CONTROLLERS

For Industrial Power Systems

TABLE OF CONTENTS

Total System Integration 6

Controllers 8

INSIGHT Controller Terminology 10

Generator Controllers 14

INSIGHT Controllers and Generator Paralleling 22

ATS Controller Comparison 30

INSIGHT ATS Controllers: Key Features 32

Paralleling Switchgear Controllers 34

Contoller Accessories 36

Service and Support 38

 We're 100 years young and
only getting better with age.
For the last century, we've
forged the future, redefining
what power means to people's
lives, careers and lifestyles.

POWER IS W
WHAT WE DO.
SO WHY KOHLER?
We’re a company of fearless
thinkers driven to empower
people all over the world —
with reliable, revolutionary
engines, generators and
power systems.

We exist for one reason:

TO MOVE YOU FORWARD.
TOTAL SYSTEM INTEGRATION
Everything works together. Just as it should.
A power system is only as good as the parts that define it.
That’s why we engineer every detail down to the last bolt.
From generators and transfer switches to paralleling switchgear
and controllers, everything works together seamlessly.
Because we designed, engineered and tested it that way.

That’s the Kohler difference.

6 / Total System Integration

 1

6
5

TOTAL SYSTEM INTEGRATION

1. KOHLER REMOTE 4. KOHLER AUTOMATIC 6. KOHLER WIRELESS
ANNUNCIATOR TRANSFER SWITCH MONITOR
Remote monitoring and testing Open, closed and programmed Performance monitoring
of transfer switches transition operating modes;
standard, bypass-isolation 7. KOHLER CONTROLLER
2. KOHLER MONITORING and service-entrance switch Controls, monitors and aids
SOFTWARE configurations system diagnostics
Monitors generators and
transfer switches from a PC 5. KOHLER PARALLELING
8. KOHLER ® GENERATOR
SWITCHGEAR
Gas generators 23-1300 kW
Low and medium voltage
3. KOHLER CONTROLLER Diesel generators 15-4000 kW
Controls, monitors and aids
system diagnostics
KOHLER CONTROLLERS ®

The smart choice in backup power.

Controllers are the brains of a power system. They continuously

monitor and manage operating conditions to ensure the reliability,
flexibility and performance of the equipment as well as protect it
from damage. We design and manufacture every detail of all KOHLER
controllers to ensure dependability, ease-of-use, safety and seamless
integration with the rest of our equipment.

Our power equipment is used in a wide variety of applications, each

of which places unique demands and challenges on its power systems,
so we design our controllers to be extremely versatile and customizable.
Each one features programmable I/O modules to support
customization and is designed to communicate and interoperate
with these advanced building- management systems (BMS).

GENERATOR SET CONTROLLERS

Available to support either single generator or parallel operation, our generator
controllers are easy to operate and provide dependable engine and alternator
control, operating information and system diagnostics.

Advanced Power Management Decision-Maker®

• APM 402: Single Generator • DEC8000: Single/Parallel Generators

• APM 603: Single/Parallel Generators • DEC3500: Single/Parallel Generators

• APM 802: Single Generator

8 / KOHLER Controllers
TRANSFER SWITCH PARALLELING REMOTE SERIAL
CONTROLLERS SWITCHGEAR ANNUCIATORS
Automatic transfer switch Each KOHLER paralleling Designed for confidence and
controllers communicate with switchgear solution is developed peace of mind, our remote serial
the generator controllers to to meet your specific needs, and annunciators provide real-time fault
bridge the gap from utility to the controls are programmed to and status updates, along with
standby power, and back again, your exact specifications. Kohler testing capabilities, for generators
ensuring a smooth, seamless deploys fault-tolerant programming and automatic transfer switches.
transition and minimal disruption. and provides an intuitive user
• RSA III
interface with real-time system
Decision-Maker® information to enable better • RSA III with a Single ATS Control
operational decisions.
• MPAC750 • RSA III with Four ATS Controls
• MPAC1200

• MPAC1500

KOHLER Controllers / 9
 T
GH
CONTROLLER
SI
TERMINOLOGY
IN

Generator power systems, and controllers specifically, involve highly

complex interactions between mechanical, electrical and electronic
systems. As you evaluate your needs and consider your options, use
this glossary of useful terms to enhance your controllers research.

10 / INSIGHT: Controller Terminology

LOAD MANAGEMENT
Load management allows you to prioritize loads and remove noncritical loads when the
power supply becomes unable to support the entire demand.

Each load is assigned a priority level. Load management determines when priority levels
are signaled to disconnect (shed) and reconnect (add). When multiple generators are
online, load management matches the load to the generator capacity. The system can
control feeder breakers or transfer switches. Dry contacts or communications can be
provided to interface with your building-management system.

In a paralleled generator system, it is imperative to plan for the unlikely

event of a generator failure. Removing or shedding load prevents the
remaining online generators from overloading and tripping offline.

Load Add
Loads can be added based on several considerations, including:

• Generator bus capacity: loads are added based on the kW capacity of the bus and an
assumed kW demand of the load.

• kW overload: When the generators reach their overload setpoints, low-priority loads
sequentially shed until the load falls below the overload setpoint.

• Number of generators online: loads are added based on how many generators are connected
to the bus; this is most effective in systems with same-size generators.

Load Shed
A load-shed event can be triggered by several causes, including:

• Generator failure: Loads are shed based on the number of failed gensets.

• Underfrequency: This is often an indication that the generators are fully loaded and cannot
supply additional power to the load. When the bus frequency reaches its underfrequency
setpoint, preset loads are shed.

GENERATOR MANAGEMENT
Generator management optimizes the number of online generators based on the load’s
kW demand, starting and stopping them as required. Generators are sequenced on
in order of operator-assigned priority (or based on runtime) and taken off in reverse
priority. Operator-defined setpoints determine the load level percentage and time delay
at which the genset will be brought on or taken offline.

VOLTAGE REGULATION
Voltage regulation helps to minimize voltage fluctuations and quickly stabilize the
system when equipment is added or removed. A common experience of voltage
fluctuation is when a piece of equipment is turned on and the lights dim or a fan
slows down for a moment. While not detrimental to most commercial and industrial
equipment, these fluctuations can be distracting.

Generator voltage can be affected by both engine speed and current, and it can be
adjusted either manually or through software. Controllers are responsible for detecting
and quickly responding to voltage fluctuations, typically maintaining a range between
0.25% and 0.50%.

INSIGHT: Controller Terminology / 11

NFPA 110

NFPA 110 is the National Fire Protection Association’s

performance standard for emergency and standby power
systems. An individual product cannot be marked as NFPA
110-compliant; the overall power system must be installed,
maintained, tested and operated per the NFPA standard to
be compliant. Kohler is committed to designing emergency
and standby power components with features that ensure
the power system’s compliance with NFPA 110.

NFPA 110 has identified two levels of requirements that

pertain to the installation, performance and maintenance
of the power system:
• Level 1 pertains to power systems where failure to perform could
result in loss of life or serious injury

• Level 2 pertains to power systems where failure to perform is less

critical to human life and safety

The installation, performance and maintenance requirements

associated with a power system depend upon the power
system level.

KOHLER controllers are designed to meet the requirements

®

of NFPA 110. Key features include:

• Emergency stop

• Master switch including Stop/Run/Auto controls

• Audible horn, visual warnings and visual fault indicators

• System faults and status monitored and annunciated

on both the controller display and remote annunciator

PROGRAMMABLE I/O
Every job is unique and using a controller that allows for
customization to support your needs is critical. Controllers
offer programmable inputs and outputs to help with the
customization.

Inputs are external signals the controller receives from various

connected monitoring and management systems, which
the controller can then process and respond to based on
its programming. Likewise, outputs are information about
the generator and/or automatic transfer switch operating
conditions that the controller provides to external systems.
• Analog Inputs and Outputs: These are typically used for sensors
that show varying amounts of a given metric, such as fuel level in
a diesel tank. Analog inputs and outputs identify a system state
within a range of values, typically from 0% to 100%.

• Digital Inputs and Outputs: These are used for sensors that show
a high or low state, such as an alarm, which is either active or
inactive. As an example, a power system can be programmed to
trigger a remote shutdown when an input reports a high state.

12 / INSIGHT: Controller Terminology

INSIGHT: Controller Terminology / 13
KOHLER GENERATOR CONTROLLERS®

Advanced technology made simple.

At Kohler, we don’t do one-size-fits-all. With our controllers, we design

custom packages, tailored to your needs—from basic controllers
managing a single node to more advanced models that enable
paralleling multiple generators.

Kohler makes each controller easy to operate, with user-friendly

displays and intuitive navigation. Plus, all of our controllers feature
advanced network communications for remote monitoring as well as
adjustable parameters to accommodate your specific application.

STANDARD FEATURES
Tested and Approved Seamless System Integration
Our controllers meet NFPA, UL Every controller works with our entire
and CE standards. range of automatic transfer switches
and switchgears for complete system
integration.

Integral Voltage Regulator Alternator Protection

KOHLER controllers deliver precise This must-have technology protects
voltage regulation to protect your the alternator from thermal overload.
sensitive equipment from poor
power quality.

14 / KOHLER Generator Controllers

CONTROLLER COMPARISON
APM802

Stationary APM603
Diesel APM402

15 kW 80 kW 800 kW 1000 kW 4000 kW

DEC8000

Stationary APM603
Gas APM402

25 kW 80 kW 450 kW 500 kW 1300 kW

Mobile/Tier 4 DEC3500
Stationary 30 kW 175 kW

COMMON FEATURES
Inputs and Outputs Alternator Status Engine Protection– Alternator Protection–
All models include digital and Condition Shutdown/Indication Shutdown/Indication
and analog input and
• Voltage, L-L and • High engine coolant • Over/under voltage
output with option for
L-N for all phases temperature frequency
additional inputs/outputs
• Current • Low coolant level • Overcurrent
Engine Status and
• Frequency for • Low oil pressure • Overpower
Condition Indicators
all phases
• Overcrank • Locked rotor
• Oil pressure/temperature
• Total kW
• High fuel level/pressure • Reverse power/VAR
• Coolant temperature
• Power factor
• Low fuel level/pressure
• Engine speed
• Per phase kW/kVA
• Overspeed
• Number of starts and kVAR
• Load-shed output
• Battery voltage

Refer to each product’s specification sheet for its exact specifications. KOHLER Generator Controllers / 15
APM402

2 1. Emergency Stop Button

1 3
2. 2-Line LCD Digital Display

3. Push-Button/Rotary Selector Dial

4. Master Control Buttons

5
5. Alarm Silence Button
4
6. USB Communication Connection
6

Stationary Gaseous <400 kW

Usage
Stationary Diesel up to 1,000 kW

Onboard Paralleling None

Protocols Supported Modbus® RTU

The APM402 generator set controller provides basic control, system monitoring
and system diagnostics for optimum performance. The APM402 controller
meets NFPA 110, Level 1 when equipped with the necessary accessories and
installed per NFPA standards.

DISPLAY, INTERFACE ONBOARD DIAGNOSTICS

AND ACCESSIBILITY • Immediate visibility for up to
• A digital display and push-button/ 1,000 events including warnings
rotary selector dial provide easy and faults
local access to data • Intuitive descriptions of ECM
• The scrolling display shows critical fault codes
data at a glance

• The controller supports Modbus

protocol. Use with serial bus or
Ethernet networks. (Ethernet requires
an external Modbus/Ethernet
converter module)

• Integrated hybrid voltage regulator

provides +/- 0.5% regulation

• Built-in alternator thermal overload

protection

• Simple programmable function for

input and output configuration

16 / KOHLER Generator Controllers

APM603
1. 7.5-inch Color TFT Touchscreen

2. High Visibility Alarm LEDs

3. Master Control Buttons

2
1 4. Alarm Silence/Lamp Test Button

5 5. USB and SiteTech Connections

4 Usage:
Stationary Gaseous and
3 Diesel Generators 80 kW+

Onboard Paralleling Up to 8 Gensets

Modbus® RTU and TCP;

Protocols Supported
SNMP; BACnet®

The APM603 generator set controller provides advanced control, system monitoring, and
system diagnostics for a single generator set or for paralleling multiple generator sets.
The APM603 connects the generator set to other power system equipment and network-
management systems using standard industry network communications. It uses a patented
hybrid voltage regulator with unique software logic to manage alternator thermal overload
protection and serve as an overcurrent protective device—features that normally require
additional hardware. The APM603 controller NFPA 110, Level 1 and UL6200, the newest UL
standard for generator controllers.

DISPLAY, INTERFACE AND ACCESSIBILITY • Store up to 3,000 events locally and download
to external USB drive
• Intuitive, dynamic 7.5-inch interface with
backlight displays key data for easy local • Data logging of customized parameter
access to data list for report generation and advanced
troubleshooting. Store to external USB drive
• Overview screen can be customized to show
for easy export and in-depth data analysis
critical data at a glance
• Intuitive descriptions of ECM fault codes
• Create a custom favorites list for quick access
to important data
ONBOARD PARALLELING
• Supports Modbus protocol through serial bus
• Parallel up to eight generator sets
and Ethernet networks, and supports SNMP
and BACnet through Ethernet networks • Automatic synchronizer with random first-on
logic built into controllerensures the first
• Integrated hybrid voltage regulator providing
available generator is used to power loads while
+/- 0.25% regulation
remaining generators synchronize to the bus
• Built-in alternator thermal overload protection
• Integrated protective relays guard power
• Real-time clock with battery backup system from potentially harmful operating
scenarios
• Integrated programmable logic function for
advanced input and output configuration • Configurable load management of up to
16 loads allows you to shed lower-priority
• Isochronous load sharing ensures that work is
loads if needed to ensure critical loads are
distributed evenly across the power system,
always powered
reducing stress on individual generator sets
• Built-in generator management extends
ONBOARD DIAGNOSTICS maintenance intervals, conserves fuel
and ensures system longevity
• Immediate visibility of warnings and faults with
text description and code display

• 15 seconds of critical data captured around

each warning and fault
KOHLER Generator Controllers / 17
APM802

2
1. 12-inch LED LCD Touchscreen Display

1 2. User Access Menus (Shortcuts, Alarms,

3 Maintenance)

3. Operating Mode Selector

4. Installation and Mechanical Values

5. Generator Set Electrical Values

4 5
6. Operator and Specialist Access Menus

6 Usage Stationary Diesel 800–4,000 kW

Onboard Paralleling None

Protocols Supported Modbus® RTU

The APM802 generator set controller provides advanced control, system

monitoring and system diagnostics for optimum performance. The APM802
controller meets NFPA 110, Level 1 when equipped with the necessary
accessories and installed per NFPA standards.

DISPLAY, INTERFACE ONBOARD DIAGNOSTICS

AND ACCESSIBILITY • Immediate visibility for up to 1,000
• Intuitive, dynamic 12-inch events including warnings and faults
touchscreen interface with • Two USB ports allow connection of
backlight displays key data for a flash drive, mouse or keypad
easy local access to data
• Electrical data, mechanical data
• Supports Modbus RTU and system settings can be saved
and TCP protocols to a USB drive
• Real-time clock with • Recording feature allows data
battery backup collection of key values
• Integrated programmable • Ethernet port allows connection to
logic function for advanced a PC-type computer and/or Ethernet
input and output configuration switch

• Intuitive descriptions of ECM

fault codes

18 / KOHLER Generator Controllers

DEC8000

3 1. 8-inch Color LCD TFT Touchscreen

1 2
2. Submenu/Suboption Context Buttons

3. Main Menu Selector Buttons

4. Master Control Buttons/Alarm

4 Silence Button
6
5. System Status Bar

5 Usage Stationary Gaseous >400 kW

Onboard Paralleling Up to 32 Gensets

Protocols Supported Modbus® RTU and TCP; SNMP

The Decision-Maker® 8000 generator set controller provides advanced control, system
monitoring, system diagnostics and advanced control for paralleling multiple generator sets.
The Decision-Maker 8000 connects the generator set to other power system equipment and
other network-management systems using standard industry network communications.

DISPLAY, INTERFACE AND ACCESSIBILITY ONBOARD PARALLELING

• Displays data on an 8-inch, color TFT display • Parallel up to 32 generator sets

with simple keypad navigation • Automatic synchronizer with random first-on
• Supports Modbus protocol through serial bus logic built into controller ensures the first
and Ethernet networks, and supports SNMP available generator is used to power loads while
and BACnet through Ethernet networks remaining generators synchronize to the bus

• Real-time clock with battery backup • Integrated protective relays guard power
system from potentially harmful operating
• Integrated programmable logic function for scenarios
advanced input and output configuration
• Isochronous load sharing ensures that work is
ONBOARD DIAGNOSTICS distributed evenly across the power system,
reducing stress on individual generator sets
• Immediate visibility for up to 4,000 events
including warnings and faults • Configurable load management of up to three
loads allows you to shed lower-priority loads
• Snapshot capabilities store up to 50 if needed to ensure critical loads are always
preshutdown records powered
• Data logging and trending of eight • Built-in generator management extends
customizable data outputs for easy maintenance intervals, conserves fuel and
troubleshooting ensures system longevity
• USB connection port to assist with
data storage

KOHLER Generator Controllers / 19

DEC3500

1. LCD Touchscreen Display

2. Annunciator Fault Light

2
1 3. Alarm Silence/Lamp Test Button

4. Master Control Buttons

5
5. Push-button/Rotary Selector Dial
6
3
6. USB Communication Connection
4

All Mobile, Marine and Stationary

Usage
Tier 4 Final Generators

Onboard Paralleling Up to 8 Gensets

Protocols Supported Modbus® RTU

The Decision-Maker® 3500 generator set controller provides advanced control, system
monitoring and system diagnostics for optimum performance and compatibility.
The Decision-Maker 3500 controller meets NFPA 110, Level 1 when equipped with
the necessary accessories and installed per NFPA standards.

DISPLAY, INTERFACE ONBOARD PARALLELING

AND ACCESSIBILITY • Parallel up to eight generator sets
• A digital display and push-button/rotary • Automatic synchronizer with random
selector dial provide easy local access first-on logic built into controller ensures
to data the first available generator is power loads
• Graphical display shows critical data while remaining generators synchronize
at a glance to the bus

• The controller supports Modbus protocol. • Integrated protective relays guard power
Use with serial bus or Ethernet networks. system from potentially harmful operating
(Ethernet requires an external Modbus/ scenarios
Ethernet converter module) • Isochronous load sharing ensures that
• Integrated hybrid voltage regulator provides work is distributed evenly across the power
+/-0.5% regulation system, reducing stress on individual
generator sets
• Built-in alternator thermal overload
protection • Configurable load management of up to
six loads allows you to shed lower-priority
• Encapsulated to protect against dust and loads if needed to ensure critical loads
dirt with sealed connectors are always powered
• Simple programmable function for • Built-in generator management extends
input and output configuration maintenance intervals, conserves fuel
and ensures system longevity
ONBOARD DIAGNOSTICS

• Immediate visibility for up to 1,000 events

including warnings and faults

• Intuitive descriptions of ECM fault codes

20 / KOHLER Generator Controllers

KOHLER GENERATOR
®

CONTROLLER COMPARISON

Decision-Maker Model® APM402 APM603 DEC8000 APM802 DEC3500

Integral voltage regulator x x x
Engine diagnostics x x x x x
Engine starting aid x x x
Event and data logging x x x x x
Programming access via laptop x x x x x
Key switch x
USER INTERFACE
Alphanumeric digital display x
Monochromatic graphical display x
Color graphical display x x x
Emergency stop (remote) x x x x x
Exercise function x x
COMMUNICATIONS
Local and remote area network capability x x x x x
Monitoring software o o x x
PARALLELING
Remote input for external paralleling controller x x x
Dead-field paralleling x
Synchronizer x x x
Real and reactive load sharing x x x
First-on logic x x x
Circuit breaker control x x x
Base load control x x x
Var/power factor control x x x
Load management o x x
Generator management o x x

KEY: STANDARD = x / OPTION = o

KOHLER Generator Controllers / 21

 T
GH
CONTROLLERS
SI
AND
GENERATOR PARALLELING
IN

While it may be common for a facility to install a single large

generator to meet its power needs, paralleling two or more
generators offers a number of practical benefits and advantages
over a single-generator system.

22 / INSIGHT: Controller Terminology

22 / INSIGHT: Controllers and Generator Paralleling
REDUNDANCY
The redundancy provided by the paralleling of two or more generators delivers
greater reliability and flexibility than a single generator can provide. In critical
applications, having more than one generator connected to the bus at all times
ensures continuous generator power in the unlikely event that a generator fails.

EFFICIENCY
Instead of one large generator that might operate at an inefficiently low kW,
several small generators can be paralleled and turned on and off as necessary
to efficiently support the varying demands of the load.

VALUE
In some cases, multiple small generators may cost less than
one large generator.

POWER REQUIREMENTS
If the largest available generator is too small to meet the power requirements,
two or more generators can be paralleled to provide the necessary power.

SPACE CONSTRAINTS
If space is limited and a large generator will not fit, multiple smaller generators
can be utilized.

FUTURE GROWTH
A paralleled system can be designed to add additional generators as your
facility’s load requirements expand.

INSIGHT: Controller Terminology / 23

GENERATOR PARALLELING
How it works.

Let’s look at a typical response to loss of utility power. When a loss of utility power occurs,
almost every system responds with the basic sequence shown here.

ENGINE START DELAY

A timer starts when there is a loss of utility. If utility returns
before the timer expires, the system does not start. If the
utility outage is long enough for the timer to expire, the
system will commit to transferring to generator power.

START / START-UP LOAD SHED

60 60
240 480 58 62

120 600 56 64

The first generator to reach the rated voltage and

frequency closes to the bus. First-on logic prevents
multiple generators from simultaneously closing to the
bus. The bus is now energized, and power is available to
the load. Low-priority loads remain shed with F2 and F3 240
60
480 58
60
62

still open. 120 600 56 64

SYNCHRONIZATION
The incoming generator’s
voltage, frequency and phase
are matched to the running bus.
When matched, the generator
paralleling breaker closes.

SECOND-GENERATOR BREAKER
CLOSES / LOAD SHARING
Additional generator power is available to the load. The
system’s load-sharing controls actively control the kW and
kVAR output of each generator in order to proportionally
share the load (maintain the same percent load on each
generator) and maintain rated frequency and voltage.

24 / How Paralleling Works INSIGHT: Controllers and Generator Paralleling / 24

SYNCHRONIZATION
Let’s take a detailed look at the synchronization process. The automatic synchronizer
matches the incoming generator’s output (waveform) to the running bus. When
the voltage, frequency and phase are all matched, the synchronizer will close
the incoming generator’s breaker.

VOLTAGE MATCH Voltage Difference

The synchronizer adjusts the

incoming generator’s voltage
to match the running bus.
Voltage

Time

FREQUENCY MATCH Frequency Difference

The synchronizer adjusts the

incoming generator’s speed
to match the frequency of the
Voltage

running bus.
Time

PHASE MATCH Phase Difference

The synchronizer adjusts the

incoming generator’s speed
to match the phase of the
Voltage

running bus. When matched, Time

the two sine waves will be
the same.

How Paralleling Works / 25

KOHLER ATS CONTROLLERS ®

Never miss a beat.

The automatic transfer switch controller tells the switch what to

do and when, dictating the logic that determines the reaction.
The automatic transfer switch (ATS) controller communicates
with the generator set controller to maintain electrical power
continuity, managing the power sensing, timing functions and
fault monitoring needed for automatic operation.

STANDARD FEATURES
Phases Load Transfer
Operate in single- or three-phase In-phase monitor capability
applications
Communications
Voltage Settings RS-485 port
Programmable normal source
voltage pickup and dropout

AC Frequencies
50 Hz and 60 Hz-compatible

26 / KOHLER ATS Controllers

MPAC750

1 2
5
3 4 1. Source N Available 6. System Alert

2. Source E Position 7. Not in Auto

3. Source N Position 8. Exercise Button

6 4. Source E Available 9. Test Button

5. USB Port Location
7
9 8
Application Stationary Gaseous >400 kW

Amperage Up to 1000 A

Voltage Range 115-480 V

RS-485 Port Standard

Ethernet Port Optional

The MPAC750 is a no-frills critical system settings controller

that gets the job done. Its functionality includes setting time
delays, creating a system exercise and transferring loads
as required.

STANDARD FEATURES
• Adjustable normal source voltage settings so you can
fine-tune the system behavior to your incoming voltage

• Seven-day generator exercise capability to automatically perform

a system check that ensures your power system is in prime
condition to handle any event

• Two programmable inputs and outputs allow for

system customization

KOHLER ATS Controllers / 27

MPAC1200
1 2

3 4 5
1. Source N Available 6. System Alert

2. Source E Position 7. Not in Auto

9 3. Source N Position 8. Exercise Button
6
4. Source E Available 9. Test Button

5. USB Port Location

7

Application Automatic Transfer Switch

Amperage Up to 4000 A

Voltage Range 115-600 V

RS-485 Port Standard

Ethernet Port Optional

A customizable solution for your specific application, the MPAC1200 gives

you full control of system behavior including extended I/O customized to
your needs.

STANDARD FEATURES
• Adjustable voltage and frequency • Transfer commit allows you to decide
settings so you can fine-tune the whether to continue with the transfer
system behavior to your specific site in the event that the utility power
requirements returns before the transfer-to-
generator is complete
• 21-event generator exercise capable to
conduct system checks to ensure your • Time-based load control available
power system is in prime condition to so you can ensure all critical loads
handle any event are powered at the time of load
transfer and control the load steps
• Two programmable inputs and outputs
on your generator
allow for system customization, with
the ability to expand capabilities with
additional inputs and outputs

28 / KOHLER ATS Controllers

MPAC1500
1 2

3 4
5 1. Source N Available 6. System Alert

2. Source E Position 7. Not in Auto

9 3. Source N Position 8. Push Buttons

6 4. Source E Available 9. Display
5. USB Port Location
7

Application Automatic Transfer Switch

Amperage Up to 4000 A

Voltage Range 115-600 V

RS-485 Port Standard

Ethernet Port Standard

When you need to manage your loads, use your system as a prime power application
or have a backup for your backup (i.e., a three-source system), this controller gets
the job done.

STANDARD FEATURES
• Adjustable voltage and frequency settings so • Transfer commit allows you to decide whether
you can fine-tune the system behavior to your to continue with the transfer in the event
specific site requirements that the utility power returns before the
transfer-to-generator is complete
• 21-event generator exercise capable to
conduct system checks to ensure your • Time-based load control available so you can
power system is in prime condition to ensure all critical loads are powered at the
handle any event time of load transfer and control the load
steps on your generator
• Two programmable inputs and outputs allow
for system customization, with the ability to • Current-based load control so you can ensure
expand capabilities with additional inputs all critical loads are powered at all times
and outputs

KOHLER ATS Controllers / 29

KOHLER ATS ®

CONTROLLER COMPARISON

DECISION-MAKER® MPAC750 MPAC1200 MPAC1500

Amperage Up to 1000 A Up to 4000 A Up to 4000 A

Phases Single/Three Single/Three Single/Three
Poles 2, 3, 4 2, 3, 4 2, 3, 4
Voltage range 115–480 V 115–600 V 115–600 V
Product Type
Standard open transition Yes Yes Yes
Standard delayed transition Yes Yes
Standard closed transition Yes Yes
Bypass-isolation open transition Yes
Bypass-isolation delayed transition Yes
Bypass-isolation closed transition Yes
Service entrance Yes
Withstand and Close-On Ratings (WCR)
WCR–Specific breaker 30–65 kA 30–65 kA 22–100 kA
WCR–Any breaker 10–100 kA 10–100 kA
WCR–Current-limiting fuses 100–200 kA 100–200 kA
Short-time withstand rating 36–65 kA 36–65 kA
User Interface
LED–Contactor position / source available Standard Standard Standard
LED–Service required (fault indication) Standard Standard Standard
LED–Not in automatic mode Standard Standard Standard
Display LCD LCD
Programming USB USB, Display USB, Display
Voltage and Frequency Settings
Pickup / Dropout normal source voltage Programmable Programmable Programmable
Pickup / Dropout emergency source voltage Programmable Programmable
Frequency selection 50/60 Hz 50/60 Hz 50/60 Hz
Pickup / Dropout normal source frequency Programmable

30 / KOHLER ATS Controller Comparison

DECISION-MAKER® MPAC750 MPAC1200 MPAC1500

Voltage and Frequency Settings

Pickup / Dropout emergency source
Programmable Programmable
frequency
Overvoltage trip Programmable Programmable
Overfrequency trip Programmable Programmable
Normal and emergency voltage unbalance Standard Standard
Inphase monitor Standard Standard Standard
Transfer commit Standard Standard
Phase rotation sensing Standard Standard
Time Delays and Configuration Settings
Transfer to emergency / Transfer to normal Programmable Programmable Programmable
Engine cooldown Fixed Programmable Programmable
Generator exerciser 7-Day 21 exercise events 21 exercise events
Remote peak shave Standard Standard
Programmable Programmable
Start-time delay Programmable
(emergency only) (emergency only)
Programmable Programmable
Fail to acquire Programmable
(emergency only) (emergency only)
Communications
RS-485 Standard Standard Standard
Ethernet Optional Optional Standard
Accessories
Programmable engine exerciser Optional external device Standard Standard
Optional Optional
Extended I/O
(Up to 4 modules) (Up to 4 modules)
Source priority selector Optional Optional
Extended engine start-time delay Optional Optional
Load shed Optional Optional
Load control Time-based Time- or current-based
Three-source system Standard

KOHLER ATS Controller Comparison / 31

 T
GH
ATS CONTROLLERS:
SI
KEY FEATURES
IN

32 / INSIGHT: Key Features of ATS Controllers

 MANUAL VS AUTOMATIC TRANSFER SWITCHES
As their names imply, manual and automatic transfer switches differ based on
how the transfer from utility to generator power is performed. During a power
outage, a manual transfer switch requires a person to physically transfer power to
the generator. This can potentially take up to several minutes to complete. And
the process is performed in reverse when utility power is restored.

With an automatic transfer switch (ATS), the transition from utility to generator
power happens automatically. In order to perform the transfer, ATS controllers
monitor a range of parameters, including voltage, frequency and phase rotation,
for both the normal and emergency power sources. An ATS senses and
seamlessly transitions back to utility power when it is restored.

DS
LOA

IN-PHASE MONITOR
When large motors or transformers are disconnected from a power source,
residual voltage is maintained due to the generator effect created by a rotating
motor or by the stored energy released from a transformer’s windings
Three-Source Systemor core.
This residual voltage can cause extremely high inrush currents to occur when
such loads are suddenly reconnected to a second (i.e., standby generator)
nonsynchronized source of power. The resulting effect, frequently described
as “bumping,” can initiate nuisance tripping of circuit protective devices, or in
extreme cases, it can cause mechanical damage to the load equipment.

The in-phase monitor inhibits load transfer until the two power sources are
synchronized. The monitor is adjusted to signal the transfer switch to operate
when the incoming power source is within an acceptable range of electrical
degrees of the newly connected power source. Ensuring that the transfer is
made at or near synchronism avoids the creation of damaging transients when
transferring loads between unsynchronized sources of power.
The Benefits to This Configuration are Many:
• One generator is available when the other is • You lengthen the time between refueling,
being serviced. because you have two fuel sources – one
THREE-SOURCE SYSTEM
• You have automatic backup power from
for each generator.

the
A second generator;
three-source many available
system, only on the •
critical power You have peace
MPAC1500 model,ofoffers
mind knowing that if one
redundancy
applications require this. generator fails, the
without the complexity or cost of a paralleling system. The system is based on other is automatic – it’s
two generators and two automatic transfer switches. a backup to your backup.
• By alternating generator runtime and extending
the
• time
Theitfirst
takes todetermines
ATS accumulateifengine hours,
the load is powered by utility or generator
you extend time between maintenance
• The second ATS determines which generator is powering the load
and overhauls.

TRANSFER COMMIT INSIGHT: Key Features of ATS Controllers / 33

Provides a “commit/no commit to transfer”

PARALLELING
SWITCHGEAR CONTROLLERS
System control at your fingertips.
The touchscreen operator interface both monitors and controls the system and is
customized to your project. It is specifically designed to be user-friendly, eliminate
guesswork and provide comprehensive information on system performance. The
operator can navigate the system simply and intuitively without reading a manual.

Kohler Paralleling Switchgear controllerss deploy fault-tolerant programming to make

sure the system can respond to a fault and seek a source of power for the load if there
is a component failure in the system. This programming also allows for a transition
from manual mode to automatic mode regardless of the state of the system. Each
action and reaction of the system is described with a sequence of operations that is
clearly defined on the user interface and embedded into the controls programming.

Controls architecture redundancy is a delicate balance between risk, cost and

complexity. With a KOHLER® Paralleling Switchgear system, you choose the level of
redundancy you are comfortable with that works with your budget. Whether it’s manual
backup or a redundant automation system, Kohler has a solution that’s right for you.

MANUAL BACKUP
Standard Option 1 Option 2
As a standard, every KOHLER This option contains all the This option contains all the
system is designed to be fully features of the standard features of option 1 and
functional in the unlikely event system and provides the ability provides the ability to manually
of a touchscreen failure. If the to synchronize and parallel synchronize generators using
touchscreen fails, the operator, (load share) generators if the hardwired speed and voltage
using hardwired switches, can touchscreen and/or the adjustment switches and
start the generators and place PLC fail. to synchronize and parallel
them online. (load share) generators if the
touchscreen and/or the PLC fail.

REDUNDANT AUTOMATION SYSTEMS

Standard Automation Controller Architecture
The standard architecture consists of a master automation
controller for system control (load add/shed, generator
management, control of main, tie or feeder breakers)
and an automation controller for each generator, along
with a dedicated communication connection between
the generator automation controller and its associated
generator. Redundant communications between
automation controllers are available as an option.

34 / Paralleling Switchgear Controllers

 1 3
5
2 4

6 9

1 Not in Auto Indication 4 System Status Indication 7 Current Screen

Flashes if any control switch Annunciator lights up to Displays current screen
is not in auto mode. Touch to indicate if any transfer, timer name. Use push-button
see all switches/controls that or mode is active. to capture screenshot
are not in auto. of current screen.
5 Login Indication
2 Alarm or Warning 8 Navigation Buttons
Shows current login
Indication
information, date and time. Touch to go forward or
Flashes to indicate an backward though screens.
unacknowledged alarm 6 Main Menu
or warning. Touch to go 9 Display Area
Touch to select submenu.
to the alarm list.
Shows screens.
3 Active Alarm
and Warning
Displays the five most recent
items on the alarm list.

Paralleling Switchgear Controllers / 35

 OPTIONAL ACCESSORIES
Maximize your investment.

REMOTE SERIAL ANNUNCIATOR III (RSA III)

Designed for accurate, reliable performance, the KOHLER ®

Remote Serial Annunciator (RSA III) connects to the transfer

switch and generator controllers, monitoring and displaying
their condition from a strategically convenient location.

RSA III Features and Benefits

• Monitors up to four automatic transfer switches

• (Standard) RS-485 Serial Modbus RTU communication

(Optional) Ethernet Modbus TCP/IP communication
• Five user-defined inputs

• Can be located at multiple locations

• Remote starts and stops of automatic transfer switch tests

RSA III RSA III with a Single ATS Control RSA III with Four ATS Controls

36 / Optional Accessories
OTHER GENERATOR ACCESSORIES OTHER ATS ACCESSORIES
• Monitor III Communications Program • Anticondensation Heater

• Analog & Digital I/O Modules • Controller Disconnect Switch

• Programmable Standard I/O Module • Current-Sensing Kit

• Programmable High-Voltage/Current I/O • Digital Meter Kit

• Programmable Alarm Module • Generator Connection Box

• External Battery Supply Module (EBSM) • Line-to-Neutral Voltage Monitor

• RSA III Annunciator • Load-Shed Module

• Modbus/Ethernet Converter • Monitor III Communications Program

• Powerscan Wireless Monitor • RSA Annunciator

• Run Relay • Supervised Three-Position Transfer Switch

• Shunt Trip Relay • Surge Protective Devices (SPD)

• Common Failure Relay • User Interface Cover

• Manual Speed Adjust

• Keyswitch with Manual Start/Stop Button

• Prime Power Switch

• Prealarm Kit for NFPA 110

• Remote Emergency Stop

Optional Accessories / 37
 SERVICE AND SUPPORT
The help you need. Any time, anywhere.

38 / Service and Support

You’re never too far from Kohler. Plus, if you ever need assistance in the middle
Across the world, more than 800 locations of the night, we’ll take care of you. Kohler
are ready to provide sales, installation power professionals are available to offer
and aftermarket support services. troubleshooting, advice, service
And each one offers expertise in power and support.
specifications, equipment and integration.
There’s no question they can’t answer. We
should know, we trained them ourselves.
 North America 800.544.2444

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