Swing the cover open on its
hinges and lift it off.
Remove the old controller.
11. Label and then disconnect any input and output
4. Open the transfer switch enclosure. leads connected to terminal strip TB1 on the
controller. See Figure 6-6.
5. Check the voltage at the source lugs to verify that
the power is off. 12. Label and then disconnect the RS-485
communication cable from terminal strip TB2 on
6. Disconnect the transfer switch harness at the P1
the controller (if connected). See Figure 6-6.
connector at the bottom of the controller. See
Figure 6-6. 13. Disconnect any other communications
connections to the ethernet port or the USB port.
7. Disconnect the programmed-transition board, if
See Figure 6-6 for connector identification.
equipped, from the controller at connector P2.
14. Disconnect the current sensing accessory at
8. Disconnect the controller ground wire at the ring
connector P3, if equipped.
terminal on the enclosure door.

9. Disconnect the accessory module assembly at

connector P16 at the top of the controller, if
connected.

3 4
2 5
1

6
8 GM85884

1. Standard input/output connection 5. Access openings to optional RJ-45 connector

2. RS-485 connection TB2 6. Latch
3. Connection for optional current sensing kit 7. Ground wire
4. Optional I/O module connection P16 8. Contactor harness connection

Figure 6-20 Controller Assembly

112 Section 6 Controller Test and Replacement TP-6921 10/14

15. Support the controller assembly and remove four Note: Power to the controller is required in order to
nuts at the corners. check and adjust the controller settings. If all
the power sources are generator sets,
16. Carefully remove the entire controller assembly, reconnect the normal source generator set
including the user interface panel, which is part of engine starting battery and move the
the assembly. generator set master switch to the AUTO
position.
Install and connect the new controller
Set up the new controller.
17. Replace the entire assembly with a new controller.
Secure the four nuts at the corners and tighten 28. If the settings file for the transfer switch was
them to no more than 6.8 Nm (5 ft. lbs. or 60 in lbs.) downloaded from the old controller, use SiteTech to
torque. load it onto the new controller.
18. Connect the controller ground wire to the terminal 29. If the settings file cannot be loaded using SiteTech,
on the enclosure door. See Figure 6-6. use the controller’s user interface or a computer
and Kohler SiteTech software to check and adjust
19. Connect the programmed-transition board, if the system settings for the application. Check the
equipped, to the controller at connector P2. See system voltage, frequency, number of phases,
Figure 6-6. phase rotation, time delays, and other
user-adjustable settings. Refer to the Transfer
20. Connect the I/O leads to terminal strip TB1, using
Switch Operation and Installation Manual for setup
the labels attached in step 11 to connect the leads
instructions.
to the appropriate terminals. See Figure 6-6.

21. Connect RS-485 communication cable, if used, to A computer and Kohler SiteTech software are
terminal strip TB2, using the labels attached in step required to check and change settings on the
12 to connect the leads to the appropriate MPAC 750 controller. See Section 3 and the
terminals. See Figure 6-6. SiteTech Software Operation Manual for
instructions.
22. Connect the accessory module assembly (if
equipped) at connector P16. Note: Contactor and ATS serial numbers can only be
entered through Modbus using Monitor III or a
23. Reconnect any other items that were disconnected customer-supplied Modbus driver and the
from the controller. See Figure 6-6 for connector distributor-level password.
identification.
30. Reconnect the generator set engine starting
24. Connect the transfer switch harness to the battery, negative (--) lead last.
connector on bottom of the controller.
31. Move the generator set master switch to the AUTO
25. Check the controller’s DIP switch settings and position or press the AUTO button on the generator
adjust them if necessary. See Section 6.8, controller.
Controller DIP Switches.
Test the operation.
26. Close and lock the transfer switch enclosure door.
32. From the main screen, press the down arrow
27. Reconnect power to the transfer switch by closing button and then press the LAMP TEST button to
circuit breakers or switches. verify that all LEDs light.

33. Run a loaded test to check the system operation.

See Section 6.4, System Test.

TP-6921 10/14 Section 6 Controller Test and Replacement 113

 Notes

114 Section 6 Controller Test and Replacement TP-6921 10/14

 Section 7 Component Replacement, 40--600 Amp KSS and
KGS/KGP

7.1 Introduction Connecting the battery and the battery charger.

Hazardous voltage can cause severe injury or death.
This section contains instructions for component Reconnect the battery correctly, positive to positive and
negative to negative, to avoid electrical shock and damage to
replacement on 40--600 Amp Model KSS and Model KG
the battery charger and battery(ies). Have a qualified
transfer switches. See Section 9 for 800--1000 Amp electrician install the battery(ies).
Model KSS component replacement procedures. See
Section 8 for Model KSP programmed-transition
DANGER
switches. See Section 10 for 800--3000 Amp Model
KGS/KGP.

Observe the following safety precautions when

performing any service procedures on the transfer
switch. Hazardous voltage.
Will cause severe injury or death.
Only authorized personnel should
WARNING open the enclosure.

DANGER

Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before
Hazardous voltage.
working on the generator set.
Will cause severe injury or death.
Remove the negative (--) lead first
when disconnecting the battery. Disconnect all power sources before
Reconnect the negative (--) lead last opening the enclosure.
when reconnecting the battery.
Servicing the transfer switch. Hazardous voltage can
Disabling the generator set. Accidental starting can cause severe injury or death. Deenergize all power sources
cause severe injury or death. Before working on the before servicing. Turn off the main circuit breakers of all
generator set or connected equipment, disable the generator transfer switch power sources and disable all generator sets
set as follows: (1) Move the generator set master switch to the as follows: (1) Move all generator set master controller
OFF position. (2) Disconnect the power to the battery charger. switches to the OFF position. (2) Disconnect power to all
(3) Remove the battery cables, negative (--) lead first. battery chargers. (3) Disconnect all battery cables, negative
Reconnect the negative (--) lead last when reconnecting the (--) leads first. Reconnect negative (--) leads last when
battery. Follow these precautions to prevent starting of the reconnecting the battery cables after servicing. Follow these
generator set by an automatic transfer switch, remote precautions to prevent the starting of generator sets by an
start/stop switch, or engine start command from a remote automatic transfer switch, remote start/stop switch, or engine
computer. start command from a remote computer. Before servicing any
components inside the enclosure: (1) Remove all jewelry. (2)
(Decision-Makerr 3+ and 550 Generator Set Controllers)
Stand on a dry, approved electrically insulated mat. (3) Test
circuits with a voltmeter to verify that they are deenergized.
Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on the (Decision-Makerr 3+ and 550 Generator Set Controllers)
generator set or equipment connected to the set, disable the
generator set as follows: (1) Press the generator set off/reset
button to shut down the generator set. (2) Disconnect the
power to the battery charger, if equipped. (3) Remove the
battery cables, negative (--) lead first. Reconnect the negative
(--) lead last when reconnecting the battery. Follow these
precautions to prevent the starting of the generator set by the
remote start/stop switch.
(RDC, DC, RDC2, DC2, Decision-Makerr 3000, 3500 and
6000 Generator Set Controllers)

TP-6921 10/14 Section 7 Component Replacement, 40--600 Amp KSS and KGS/KGP 115
Servicing the transfer switch. Hazardous voltage can Servicing the transfer switch. Hazardous voltage can
cause severe injury or death. Deenergize all power sources cause severe injury or death. Deenergize all power sources
before servicing. Turn off the main circuit breakers of all before servicing. Turn off the main circuit breakers of all
transfer switch power sources and disable all generator sets transfer switch power sources and disable all generator sets
as follows: (1) Press the generator set off/reset button to shut as follows: (1) Move all generator set master controller
down the generator set. (2) Disconnect power to all battery switches to the OFF position. (2) Disconnect power to all
chargers. (3) Disconnect all battery cables, negative (--) leads battery chargers. (3) Disconnect all battery cables, negative
first. Reconnect negative (--) leads last when reconnecting the (--) leads first. Reconnect negative (--) leads last when
battery cables after servicing. Follow these precautions to reconnecting the battery cables after servicing. Follow these
prevent the starting of generator sets by an automatic transfer precautions to prevent the starting of generator sets by an
switch, remote start/stop switch, or engine start command automatic transfer switch, remote start/stop switch, or engine
from a remote computer. Before servicing any components start command from a remote computer. Before servicing any
inside the enclosure: (1) Remove all jewelry. (2) Stand on a components inside the enclosure: (1) Remove all jewelry. (2)
dry, approved electrically insulated mat. (3) Test circuits with a Stand on a dry, approved electrically insulated mat. (3) Test
voltmeter to verify that they are deenergized. circuits with a voltmeter to verify that they are deenergized.
(RDC, DC, RDC2, DC2, Decision-Makerr 3000, 3500 and (Decision-Makerr 3+ and 550 Generator Set Controllers)
6000 Generator Set Controllers)
Servicing the transfer switch. Hazardous voltage can
Testing live electrical circuits. Hazardous voltage or cause severe injury or death. Deenergize all power sources
current can cause severe injury or death. Have trained and before servicing. Turn off the main circuit breakers of all
qualified personnel take diagnostic measurements of live transfer switch power sources and disable all generator sets
circuits. Use adequately rated test equipment with electrically as follows: (1) Press the generator set off/reset button to shut
insulated probes and follow the instructions of the test down the generator set. (2) Disconnect power to all battery
equipment manufacturer when performing voltage tests. chargers. (3) Disconnect all battery cables, negative (--) leads
Observe the following precautions when performing voltage first. Reconnect negative (--) leads last when reconnecting the
tests: (1) Remove all jewelry. (2) Stand on a dry, approved battery cables after servicing. Follow these precautions to
electrically insulated mat. (3) Do not touch the enclosure or prevent the starting of generator sets by an automatic transfer
components inside the enclosure. (4) Be prepared for the switch, remote start/stop switch, or engine start command
system to operate automatically. from a remote computer. Before servicing any components
(600 volts and under) inside the enclosure: (1) Remove all jewelry. (2) Stand on a
dry, approved electrically insulated mat. (3) Test circuits with a
Making line or auxiliary connections. Hazardous voltage voltmeter to verify that they are deenergized.
can cause severe injury or death. To prevent electrical
shock deenergize the normal power source before making any (RDC, DC, RDC2, DC2, Decision-Makerr 3000, 3500 and
line or auxiliary connections. 6000 Generator Set Controllers)

Connecting the battery and the battery charger.

7.2 Microswitch Replacement Hazardous voltage can cause severe injury or death.
Reconnect the battery correctly, positive to positive and
negative to negative, to avoid electrical shock and damage to
Required tools and equipment: the battery charger and battery(ies). Have a qualified
Basic electrician’s hand tools electrician install the battery(ies).
Microswitch
Required protective equipment: Microswitch Replacement Procedure
Rubber insulating gloves class 0 1. Prevent all connected generator sets from starting.
Safety glasses
Electrical hazard safety shoes a. Place the generator set master switch in the
OFF position or press the OFF button on the
generator set controller.
7.2.1 40--260 Amp
b. Disconnect the power to the battery charger, if
DANGER equipped.

c. Disconnect the generator set engine starting

battery(ies), negative (--) lead first.

Note: On systems with multiple transfer

Hazardous voltage.
switches connected to a single
Will cause severe injury or death.
generator set, disconnect all power
Disconnect all power sources before sources to the generator set before
opening the enclosure. proceeding.

116 Section 7 Component Replacement, 40--600 Amp KSS and KGS/KGP TP-6921 10/14
 2. Disconnect power to the transfer switch. 15. Enable the generator set.

3. Open the transfer switch enclosure. a. Check that the generator set master switch is in
the OFF position.
4. Verify zero volts across each phase.
b. Reconnect the generator set engine starting
5. Note the location of the fast-on connectors to the battery, negative (--) lead last.
microswitch terminals. See Figure 7-1.
c. Reconnect power to the battery charger, if
equipped.

Figure 7-1 Microswitches 1. End plate

6. Disconnect the fast-on connectors. Figure 7-2 End Plate (required for assemblies with
four microswitches)
7. Remove the holding screws.
16. Move the generator set master switch to the AUTO
8. Remove the suspect microswitch. position or press the AUTO button on the generator
set controller.
Note: For SN/SE assemblies that have four
microswitches, you must remove the end 17. Test the transfer switch operation by performing
plate to access the microswitches. See the Automatic Operation Test described in
Figure 7-2. Section 6.4.4.
9. Install the new microswitch. Note: Do not leave the transfer switch in the Test
Note: For SN/SE assemblies that have four mode.
microswitches, you must install an end plate
for stability. See Figure 7-2. 7.2.2 400--600 Amp
10. Install the holding screws.
DANGER
11. Tighten the holding screws to 0.3 Nm (3 in. lb.).

12. Connect the fast-on connections to the

microswitch terminals. See Figure 7-1.
Hazardous voltage.
Note: The terminals used were noted in step 5. Will cause severe injury or death.

13. Close the ATS enclosure. Disconnect all power sources before
opening the enclosure.
14. Connect power to the ATS.

TP-6921 10/14 Section 7 Component Replacement, 40--600 Amp KSS and KGS/KGP 117
Servicing the transfer switch. Hazardous voltage can c. Disconnect the generator set engine starting
cause severe injury or death. Deenergize all power sources battery(ies), negative (--) lead first.
before servicing. Turn off the main circuit breakers of all
transfer switch power sources and disable all generator sets Note: On systems with multiple transfer
as follows: (1) Move all generator set master controller switches connected to a single
switches to the OFF position. (2) Disconnect power to all
battery chargers. (3) Disconnect all battery cables, negative
generator set, disconnect all power
(--) leads first. Reconnect negative (--) leads last when sources to the generator set before
reconnecting the battery cables after servicing. Follow these proceeding.
precautions to prevent the starting of generator sets by an
automatic transfer switch, remote start/stop switch, or engine 2. Disconnect power to the transfer switch.
start command from a remote computer. Before servicing any
components inside the enclosure: (1) Remove all jewelry. (2) 3. Open the transfer switch enclosure.
Stand on a dry, approved electrically insulated mat. (3) Test
circuits with a voltmeter to verify that they are deenergized. 4. Verify zero volts across each phase.
(Decision-Makerr 3+ and 550 Generator Set Controllers)
Note: A3/A4 microswitches can still be energized
Servicing the transfer switch. Hazardous voltage can with customer power. The microswitches
cause severe injury or death. Deenergize all power sources may be used for primary alarm circuits or
before servicing. Turn off the main circuit breakers of all primary controlling devices. Verify that all
transfer switch power sources and disable all generator sets power is disconnected before proceeding.
as follows: (1) Press the generator set off/reset button to shut
down the generator set. (2) Disconnect power to all battery 5. Note the location of the fast-on connectors to the
chargers. (3) Disconnect all battery cables, negative (--) leads
microswitch terminals. See Figure 7-3.
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
6. Disconnect the fast-on connectors. See
switch, remote start/stop switch, or engine start command Figure 7-4.
from a remote computer. Before servicing any components
inside the enclosure: (1) Remove all jewelry. (2) Stand on a 7. Remove the microswitch holding screws. See
dry, approved electrically insulated mat. (3) Test circuits with a Figure 7-5.
voltmeter to verify that they are deenergized.
(RDC, DC, RDC2, DC2, Decision-Makerr 3000, 3500 and
6000 Generator Set Controllers)

Connecting the battery and the battery charger.

Hazardous voltage can cause severe injury or death.
Reconnect the battery correctly, positive to positive and
negative to negative, to avoid electrical shock and damage to
the battery charger and battery(ies). Have a qualified
electrician install the battery(ies).

Microswitch Replacement Procedure

1. Prevent all connected generator sets from starting.

a. Place the generator set master switch in the

OFF position or press the OFF button on the #

generator controller.
Figure 7-3 Microswitches
b. Disconnect the power to the battery charger, if
equipped.

118 Section 7 Component Replacement, 40--600 Amp KSS and KGS/KGP TP-6921 10/14
 8. Remove the suspect microswitch.

9. Install the new microswitch.

10. Install the holding screws.

11. Tighten the holding screws to 0.3 Nm (3 in. lb.).

12. Connect the fast-on connections to the

microswitch terminals as noted in step 5.

13. Close the transfer switch enclosure.

14. Connect power to the ATS.

15. Enable the generator set startup.

Figure 7-4 Microswitch Fast-On Connectors
a. Check that the generator set master switch is in
the OFF position.

b. Reconnect the generator set engine starting

battery, negative (--) lead last.

c. Reconnect power to the battery charger, if

equipped.

16. Test the transfer switch operation by performing

the Automatic Operation Test described in
Section 6.4.4.

Note: Do not leave the transfer switch in the Test

mode.
#

Figure 7-5 Microswitch Holding Screws

TP-6921 10/14 Section 7 Component Replacement, 40--600 Amp KSS and KGS/KGP 119
7.3 Power Panel Replacement Connecting the battery and the battery charger.
Hazardous voltage can cause severe injury or death.
Reconnect the battery correctly, positive to positive and
Required tools and equipment: negative to negative, to avoid electrical shock and damage to
Basic electrician’s hand tools the battery charger and battery(ies). Have a qualified
Multimeter digital or analog
electrician install the battery(ies).

Wiring harness
Power Panel Replacement Procedure
Tie wraps
Required protective equipment: 1. Prevent all connected generator sets from starting.
Rubber insulating gloves class 0
a. Place the generator set master switch in the
Safety glasses
OFF position or press the OFF button on the
Electrical hazard safety shoes generator set controller.

DANGER b. Disconnect the battery charger, if equipped.

c. Disconnect the generator set engine starting

batter(ies), negative (--) lead first.

2. Disconnect primary and emergency power to the

Hazardous voltage.
transfer switch.
Will cause severe injury or death.
Disconnect all power sources before 3. Open the transfer switch enclosure.
opening the enclosure.
4. Check for zero volts on the normal and emergency
power lugs.
Servicing the transfer switch. Hazardous voltage can
cause severe injury or death. Deenergize all power sources
5. Remove the tie wraps securing the harness.
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
6. Disconnect the power panel harness from the
switches to the OFF position. (2) Disconnect power to all controller harness.
battery chargers. (3) Disconnect all battery cables, negative
(--) leads first. Reconnect negative (--) leads last when Note: The replacement power panel is shipped
reconnecting the battery cables after servicing. Follow these with a factory-wired power panel harness.
precautions to prevent the starting of generator sets by an
automatic transfer switch, remote start/stop switch, or engine 7. Disconnect the engine start leads from the ATS
start command from a remote computer. Before servicing any engine start terminals.
components inside the enclosure: (1) Remove all jewelry. (2)
Stand on a dry, approved electrically insulated mat. (3) Test 8. Disconnect the emergency power supply cables
circuits with a voltmeter to verify that they are deenergized. from the switch.
(Decision-Makerr 3+ and 550 Generator Set Controllers)
Note: Mark each cable as to its position as it is
Servicing the transfer switch. Hazardous voltage can removed from the switch. Example: E1, E2
cause severe injury or death. Deenergize all power sources and E3 for the emergency side of the switch.
before servicing. Turn off the main circuit breakers of all
transfer switch power sources and disable all generator sets 9. Disconnect the normal power supply cables from
as follows: (1) Press the generator set off/reset button to shut
the switch, marking the cables as they are
down the generator set. (2) Disconnect power to all battery
chargers. (3) Disconnect all battery cables, negative (--) leads removed.
first. Reconnect negative (--) leads last when reconnecting the
battery cables after servicing. Follow these precautions to 10. Disconnect the load cables from the switch,
prevent the starting of generator sets by an automatic transfer marking the cables as they are removed.
switch, remote start/stop switch, or engine start command
from a remote computer. Before servicing any components 11. Remove the four nuts securing the power panel.
inside the enclosure: (1) Remove all jewelry. (2) Stand on a
dry, approved electrically insulated mat. (3) Test circuits with a 12. Remove the power panel.
voltmeter to verify that they are deenergized.
(RDC, DC, RDC2, DC2, Decision-Makerr 3000, 3500 and 13. Install the new power panel onto the studs in the
6000 Generator Set Controllers) back of the enclosure. See Figure 7-6.

120 Section 7 Component Replacement, 40--600 Amp KSS and KGS/KGP TP-6921 10/14
14. Fasten the power panel with flat washers, lock 20. Tighten the connecting bolts to 16.3 Nm (12 ft. lb.).
washers and nuts.
21. Connect the emergency supply cables to the E
15. Torque the nuts to 7.3 Nm (65 in. lb.). terminals.

16. Connect the power panel harness to the controller 22. Tighten the connecting bolts to 16.3 Nm (12 ft. lb.).
harness at the inline connector.
23. Install tie wraps as needed to secure the harness.
17. Connect the load cables to the T terminals.
24. Connect the generator set engine start leads.
18. Tighten the connecting bolts to 16.3 Nm (12 ft. lb.).
25. Close the transfer switch enclosure.
19. Connect the normal cables to the N terminals.
26. Connect power to the ATS.

27. Enable the generator set.

a. Check that the generator set master switch is in

the OFF position.

b. Reconnect the generator set engine starting

battery, negative (--) lead last.

c. Reconnect power to the battery charger, if

equipped.

28. Move the generator set master switch to the AUTO

position or press the AUTO button on the generator
set controller.

29. Test the transfer switch operation by performing

Figure 7-6 Installing the Power Panel the Automatic Operation Test described in
Section 6.4.4.

Note: Do not leave the transfer switch in the Test

mode.

TP-6921 10/14 Section 7 Component Replacement, 40--600 Amp KSS and KGS/KGP 121
7.4 Arc Chute Replacement Connecting the battery and the battery charger.
Hazardous voltage can cause severe injury or death.
Reconnect the battery correctly, positive to positive and
Required tools and equipment: negative to negative, to avoid electrical shock and damage to
Basic electrician’s hand tools the battery charger and battery(ies). Have a qualified
Arc chute
electrician install the battery(ies).

Required protective equipment:

Arc Chute Replacement Procedure
Rubber insulating gloves class 0
Safety glasses 1. Prevent all connected generator sets from starting.
Electrical hazard safety shoes
a. Place the generator set master switch in the
OFF position or press the OFF button on the
DANGER
generator set controller.

b. Disconnect the battery charger, if equipped.

c. Disconnect the generator set engine starting

Hazardous voltage. batter(ies), negative (--) lead first.
Will cause severe injury or death.
2. Disconnect power to the transfer switch.
Disconnect all power sources before
opening the enclosure. 3. Open the transfer switch enclosure.

Servicing the transfer switch. Hazardous voltage can 4. Verify zero volts across each phase.
cause severe injury or death. Deenergize all power sources
before servicing. Turn off the main circuit breakers of all 5. Remove the arc chute hold down screws. See
transfer switch power sources and disable all generator sets Figure 7-7.
as follows: (1) Move all generator set master controller
switches to the OFF position. (2) Disconnect power to all 6. Remove the arc chute.
battery chargers. (3) Disconnect all battery cables, negative
(--) leads first. Reconnect negative (--) leads last when 7. Inspect the movable contact for damage. See
reconnecting the battery cables after servicing. Follow these Figure 7-8. If damage is found, order a
precautions to prevent the starting of generator sets by an replacement power panel and continue to Step 8.
automatic transfer switch, remote start/stop switch, or engine
start command from a remote computer. Before servicing any
8. Install the new arc chute.
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.
9. Install the holding screws and washers.
(Decision-Makerr 3+ and 550 Generator Set Controllers) 10. Torque screws to 2.8 Nm (25 in. lb.).
Servicing the transfer switch. Hazardous voltage can 11. Manually operate the switch several times to
cause severe injury or death. Deenergize all power sources
ensure that it does not stick. See Figure 7-9.
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.
(RDC, DC, RDC2, DC2, Decision-Makerr 3000, 3500 and
6000 Generator Set Controllers)

122 Section 7 Component Replacement, 40--600 Amp KSS and KGS/KGP TP-6921 10/14
 1

1. Arc chute hold down screws

Figure 7-7 Arc Chute Screws

Figure 7-9 Manual Operation Handle Inserted

12. Close the transfer switch enclosure.

13. Reconnect power to the ATS.

14. Enable the generator set.

a. Check that the generator set master switch is in

the OFF position.

b. Reconnect the generator set engine starting

batter(ies), negative (--) lead last.

c. Reconnect the battery charger, if equipped.

Figure 7-8 Movable Contacts (arc chute removed) 15. Move the generator set master switch to the AUTO
position or press the AUTO button on the generator
set controller.

16. Test the transfer switch operation by performing

the Automatic Operation Test Procedure described
in Section 6.4.4.

Note: Do not leave the transfer switch in the Test

mode.

TP-6921 10/14 Section 7 Component Replacement, 40--600 Amp KSS and KGS/KGP 123
7.5 Limit Switch Assembly Connecting the battery and the battery charger.
Hazardous voltage can cause severe injury or death.
Replacement Reconnect the battery correctly, positive to positive and
negative to negative, to avoid electrical shock and damage to
Required tools and equipment: the battery charger and battery(ies). Have a qualified
electrician install the battery(ies).
Basic electrician’s hand tools
Multimeter digital or analog
Procedure
Limit switch
Required protective equipment: 1. Prevent all connected generator sets from starting.
Rubber insulating gloves class 0
a. Place the generator set master switch in the
Safety glasses OFF position or press the OFF button on the
Electrical hazard safety shoes generator set controller.

DANGER b. Disconnect the battery charger, if equipped.

c. Disconnect the generator set engine starting

batter(ies), negative (--) lead first.

2. Disconnect power to the transfer switch.

Hazardous voltage.
Will cause severe injury or death. 3. Open the transfer switch enclosure.
Disconnect all power sources before
opening the enclosure. 4. Verify zero volts across each phase.

5. Note the location of the fast-on connections to the

Servicing the transfer switch. Hazardous voltage can SCN/SCE microswitch terminals.
cause severe injury or death. Deenergize all power sources
before servicing. Turn off the main circuit breakers of all 6. Disconnect the fast-on connectors. See
transfer switch power sources and disable all generator sets Figure 7-10.
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.
(Decision-Makerr 3+ and 550 Generator Set Controllers)

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 Figure 7-10 Microswitch Fast-On Connectors
first. Reconnect negative (--) leads last when reconnecting the
battery cables after servicing. Follow these precautions to 7. Remove the holding screws. Note the microswitch
prevent the starting of generator sets by an automatic transfer labels on the insulators. See Figure 7-11.
switch, remote start/stop switch, or engine start command
from a remote computer. Before servicing any components 8. Remove the microswitch assembly.
inside the enclosure: (1) Remove all jewelry. (2) Stand on a
dry, approved electrically insulated mat. (3) Test circuits with a 9. Remove the suspect microswitch. See
voltmeter to verify that they are deenergized. Figure 7-12.
(RDC, DC, RDC2, DC2, Decision-Makerr 3000, 3500 and
6000 Generator Set Controllers)

124 Section 7 Component Replacement, 40--600 Amp KSS and KGS/KGP TP-6921 10/14
10. Install the new microswitch into the assembly. 12. Clean the inside of the ATS.

Note: Replace SCN/SCE insulators in the correct 13. Close and lock the enclosure.
order. Normally, the SCE is closest to the
base. 14. Connect power to the ATS.

11. Reinstall the microswitch assembly. See 15. Enable the generator set startup.
Figure 7-13.
a. Check that the generator set master switch is in
a. Install the holding screws. the OFF position.

b. Tighten the holding screws. b. Reconnect the generator set engine starting
batter(ies), negative (--) lead last.
c. Connect the fast-on connections to the
microswitch terminals as noted in step 5. c. Reconnect the battery charger, if equipped.

16. Move the generator set master switch to the AUTO

position or press the AUTO button on the generator
set controller.

17. Test the transfer switch operation by performing

the Automatic Operation Test Procedure described
in Section 6.4.4.

Note: Do not leave the transfer switch in the Test

mode.

Figure 7-11 Microswitch Insulator with Label

Figure 7-12 Microswitch

Figure 7-13 Microswitch Installation

TP-6921 10/14 Section 7 Component Replacement, 40--600 Amp KSS and KGS/KGP 125
7.6 Solenoid and Rectifier Servicing the transfer switch. Hazardous voltage can
cause severe injury or death. Deenergize all power sources
Replacement 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
7.6.1 Solenoid and Rectifier down the generator set. (2) Disconnect power to all battery
Replacement, 40--225 Amp Models chargers. (3) Disconnect all battery cables, negative (--) leads
first. Reconnect negative (--) leads last when reconnecting the
Required tools and equipment: battery cables after servicing. Follow these precautions to
prevent the starting of generator sets by an automatic transfer
Basic electricians hand tools switch, remote start/stop switch, or engine start command
Multimeter digital or analog from a remote computer. Before servicing any components
Solenoid
inside the enclosure: (1) Remove all jewelry. (2) Stand on a
dry, approved electrically insulated mat. (3) Test circuits with a
Tie wraps voltmeter to verify that they are deenergized.
Required protective equipment: (Kohler RDC, DC, RDC2, DC2, Decision-Makerr 3000,
Rubber insulating gloves class 0 3500 and 6000 Generator Set Controllers)
Safety glasses
Connecting the battery and the battery charger.
Electrical hazard safety shoes Hazardous voltage can cause severe injury or death.
Reconnect the battery correctly, positive to positive and
DANGER negative to negative, to avoid electrical shock and damage to
the battery charger and battery(ies). Have a qualified
electrician install the battery(ies).

Procedure
Hazardous voltage. 1. Prevent all connected generator sets from starting.
Will cause severe injury or death.
Disconnect all power sources before a. Place the generator set master switch in the
opening the enclosure. OFF position or press the OFF button on the
generator set controller.
Servicing the transfer switch. Hazardous voltage can
b. Disconnect the battery charger, if equipped.
cause severe injury or death. Deenergize all power sources
before servicing. Turn off the main circuit breakers of all
c. Disconnect the generator set engine starting
transfer switch power sources and disable all generator sets
as follows: (1) Move all generator set master controller batter(ies), negative (--) lead first.
switches to the OFF position. (2) Disconnect power to all
battery chargers. (3) Disconnect all battery cables, negative 2. Disconnect main power.
(--) leads first. Reconnect negative (--) leads last when
reconnecting the battery cables after servicing. Follow these 3. Open the ATS enclosure.
precautions to prevent the starting of generator sets by an
automatic transfer switch, remote start/stop switch, or engine 4. Verify zero volts across each phase.
start command from a remote computer. Before servicing any
components inside the enclosure: (1) Remove all jewelry. (2) 5. Remove DC fast-on connections from the rectifier
Stand on a dry, approved electrically insulated mat. (3) Test terminals. See Figure 7-14.
circuits with a voltmeter to verify that they are deenergized.
(Kohler Decision-Makerr 3+ and 550 Generator Set
Controllers)

126 Section 7 Component Replacement, 40--600 Amp KSS and KGS/KGP TP-6921 10/14
 Rectifier Check and Replacement
7. Remove the AC fast-on connections from the AC
terminals of the rectifier.

8. Check the diode operation of the rectifier. See

Figure 7-16 and Section 5.3 for rectifier test
instructions. If the rectifier is good, go to step 11. If
the rectifier is bad, continue on.

9. Remove the faulty rectifier.

10. Install the new rectifier so that the red dot is in the
upper right corner.

11. Connect the AC fast-on connections to the AC

terminals.
Figure 7-14 Rectifier Connections (DC solenoid
leads shown disconnected) Note: The AC terminals are in the upper left and
lower right hand corners.
6. Check the coil resistance. See Figure 7-15.

Note: If the resistance reading is infinite or

shorted, replace the coil.

Figure 7-16 Checking Diode Operation of Rectifier

Figure 7-15 Checking Coil Resistance

TP-6921 10/14 Section 7 Component Replacement, 40--600 Amp KSS and KGS/KGP 127
Solenoid Replacement

WARNING

Spring-loaded parts.
Can cause severe personal injury
or property damage.
Wear protective goggles when
servicing spring-loaded parts. Hold
parts securely during disassembly.

Disassembling the solenoid. Spring-loaded parts can

cause severe personal injury or property damage. The
spring in the solenoid assembly exerts substantial force on the
coil. Hold the coil assembly securely when removing the
screws.

12. Remove tie wraps, as necessary.

Note: Do not cut the insulation on the wiring.

13. Remove the front bolt of the coil securing the strap.
See Figure 7-17.

14. Loosen the rear bolt of the coil securing the strap. Figure 7-18 Spring and Plunger Assembly

15. Remove the coil. 16. Lubricate the spring and plunger assembly.

Note: The plunger assembly is spring-loaded. 17. Insert the spring into the new coil.
See Figure 7-18.
Note: Insert and seat the spring into the spring
holder of the coil. The spring should be
centered in the hole. See Figure 7-19.

Figure 7-17 Coil Securing Strap

Figure 7-19 Spring Holder in Coil

128 Section 7 Component Replacement, 40--600 Amp KSS and KGS/KGP TP-6921 10/14
18. Install the plunger into the new coil. 7.6.2 Solenoid and Rectifier
Replacement, 400--600 Amp
Note: The spring will slide into the plunger. See
Figure 7-18. Models

19. Install the new coil into the coil slot. Required tools and equipment:
Basic electricians hand tools
20. Install the coil holding strap.
Multimeter digital or analog

21. Tighten the bolts for the coil holding strap. See Solenoid
Figure 7-17. Tie wraps
Required protective equipment:
22. Connect the DC fast-on connections to the DC
Rubber insulating gloves class 0
terminals of the rectifier.
Safety glasses
Note: The DC terminals are in the lower left and Electrical hazard safety shoes
upper right hand corners.
DANGER
23. Install any required tie wraps.

24. Close the enclosure.

25. Reconnect power to the ATS.

Hazardous voltage.
26. Enable the generator set startup. Will cause severe injury or death.
Disconnect all power sources before
a. Check that the generator set master switch is in
opening the enclosure.
the OFF position or press the OFF button on the
generator set controller.
Servicing the transfer switch. Hazardous voltage can
b. Reconnect the generator set engine starting cause severe injury or death. Deenergize all power sources
batter(ies), negative (--) lead last. before servicing. Turn off the main circuit breakers of all
transfer switch power sources and disable all generator sets
c. Reconnect the battery charger, if equipped. 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
27. Move the generator set master switch to the AUTO
(--) leads first. Reconnect negative (--) leads last when
position or press the AUTO button on the generator reconnecting the battery cables after servicing. Follow these
set controller. precautions to prevent the starting of generator sets by an
automatic transfer switch, remote start/stop switch, or engine
28. Test the transfer switch operation by performing start command from a remote computer. Before servicing any
the Automatic Operation Test Procedure described components inside the enclosure: (1) Remove all jewelry. (2)
in Section 6.4.4. Stand on a dry, approved electrically insulated mat. (3) Test
circuits with a voltmeter to verify that they are deenergized.
Note: Do not leave the transfer switch in the Test (Kohler Decision-Makerr 3+ and 550 Generator Set
mode. Controllers)

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.
(Kohler RDC, DC, RDC2, DC2, Decision-Makerr 3000,
3500 and 6000 Generator Set Controllers)

TP-6921 10/14 Section 7 Component Replacement, 40--600 Amp KSS and KGS/KGP 129
Connecting the battery and the battery charger. Rectifier Check and Replacement
Hazardous voltage can cause severe injury or death.
Reconnect the battery correctly, positive to positive and 6. Remove the AC fast-on connections from the AC
negative to negative, to avoid electrical shock and damage to terminals of the rectifier.
the battery charger and battery(ies). Have a qualified
electrician install the battery(ies). 7. Check the diode operation of the rectifier. See
Figure 7-21 and Section 5.3 for rectifier test
Procedure instructions. If the rectifier is bad, replace it. If the
rectifier is good, proceed to step 9.
1. Prevent all connected generator sets from starting.
8. Replace the rectifier. Orient the new rectifier so
a. Place the generator set master switch in the that the red dot is in the upper right corner when the
OFF position or press the OFF button on the contactor is mounted in the enclosure.
generator set controller.
9. Connect AC fast-on connections to AC terminals.
b. Disconnect the battery charger, if equipped.

c. Disconnect the generator set engine starting

batter(ies), negative (--) lead first.

2. Disconnect main power and open the transfer

switch enclosure.

3. Verify zero volts across each phase.

4. Remove the DC fast-on connections from the

rectifier terminals. See Figure 7-20.

Note: A red dot identifies one DC terminal. The

other DC terminal is at the opposite corner of
the rectifier.

5. Check the coil resistance.

Note: If reading is infinite or shorted, replace coil.

Figure 7-21 Checking Rectifier Diode Operation

Figure 7-20 Rectifier Fast-On Connectors

(contactor shown on the bench)

130 Section 7 Component Replacement, 40--600 Amp KSS and KGS/KGP TP-6921 10/14
Solenoid Replacement 12. Place the switch in the Normal position.

WARNING 13. Mark the location of the solenoid assembly

mounting bracket.

14. Hold the solenoid coil firmly and remove the four
screws and washers. See Figure 7-22.

15. Pull the solenoid assembly with the attached

Spring-loaded parts.
Can cause severe personal injury linkage away from the contactor.
or property damage.
Note: The sealed solenoid coil assembly contains
Wear protective goggles when the coil and the plunger. Do not attempt to
servicing spring-loaded parts. Hold remove the plunger from the coil assembly.
parts securely during disassembly.
16. Remove the clip that secures the plunger to the
Disassembling the solenoid. Spring-loaded parts can linkage and remove the linkage from the coil
cause severe personal injury or property damage. The assembly.
spring in the solenoid assembly exerts substantial force on the
coil. Hold the coil assembly securely when removing the 17. Use the clip to attach the linkage to the new coil
screws. assembly.
10. Note the rectifier connections and disconnect the 18. Place the new solenoid assembly into position,
AC leads. See Figure 7-22. aligning the linkage pins with the mechanism slots.
See Figure 7-22.
11. Remove tie wraps as necessary.

Note: Be careful to avoid cutting the insulation on

the leads.

TP-6921 10/14 Section 7 Component Replacement, 40--600 Amp KSS and KGS/KGP 131
 1

5
1. Mounting screws with washers (4 ea.) 4. Plunger
2. Linkage 5. Rectifier connections
3. Clip location (not visible this view)

Figure 7-22 Solenoid Assembly (shown on the bench)

132 Section 7 Component Replacement, 40--600 Amp KSS and KGS/KGP TP-6921 10/14
19. Insert four mounting screws with washers and align 27. Test the transfer switch operation by performing
the mounting bracket with marks made in step 13. the Automatic Operation Test Procedure described
in Section 6.4.4.
20. Tighten all four bolts to 10.8 Nm (96 in. lb).
Note: Do not leave transfer switch in Test mode.
21. Connect the DC fast-on connections to the DC
terminals of the rectifier. See Figure 7-23.

Note: A red dot identifies one DC terminal. The

other DC terminal is at the opposite corner.

22. Install any required tie wraps. See Figure 7-23.

23. Close the ATS enclosure.

24. Reconnect power to the ATS.

25. Enable the generator set startup.

a. Check that the generator set master switch is in

the OFF position or press the OFF button on the
generator set controller.

b. Reconnect the generator set engine starting

batter(ies), negative (--) lead last.

c. Reconnect the battery charger, if equipped.

26. Move the generator set master switch to the AUTO

position or press the AUTO button on the generator Figure 7-23 Rectifier Connections and Tie Wraps
set controller.

TP-6921 10/14 Section 7 Component Replacement, 40--600 Amp KSS and KGS/KGP 133
 Notes

134 Section 7 Component Replacement, 40--600 Amp KSS and KGS/KGP TP-6921 10/14
 Section 8 Component Replacement, 100--600 Amp KSP

8.1 Introduction Servicing the transfer switch. Hazardous voltage can

cause severe injury or death. Deenergize all power sources
This section contains instructions for component before servicing. Turn off the main circuit breakers of all
transfer switch power sources and disable all generator sets
replacement on the following models:
as follows: (1) Press the generator set off/reset button to shut
down the generator set. (2) Disconnect power to all battery
D 800--1000 Amp Model KSS transfer switches chargers. (3) Disconnect all battery cables, negative (--) leads
first. Reconnect negative (--) leads last when reconnecting the
D All Model KSP programmed-transition transfer battery cables after servicing. Follow these precautions to
switches. prevent the starting of generator sets by an automatic transfer
switch, remote start/stop switch, or engine start command
Illustrations in this section show the transfer switch from a remote computer. Before servicing any components
removed from the enclosure and placed on a bench. inside the enclosure: (1) Remove all jewelry. (2) Stand on a
Remove the transfer switch from the enclosure if dry, approved electrically insulated mat. (3) Test circuits with a
voltmeter to verify that they are deenergized.
necessary to access components.
(Kohler RDC, DC, RDC2, DC2, Decision-Makerr 3000,
Read and follow all safety precautions before servicing 3500 and 6000 Controllers)
the transfer switch.
Before performing any of the following service
procedures, disable all connected generator sets and
8.2 Disconnect Power disconnect power to the ATS as described below.

DANGER Procedure
1. Prevent all connected generator sets from starting.

a. Place the generator set master switch in the

OFF position or press the OFF button on the
Hazardous voltage. generator set controller.
Will cause severe injury or death.
Disconnect all power sources before b. Disconnect the battery charger, if equipped.
opening the enclosure.
c. Disconnect the generator set engine starting
Servicing the transfer switch. Hazardous voltage can batter(ies), negative (--) lead first.
cause severe injury or death. Deenergize all power sources
before servicing. Turn off the main circuit breakers of all 2. Disconnect power to the transfer switch.
transfer switch power sources and disable all generator sets
as follows: (1) Move all generator set master controller 3. Open the transfer switch enclosure.
switches to the OFF position. (2) Disconnect power to all
battery chargers. (3) Disconnect all battery cables, negative 4. Use a voltmeter to verify zero volts across each
(--) leads first. Reconnect negative (--) leads last when phase.
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.
(Kohler Decision-Makerr 3+ and 550 Controllers)

TP-6921 10/14 Section 8 Component Replacement, 100--600 Amp KSP 135

8.3 Component Replacement, 3. Remove the ON/OFF indicators. Save the
indicators for installation during reassembly. See
100--400 Amp Model KSP Figure 8-2.

8.3.1 Disassembly, 100--400 Amps

Disassemble the mechanical unit and the current-
carrying unit.

DANGER

Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.
6226

1. Disconnect power and open the transfer switch 1

enclosure as described in Section 8.2. 1. ON/OFF indicators

Figure 8-2 ON/OFF Indicators

2. Loosen the M4 bolt and remove the cover from the
mechanical unit. See Figure 8-1. 4. Remove the auxiliary switches. See Figure 8-3.

1
6226
1. M4 bolt 6226

1. Auxiliary switches 1
Figure 8-1 Removing Cover
Figure 8-3 Auxiliary Switches

136 Section 8 Component Replacement, 100--600 Amp KSP TP-6921 10/14

 5. Loosen four bolts and separate the mechanical unit
from the current-carrying unit. See Figure 8-4,
Figure 8-5, and Figure 8-6.

Note: The current-carrying unit on 400-amp

models is made up of sections that will
separate when disassembled.

6226

Figure 8-6 Mechanical Unit

8.3.2 Reassembly, 100--400 Amps

Reassemble the mechanical unit and the
current-carrying unit.
6226
1. Loosen four M5 bolts 1 1. Assemble the current-carrying unit and the
Figure 8-4 Separating Units, 100 and 200 Amp mechanical unit. Make sure that the shaft from the
mechanical unit goes through both main shaft
levers. See Figure 8-7.

On 400-amp units, the current-carrying unit is

made up of separate sections. Make sure that the
sections are flush across the front when
reassembling.

6226

1. Loosen four M6 bolts 1

Figure 8-5 Separating Units, 400 Amp

6226

1 2

1. Openings for shaft from coil

2. Main shaft levers

Figure 8-7 Current-Carrying Unit

TP-6921 10/14 Section 8 Component Replacement, 100--600 Amp KSP 137

 2. Replace the ON/OFF indicators and the cover.

Note: The ON/OFF indicators are not identical.

Install them as shown in Figure 8-8.

6226

1 2

1. Auxiliary switch levers

2. Auxiliary switches

Figure 8-9 100 and 200 Amp Models

6226
1
1. ON/OFF indicators

Figure 8-8 Assembled Units

3. Reinstall the auxiliary switch levers, if removed,

aligning the square indentation with the end of the
square shaft. See Figure 8-9 and Figure 8-10.

4. Reinstall the auxiliary switches, if removed. The

100 and 200 amp models use one bolt and one
alignment pin per switch. See Figure 8-9. Larger
models use two bolts per switch. See Figure 8-10. 6226

1 2
1. Auxiliary switch levers
2. Auxiliary switches

Figure 8-10 400 Amp Models

138 Section 8 Component Replacement, 100--600 Amp KSP TP-6921 10/14

8.3.3 Printed Circuit Board
Replacement, 100--400 Amps

DANGER

Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.

NOTICE 6226
1 2
Electrostatic discharge damage. Electrostatic discharge 1. Coil leads
(ESD) damages electronic circuit boards. Prevent 2. Bolt
electrostatic discharge damage by wearing an approved
grounding wrist strap when handling electronic circuit boards Figure 8-11 Circuit Board Connections
or integrated circuits. An approved grounding wrist strap
provides a high resistance (about 1 megohm), not a direct
short, to ground.

Separate the current-carrying unit from the mechanical

unit. See Section 8.3.1.

1. Note the connections (for reconnection later) and

disconnect the printed circuit board leads. See
Figure 8-11 or Figure 8-12.

2. Disconnect the control switch leads at three

terminals. See Figure 8-12.

Note: Hold the terminals while loosening the

6226
screws to avoid damage.
1 2
3. Note the connections (for reconnection later) and 1. Printed circuit board leads
2. Switch leads
disconnect the control switch leads at eight
locations. See Figure 8-13. Figure 8-12 Control Switch Wiring
4. Remove the bolt and replace the printed circuit
board. See Figure 8-11.

5. Reconnect all leads as noted during step 1.

6226
1
1. Control switches

Figure 8-13 Control Switches

TP-6921 10/14 Section 8 Component Replacement, 100--600 Amp KSP 139

8.3.4 Closing Coil Replacement,
100--400 Amps

DANGER

Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.
1

1. Disconnect power and open the transfer switch 2 6226

enclosure as described in Section 8.2. 1. M6 nut and washer

2. Movable steel shaft
2. Loosen the M4 bolt and remove the cover from the
Figure 8-15 Movable Steel Shaft, 100--400 Amp
mechanical unit. See Figure 8-1.
Models
3. Push the trip button.
1 2
4. See Figure 8-15. Remove the M6 nut and washer.
Turn the movable steel shaft counterclockwise to
remove it.

5. Remove the printed circuit board. See Figure 8-16

and Section 8.3.3.

6226

1. Printed circuit board

2. M6 bolt location

1 Figure 8-16 Printed Circuit Board and M6 Bolt (for

6226 closing coil)
1. M4 bolt

Figure 8-14 Removing Cover

140 Section 8 Component Replacement, 100--600 Amp KSP TP-6921 10/14

 6. Loosen the M6 bolt and remove the frame with the 8.3.5 Select Coil Replacement,
coil. See Figure 8-16 and Figure 8-17. 100--400 Amps
7. Loosen the M12 nut and replace the closing coil. 1. Note connections and disconnect select coil leads.
See Figure 8-17. See Figure 8-18. Cut the cable tie, if necessary.

2. Remove two M4 bolts shown in Figure 8-19 and

remove the select coil assembly.

1. M12 nut 6226

Figure 8-17 Closing Coil with Frame, 100--400 Amp 6226

1. Select coil
Models 1 2
2. Select coil leads

8. Reinstall movable steel shaft. To adjust the shaft: Figure 8-18 Select Coil Connections
a. Turn the large round shaft in (clockwise) until
mechanism just latches when operated with the
manual handle. If turned too far, it won’t latch.

b. Back the shaft out (counterclockwise) one full

rotation from the limit of the switching range.

c. Install the washer and nut. Hold the shaft to

prevent it from turning while tightening the nut.

6226
1. M4 bolts 1

Figure 8-19 Select Coil Assembly Bolts

TP-6921 10/14 Section 8 Component Replacement, 100--600 Amp KSP 141

 3. Remove the upper plate from the select coil 8.3.6 Trip Coil Replacement,
assembly. See Figure 8-20. 100--400 Amps
4. Replace the select coil. See Figure 8-21. Note: Remove the select coil first for easier access to
the trip coil. See Section 8.3.5.

1. Locate the trip coil. See Figure 8-22.

1. Upper plate 6226

Figure 8-20 Select Coil Assembly

1
6226
1. Trip coil

Figure 8-22 Trip Coil Location

2. Note the connections and disconnect the trip coil

leads from the printed circuit board. See
Figure 8-23.

6226
1. Select coil

Figure 8-21 Select Coil

6226

1. Trip coil connections

Figure 8-23 Trip Coil Connections

142 Section 8 Component Replacement, 100--600 Amp KSP TP-6921 10/14

 3. Remove two M4 bolts that secure the trip coil. See
Figure 8-24.

6226
1 2
1. Trip shaft
6226 2. M4 bolt

1 2 3 Figure 8-25 Trip Shaft Location

1. Trip coil M4 bolts (2)
2. Trip shaft M4 bolt (and ring, not visible in this view)
3. Trip lever

Figure 8-24 Trip Coil and Trip Shaft Bolts

WARNING

Spring-loaded parts. 6226

Can cause severe personal injury
or property damage. Figure 8-26 Trip Shaft Parts
Wear protective goggles when
servicing spring-loaded parts. Hold
parts securely during disassembly.

4. The trip shaft is spring-loaded. Hold the shaft

securely while removing the trip shaft bolt. See
Figure 8-25. Remove the M4 bolt with ring, trip
shaft, spring, and L-shaped bracket. See
Figure 8-26. Keep the parts for reassembly later.

5. Loosen three bolts shown in Figure 8-27, remove

the side plate, and replace the trip coil. See
Figure 8-27.

6. Reassemble in reverse order:

6226
Align the bosses on the coil with the holes in the
L-shaped bracket. 1
1. Bolts (3)
Be sure to reinstall the ring on the trip shaft bolt and
Figure 8-27 Side Plate Bolts
align the parts so that the ring fits into the hole on
the trip lever.

TP-6921 10/14 Section 8 Component Replacement, 100--600 Amp KSP 143

8.3.7 Arc Chute Replacement,
100--400 Amps
1
DANGER

Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before 6226
opening the enclosure. 1. Arc chute retainer clips

Figure 8-28 Arc Chutes

1. Disconnect power as described in Section 8.2.

2. Remove the retainer clips shown in Figure 8-28.

3. Replace the required arc chute.

4. Reinstall the retainer clips.

144 Section 8 Component Replacement, 100--600 Amp KSP TP-6921 10/14

8.4 Component Replacement,
600 Amp Model KSP

8.4.1 Closing Coil Replacement,

600 Amp Model KSP

DANGER

Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before 6226
opening the enclosure. 1
1. Closing coil leads

1. Disconnect power and open the transfer switch Figure 8-30 Closing Coil Connections
enclosure as described in Section 8.2.

2. Remove the M4 bolts and the M6 bolt. Remove the WARNING

cover from the mechanical unit. See Figure 8-29.

3. Note the connections shown in Figure 8-30 and

disconnect the closing coil leads at four locations.

Spring-loaded parts.
Can cause severe personal injury
or property damage.
Wear protective goggles when
servicing spring-loaded parts. Hold
parts securely during disassembly.

Disassembling the solenoid. Spring-loaded parts can

cause severe personal injury or property damage. The
spring in the solenoid assembly exerts substantial force on the
coil. Hold the coil assembly securely when removing the
screws.

4. The closing coil is spring-loaded. Hold the closing

coil securely and remove four M8 bolts. Remove
6226
the closing coil. See Figure 8-31.
1 2
1. M4 bolts
2. M6 bolt

Figure 8-29 Removing the Cover

TP-6921 10/14 Section 8 Component Replacement, 100--600 Amp KSP 145

 8.4.3 Trip Coil Replacement,
600 Amp Models
WARNING

Spring-loaded parts.
Can cause severe personal injury
or property damage.
Wear protective goggles when
servicing spring-loaded parts. Hold
parts securely during disassembly.
6226

1 2 Disassembling the solenoid. Spring-loaded parts can

1. M8 bolts
cause severe personal injury or property damage. The
2. Nut, movable steel shaft spring in the solenoid assembly exerts substantial force on the
coil. Hold the coil assembly securely when removing the
Figure 8-31 Closing Coil Bolts and Nut screws.

1. Note the connections and disconnect the trip coil

5. Replace the closing coil. leads from the printed circuit board and the control
switch. See Figure 8-32 and Figure 8-33.
a. Reuse the spring from the original coil.

b. Align the boss on the coil into the recess in the

frame.

c. Replace the four M8 bolts. See Figure 8-31.

d. Reconnect four leads shown in Figure 8-30.

6. Adjust the movable steel shaft as described in the

following procedure.

8.4.2 Shaft Adjustment, 600 Amp Model

KSP
Note: It is not necessary to remove the movable steel
shaft when replacing the closing coil. 6226

1. Turn the large round shaft in (clockwise) until the 1 2 3

mechanism just latches when operated with the 1. Printed circuit board
manual handle. If turned too far, it won’t latch. 2. Trip coil (TC) leads
3. Select coil (SC) leads
2. Turn the shaft back 1.5 rotations from the limit of the
Figure 8-32 Circuit Board Connections
switching range.

3. Hold the shaft and tighten the nut.

4. Replace the cover on the mechanical unit.

146 Section 8 Component Replacement, 100--600 Amp KSP TP-6921 10/14

 8.4.4 Select Coil Replacement,
600 Amp Models
WARNING

Spring-loaded parts.
Can cause severe personal injury
or property damage.
Wear protective goggles when
6226 servicing spring-loaded parts. Hold
1. Trip coil M4 bolts 1 2 3 parts securely during disassembly.
2. Control switch
3. Insulator Disassembling the solenoid. Spring-loaded parts can
Figure 8-33 Trip Coil Replacement, 600 Amp cause severe personal injury or property damage. The
spring in the solenoid assembly exerts substantial force on the
Models
coil. Hold the coil assembly securely when removing the
screws.
2. Remove two M4 bolts and replace the trip coil.
Retain the small spring for the trip coil lever. See 1. Note the connections and disconnect the select
Figure 8-33 and Figure 8-34. coil leads from the printed circuit board and the
control switch. See Figure 8-32 and Figure 8-33.
3. Connect the trip coil leads to the printed circuit
board and control switch as noted during 2. Loosen the M5 bolt and remove the select coil
disassembly. Tighten control switch connections movable steel shaft and the spring. See
to 0.14 Nm (1 in. lb.), maximum. Figure 8-35 and Figure 8-36.

3. Loosen the M4 bolts and replace the select coil.

1 See Figure 8-35.

4. Connect the select coil leads to the control switch

and circuit board.

3 1

6226
1. Trip lever
2. Spring
3. Trip coil

Figure 8-34 Trip Coil

6226
3
1. Steel shaft (and spring, see Figure 8-36)
2. Select coil
3. Select coil M4 bolts

Figure 8-35 Select Coil Replacement, 600 Amp

Models

TP-6921 10/14 Section 8 Component Replacement, 100--600 Amp KSP 147

 8.4.6 Auxiliary Switch Replacement

DANGER

1 Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.

1. Disconnect power and open the transfer switch

enclosure as described in Section 8.2.
6226
1. Spring
2. Loosen the M4 bolts and replace the auxiliary
Figure 8-36 Spring Location switches. See Figure 8-37.

3. Tighten the mounting screws to 0.14 Nm (1 in. lb.),

maximum.
8.4.5 Printed Circuit Board
Replacement, 600 Amp Models
NOTICE
Electrostatic discharge damage. Electrostatic discharge
(ESD) damages electronic circuit boards. Prevent
electrostatic discharge damage by wearing an approved
grounding wrist strap when handling electronic circuit boards
or integrated circuits. An approved grounding wrist strap
provides a high resistance (about 1 megohm), not a direct
short, to ground.

Note: The individual rectifiers are not replaceable.

Replace the entire printed circuit board in the
case of rectifier failure.

1. Note the connections and disconnect all leads to

the circuit board. See Figure 8-32. 6226

1 2
2. Loosen the M4 bolts to replace the printed circuit
board. 1. Auxiliary switches
2. M4 bolts
3. Reconnect all leads.
Figure 8-37 Auxiliary Switches, 600 Amp Models

148 Section 8 Component Replacement, 100--600 Amp KSP TP-6921 10/14

8.4.7 Arc Chute Replacement, DANGER
600 Amp Models
Note: Some units use retainers (part number 295010)
instead of M6 nuts. See Figure 8-38. Obtain new
retainers before disassembly.
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.

1. Disconnect power and open the transfer switch

enclosure as described in Section 8.2.

2. Remove the insulation plate. See Figure 8-39.

1

6226

6226 1
1. Retainer 1. Insulation plate

Figure 8-38 Retainer Figure 8-39 600 Amp Contactor

TP-6921 10/14 Section 8 Component Replacement, 100--600 Amp KSP 149

 3. Attach a clamp or fixture similar to the one shown in 8.4.8 Contact Replacement
Figure 8-40.
Source A Side
Note: The transfer switch will come apart if the
parts are not clamped as shown before the
nuts or retainers are removed.
DANGER

4. Loosen the M6 nuts or remove the retainers. See

Figure 8-40.

5. Remove the upper rod shown in Figure 8-40. Hazardous voltage.

Will cause severe injury or death.
1
Disconnect all power sources before
opening the enclosure.

1. Disconnect power and open the transfer switch

enclosure as described in Section 8.2.

2. Loosen three (3) M6 bolts for the fixed contacts and

two (2) M6 bolts for the movable contacts as shown
in Figure 9-14.

3. Remove the M6 capscrews and all M4 bolts as

shown in Figure 9-15.

4. Install the new contacts.

5. After replacing the movable contact, check the

tp6226
contact pressure with the contact wipe gauge at the
closed position as shown in Figure 9-16. You
1. Remove this rod 2 3 should NOT be able to insert the gauge.
2. Fixture
3. M6 nuts or retainers 6. If the gauge can be inserted, add a 0.5 mm
(0.02 in.) spacer as shown in Figure 9-17.
Figure 8-40 Fixture or Clamp, 600 Amp Models

6. Replace the arc chutes. 1

7. Replace the rod.

8. Reinstall and tighten the M6 nuts or install new

retainers and then remove the clamp.

9. Reinstall the insulation plate.

2
1. M6 bolts for fixed contacts (qty. 3)
2. M6 bolts for movable contacts (qty. 2)

Figure 8-41 Loosen Bolts (back)

150 Section 8 Component Replacement, 100--600 Amp KSP TP-6921 10/14

 1
1

2
1. Spacer. 0.5 mm (0.02 in.) thick
1. Remove the M6 capscrews (2).
2. Remove all M4 bolts. Figure 8-44 Add Spacer if Needed
Figure 8-42 Remove Contact Screws

1. Contact wipe gauge

Figure 8-43 Check New Contact

TP-6921 10/14 Section 8 Component Replacement, 100--600 Amp KSP 151

Source B Side
1
DANGER

Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.

1. Disconnect power and open the transfer switch

enclosure as described in Section 8.2.

2. Loosen the M6 capscrews (qty. 2) to replace the

movable contacts. See Figure 8-45.
1. Load-side terminal 2
3. Remove the load-side terminal. See Figure 8-46. 2. Insulation plate

4. Remove the insulation plate. See Figure 8-46. Figure 8-46 Source B Side

5. To replace the fixed contacts, loosen the M6

capscrews (qty. 3). See Figure 8-45.

Refer to the replacement method of Source A side for

the adjustment of contact pressure on the movable
contacts.

2
1. M6 capscrews for movable contacts, qty. 2
2. M6 capscrews for fixed contacts, qty. 3

Figure 8-45 Loosen Screws

152 Section 8 Component Replacement, 100--600 Amp KSP TP-6921 10/14

8.4.9 Replacement of the Mechanical 1
Unit

DANGER

Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.

1. Disconnect power and open the transfer switch

enclosure as described in Section 8.2.

2. Remove the split pin and pull out the switch pin.
1. M6 bolts (qty. 3)
3. Remove the M6 bolts (qty. 3).
Figure 8-48 Remove M6 Bolts
4. Remove the M8 bolt to replace the mechanical unit.

1
1

1. M8 bolt
1. Remove split pin and pull out switch pin.
Figure 8-49 Remove M8 Bolt
Figure 8-47 Remove pins

TP-6921 10/14 Section 8 Component Replacement, 100--600 Amp KSP 153

 Notes

154 Section 8 Component Replacement, 100--600 Amp KSP TP-6921 10/14

 Section 9 Component Replacement, 800-1000 Amp Model KSS

9.1 Introduction Servicing the transfer switch. Hazardous voltage can

cause severe injury or death. Deenergize all power sources
This section contains instructions for component before servicing. Turn off the main circuit breakers of all
transfer switch power sources and disable all generator sets
replacement on 800--1000 amp Model KSS
as follows: (1) Press the generator set off/reset button to shut
standard-transition transfer switches. See Section 7 for down the generator set. (2) Disconnect power to all battery
component replacement procedures for 40--600 amp chargers. (3) Disconnect all battery cables, negative (--) leads
Model KSS. See Section 8 for programmed-transition first. Reconnect negative (--) leads last when reconnecting the
switches. battery cables after servicing. Follow these precautions to
prevent the starting of generator sets by an automatic transfer
Observe the safety precautions in the following sections switch, remote start/stop switch, or engine start command
from a remote computer. Before servicing any components
when performing any service procedures on the transfer
inside the enclosure: (1) Remove all jewelry. (2) Stand on a
switch. dry, approved electrically insulated mat. (3) Test circuits with a
voltmeter to verify that they are deenergized.
(RDC, DC, RDC2, DC2, Decision-Makerr 3000, 3500 and
9.2 Disconnect Power 6000 Generator Controllers)

DANGER Before performing any of the following service

procedures, disable all connected generator sets and
disconnect power to the ATS as described below.

Procedure
Hazardous voltage.
Will cause severe injury or death. 1. Prevent all connected generator sets from starting.
Only authorized personnel should
a. Place the generator set master switch in the
open the enclosure.
OFF position or press the OFF button on the
generator set controller.
DANGER
b. Disconnect the battery charger, if equipped.

c. Disconnect the generator set engine starting

batter(ies), negative (--) lead first.

Hazardous voltage. 2. Disconnect power to the transfer switch.

Will cause severe injury or death.
3. Open the transfer switch enclosure.
Disconnect all power sources before
opening the enclosure. 4. Use a voltmeter to verify zero volts across each
phase.
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.
(Decision-Makerr 3+ and 550 Generator Controllers)

TP-6921 10/14 Section 9 Component Replacement, 800-1000 Amp Model KSS 155
9.3 Remove the Cover 9.4 Rectifier Circuit Board
Remove the cover from the mechanical unit to gain Replacement
access to the circuit board and solenoid coil.
DANGER
1. Remove the two screws securing the cover. See
Figure 9-1.

2. Remove the cover from the mechanical unit. See

Figure 9-2.
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.

NOTICE
Electrostatic discharge damage. Electrostatic discharge
(ESD) damages electronic circuit boards. Prevent
2 electrostatic discharge damage by wearing an approved
1 grounding wrist strap when handling electronic circuit boards
or integrated circuits. An approved grounding wrist strap
provides a high resistance (about 1 megohm), not a direct
short, to ground.

1. Disconnect power as described in Section 9.2.

2. Remove the circuit board cover. See Figure 9-3.

3. The leads are soldered to the circuit board. Note

1. M6 screw the connections and disconnect the leads at the
2. M4 screw
contactor and coil.
Figure 9-1 Mechanical Unit Cover 4. Remove the M4 screws securing the circuit board.
See Figure 9-4.

5. Install the new circuit board and secure it with the

M4 screws.

6. Connect the new circuit board leads to the

contactor and coil.

7. Replace the covers for the circuit board and the

mechanical unit.

Figure 9-2 Mechanical Unit with Cover Removed

156 Section 9 Component Replacement, 800-1000 Amp Model KSS TP-6921 10/14
 9.5 Closing Coil Replacement
DANGER

Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.

WARNING
2

Spring-loaded parts.
Can cause severe personal injury
1. Circuit board cover or property damage.
2. M4 Screws
Wear protective goggles when
Figure 9-3 Rectifier Circuit Board Cover servicing spring-loaded parts. Hold
parts securely during disassembly.

Disassembling the solenoid. Spring-loaded parts can

cause severe personal injury or property damage. The
spring in the solenoid assembly exerts substantial force on the
coil. Hold the coil assembly securely when removing the
screws.

2 1. Disconnect power and open the transfer switch

enclosure as described in Section 9.2.

2. Remove the cover from the mechanical unit as

1
described in Section 9.3.

3. Hold the bottom plate securely and remove the four

M8 bolts that secure the bottom plate to the coil
assembly. See Figure 9-5.

4. Remove the plate. See Figure 9-6.

5. Remove the two M4 bolts shown in Figure 9-7 (240

volt models) or Figure 9-8 (480 volt models).
Figure 9-9 shows the unit after the coil has been
removed.
1. M4 screws
2. Rectifier leads

Figure 9-4 Rectifier Circuit Board

TP-6921 10/14 Section 9 Component Replacement, 800-1000 Amp Model KSS 157
 1 1

1. M8 bolts (qty. 4) 1. Remove two M4 bolts

Note: The coil is spring-loaded. Hold the plate securely

while removing the bolts. Figure 9-7 240 Volt Coil

Figure 9-5 Closing Coil Bottom Plate

1
1. Closing coil 1. M4 bolts, qty. 2
2. Spring
3. Steel Core Figure 9-8 480 Volt Coil
Figure 9-6 Remove the Bottom Plate

158 Section 9 Component Replacement, 800-1000 Amp Model KSS TP-6921 10/14
 9.6 Auxiliary Switch Replacement
DANGER

Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.

1. Disconnect power and open the transfer switch

enclosure as described in Section 9.2.

2. Loosen the M4 bolts and replace the auxiliary

switches.

3. Tighten the mounting screws to 0.14 Nm (1 in. lb.),

maximum. See Figure 9-10.
Figure 9-9 Coil Removed

6226

1 2
1. Auxiliary switches
2. M4 bolts

Figure 9-10 Auxiliary Switches

TP-6921 10/14 Section 9 Component Replacement, 800-1000 Amp Model KSS 159
9.7 Arc Chute Replacement Arc Chute Replacement Procedure

Note: Some units use retainers (part number 295010) DANGER

instead of M6 nuts. See Figure 9-11. Obtain new
retainers before disassembly.

Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.

1. Disconnect power and open the transfer switch

1 enclosure as described in Section 9.2.

2. Remove the insulation plate. See Figure 9-12.

6226
1. Retainer
6226
Figure 9-11 Retainer 1
1. Insulation plate

Figure 9-12 Contactor

160 Section 9 Component Replacement, 800-1000 Amp Model KSS TP-6921 10/14
 3. Attach a clamp or fixture similar to the one shown in 1
Figure 9-13.

Note: The transfer switch will come apart if the

parts are not clamped as shown before the
nuts or retainers are removed.

4. Loosen the M6 nuts or remove the retainers. See

Figure 9-13.

5. Remove the upper rod shown in Figure 9-13.

6. Replace the arc chutes.

7. Replace the rod.

8. Reinstall and tighten the M6 nuts or install new

retainers and then remove the clamp.
tp6226

9. Reinstall the insulation plate. 2 3

1. Remove this rod
2. Fixture
3. M6 nuts or retainers

Figure 9-13 Fixture or Clamp

TP-6921 10/14 Section 9 Component Replacement, 800-1000 Amp Model KSS 161
9.8 Contact Replacement 1

9.8.1 Source A Side

DANGER

Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.

1. Disconnect power and open the transfer switch

enclosure as described in Section 9.2. 2
1. M6 bolts for fixed contacts (qty. 3)
2. Loosen three (3) M6 bolts for the fixed contacts and 2. M6 bolts for movable contacts (qty. 2)
two (2) M6 bolts for the movable contacts as shown
in Figure 9-14. Figure 9-14 Loosen Bolts (back)

3. Remove the M6 cap screws and all M4 bolts as

shown in Figure 9-15. 1

4. Install the new contacts.

5. After replacing the movable contact, check the

contact pressure with the contact wipe gauge at the
closed position as shown in Figure 9-16. You
should NOT be able to insert the gauge.

6. If the gauge can be inserted, add a 0.5 mm

(0.02 in.) spacer as shown in Figure 9-17.

1. Remove the M6 cap screws (2).

2. Remove all M4 bolts.

Figure 9-15 Remove Contact Screws

162 Section 9 Component Replacement, 800-1000 Amp Model KSS TP-6921 10/14
 1 1

1. Contact wipe gauge 1. Spacer. 0.5 mm (0.02 in.) thick

Figure 9-16 Check New Contact Figure 9-17 Add Spacer if Needed

TP-6921 10/14 Section 9 Component Replacement, 800-1000 Amp Model KSS 163
9.8.2 Source B Side
1
DANGER

Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.

1. Disconnect power and open the transfer switch

enclosure as described in Section 9.2.

2. Loosen the M6 cap screws (qty. 2) to replace the

movable contacts. See Figure 9-18. 2
1. Load-side terminal
2. Insulation plate
3. Remove the load-side terminal. See Figure 9-19.

4. Remove the insulation plate. See Figure 9-19. Figure 9-19 Load Side Terminal and Insulation
Plate
5. To replace the fixed contacts, loosen the M6 cap
screws (qty. 3). See Figure 9-18.

6. Install the new contacts.

Refer to the procedure in Section 9.8.1, Source A Side,

for the adjustment of contact pressure on the movable
contacts.

2
1. M6 cap screws for movable contacts, qty. 2
2. M6 cap screws for fixed contacts, qty. 3

Figure 9-18 Contact Screws

164 Section 9 Component Replacement, 800-1000 Amp Model KSS TP-6921 10/14
9.8.3 Replacement of the Mechanical 1
Unit

DANGER

Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.

1. Disconnect power and open the transfer switch

enclosure as described in Section 9.2.

2. Remove the split pin and pull out the switch pin.
See Figure 9-20. 1. M6 bolts (qty. 3)

3. Remove the M6 bolts (qty. 3). See Figure 9-21. Figure 9-21 Remove M6 Bolts
4. Remove the M8 bolt to replace the mechanical unit.
See Figure 9-22. 1

1. M8 bolt

Figure 9-22 Remove M8 Bolt

1. Remove split pin and pull out switch pin.

Figure 9-20 Remove pins

TP-6921 10/14 Section 9 Component Replacement, 800-1000 Amp Model KSS 165
9.9 Reconnect Power and Test After service, reconnect power and test operation as
described below.
WARNING 1. Close and secure the transfer switch enclosure
door.

2. Reconnect power to the transfer switch by closing

circuit breakers or switches.

Accidental starting. 3. Reconnect the generator set engine starting

Can cause severe injury or death. battery, negative lead last.
Disconnect the battery cables before
working on the generator set. 4. Move the generator set master switch to AUTO or
Remove the negative (--) lead first press the AUTO button on the generator set
when disconnecting the battery. controller.
Reconnect the negative (--) lead last
when reconnecting the battery. 5. Test the system operation by running a test as
described in Section 6.4 or 6.5.
Connecting the battery and the battery charger.
Hazardous voltage can cause severe injury or death.
Reconnect the battery correctly, positive to positive and
negative to negative, to avoid electrical shock and damage to
the battery charger and battery(ies). Have a qualified
electrician install the battery(ies).

166 Section 9 Component Replacement, 800-1000 Amp Model KSS TP-6921 10/14
 Section 10 Component Replacement, 800--3000 Amp KGS/KGP

10.1 Introduction Before performing any of the following service

procedures, disable all connected generator sets and
This section contains component removal and disconnect power to the ATS as described below.
replacement procedures for 800--3000 Amp Model
KGS/KGP bypass/isolation switches. This section Procedure
contains information available at the time of publication.
1. Prevent all connected generator sets from starting.

10.2 Disconnect Power a. Place the generator set master switch in the
OFF position or press the OFF button on the
DANGER generator set controller.

b. Disconnect the battery charger, if equipped.

c. Disconnect the generator set engine starting

batter(ies), negative (--) lead first.
Hazardous voltage.
Will cause severe injury or death. 2. Disconnect power to the transfer switch.
Disconnect all power sources before 3. Open the transfer switch enclosure.
opening the enclosure.
4. Use a voltmeter to verify zero volts across each
Servicing the transfer switch. Hazardous voltage can phase.
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.
(Kohler Decision-Makerr 3+ and 550 Controllers)

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.
(Kohler RDC, DC, RDC2, DC2, Decision-Makerr 3000,
3500 and 6000 Controllers)

TP-6921 10/14 Section 10 Component Replacement, 800--3000 Amp KGS/KGP 167

10.3 Contact Assembly Removal Removing Contact Assemblies, 800--1200
Amp Models
and Replacement
1. Remove the machine screws and flat washers that
10.3.1 800--1200 Amp Models secure the blue plastic switch cover.

2. Remove the cover.

DANGER
3. Manually place the movable contact assembly in
the open position.

4. Remove the screws that secure the arc chute.

Hazardous voltage.
Will cause severe injury or death. 5. Remove the arc chute and arc chute pad.

Disconnect all power sources before 6. Remove the two retaining rings and slide the
opening the enclosure. actuator arms from the contact posts.

7. Remove one of the retaining rings from the pivot

Disconnect power as described in Section 10.2.
pin.
Refer to Figure 10-1 and Figure 10-2 for the following
procedure.
1
2
1

8
3
7
2 7 4

5
3

3 6
4 3
5
6

566867

566866 1. Bus stub bolt 5. Pivot pin

2. Clamp bracket 6. Movable contact assembly
1. Arc chute retaining screws 5. Stationary contact assembly 3. Retaining ring 7. Contact posts
2. Arc chute 6. Transfer switch panel 4. Actuator arms
3. Arc chute pad 7. Lug terminal
4. Machine screws 8. Hex head cap screw Figure 10-2 Movable Contact, 800--1200 Amp

Figure 10-1 Stationary Contact, 800--1200 Amp

168 Section 10 Component Replacement, 800--3000 Amp KGS/KGP TP-6921 10/14

 8. Slide out the pivot pin. same time. For 4 pole switches poles A, B, and C
should close at approximately at the same time.
9. Remove the bus stud bolt, compression washer, The neutral pole should close approximately
and clamp bracket. 12.7 mm (1/2 in.) before the other three poles.
10. Remove the movable contact assembly.

11. If replacing the stationary contact, proceed to

step 12. If not replacing the stationary contact,
proceed to the replacement procedure. 3 2 1

12. Remove the hex head cap screws and the

compression washers (2) that secure the lug
terminal. 3 Pole
13. Remove the machine screws (2) that secure the 5
other end of the stationary contact to the transfer
switch panel.

14. Remove the stationary contact.

4 3 2 1

Replacing Contact Assemblies,

800--1200 Amp Models
4 Pole
Refer to Figure 10-1, Figure 10-2, Figure 10-4,
Figure 10-3, and Figure 10-5 for the following 566868

procedure: 1. C Pole 3. A Pole 5. Operator

2. B Pole 4. Neutral pole
1. If replacing the stationary contact, position the new
stationary contact on the transfer switch panel. Figure 10-3 Contact Adjustment Order

2. Secure the new stationary contact and the lug 9. Manually close the contacts until the arcing
assembly using hex head cap screws, contacts touch. See Figure 10-4. The main
compression washers, and machine screws (2). contacts should have a 1.59 mm (1/16 in.)
minimum gap. If they do not, reject the contact
3. Torque the cap screws to 31.2 Nm (23 ft. lb.) and assembly. Measure and record the prespring gap.
the machine screws to 13.6 Nm (10 ft. lb.).

4. Using the new hardware supplied with the contact 1

assemblies kit secure the new movable contact 2
assembly with the bus stud bolt, compression
washer, and clamp bracket. 3

5. Torque the bus stud bolt to 31.2 Nm (23 ft. lb.)

6. Install the pivot pin and secure with the retaining

ring.
566869
7. Connect the actuator arms to the contact posts and
secure with the two retaining rings. See
Figure 10-2. 1. Prespring gap
2. Main contact gap
3. Arcing contact
8. Adjust the contacts (steps 9, 10, 12, and 13) in the
sequence shown in Figure 10-3. For 3-pole switch
Figure 10-4 Contact Adjustment Part 1
all contacts should close at approximately the

TP-6921 10/14 Section 10 Component Replacement, 800--3000 Amp KGS/KGP 169

10. Close the contacts fully. See Figure 10-5. 10.3.2 1600--2000 Amp Models

1 2 Removing Contact Assembly, 1600--2000 Amp

3
Models

DANGER
4

566860 Hazardous voltage.

Will cause severe injury or death.
1. Spring gap 3. Adjustment screw
2. Locknuts 4. Arcing contacts 0.003 gap Disconnect all power sources before
opening the enclosure.
Figure 10-5 Contact Adjustment Part 2

11. Rock the arcing contact from toe to heel and verify Disconnect power as described in Section 10.2.
that there is a 0.0762 mm (0.003 in.) minimum gap
at the arcing contacts. The feeler gauge must enter Refer to Figure 10-1 and Figure 10-6 for the following
1.59 mm (1/16 in.) past the edge of the silver. procedure:

12. Adjust the spring gap dimension to 3.175 mm

(1/8 in.) maximum to 1.59 mm (1/16 in.) minimum 1 2 3
deflection on the mains less than the prespring
gap, measured in step 9, bias to 1.59 mm (1/16 in.)
4
13. Turn the adjustment screw by hand to set the
spring gap dimension.

14. Lock the setting by tightening the locknuts.

5
15. Check both sides of the main contacts to ensure 8
they are level. Recheck the arc contact to make
sure that it has not changed.

16. Secure the arc chute and arc chute pad with the two
machine screws.
6
17. Check the operation of the transfer switch by 7
manually opening and closing the switch
assemblies.

18. Reinstall and secure the blue plastic cover. 7 566861

6
19. Close and secure the transfer switch enclosure
door.
1. Contact assembly 5. Braid lug
2. Actuator arms 6. Locknuts
20. Reconnect power to the transfer switch by closing 3. Retaining rings 7. Pivot studs
circuit breakers or switches. 4. Bolts 8. Contact posts

21. Reconnect the generator set engine starting Figure 10-6 Movable Contact, 1600--2000 Amp
battery, negative lead last.

22. Move the generator set master switch to AUTO or

press the AUTO button on the generator set
controller.

23. Test the system operation by running a test as

described in Section 6.4.

170 Section 10 Component Replacement, 800--3000 Amp KGS/KGP TP-6921 10/14

 1. Remove the machine screws and flat washers that 4. Torque the bolts to 31.2 Nm (23 ft. lb.).
secure the blue plastic switch cover.
5. Connect the actuator arms to the contact posts and
2. Remove the cover. secure with the two retaining rings.

3. Remove the screws that secure the arc chute. 6. Manually close the contacts slowly until the arcing
contacts touch. The main contacts should have
4. Remove the arc chute and arc chute pad. 6.35 mm (1/4 in.) minimum gap. If not, adjust the
arc finger adjustment nut as required. If the
5. Manually place the movable contact assembly that contacts cannot be brought within specifications,
will be removed in the open position. reject the contact assembly.
6. Remove the two retaining rings and slide the actuator 7. Measure and record the gap at the prespring gap.
arms from the contact posts. See Figure 10-6.
8. Close the contacts fully.
7. Remove the bolts and compression washers (2)
from the braid lug. 9. Rock the arcing contact from toe to heel and verify
that there is a 0.0762 mm (0.003 in.) minimum gap
8. Loosen the locknuts and remove the pivot studs. at the arcing contacts. The feeler gauge must enter
1.59 mm (1/16 in.) past the edge of the silver.
9. Remove the contact assembly.
10. The spring gap dimension must be 1.59 mm
Replacing Contact Assembly 1600--2000 Amp (1/16 in.) less than prespring gap measured in
Models step 7. If the contacts are not within specs, reject
the contact assembly.
Refer to Figure 10-6 and Figure 10-7 for the following
procedure: 11. Check that the contact pressure of each of the
three outside main contacts is between 1.7--2 kg
(3.75--4.5 lb.).
2
1
12. Check that the contact pressure of the arc finger is
between 4--6.4 kg (9--14 lb.).
6
13. Check that both main and arc contact fingers are
not bottomed out when closed.

3 14. Secure the arc chute and arc chute pad with the two
machine screws.

4 15. Check the operation of the transfer switch by

5 manually opening and closing the switch
assemblies.

16. Reinstall and secure the blue plastic cover.

17. Close and secure the transfer switch enclosure

door.

566862 18. Reconnect power to the transfer switch by closing

1. Prespring gap 4. Arc finger circuit breakers or switches.
2. Arc finger adjustment nut 5. Spring gap
3. Main contacts 6. Arcing contacts 19. Reconnect the generator set engine starting
battery, negative lead last.
Figure 10-7 Contact Adjustment
20. Move the generator set master switch to AUTO or
1. Secure the new movable contact assembly with
press the AUTO button on the generator set
the pivot studs, locknuts, and lock washers.
controller.
2. Torque the locknuts to 13.6 Nm (10 ft. lb.).
21. Test the system operation by running a test as
3. Secure the braid lug with the braid lug bolts and described in Section 6.4.
compression washers.

TP-6921 10/14 Section 10 Component Replacement, 800--3000 Amp KGS/KGP 171

10.3.3 3000 Amp Model
1 2
3
Removing Contact Assembly, 3000 Amp 4
Model
5

DANGER
6

Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure. 10

8
Disconnect power as described in Section 10.2.

Note: Replace the B-phase contact assembly only by

first removing two bolts from the adjacent 9
C-phase contact assembly. Refer to step 7b. for 566863

this replacement procedure.

1. Arc finger adjustment nuts 6. Braid lug
Refer to Figure 10-8 and Figure 10-9 during the 2. Contact post 7. Socket head cap screws
3. Retaining rings 8. Anchor bars
following procedure. 4. Actuator arms 9. Braid lug bolts
5. Contact assembly 10. Pivot studs

Figure 10-9 Movable Contact A or C Phase,

1
2 3000 Amp

1. Remove the machine screws and flat washers that

secure the blue plastic switch cover.
3
2. Remove the cover.

7 4 3. Remove the screws that secure the arc chute.

4. Remove the arc chute and arc chute pad.

5 5. Manually place the movable contact assembly that

will be removed in the open position.

3
6. Remove the two retaining rings and slide the
6
actuator arms from the contact posts.
3
7. Remove the twelve 1/4-20 socket head cap screws
from the load bus assembly and lift out the anchor
bars. The longer cap screws are used on the sides.

a. To remove an A-phase, C-phase, or neutral

566867
contact assembly: Remove the bolts, nuts, and
1. Bus stub bolt 5. Pivot pin compression washers that secure the braid
2. Clamp bracket 6. Movable contact assembly lugs to the bus bars. To remove a B-phase
3. Retaining ring 7. Contact posts
4. Actuator arms contact assembly follow the procedure
described in step 7b.
Figure 10-8 Stationary Contact

172 Section 10 Component Replacement, 800--3000 Amp KGS/KGP TP-6921 10/14

 b. To remove a B-phase contact assembly: the bolts, nuts and compression washers. Torque
the nuts to 19 Nm (14 ft. lb.). To replace a B-phase
D Remove the nuts and compression contact assembly, follow the procedure described
washers from the ends of the braid lug in step 3b.
studs.
OR
D Remove the nut and washers from the
lower bolt on the C-phase braid lug. 3. To replace a B-phase contact assembly:

D Remove the bolt. a. Use a bent wire to align the bus bar holes with
the braid lug holes.
D Slide the lower B-phase threaded stud into
the hole where the C-phase bolt had been. b. Use the braid lug bolts that were removed from
the C-phase assembly to push the B-phase
D Repeat this procedure with the upper braid lug studs back into position in the B-phase
C-phase bolt and corresponding upper assembly. Tap the bolts lightly with a hammer, if
B-phase stud. Keep the threaded studs in necessary.
the C-phase assembly to hold the C-phase
braid lugs in position. c. Secure the B-phase studs and C-phase bolts
with compression washers and nuts. Torque
8. Loosen the locknuts and remove the pivot studs. the nuts to 19 Nm (14 ft. lb.).
9. Remove the contact assembly. 4. Install the anchor bars on the load bus assembly
with twelve 1/4-20 socket head cap screws. The
Replacing Contact Assembly, 3000 Amp longer cap screws are used on the sides. Torque
Model the cap screws to 10.2 Nm (90 in. lb.).

Refer to Figure 10-7, Figure 10-9, and Figure 10-10 for 5. Connect the actuator arms to the contact posts and
the following procedure. secure with two retaining rings.

6. Close the contacts slowly until the arcing contacts

8. touch. The main contacts should have a 6.35 mm
1 (1/4 in.) minimum gap. If they do not, adjust the arc
4
2 5 finger adjustment nut as required. If the contacts
3 cannot be brought within specifications, reject the
contact assembly.

7. Measure and record the prespring gap.

8. Close the contacts fully.

9. Rock the arcing contact from toe to heel and verify

7 that there is an 0.0762 mm (0.003 in.) minimum
gap at the arcing contact. A feeler gauge must
enter 1.59 mm (1/16 in.) past the edge of the silver.
6
566864 10. The spring gap dimension must be 1.59 mm
(1/16 in.) less than the prespring gap dimension
measured in step 7. If the contacts are not within
1. Arc finger, adjustment nut 5. C-Phase braid lug bolts
2. Contact assembly 6. Braid lug nuts and washers specifications, reject the contact assembly.
3. Braid lug 7. Pivot stud
4. B-Phase braid lug studs 11. Check that the contact pressure of each of the
three outside main contacts is between 1.7--2 kg
Figure 10-10 Movable Contact B Phase, 3000 Amp (3.75--4.5 lb.). Check that the contact pressure of
the arc finger, is between 4--6.4 kg (9--14 lb.).
1. Secure the new movable contact assembly with
the pivot studs, locknuts, and lock washers. Torque 12. Check that both main and arc contact fingers are
the locknuts to 13.6 Nm (10 ft. lb.). not bottomed out when closed.
2. To replace an A-phase, C-phase, or neutral contact
assembly secure the braid lugs to the bus bars with

TP-6921 10/14 Section 10 Component Replacement, 800--3000 Amp KGS/KGP 173

13. Secure the arc chute and arc chute pad with two 10.4 Auxiliary Switch Removal and
machine screws.
Replacement
14. Check the operation of the transfer switch by
manually opening and closing the switch
assemblies. 1

15. Reinstall and secure the blue plastic cover.

16. Close and secure the transfer switch enclosure

2
door.

17. Reconnect power to the transfer switch by closing 3

circuit breakers or switches. 4 4

18. Reconnect the generator set engine starting

battery, negative lead last.
5 6
19. Move the generator set master switch to AUTO or
press the AUTO button on the generator set 3
4
controller.

20. Test the system operation by running a test as

described in Section 6.4.
7

566865

1. 1200 amp 2-position switches

2. 1600--3000 amp 2-position switches
3. SE switches
4. SN switches
5. Mounting screws
6. 1200--3000 amp 3-position switches
7. SNO switches

Figure 10-11 Auxiliary Switches

174 Section 10 Component Replacement, 800--3000 Amp KGS/KGP TP-6921 10/14

Removing and Replacing Auxiliary Switch 7. Check the following on the new auxiliary switch:
Assembly
a. SN/SNO and SE/SEO pairs are adjusted to
have the same over travel.
DANGER
b. The auxiliary switch trips 1.59 mm (1/16 in.)
before it reaches its fully seated position.

c. After the auxiliary switch trips, there must be

Hazardous voltage. over travel to ensure good switch operation.
Will cause severe injury or death.
d. Do not force the auxiliary switch into the fully
Disconnect all power sources before operated position.
opening the enclosure.
e. The auxiliary switches that operate as the main
Disconnect power as described in Section 10.2. contacts are closing should trip just as the
contact mechanism reaches the over-center
1. Remove the four machine screws, if applicable, point.
and lift off the metal solenoid cover.
1
2. Remove the two mounting screws that secure the
bracket-mounted switch assembly to the panel. 2

3. Before disconnecting the control wiring leads from 3

the auxiliary switch, observe and note the switch 4
terminal markings, NO, NC, and C, and which wire
connects to each.

4. Disconnect the wires and connect them to the

corresponding terminals of the replacement switch
assembly. 566865

1. Full release position 3. Over travel position

5. Install the new auxiliary switch assembly with the 2. Trip position 4. Fully operated position
two mounting screws.
Figure 10-12 Auxiliary Adjustment
6. Manually operate the transfer switch to make sure
that the new auxiliary switch trips. Listen for an
audible click when the switch trips. 10.5 Reconnect Power and Test
After service, reconnect power and test operation as
described below.

1. Close and secure the transfer switch enclosure

door.

2. Reconnect power to the transfer switch by closing

circuit breakers or switches.

3. Reconnect the generator set engine starting

battery, negative lead last.

4. Move the generator set master switch to AUTO or

press the AUTO button on the generator set
controller.

5. Test the system operation by running a test as

described in Section 6.4.

TP-6921 10/14 Section 10 Component Replacement, 800--3000 Amp KGS/KGP 175

 Notes

176 Section 10 Component Replacement, 800--3000 Amp KGS/KGP TP-6921 10/14

 Appendix A Abbreviations
The following list contains abbreviations that may appear in this publication.
A, amp ampere cfm cubic feet per minute est. estimated
ABDC after bottom dead center CG center of gravity E-Stop emergency stop
AC alternating current CID cubic inch displacement etc. et cetera (and so forth)
A/D analog to digital CL centerline exh. exhaust
ADC advanced digital control; cm centimeter ext. external
analog to digital converter CMOS complementary metal oxide F Fahrenheit, female
adj. adjust, adjustment substrate (semiconductor) fglass. fiberglass
ADV advertising dimensional cogen. cogeneration FHM flat head machine (screw)
drawing com communications (port) fl. oz. fluid ounce
Ah amp-hour coml commercial flex. flexible
AHWT anticipatory high water Coml/Rec Commercial/Recreational freq. frequency
temperature conn. connection FS full scale
AISI American Iron and Steel cont. continued
Institute ft. foot, feet
CPVC chlorinated polyvinyl chloride ft. lb. foot pounds (torque)
ALOP anticipatory low oil pressure
crit. critical ft./min. feet per minute
alt. alternator
CRT cathode ray tube ftp file transfer protocol
Al aluminum
CSA Canadian Standards g gram
ANSI American National Standards Association
Institute (formerly American ga. gauge (meters, wire size)
Standards Association, ASA) CT current transformer gal. gallon
AO anticipatory only Cu copper gen. generator
APDC Air Pollution Control District cUL Canadian Underwriter’s genset generator set
Laboratories
API American Petroleum Institute GFI ground fault interrupter
CUL Canadian Underwriter’s
approx. approximate, approximately Laboratories GND, ground
AQMD Air Quality Management District cu. in. cubic inch gov. governor
AR as required, as requested cw. clockwise gph gallons per hour
AS as supplied, as stated, as CWC city water-cooled gpm gallons per minute
suggested
cyl. cylinder gr. grade, gross
ASE American Society of Engineers
D/A digital to analog GRD equipment ground
ASME American Society of
Mechanical Engineers DAC digital to analog converter gr. wt. gross weight
assy. assembly dB decibel HxWxD height by width by depth
ASTM American Society for Testing dB(A) decibel (A weighted) HC hex cap
Materials DC direct current HCHT high cylinder head temperature
ATDC after top dead center DCR direct current resistance HD heavy duty
ATS automatic transfer switch deg.,  degree HET high exhaust temp., high
auto. automatic dept. department engine temp.
aux. auxiliary DFMEA Design Failure Mode and hex hexagon
avg. average Effects Analysis Hg mercury (element)
AVR automatic voltage regulator dia. diameter HH hex head
AWG American Wire Gauge DI/EO dual inlet/end outlet HHC hex head cap
AWM appliance wiring material DIN Deutsches Institut fur Normung HP horsepower
e. V. (also Deutsche Industrie hr. hour
bat. battery Normenausschuss)
BBDC before bottom dead center HS heat shrink
DIP dual inline package hsg. housing
BC battery charger, battery DPDT double-pole, double-throw
charging HVAC heating, ventilation, and air
DPST double-pole, single-throw conditioning
BCA battery charging alternator
DS disconnect switch HWT high water temperature
BCI Battery Council International
DVR digital voltage regulator Hz hertz (cycles per second)
BDC before dead center
E, emer. emergency (power source) IC integrated circuit
BHP brake horsepower
ECM electronic control module, ID inside diameter, identification
blk. black (paint color), block engine control module
(engine) IEC International Electrotechnical
EDI electronic data interchange Commission
blk. htr. block heater
EFR emergency frequency relay IEEE Institute of Electrical and
BMEP brake mean effective pressure
e.g. for example (exempli gratia) Electronics Engineers
bps bits per second
EG electronic governor IMS improved motor starting
br. brass
EGSA Electrical Generating Systems in. inch
BTDC before top dead center Association in. H2O inches of water
Btu British thermal unit EIA Electronic Industries in. Hg inches of mercury
Btu/min. British thermal units per minute Association in. lb. inch pounds
C Celsius, centigrade EI/EO end inlet/end outlet Inc. incorporated
cal. calorie EMI electromagnetic interference ind. industrial
CAN controller area network emiss. emission int. internal
CARB California Air Resources Board eng. engine int./ext. internal/external
CB circuit breaker EPA Environmental Protection I/O input/output
cc cubic centimeter Agency
IP iron pipe
CCA cold cranking amps EPS emergency power system
ISO International Organization for
ccw. counterclockwise ER emergency relay Standardization
CEC Canadian Electrical Code ES engineering special, J joule
cert. certificate, certification, certified engineered special
JIS Japanese Industry Standard
cfh cubic feet per hour ESD electrostatic discharge

TP-6921 10/14 Appendix 177

k kilo (1000) MTBO mean time between overhauls rms root mean square
K kelvin mtg. mounting rnd. round
kA kiloampere MTU Motoren-und Turbinen-Union ROM read only memory
KB kilobyte (210 bytes) MW megawatt rot. rotate, rotating
KBus Kohler communication protocol mW milliwatt rpm revolutions per minute
kg kilogram F microfarad RS right side
kg/cm2 kilograms per square N, norm. normal (power source) RTU remote terminal unit
centimeter NA not available, not applicable RTV room temperature vulcanization
kgm kilogram-meter nat. gas natural gas RW read/write
kg/m3 kilograms per cubic meter NBS National Bureau of Standards SAE Society of Automotive
kHz kilohertz NC normally closed Engineers
kJ kilojoule NEC National Electrical Code scfm standard cubic feet per minute
km kilometer NEMA National Electrical SCR silicon controlled rectifier
kOhm, k kilo-ohm Manufacturers Association s, sec. second
kPa kilopascal NFPA National Fire Protection SI Systeme international d’unites,
kph kilometers per hour Association International System of Units
kV kilovolt Nm newton meter SI/EO side in/end out
kVA kilovolt ampere NO normally open sil. silencer
kVAR kilovolt ampere reactive no., nos. number, numbers SN serial number
kW kilowatt NPS National Pipe, Straight SNMP simple network management
kWh kilowatt-hour NPSC National Pipe, Straight-coupling protocol
kWm kilowatt mechanical NPT National Standard taper pipe SPDT single-pole, double-throw
kWth kilowatt-thermal thread per general use SPST single-pole, single-throw
L liter NPTF National Pipe, Taper-Fine spec specification
LAN local area network NR not required, normal relay specs specification(s)
L x W x H length by width by height ns nanosecond sq. square
lb. pound, pounds OC overcrank sq. cm square centimeter
lbm/ft3 pounds mass per cubic feet OD outside diameter sq. in. square inch
LCB line circuit breaker OEM original equipment SS stainless steel
manufacturer std. standard
LCD liquid crystal display
OF overfrequency stl. steel
ld. shd. load shed
opt. option, optional tach. tachometer
LED light emitting diode
OS oversize, overspeed TD time delay
Lph liters per hour
OSHA Occupational Safety and Health TDC top dead center
Lpm liters per minute Administration
LOP low oil pressure TDEC time delay engine cooldown
OV overvoltage TDEN time delay emergency to
LP liquefied petroleum oz. ounce normal
LPG liquefied petroleum gas p., pp. page, pages TDES time delay engine start
LS left side PC personal computer TDNE time delay normal to
Lwa sound power level, A weighted PCB printed circuit board emergency
LWL low water level pF picofarad TDOE time delay off to emergency
LWT low water temperature PF power factor TDON time delay off to normal
m meter, milli (1/1000) ph.,  phase temp. temperature
M mega (106 when used with SI PHC Phillipsr head Crimptiter term. terminal
units), male (screw) THD total harmonic distortion
m3 cubic meter PHH Phillipsr hex head (screw) TIF telephone influence factor
m3/hr. cubic meters per hour PHM pan head machine (screw) TIR total indicator reading
m3/min. cubic meters per minute PLC programmable logic control tol. tolerance
mA milliampere PMG permanent magnet generator turbo. turbocharger
man. manual pot potentiometer, potential typ. typical (same in multiple
max. maximum ppm parts per million locations)
MB megabyte (220 bytes) PROM programmable read-only UF underfrequency
MCCB molded-case circuit breaker memory UHF ultrahigh frequency
MCM one thousand circular mils psi pounds per square inch UL Underwriter’s Laboratories, Inc.
meggar megohmmeter psig pounds per square inch gauge UNC unified coarse thread (was NC)
MHz megahertz pt. pint UNF unified fine thread (was NF)
mi. mile PTC positive temperature coefficient univ. universal
mil one one-thousandth of an inch PTO power takeoff US undersize, underspeed
min. minimum, minute PVC polyvinyl chloride UV ultraviolet, undervoltage
misc. miscellaneous qt. quart, quarts V volt
MJ megajoule qty. quantity VAC volts alternating current
mJ millijoule R replacement (emergency) VAR voltampere reactive
mm millimeter power source VDC volts direct current
mOhm, mmilliohm rad. radiator, radius VFD vacuum fluorescent display
MOhm, Mmegohm RAM random access memory VGA video graphics adapter
MOV metal oxide varistor RDO relay driver output VHF very high frequency
MPa megapascal ref. reference W watt
mpg miles per gallon rem. remote WCR withstand and closing rating
mph miles per hour Res/Coml Residential/Commercial w/ with
MS military standard RFI radio frequency interference w/o without
ms millisecond RH round head wt. weight
m/sec. meters per second RHM round head machine (screw) xfmr transformer
MTBF mean time between failure rly. relay

178 Appendix TP-6921 10/14

Appendix B Screen Summaries

For reference, this section lists the items displayed during normal operation, and the information and settings shown in
the View screens and Setup menus on Decision-Makerr MPAC 1200 and 1500 controllers.

Operation Screens View Screens

Main Screen Main Screen
D System Status D System Status
D Next Exercise Time and Date D Next Exercise Time and Date
D Normal Source Voltage D Normal and Emergency Voltage
D Emergency Source Voltage * View Event History
D Frequency D Event Description
D Lamp Test D Date and Time of event
D Current, Amps View Maintenance Records
D Time/Date D Total Min Not Preferred
D Daylight Saving Time Info D Reset Min Not Preferred
D Preferred Source D Total Min in Standby
D Source-Source Type D Reset Min in Standby
D Commit/No Commit to Transfer D Total Min Operation
D Standard/Programmed/Closed Transition [ D Reset Min Operation
D Phase Rotation (3-phase only) D Total Transfers
D In-Phase Monitoring Enabled/Disabled D Reset Transfers
Test Sequence Screens D Total Fail Transfer
D Enter Password D Reset Fail Transfer
D Type of Test D Total Loss Pref Tran
d Loaded/Unloaded/Auto Load/Sync Check D Reset Lodd Pref Tran
d Auto Load Test Run Time D Transfer Time N>E
D Test Sequence Status Screens D Transfer Time E>N
d Active Time Delay with Time Remaining D System Start Date
d Source Voltages D Last Maint Date
d End Delay Button D Last Loss Duration
d End Test Button D Last Loss Date/Time
d Phase Angle (sync check only) D Dual Source Connect Time *
Exerciser Sequence (during exercise run) D S1 to Open Time *
D Exerciser Active D S1 to Close time *
D Source Voltages D S2 to Open Time *
D Time Remaining (in exercise run) D S2 to Close Time *
D End Exercise Button

* Decision-Maker MPAC 1500 controller only

[ Closed-transition and seervice entrance models are not covered in this manual.

TP-6921 10/14 Appendix 179

 View Exerciser Setup View Source Setup, Continued
D Exercise Event Number D Synchronization (for closed-transition)
D Enabled/Disabled d Voltage Differential
D Exercise Run Time d Frequency Differential
D Start Date d Angle differential
D Start Time D Fail toSync
D Weekly/Biweekly d Enabled/Disabled
D Loaded/Unloaded d Time Delay min:sec
View System Setup View Time Delays, Source S1 and Source S2
D Standard/Programmed/Closed Transition [ D Engine Start (gen set only)
D Source Type: Util/Gen, Gen/Gen*, Util/Util* or Util/Gen/Gen* D Engine Cooldown
D Service Entrance: Yes/No *[ D Xfr Preferred>Standby (Standby>Preferred)
D In--Phase Monitor Enabled/Disabled D Xfr Off > Standby (Off >Preferred)
(programmed--transition only)
D Commit/No Commit to Transfer
D Fail to Acquire Preferred *
D # I/O Modules Installed
D Fail to Acquire Standby
D Rated Current
D Load Control
D 3 Src Engine Start Mode Mode1/Mode2 *
d Mode: None/Time/Current *
D Remote Test Loading Loaded/Unloaded
d Loads to Control (1--9)
D Peak Shave Delay Enabled/Disabled
D Time-Based Control
View Source Setup
d Load Disconnect N>E (E>N) Time Delay min:sec
D ABC/BAC Rotation (3-phase only)
d Load Add E>N (N>E) Time Delay min:sec
D System Voltage, Normal/Emergency
D Current-Based Control *
D Frequency (Hz), Source N and E
d Load Disc N>E (E>N) time delay min:sec
D Normal Under Voltage PU% and DO%
d Load control Source1 (Source2) Enabled/Disabled
d Normal Over Voltage PU% and DO%
d Load Add Source1 (Source2) Time Delay min:sec
d Debounce Time, Seconds
d Load Add Source1 (Source2) Priority
D Normal Under Frequency PU% and DO%
d Load Remove Source1 (Source2) Time Delay min:sec
d Debounce Time
d Load RemoveSource1 (Source2) Priority
D Normal Voltage Unbalance Enable/Disable
d Amps Level Remove Source1 (Source2)
d Normal Voltage Unbalance PU% and DO%
d Amps Level Add Source1 (Source2)
D Emergency Under Voltage PU% and DO%
View Inputs/Outputs
d Emergency Over Voltage PU% and DO%
D Main Board I/O
d Debounce Time
d Input Function Descriptions (2)
D Emergency Under Frequency PU% and DO%
d Output Function Descriptions (2)
d Emergency Over Frequency PU% and DO%
D Auxiliary Inputs/ Outputs (optional modules)
d Debounce Time
d Module Type and Address
D Emergency Voltage Unbalance Enable/Disable
d Module Status
d Emergency Voltage Unbalance PU% and DO%
d Input Function Descriptions
D In-Phase Monitor
d Output Function Descriptions
d Enabled/Disabled
d Angle, degrees View Common Alarms

D In-Phase Transfer Fail D Alarm Group (1 and 2)

d Enabled/Disabled D Alarm Description
d Time Delay min:sec D Audible (Yes or No)
D Common (Yes or No)

* Decision-Maker MPAC 1500 controller only

[ Closed-transition and seervice entrance models are not covered in this manual.

180 Appendix TP-6921 10/14

View Communications Setup View Control Parameters
D Modbus Server TCP Enabled/Disabled D Application Version (factory-set)
D Modbus Server Port 0 Enable/Disabled D ATS Serial Number (factory-set)
D Modbus Address Port 0 D Controller Serial Number (factory-set)
D Baud Rate Port 0 9600/19200/57600 D Contactor Serial Number (factory-set)
D Modbus TCP Unit ID D Site Designation (optional; use SiteTech to set)
D IP Address D Load Description (optional; use SiteTech to set)
D Subnet Mask D Branch Description (optional; use SiteTech to set)
D MAC Address D Location (optional; use SiteTech to set)

TP-6921 10/14 Appendix 181

Setup Menus Set Source
D Phase Rotation ABC/BAC/Disabled
Set Time/Date
D Set In-Phase Monitor
D Set Time
d Enable/Disable
D Set Date
d Angle
D Set Automatic Daylight Saving Time
d In-Phase Transfer Fail Time Delay
Set Exerciser d Enable/Disable
For each exerciser event:
d Time Delay min:sec
D Enable/Disable D Set Synchronization (closed-transition models [)
D Loaded/Unloaded d Voltage Differential
D Interval d Frequency Differential
D Repeat Rate d Angle Differential
D Duration d Fail to Sync
D Start Date d Enable/Disable
D Start time d Time Delay min:sec
Set Prime Power Run * D Set Preferred Source Normal/Emergency (alarm module
D Enable/Disable required)
D Duration at Source1 DD:HH:MM D Set Normal (Emergency) Source:
D Duration at Source2 DD:HH:MM d Number of Phases
D Sequence Start/Stop d Voltage
Set S1 Time Delays (Set S2 Time Delays) d Frequency
D Engine Start d Under Voltage Pickup
d External Battery? Y or N d Under Voltage Dropout
d Time Delay min:sec d Over Voltage Pickup
D Engine Cooldown Time Delay min:sec d Over Voltage dropout
D Xfr Preferred>Standby (Standby>Preferred) d Voltage Debounce Time
D Xfr Off > Standby (Off >Preferred) d Voltage Unbalance Enable/Disable (3-phase only)
(programmed--transition only) d Voltage Unbalance Pickup (3-phase only)
D Fail to Acquire Standby (Preferred *) d Voltage Unbalance Dropout (3-phase only)
d Enable/Disable d Under Frequency Pickup
d Time Delay min:sec d Under Frequency Dropout
D Load Control d Over Frequency Pickup
d Mode: None/Time/Current d Over Frequency Dropout
d Loads to Control (1--9) d Frequency Debounce time
D Time-Based Control (for each connected load) Set Input/Output
d Load Disconnect N>E (E>N) Time Delay min:sec D Set Main Board I/O
d Load Add E>N (N>E) Time Delay min:sec d Set Input Functions
D Current-Based Control * d Set Output Functions
d Load Disc N>E (E>N) time delay min:sec D Set Auxiliary I/O (Modules)
d For each connected load: d Set Input Functions
d Load Add Source1 (Source2) Time Delay min:sec d Set Output Functions
d Load Add Source1 (Source2) Priority Set Common Alarms
d Load Remove Source1 (Source2) Time Delay min:sec D Alarm Group 1 or 2
d Load RemoveSource1 (Source2) Priority D Modify Alarm
d Load Control Enable/Diable d Common (Yes/No)
d Set Hi current Level, Load Remove Source1 (Source2) d Audible (Yes/No)
d Set Lo Current Level, Load Add Source1 (Source2) D Remove All Alarms Yes/No

* Decision-Maker MPAC 1500 controller only

[ Closed-transition and seervice entrance models are not covered in this manual.

182 Appendix TP-6921 10/14

 Set System Set Passwords
D Source Type: Utility/Generator, Generator/Generator*, D Setup Password
Utility/Utility*, Utility/Generator/Generator (3--source system)*
D Test Password
D Transition Type: Standard/Programmed/Closed [
Calibration
d Prog Transition Override Automatic/Manual
(closed-transition only) [
D Line-Neutral Voltages, Source N and E

D Service Entrance No/ICCB/MCCB [ D Line-Line Voltages, Source N and E

D Rated Current, Amps D Load Current, LA, LB, and LC

D 3 Source Engine Start Mode * Reset Data

d Mode1/Mode2 D Reset Maintenance Records, Yes or No
d Preferred Source Toggle Enable/Disable D Reset Event History, Yes or No
D Transfer Commit Commit/No Commit D Reset Default Parameters, Yes or No
D Remote Test Loading Loaded/Unloaded D Reset Exercise Setup, Yes or No
D Peak Shave TD Bypass Enable/Disable D Reset Test Password, Yes or No

Set Communications D Disable Test Password, Yes or No

D Modbus Server TCP Enable/Disable

D Modbus Server Port 0 Enable/Disable
D Modbus Address Port 0
D Baud Rate Port 0 9600/19200/57600
D Modbus TCP Unit ID
D IP Address
D Subnet Mask
D Default Gateway
D DHCP Status

* Decision-Maker MPAC 1500 controller only

[ Closed-transition and seervice entrance models are not covered in this manual.

TP-6921 10/14 Appendix 183

 Appendix C Noise and Wiring Practices

Electrical noise is an unwanted electrical signal that can D General Purpose Power Distribution. Circuits to
cause errors in measurement, loss of control, medium-power loads such as lighting, offices, light-
malfunctions in microprocessor-based control systems, duty equipment, and small motors such as fans and
errors in data transfer between systems over pumps can emit transient, medium levels of broad-
communication links, or reductions in system spectrum noise. Some electronic equipment, such as
performance. computers, emits constant levels of broad-spectrum
noise in addition to transient broad-spectrum noise.
Good system design and wiring practices can minimize Loads on general-purpose circuits, except for
noise levels and the effects of noise. sensitive electronic equipment, are nearly immune to
noise.
Noise, because of its random nature, is typically
characterized by frequency distribution. Many noise D Control. Control circuits include DC circuits and
sources are broad-spectrum, that is, they produce many 120 VAC maximum AC circuits that operate at a low
frequencies distributed over a wide range. Broad- power level (less than 1 W). Typical circuits include
spectrum noise is particularly troublesome because it circuits to switches, actuators, and dry-contact relays,
cannot be removed easily by filtering, and because it including the generator engine-start circuit. Control
can affect a variety of systems in unpredictable ways. circuits emit transient low levels of broad-spectrum
noise and are fairly immune to noise.
One common source of broad-spectrum noise is a
switch, which can produce voltage and current changes D Analog. Analog circuits are low-voltage DC circuits
when an electrical circuit is connected and that convey measurement information as relatively
disconnected. small changes in current or voltage. Typical circuits
include those connected to the controller’s analog
Coupling is the transfer of signals between separate inputs. Analog circuits create the lowest noise levels
circuits. Signals from one circuit become noise in and are the most sensitive to noise.
another. The amount of coupling is cumulative and is a
function of the proximity of the circuits, their orientation, D Communication and Signaling. Communication
exposed area, and length of run. Minimize coupling by and signaling circuits are low-voltage circuits that
the following: convey information. Typical circuits include RS-232
and RS-485 serial communication lines, telephone
D Isolating circuits from each other by using separate lines, and computer network lines. These circuits
raceways or conduit create noise with frequencies related to the
communication signaling rate. These circuits have
D Separating circuits from each other by locating them some level of built-in noise immunity. Typical systems
as far apart as possible will detect or correct errors caused by noise below
certain levels, but with a corresponding reduction in
D Enclosing circuits with a grounded metallic shield
the data transfer rate.
such as an enclosure, metallic conduit, or cable shield
When planning an installation, separate all of these
D Running conductors perpendicular, rather than
types of circuits as much as possible to minimize the
parallel, to each other
hazards of insulation failure, accidental miswiring, and
D Running wires loosely and randomly rather than noise coupling. For best results, install control circuits,
bundling them tightly together analog circuits, and communication and signaling
circuits separately. Combining circuit types is
D Twisting a circuit’s wires together in pairs unavoidable in the controller’s enclosure and some
other areas.
In an industrial environment, there are typically five
types of circuits with different noise emission and Note: It is very important to isolate high- and medium-
rejection capabilities. The five types of circuits are as power circuits in raceways or conduit separate
follows: from the other types of circuits.

D High-Power Distribution. Circuits to high-power

loads such as large electric motors and heaters can
emit transient high levels of broad-spectrum noise.
Loads on high-power distribution circuits are nearly
immune to noise.

184 Appendix TP-6921 10/14

 Appendix D Common Hardware Application Guidelines

Use the information below and on the following pages to Steps for common hardware application:
identify proper fastening techniques when no specific
reference for reassembly is made. 1. Determine entry hole type: round or slotted.

Bolt/Screw Length: When bolt/screw length is not given, 2. Determine exit hole type: fixed female thread
use Figure 1 as a guide. As a general rule, a minimum (weld nut), round, or slotted.
length of one thread beyond the nut and a maximum
length of 1/2 the bolt/screw diameter beyond the nut is For round and slotted exit holes, determine if
the preferred method. hardware is greater than 1/2 inch in diameter, or
1/2 inch in diameter or less. Hardware that is
Washers and Nuts: Use split lock washers as a bolt greater than 1/2 inch in diameter takes a standard
locking device where specified. Use SAE flat washers nut and SAE washer. Hardware 1/2 inch or less in
with whiz nuts, spiralock nuts, or standard nuts and diameter can take a properly torqued whiz nut or
preloading (torque) of the bolt in all other applications. spiralock nut. See Figure 2.

3. Follow these SAE washer rules after determining

See Appendix E, General Torque Specifications, and
exit hole type:
other torque specifications in the service literature.
a. Always use a washer between hardware and a
slot.
Preferred Nut/Bolt Clearance
1 2 b. Always use a washer under a nut (see 2 above
for exception).

c. Use a washer under a bolt when the female

thread is fixed (weld nut).

4. Refer to Figure 2, which depicts the preceding

hardware configuration possibilities.

Unacceptable Nut/Bolt Clearance

2
3 1

G-585

1. 1/2 of bolt diameter

2. Min. 1 full thread beyond top of nut
3. Below top of nut

Figure 1 Acceptable Bolt Lengths

5
4
6

G-585

1. Cap screw
2. Entry hole types
3. Standard nut and SAE washer
4. Whiz nut or spiralock: up to 1/2 in. dia. hardware
5. Weld nuts: above 1/2 in. dia. hardware
6. Exit hole types

Figure 2 Acceptable Hardware Combinations

TP-6921 10/14 Appendix 185

Appendix E General Torque Specifications

American Standard Fasteners Torque Specifications

Assembled into Cast Iron or Steel Assembled into

Torque Aluminum
Size Measurement Grade 2 Grade 5 Grade 8 Grade 2 or 5
8-32 Nm (in. lb.) 1.8 (16) 2.3 (20) —
10-24 Nm (in. lb.) 2.9 (26) 3.6 (32) —
10-32 Nm (in. lb.) 2.9 (26) 3.6 (32) —
1/4-20 Nm (in. lb.) 6.8 (60) 10.8 (96) 14.9 (132)
1/4-28 Nm (in. lb.) 8.1 (72) 12.2 (108) 16.3 (144)
5/16-18 Nm (in. lb.) 13.6 (120) 21.7 (192) 29.8 (264)
5/16-24 Nm (in. lb.) 14.9 (132) 23.1 (204) 32.5 (288)
3/8-16 Nm (ft. lb.) 24.0 (18) 38.0 (28) 53.0 (39)
3/8-24 Nm (ft. lb.) 27.0 (20) 42.0 (31) 60.0 (44)
7/16-14 Nm (ft. lb.) 39.0 (29) 60.0 (44) 85.0 (63)
7/16-20 Nm (ft. lb.) 43.0 (32) 68.0 (50) 95.0 (70) See Note 3
1/2-13 Nm (ft. lb.) 60.0 (44) 92.0 (68) 130.0 (96)
1/2-20 Nm (ft. lb.) 66.0 (49) 103.0 (76) 146.0 (108)
9/16-12 Nm (ft. lb.) 81.0 (60) 133.0 (98) 187.0 (138)
9/16-18 Nm (ft. lb.) 91.0 (67) 148.0 (109) 209.0 (154)
5/8-11 Nm (ft. lb.) 113.0 (83) 183.0 (135) 259.0 (191)
5/8-18 Nm (ft. lb.) 128.0 (94) 208.0 (153) 293.0 (216)
3/4-10 Nm (ft. lb.) 199.0 (147) 325.0 (240) 458.0 (338)
3/4-16 Nm (ft. lb.) 222.0 (164) 363.0 (268) 513.0 (378)
1-8 Nm (ft. lb.) 259.0 (191) 721.0 (532) 1109.0 (818)
1-12 Nm (ft. lb.) 283.0 (209) 789.0 (582) 1214.0 (895)

Metric Fasteners Torque Specifications, Measured in Nm (ft. lb.)

Assembled into
Assembled into Cast Iron or Steel
Aluminum
Size (mm) Grade 5.8 Grade 8.8 Grade 10.9 Grade 5.8 or 8.8
M6 x 1.00 6.2 (4.6) 9.5 (7) 13.6 (10)
M8 x 1.25 15.0 (11) 23.0 (17) 33.0 (24)
M8 x 1.00 16.0 (11) 24.0 (18) 34.0 (25)
M10 x 1.50 30.0 (22) 45.0 (34) 65.0 (48)
M10 x 1.25 31.0 (23) 47.0 (35) 68.0 (50)
M12 x 1.75 53.0 (39) 80.0 (59) 115.0 (85)
M12 x 1.50 56.0 (41) 85.0 (63) 122.0 (90) See Note 3
M14 x 2.00 83.0 (61) 126.0 (93) 180.0 (133)
M14 x 1.50 87.0 (64) 133.0 (98) 190.0 (140)
M16 x 2.00 127.0 (94) 194.0 (143) 278.0 (205)
M16 x 1.50 132.0 (97) 201.0 (148) 287.0 (212)
M18 x 2.50 179.0 (132) 273.0 (201) 390.0 (288)
M18 x 1.50 189.0 (140) 289.0 (213) 413.0 (305)

Notes:
1. The torque values above are general guidelines. Always use the torque values specified in the service manuals and/or assembly drawings
when they differ from the above torque values.
2. The torque values above are based on new plated threads. Increase torque values by 15% if non-plated threads are used.
3. Hardware threaded into aluminum must have either two diameters of thread engagement or a 30% or more reduction in the torque to
prevent stripped threads.
4. Torque values are calculated as equivalent stress loading on American hardware with an approximate preload of 90% of the yield strength
and a friction coefficient of 0.125.

186 Appendix TP-6921 10/14

 Appendix F Common Hardware Identification

Screw/Bolts/Studs Nuts Hardness Grades

Head Styles Nut Styles American Standard

Hex Head or Machine Head Hex Head Grade 2

Hex Head or Machine Head

Lock or Elastic Grade 5
with Washer

Flat Head (FHM) Square Grade 8

Grade 8/9 (Hex Socket

Round Head (RHM) Cap or Acorn
Head)
Metric
Pan Head Wing
Number stamped on
5.8
Hex Socket Head Cap or Washers hardware; 5.8 shown
Allent Head Cap
Washer Styles
Hex Socket Head or Allent
Head Shoulder Bolt Plain

Sheet Metal Screw Split Lock or Spring

Stud Spring or Wave

Drive Styles
External Tooth Lock
Hex
Internal Tooth Lock
Hex and Slotted
Internal-External Tooth Lock
Phillipsr

Slotted

Hex Socket

Allent head screw is a trademark of Holo-Krome Co.

Phillipsr screw is a registered trademark of Phillips Screw Company.

Sample Dimensions
American Standard (Screws, Bolts, Studs, and Nuts) Plain Washers
1/4-20 x 1 9/32 x 5/8 x 1/16
Length In Inches (Screws and Bolts) Thickness
Threads Per Inch External Dimension
Major Thread Diameter In Fractional Inches Or Screw Number Size Internal Dimension
Metric (Screws, Bolts, Studs, and Nuts)
M8-1.25 x 20 Lock Washers
Length In Millimeters (Screws and Bolts) 5/8
Distance Between Threads In Millimeters Internal Dimension
Major Thread Diameter In Millimeters

TP-6921 10/14 Appendix 187

Appendix G Common Hardware List

The Common Hardware List lists part numbers and dimensions for common hardware items.

American Standard
Part No. Dimensions Part No. Dimensions Part No. Dimensions Type
Hex Head Bolts (Grade 5) Hex Head Bolts, cont. Hex Nuts
X-465-17 1/4-20 x .38 X-6238-14 3/8-24 x .75 X-6009-1 1-8 Standard
X-465-6 1/4-20 x .50 X-6238-16 3/8-24 x 1.25
X-465-2 1/4-20 x .62 X-6238-21 3/8-24 x 4.00 X-6210-3 6-32 Whiz
X-465-16 1/4-20 x .75 X-6238-22 3/8-24 x 4.50 X-6210-4 8-32 Whiz
X-465-18 1/4-20 x .88 X-6210-5 10-24 Whiz
X-465-7 1/4-20 x 1.00 X-6024-5 7/16-14 x .75
X-6024-2 7/16-14 x 1.00 X-6210-1 10-32 Whiz
X-465-8 1/4-20 x 1.25
X-465-9 1/4-20 x 1.50 X-6024-8 7/16-14 x 1.25 X-6210-2 1/4-20 Spiralock
X-465-10 1/4-20 x 1.75 X-6024-3 7/16-14 x 1.50 X-6210-6 1/4-28 Spiralock
X-465-11 1/4-20 x 2.00 X-6024-4 7/16-14 x 2.00 X-6210-7 5/16-18 Spiralock
X-465-12 1/4-20 x 2.25 X-6024-11 7/16-14 x 2.75 X-6210-8 5/16-24 Spiralock
X-465-14 1/4-20 x 2.75 X-6024-12 7/16-14 x 6.50
X-6210-9 3/8-16 Spiralock
X-465-21 1/4-20 x 5.00 X-129-15 1/2-13 x .75 X-6210-10 3/8-24 Spiralock
X-465-25 1/4-28 x .38 X-129-17 1/2-13 x 1.00 X-6210-11 7/16-14 Spiralock
X-465-20 1/4-28 x 1.00 X-129-18 1/2-13 x 1.25 X-6210-12 1/2-13 Spiralock
X-125-33 5/16-18 x .50 X-129-19 1/2-13 x 1.50 X-6210-15 7/16-20 Spiralock
X-125-23 5/16-18 x .62 X-129-20 1/2-13 x 1.75 X-6210-14 1/2-20 Spiralock
X-125-3 5/16-18 x .75 X-129-21 1/2-13 x 2.00
X-129-22 1/2-13 x 2.25 X-85-3 5/8-11 Standard
X-125-31 5/16-18 x .88 X-88-12 3/4-10 Standard
X-125-5 5/16-18 x 1.00 X-129-23 1/2-13 x 2.50
X-129-24 1/2-13 x 2.75 X-89-2 1/2-20 Standard
X-125-24 5/16-18 x 1.25
X-125-34 5/16-18 x 1.50 X-129-25 1/2-13 x 3.00
X-125-25 5/16-18 x 1.75 X-129-27 1/2-13 x 3.50
X-125-26 5/16-18 x 2.00 X-129-29 1/2-13 x 4.00 Washers
230578 5/16-18 x 2.25 X-129-30 1/2-13 x 4.50 Bolt/
X-125-29 5/16-18 x 2.50 X-463-9 1/2-13 x 5.50
X-129-44 1/2-13 x 6.00 Part No. ID OD Thick. Screw
X-125-27 5/16-18 x 2.75
X-125-28 5/16-18 x 3.00 X-129-51 1/2-20 x .75 X-25-46 .125 .250 .022 #4
X-125-22 5/16-18 x 4.50 X-129-45 1/2-20 x 1.25 X-25-9 .156 .375 .049 #6
X-125-32 5/16-18 x 5.00 X-129-52 1/2-20 x 1.50 X-25-48 .188 .438 .049 #8
X-125-35 5/16-18 x 5.50 X-25-36 .219 .500 .049 #10
X-125-36 5/16-18 x 6.00 X-6021-3 5/8-11 x 1.00 X-25-40 .281 .625 .065 1/4
X-125-40 5/16-18 x 6.50 X-6021-4 5/8-11 x 1.25 X-25-85 .344 .687 .065 5/16
X-6021-2 5/8-11 x 1.50 X-25-37 .406 .812 .065 3/8
X-125-43 5/16-24 x 1.75 X-6021-1 5/8-11 x 1.75 X-25-34 .469 .922 .065 7/16
X-125-44 5/16-24 x 2.50 273049 5/8-11 x 2.00
X-125-30 5/16-24 x .75 X-25-26 .531 1.062 .095 1/2
X-6021-5 5/8-11 x 2.25 X-25-15 .656 1.312 .095 5/8
X-125-39 5/16-24 x 2.00 X-6021-6 5/8-11 x 2.50
X-125-38 5/16-24 x 2.75 X-25-29 .812 1.469 .134 3/4
X-6021-7 5/8-11 x 2.75
X-25-127 1.062 2.000 .134 1
X-6238-2 3/8-16 x .62 X-6021-12 5/8-11 x 3.75
X-6238-10 3/8-16 x .75 X-6021-11 5/8-11 x 4.50
X-6238-3 3/8-16 x .88 X-6021-10 5/8-11 x 6.00
X-6238-11 3/8-16 x 1.00 X-6021-9 5/8-18 x 2.50
X-6238-4 3/8-16 x 1.25
X-6238-5 3/8-16 x 1.50 X-6239-1 3/4-10 x 1.00
X-6238-1 3/8-16 x 1.75 X-6239-8 3/4-10 x 1.25
X-6238-6 3/8-16 x 2.00 X-6239-2 3/4-10 x 1.50
X-6238-17 3/8-16 x 2.25 X-6239-3 3/4-10 x 2.00
X-6238-7 3/8-16 x 2.50 X-6239-4 3/4-10 x 2.50
X-6238-8 3/8-16 x 2.75 X-6239-5 3/4-10 x 3.00
X-6238-9 3/8-16 x 3.00 X-6239-6 3/4-10 x 3.50
X-6238-19 3/8-16 x 3.25 X-792-1 1-8 x 2.25
X-6238-12 3/8-16 x 3.50 X-792-5 1-8 x 3.00
X-6238-20 3/8-16 x 3.75 X-792-8 1-8 x 5.00
X-6238-13 3/8-16 x 4.50
X-6238-18 3/8-16 x 5.50
X-6238-25 3/8-16 x 6.50

188 Appendix TP-6921 10/14

Metric
Hex head bolts are hardness grade 8.8 unless noted.

Part No. Dimensions Part No. Dimensions Part No. Dimensions

Hex Head Bolts (Partial Thread) Hex Head Bolts (Partial Thread), Hex Head Bolts (Full Thread),
M931-05055-60 M5-0.80 x 55 continued continued
M931-06040-60 M6-1.00 x 40 M960-16090-60 M16-1.50 x 90 M933-12016-60 M12-1.75 x 16
M931-06055-60 M6-1.00 x 55 M931-16090-60 M16-2.00 x 90 M933-12020-60 M12-1.75 x 20
M931-06060-60 M6-1.00 x 60 M931-16100-60 M16-2.00 x 100 M961-12020-60F M12-1.50 x 20
M931-06060-SS M6-1.00 x 60 M931-16100-82 M16-2.00 x 100* M933-12025-60 M12-1.75 x 25
M931-06070-60 M6-1.00 x 70 M931-16120-60 M16-2.00 x 120 M933-12025-82 M12-1.75 x 25*
M931-06070-SS M6-1.00 x 70 M931-16150-60 M16-2.00 x 150 M961-12030-60 M12-1.25 x 30
M931-06075-60 M6-1.00 x 75 M933-12030-82 M12-1.75 x 30*
M931-06090-60 M6-1.00 x 90 M931-20065-60 M20-2.50 x 65 M961-12030-82F M12-1.50 x 30*
M931-06145-60 M6-1.00 x 145 M931-20090-60 M20-2.50 x 90 M933-12030-60 M12-1.75 x 30
M931-06150-60 M6-1.00 x 150 M931-20100-60 M20-2.50 x 100 M933-12035-60 M12-1.75 x 35
M931-20120-60 M20-2.50 x 120 M961-12040-82 M12-1.25 x 40*
M931-08035-60 M8-1.25 x 35 M931-20140-60 M20-2.50 x 140 M933-12040-60 M12-1.75 x 40
M931-08040-60 M8-1.25 x 40 M931-20160-60 M20-2.50 x 160 M933-12040-82 M12-1.75 x 40*
M931-08045-60 M8-1.25 x 45
M931-08050-60 M8-1.25 x 50 M931-22090-60 M22-2.50 x 90 M961-14025-60 M14-1.50 x 25
M931-08055-60 M8-1.25 x 55 M931-22120-60 M22-2.50 x 120 M933-14025-60 M14-2.00 x 25
M931-08055-82 M8-1.25 x 55* M931-22160-60 M22-2.50 x 160 M961-14050-82 M14-1.50 x 50*
M931-08060-60 M8-1.25 x 60 M931-24090-60 M24-3.00 x 90
M931-08070-60 M8-1.25 x 70 M961-16025-60 M16-1.50 x 25
M931-24120-60 M24-3.00 x 120 M933-16025-60 M16-2.00 x 25
M931-08070-82 M8-1.25 x 70* M931-24160-60 M24-3.00 x 160
M931-08075-60 M8-1.25 x 75 M961-16030-82 M16-1.50 x 30*
M931-24200-60 M24-3.00 x 200 M933-16030-82 M16-2.00 x 30*
M931-08080-60 M8-1.25 x 80
M931-08090-60 M8-1.25 x 90 M933-16035-60 M16-2.00 x 35
M931-08095-60 M8-1.25 x 95 Hex Head Bolts (Full Thread) M961-16040-60 M16-1.50 x 40
M931-08100-60 M8-1.25 x 100 M933-16040-60 M16-2.00 x 40
M933-04006-60 M4-0.70 x 6 M961-16045-82 M16-1.50 x 45*
M931-08110-60 M8-1.25 x 110
M931-08120-60 M8-1.25 x 120 M933-05030-60 M5-0.80 x 30 M933-16045-82 M16-2.00 x 45*
M931-08130-60 M8-1.25 x 130 M933-05035-60 M5-0.80 x 35 M933-16050-60 M16-2.00 x 50
M931-08140-60 M8-1.25 x 140 M933-05050-60 M5-0.80 x 50 M933-16050-82 M16-2.00 x 50*
M931-08150-60 M8-1.25 x 150 M933-16060-60 M16-2.00 x 60
M933-06010-60 M6-1.00 x 10 M933-16070-60 M16-2.00 x 70
M931-08200-60 M8-1.25 x 200 M933-06012-60 M6-1.00 x 12
M931-10040-82 M10-1.25 x 40* M933-06014-60 M6-1.00 x 14 M933-18035-60 M18-2.50 x 35
M931-10040-60 M10-1.50 x 40 M933-06016-60 M6-1.00 x 16 M933-18050-60 M18-2.50 x 50
M931-10045-60 M10-1.50 x 45 M933-06020-60 M6-1.00 x 20 M933-18060-60 M18-2.50 x 60
M931-10050-60 M10-1.50 x 50 M933-06025-60 M6-1.00 x 25 M933-20050-60 M20-2.50 x 50
M931-10050-82 M10-1.25 x 50* M933-06030-60 M6-1.00 x 30 M933-20055-60 M20-2.50 x 55
M931-10055-60 M10-1.50 x 55 M933-06040-60 M6-1.00 x 40
M931-10060-60 M10-1.50 x 60 M933-06050-60 M6-1.00 x 50 M933-24060-60 M24-3.00 x 60
M931-10065-60 M10-1.50 x 65 M933-24065-60 M24-3.00 x 65
M933-07025-60 M7-1.00 x 25 M933-24070-60 M24-3.00 x 70
M931-10070-60 M10-1.50 x 70
M931-10080-60 M10-1.50 x 80 M933-08010-60 M8-1.25 x 10
M931-10080-82 M10-1.25 x 80* M933-08012-60 M8-1.25 x 12 Pan Head Machine Screws
M931-10090-60 M10-1.50 x 90 M933-08016-60 M8-1.25 x 16
M931-10090-82 M10-1.50 x 90* M933-08020-60 M8-1.25 x 20 M7985A-03010-20 M3-0.50 x 10
M931-10100-60 M10-1.50 x 100 M933-08025-60 M8-1.25 x 25 M7985A-03012-20 M3-0.50 x 12
M931-10110-60 M10-1.50 x 110 M933-08030-60 M8-1.25 x 30 M7985A-04010-20 M4-0.70 x 10
M931-10120-60 M10-1.50 x 120 M933-08030-82 M8-1.25 x 30* M7985A-04016-20 M4-0.70 x 16
M931-10130-60 M10-1.50 x 130 M7985A-04020-20 M4-0.70 x 20
M931-10140-60 M10-1.50 x 140 M933-10012-60 M10-1.50 x 12
M961-10020-60 M10-1.25 x 20 M7985A-04050-20 M4-0.70 x 50
M931-10180-60 M10-1.50 x 180 M7985A-04100-20 M4-0.70 x 100
M931-10235-60 M10-1.50 x 235 M933-10020-60 M10-1.50 x 20
M933-10025-60 M10-1.50 x 25 M7985A-05010-20 M5-0.80 x 10
M931-10260-60 M10-1.50 x 260
M961-10025-60 M10-1.25 x 25 M7985A-05012-20 M5-0.80 x 12
M960-10330-60 M10-1.25 x 330
M933-10025-82 M10-1.50 x 25* M7985A-05016-20 M5-0.80 x 16
M931-12045-60 M12-1.75 x 45 M961-10030-60 M10-1.25 x 30 M7985A-05020-20 M5-0.80 x 20
M960-12050-60 M12-1.25 x 50 M933-10030-60 M10-1.50 x 30 M7985A-05025-20 M5-0.80 x 25
M960-12050-82 M12-1.25 x 50* M933-10030-82 M10-1.50 x 30* M7985A-05030-20 M5-0.80 x 30
M931-12050-60 M12-1.75 x 50 M961-10035-60 M10-1.25 x 35 M7985A-05080-20 M5-0.80 x 80
M931-12050-82 M12-1.75 x 50* M933-10035-60 M10-1.50 x 35 M7985A-05100-20 M5-0.80 x 100
M931-12055-60 M12-1.75 x 55 M933-10035-82 M10-1.50 x 35*
M931-12060-60 M12-1.75 x 60 M961-10040-60 M10-1.25 x 40 M7985A-06100-20 M6-1.00 x 100
M931-12060-82 M12-1.75 x 60*
M931-12065-60 M12-1.75 x 65 Flat Head Machine Screws
M931-12075-60 M12-1.75 x 75
M931-12080-60 M12-1.75 x 80 M965A-04012-SS M4-0.70 x 12
M931-12090-60 M12-1.75 x 90 M965A-05012-SS M5-0.80 x 12
M931-12100-60 M12-1.75 x 100 M965A-05016-20 M5-0.80 x 16
M931-12110-60 M12-1.75 x 110 M965A-06012-20 M6-1.00 x 12

* This metric hex bolt’s hardness is grade 10.9.

TP-6921 10/14 Appendix 189

Metric, continued
Part No. Dimensions Type
Hex Nuts
M934-03-50 M3-0.50 Standard
M934-04-50 M4-0.70 Standard
M934-04-B M4-0.70 Brass
M934-05-50 M5-0.80 Standard
M934-06-60 M6-1.00 Standard
M934-06-64 M6-1.00 Std. (green)
M6923-06-80 M6-1.00 Spiralock
M982-06-80 M6-1.00 Elastic Stop
M934-08-60 M8-1.25 Standard
M6923-08-80 M8-1.25 Spiralock
M982-08-80 M8-1.25 Elastic Stop
M934-10-60 M10-1.50 Standard
M934-10-60F M10-1.25 Standard
M6923-10-80 M10-1.50 Spiralock
M6923-10-62 M10-1.50 Spiralock[
M982-10-80 M10-1.50 Elastic Stop
M934-12-60 M12-1.75 Standard
M934-12-60F M12-1.25 Standard
M6923-12-80 M12-1.75 Spiralock
M982-12-80 M12-1.75 Elastic Stop
M982-14-60 M14-2.00 Elastic Stop
M6923-16-80 M16-2.00 Spiralock
M982-16-80 M16-2.00 Elastic Stop
M934-18-80 M18-2.5 Standard
M982-18-60 M18-2.50 Elastic Stop
M934-20-80 M20-2.50 Standard
M982-20-80 M20-2.50 Elastic Stop
M934-22-60 M22-2.50 Standard
M934-24-80 M24-3.00 Standard
M982-24-60 M24-3.00 Elastic Stop
M934-30-80 M30-3.50 Standard

Washers
Bolt/
Part No. ID OD Thick. Screw
M125A-03-80 3.2 7.0 0.5 M3
M125A-04-80 4.3 9.0 0.8 M4
M125A-05-80 5.3 10.0 1.0 M5
M125A-06-80 6.4 12.0 1.6 M6
M125A-08-80 8.4 16.0 1.6 M8
M125A-10-80 10.5 20.0 2.0 M10
M125A-12-80 13.0 24.0 2.5 M12
M125A-14-80 15.0 28.0 2.5 M14
M125A-16-80 17.0 30.0 3.0 M16
M125A-18-80 19.0 34.0 3.0 M18
M125A-20-80 21.0 37.0 3.0 M20
M125A-24-80 25.0 44.0 4.0 M24

[ This metric hex nut’s hardness is grade 8.

190 Appendix TP-6921 10/14

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