Kohler M340+ Service And Parts Manual
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Kohler M340+ Service And Parts Manual

Kohler M340+ Service And Parts Manual

Automatic transfer switches
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Service and Parts
Automatic Transfer Switches
Models:
M340+
Logic:
Microprocessor
U.S.A. Plant ISO Registered
TP-5672 11/95d

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  • Page 1 Service and Parts Automatic Transfer Switches Models: M340+ Logic: Microprocessor U.S.A. Plant ISO Registered TP-5672 11/95d...

  • Page 2: Table Of Contents

    Table of Contents SUBJECT PAGE SUBJECT PAGE Safety Precautions and Instructions ... Area Protection ......4-20 Introduction .

  • Page 3: Safety Precautions And Instructions

    Safety Precautions and Instructions A transfer switch, like any other electromechanical NOTE device, can pose potential dangers to life and limb if Note communicates installation, operation, improperly maintained or imprudently operated. The maintenance information that is important but not best way to prevent accidents is to be aware of the hazard related.
  • Page 4 Accidental Starting Accidental starting can cause severe injury or death. Turn generator set master switch to OFF position, disconnect power to battery charger, and WARNING remove battery cables (remove negative lead first and reconnect it last) to disable generator set before working on any equipment connected to generator set.
  • Page 5 Battery Sulfuric acid in batteries can cause severe injury or death. Sulfuric acid in battery can cause permanent damage to eyes, burn skin, and eat holes in clothing. WARNING Always wear splash-proof safety goggles when working around the battery. If battery electrolyte is splashed in the eyes or on skin, immediately flush the affected area with large quantities of clean water.
  • Page 6 Hazardous Voltage/ WARNING Electrical Shock DANGER Hazardous voltage. Can cause severe injury or death. Do not open enclosure until all power sources are disconnected. Hazardous voltage. (under 600 Volt) Will cause severe injury or death. Hazardous voltage can cause severe injury or Do not open enclosure until all power sources are death.
  • Page 7 Hazardous voltage can cause severe injury or Hazardous voltage can cause severe injury or death. To prevent the possibility of electrical shock, death. Disconnect inner panel harness at in-line de-energize the normal power source to be connected connector. This will de-energize circuit board and logic to the transfer switch before making any line or auxiliary circuitry, but allow transfer switch to continue to supply connections.
  • Page 8 Heavy Equipment WARNING Unbalanced weight. Improper lift can cause severe injury or death and/or equipment damage. Use adequate lifting capacity. Never leave transfer switch standing upright unless it is securely bolted in place or stabilized. VI Safety Precautions and Instructions TP-5672 11/95...
  • Page 9 Notes NOTE These battery chargers are designed strictly for use in NOTE this transfer switch and conform with UL and CSA listing Hardware Damage! Transfer switch may use both requirements where specified. Do not use battery American standard and metric hardware. Use the charger before reading instructions.

  • Page 10: Introduction

    GENERATORS— ELECTRIC for an authorized Part and serial numbers are provided on the nameplate service distributor/dealer or call 1-800-544-2444. attached to the transfer switch. KOHLER CO., Kohler, Wisconsin 53044 U.S.A. Part No. Phone: 920-565-3381 Fax: 920-459-1646 (U.S.A. Sales) Serial No.
  • Page 11 Notes Introduction ii TP-5672 11/95...

  • Page 12: Section 1. Specifications

    Section 1. Specifications Purpose of Switch An automatic transfer switch (ATS) is a device used for transfer to the emergency source. The automatic transferring critical electrical loads from a normal transfer switch controller continuously senses for an (preferred) source of electrical power to an emergency acceptable normal source and will retransfer the load to (standby) source.

  • Page 13: Ratings

    Also copy the part number and serial number from the PHASE WIRES HERTZ POLES nameplate into the spaces provided in the Service Assistance Section of the Introduction for use when KOHLER CO. KOHLER WISCONSIN 53044 requesting service or parts. 295232 Figure 1-3. Transfer Switch Nameplate 1-2 Specifications TP-5672 11/95...

  • Page 14: Interpreting A Transfer Switch Part Number

    Kohler Part Number Key SAMPLE PART NUMBER This chart explains the Kohler transfer switch part numbering code system. The sample part number shown is for a standard molded-case switch with M340+ logic rated at 480 volts, 60 hertz, 3-phase, 3-pole, and 4 wires in a NEMA 1 enclosure with MNS-566341-0080 an amperage rating of 80 amperes.

  • Page 15: Specifications

    Specifications The specifications listed below are for the M340+ logic controller. See the respective power switching device manual for its specifications. Standard Features D Normal source voltage sensing adjustable from D LCD digital transfer counter. 75% to 130% of normal for pickup and from 70% to D LCD digital frequency meter.

  • Page 16: Shunt-Jumper-Controlled Accessories

    Shunt-Jumper-Controlled Accessories Enable or disable shunt-jumper-controlled accessories operate. The transfer may be from utility to generator, from generator to generator, or utility to by altering socket JP1 on the main logic board. See utility. Figure 1-5. All shunt-jumper features are disabled from the factory unless the function was ordered at the time of NOTE purchase.

  • Page 17: Section 2. Operation

    Section 2. Operation Control Switches and Indicators Various optional control switches and indicator lamps on the options chosen. See Figure 2-1 for LED, Switch, may be present on the transfer switch door depending and Key locations. Contactor Position Time Delays TEST SWITCH AUTO MANUAL...
  • Page 18 Time Delays transfer from emergency to normal and normal to emergency when sources are near synchronization. Engine Start (If emergency source is a generator set). NOTE ON LED indicates that engine-start time delay is timing. END LED indicates that the engine has been signaled to When a programmed transition switch is ordered, the start.

  • Page 19: Sequence Of Operation

    Sequence of Operation This section describes the correct operation of a microprocessor-controlled transfer switch. Sequence of Operation Standard Switch When the Normal Source Fails 7. The load-shed LED illuminates at the same time all loads to be shed are disconnected from the 1.
  • Page 20 When the Normal Source Returns completed timing. contactor-position emergency turns 1. The source-available, normal LED illuminates. contactor-position normal LED illuminates. 2. The time-delay emergency-to-normal ON LED 7. After the load-shed time-after-transfer timer has illuminates to indicate the emergency-to-normal completed timing, the selected loads for the time delay is timing.

  • Page 21: Normal Source Failure

    Microprocessor-Controlled Transfer Logic Standard Switch Normal Source Failure Time Delay Engine Start Time Delay Normal-to-Emergency Load Shed (all)— if equipped Inphase Monitor— if equipped Contactor Transfer to Emergency Position Load Return (programmed sequence)— if equipped Normal Source Return Time Delay Emergency-to-Normal Load Shed (all)—...

  • Page 22: Sequence Of Operation Programmed Transition

    Sequence of Operation Programmed Transition Switch When the Normal Source Fails 7. The load-shed LED illuminates at the same time all loads to be shed are disconnected from the NOTE switch (if equipped with load-shed option). When a programmed transition switch is ordered, the 8.
  • Page 23 When the Normal Source Returns 7. The time-delay off-position END LED illuminates to indicate the time delay has completed timing. 1. The source-available, normal LED illuminates. 8. The contactor transfers to the normal position. 2. The time-delay emergency-to-normal ON LED The contactor-position OFF LED turns off and the illuminates to indicate the emergency-to-normal contactor-position normal LED illuminates.

  • Page 24: Normal Source Failure

    Microprocessor-Controlled Transfer Logic Programmed Transition Switch Normal Source Failure Time Delay Engine Start Time Delay Normal-to-Emergency Load Shed (all)— if equipped Contactor Transfer to Off Position Time Delay Off-to-Emergency Contactor Transfer to Emergency Position Load Return (programmed sequence)— if equipped Normal Source Return Time Delay Emergency-to-Normal Load Shed (all)—...

  • Page 25: To Disconnect The P1 Plug

    To Disconnect The P1 Plug it is available, after a time delay. For immediate retransfer, open then reclose 1. If the transfer switch is in the normal position, open emergency-source circuit breaker. Place the the emergency-source circuit breaker. generator set start switch in the AUTO position. 2.

  • Page 26: Section 3. Troubleshooting Guide

    Section 3. Troubleshooting Guide For location of pushbuttons, switches, LEDs, and keys the microprocessor logic controller. Refer to Figure 3-2 referred to in this section, see Figure 2-1. Refer to as guide to troubleshooting problems with the Figure 3-1 as a guide to troubleshooting problems with microprocessor accessories.
  • Page 27 Problem Refer to Section 5— Accessory Troubleshooting Controller will not sense three-phase emergency voltage Phase sequencer, accessory DD-05 The generator set does not start when the test switch is in the Test switch, accessory DD-06 and DD-07 engine start position The generator set does not start when the test switch is in the test Test switch, accessory DD-06 and DD-07 position...

  • Page 28: Section 4. Controller Troubleshooting

    Section 4. Controller Troubleshooting The following section will assist in solving common and review their operation in section 5— Accessory problems with the M340+ controller. Note any optional Troubleshooting. accessories that may have been furnished on this switch Is the LCD screen blank Troubleshooting and no LEDs illuminated? complete.

  • Page 29: Power To The System

    Power to the System If there is a problem with the logic board, the first step is to 6. Connect the positive test lead to TB-DC1-23, and the negative test lead to TB-DC1-34. If the check the status panel. If no LEDs on the status panel voltmeter does not read between approximately 12 are illuminated and the liquid crystal display (LCD) is and 30 volts DC, check if an accessory is connected...

  • Page 30: Keypad And Status Panel

    Keypad And Status Panel For location of pushbuttons, switches, LEDs, and keys 5. If after pressing the LAMP TEST key no LEDs are on, and the character blocks in the LCD are black, referred to in this section, see Figure 2-1. verify that there is power to the system by 1.
  • Page 31 If the normal source is available, but the source available normal LED Correct the trip point settings is not illuminated. Check the trip point settings in index 6. See TP-5664 in index 6. See TP-5664 for for programming information. Are the trip points programmed correctly? programming information.

  • Page 32: Normal Source Voltage And Frequency

    For location of pushbuttons, switches, LEDs, and keys Next check Index 1 in the program menu for correct referred to in this section, see Figure 2-1. normal source voltage and frequency reading. If the voltage and frequency values in Index 1 match the This section covers the condition in which the normal voltage and frequency values in Index 6, perform the source is available but the Source-Available, Normal...
  • Page 33 Incorrect Normal Source Voltage And Frequency Values See Appendix B, Figure B-9 for location of TB-AC1 and e. If the system is three-phase, connect one test lead to P2-18 and the other to TB-DC1-34. The other power supply board components referred to in this voltmeter should read approximately 1/25 of the section.
  • Page 34 7. When the message on the LCD again reads, 10. Press the RESET MENU key and then the ENTER N-AUTO-ZERO?, restore the normal power source. key to store the set points. NOTE 8. If single-phase sensing is used, perform this step. Press the MENU Arrow Down key so the LCD reads If the system will not calibrate, replace the logic N-VOLT VAC.
  • Page 35 If the emergency source is available, but Correct the setpoints the source available emergency LED is not illuminated, check the trip point settings in in Index 7. index 7. Are the settings correct? Does the microprocessor display, in index 2, rated emergency source voltages and frequency? Measure the voltage between terminals TB-AC1-EB and...

  • Page 36: Emergency Source Voltage And Frequency

    For location of pushbuttons, switches, LEDs, and keys Next check Index 2 of the program menu for correct referred to in this section, see Figure 2-1. emergency source voltage and frequency reading. If the values in Index 2 are correct, perform the following steps. This section covers the condition in which the emergency source is available but the Source-Available, Emergency 1.
  • Page 37 voltmeter should read approximately 1/25 of the 4. Disconnect the emergency power source. line voltage. See Appendix B, Figure B-5. 5. Press the ENTER key. b. If system three-phase 6. Observe the ENTRY ACCEPTED message on the three-phase-sensing option is installed, connect LCD.

  • Page 38: System-Status, Not-In-Automatic Error

    System-Status, Not-In-Automatic description of P2 ribbon cable pins. See Figure 4-7 System-Status, Error Not-In-Automatic LED wiring diagram. For location of pushbuttons, switches, LEDs, and keys c. If the System-Status, Not-In-Automatic LED is referred to in this section, see Figure 2-1. not flashing when P2-6 is grounded, remove the connection from P2-6 to TB-DC1-34, and check NOTE...

  • Page 39: System-Status, System-Alert

    System-Status, System-Alert 3. While the contactor is in the EMERGENCY position, connect one test lead of an ohmmeter to For location of pushbuttons, switches, LEDs, and keys the contactor side of P1-16. Connect the other test lead to the contactor side of P1-8. Note the referred to in this section, see Figure 2-1.

  • Page 40: Ram Or Memory Error Message

    remove the power source by disconnecting the WARNING in-line disconnect plug. Leave the power source disconnected for six seconds. After six seconds note the voltmeter reading. b. If the voltage is less than six volts, replace the power supply board. c.

  • Page 41: Fault #1 Or Fault #2 Message

    P2-7 P2-7 Fault LED TB-DC1-8 Main Logic Board Power Supply Board 560449 Figure 4-9. Wiring Diagram— Fault #1 or Fault #2 message Fault #1 Or Fault #2 Message b. If there is not an accessory connected to TB-DC1-8, remove power from the logic board and disconnect the P2 ribbon cable connector The external fault function can be used to identify a from the power supply board.

  • Page 42: Programming Mode Not-In-Off

    Programming Mode Not-In-Off For location of pushbuttons, switches, LEDs, and keys Remote programming mode, the Programming Mode referred to in this section, see Figure 2-1. Not-In-Off LED should be on steadily. When the Programming-Mode key is set to Off, the Programming The Programming Mode Not-In-Off LED signals the Mode Not-In-Off LED should be off.

  • Page 43: Engine Operates When It Should Not

    Engine Operates When it Should Not If the engine continues to operate after the logic ohmmeter, connect one test lead to TB-DC1-22. Connect the other test lead to controller removes the start signal, check the power TB-DC1-21. If the resistance is high supply board Start LED and perform the following indicating lack of continuity, replace the procedure.
  • Page 44 Is the start LED illuminated? Disconnect the start terminals 3 and Is there 19 vac between terminals 4 on the power conversion unit. Does TB-DC1-23 and TB-DC1-34 of the the generator set continue to run? power supply board? Check the generator set See Power to the System and generator set wiring.

  • Page 45: Engine Will Not Start

    Engine Will Not Start If the engine will not operate, check the power supply check if there is a jumper between TB-DC1-22 and TB-DC1-31. If there is not a board START LED and perform the following procedure. jumper, add one. If the engine still does not For location of the START LED and other power supply start when TB-DC1-21 and TB-DC1-22 are board components referred to in this section, see...
  • Page 46 Is the start LED illuminated? Is there 1 vdc between pin P4-1 Jumper terminals 3 and 4 on of plug 4 and terminal TB-DC1-34 the power conversion unit. of the power supply board? Does the generator set start? Replace the Replace the power Check the generator set and logic board.

  • Page 47: Area Protection

    Area Protection Area Protection turns on the emergency source when a 2. If the Area-Protection LED does not turn off after grounding TB-DC1-6, connect P2-5 to ground. If the loss of normal power is expected because of an Area-Protection LED does not turn off, replace the approaching storm or for some other reason.

  • Page 48: Shunt Jumper-Controlled Options

    Shunt Jumper-Controlled Options Jumpers installed in the shunt-jumper socket JP1 on the 3. Power down the controller by disconnecting the inline disconnect plug P1. main logic board control the following options. D Extended Time Delays— DD-100-B 4. Wait a minimum of 1 minute then reconnect plug P1 to power up the controller.
  • Page 49 Does an entry appear in Index 20 that says OPTIONS LOCK? NO ? Options are not locked. Lock the options to change: Answer YES and ENTER to OPTIONS LOCK? NO in Index 20, then Options are locked. Does press RESET MENU then ENTER to OFF DELAYS not have a store the setpoints before repeating jumper and displays YES ?

  • Page 50: Inphase Monitor

    Inphase Monitor Motors and related equipment can be damaged by utility. To enable this option, the IN-PHASE MONITOR abnormal inrush currents when switched between two jumper must be installed on the main logic board. See live power sources. The purpose of the Inphase Monitor, Figure 4-15.

  • Page 51: Source Monitors

    Source Monitors The Source Monitor Phase Sequencer accessory on one emergency source phase. This accessory is DD-34-Z provides source monitoring for both the normal enabled by installing the VOLT/FREQ jumper on the and emergency sources. The features include phase main logic board. See Figure 4-15. See Appendix B, rotation and anti-single phasing protection.
  • Page 52 MICROCONTROLLER TB--AC1 TB--DC1 MANUAL OVRIDE TIME DELAY PLANT EXER VOLT/ FREQ PHASE SEQUENCER IN--PHASE MONITOR DELAYS Programming shunt (294634) must be installed to activate accessory 560456 Figure 4-22. Wiring Diagram— Voltage/Frequency Sensing, option DD-34-J Is the Phase Sequencer Install the Phase Sequencer jumper installed in JP1 on jumper on JP1 and power the logic board?
  • Page 53 Is the Volt/Freq jumper Install the Volt/Freq jumper installed in JP1 on the on JP1 and power down the logic board? controller for 1 minute mininum. Troubleshoot shunt-jumper In Index 11 is Norm & controlled options. See Emer sensing enabled? Figure 4-18.

  • Page 54: Plant Exerciser

    Plant Exerciser The Plant Exerciser is an accessory which periodically The plant exerciser is programmed in Index 8. The tests the emergency source for proper operation. To following information is needed to program the plant enable this option, the PLANT EXER jumper must be exerciser.
  • Page 55 EXERCISOR SELECT MICROCONTROLLER TB--DC1 TB--AC1 W/LOAD LOAD 1 — 2 OVRIDE MANUAL TIME DELAY EXER PLANT FREQ VOLT/ SEQUENCER PHASE IN--PHASE MONITOR DELAYS Programming shunt (294634) must be installed to activate accessory 560453 Figure 4-26. Wiring Diagram— Plant exerciser, option DD-23-G Install the Plant Exer jumper Is the Plant Exer jumper installed in JP1 on the logic...
  • Page 56 Install the Plant Exer jumper Is the Plant Exer jumper on JP1 and power down the installed in JP1 on the logic controller for 1 minute board? mininum. In Index 11 is Plant Troubleshoot Exerciser enabled? shunt-jumper controlled options. See Figure 4-18. Is there a jumper from terminals TB-DC1-10 to TB-DC1-32 on the power supply board?
  • Page 57 Install the Plant Exer jumper Is the Plant Exer jumper on JP1 and power down the installed in JP1 on the logic controller for 1 minute board? mininum. In Index 11 is Plant Troubleshoot Exerciser enabled? shunt-jumper controlled options. See Figure 4-18. Is the Load/No Load Place the Load/No Load selector switch in the...
  • Page 58 Is the Plant Exer jumper Install the Plant Exer jumper on JP1 and power down the installed in JP1 on the logic board? controller for 1 minute mininum. Troubleshoot In Index 11 is the Plant shunt-jumper Exerciser enabled? controlled options. See Figure 4-18.

  • Page 59: Time Delays

    Time Delays D DD-100-B. This accessory allows all time delays to must be installed on the main logic board to increase the be adjusted from 0 to 99 minutes. adjustable range of standard time delays up to 99 minutes. See Figure 4-15. To extend TDES time Time Delay accessory DD-100-B increases all of the time delays an external 12-32 vdc power supply is required.

  • Page 60: Manual Override

    Manual Override It is important that the MANUAL OVRIDE jumper always See Figure 4-32 for a troubleshooting flowchart for this be in place on the main logic board. See Figure 4-15. Do option. not remove it! Install the Manual Ovride jumper Is the Manual Ovride on JP1 and power down the jumper installed in JP1...

  • Page 61: Off Delays

    Off Delays The Off position time delay allows an off position power conversion units with an Off position except the MM and MN, the off delays can be set to zero. On the MM and MN conversion unit to stop for a defined period of time in the power conversion units the minimum off delay is off position.

  • Page 62: Section 5. Accessory Troubleshooting

    Section 5. Accessory Troubleshooting This section contains a brief description, wiring commonly used accessories. diagrams, and troubleshooting flowcharts for many of See Figure 5-1 for the relationship between the the logic board accessories. microprocessor main functions and the affect that certain Refer to Appendix C for a comprehensive list of accessories can have on those functions.

  • Page 63: Optional Accessories

    Optional Accessories Three-Phase Emergency Source Sensing Accessory, DD-05-K The three-phase emergency source sensing accessory sensing for all three phases of the emergency source. DD-05-K provides source monitoring for the emergency Refer to Figure 5-2 for the troubleshooting flowchart. source. The accessory includes over/undervoltage In Index 7 of the microprocessor menu is three-phase emergency source sensing enabled?
  • Page 64 TB--AC1 TB--DC1 MICROCONTROLLER RIBBON CABLE 294638 BLUE STRIPE TO SLOTTED SIDE OF DIPSOCKET PCB ASSY C--294493 MANUAL OVRIDE TIME DELAY Programming Shunt (294634) PLANT EXER VOLT/ FREQ must be installed to activate accessory PHASE SEQUENCER IN--PHASE MONITOR DELAYS 560457 Figure 5-3. Wiring Diagram— Three-phase emergency source sensing, Option DD-05-K TP-5672 11/95 Accessory Troubleshooting...

  • Page 65: Test Switches

    Test Switches Refer to Figure 5-4 for wiring diagram for the Test switch. NOTE Refer to Figure 5-5 through Figure 5-10 for the When taking a voltage or resistance measurement at a troubleshooting flowcharts. ribbon cable pin, do not disconnect the ribbon cable from the board.
  • Page 66 TBDC1--9 TB--AC1 TB--DC1 MICROCONTROLLER TBDC1--34 TBDC1--24 TBDC1--21 TBDC1--22 S1--5 S1--6 S1--3 TEST SWITCH S1--1 ENG. AUTO TEST START 1--2 3--4 5--6 S1--2 Wire Code Example Device Name Wire Number S10--13— 201 Device Terminal 5604516 Number Figure 5-4. Wiring Diagram— Test switches, Options DD-06-N, -P, -R, -T Place a jumper between terminals TB-DC1-21 and TB-DC1-31 on the power supply board.
  • Page 67 Does the generator set start when the test switch is in the TEST position? Does the Not-In-Automatic LED illuminate when the test button is pressed? Option is functioning properly. Place a jumper between terminals Is there continuity between TB-DC1-9 and TB-DC1-34 on the terminal TB--DC1--9 on the power supply board.
  • Page 68 Place a jumper between terminals TB-DC1-21 and TB-DC1-31 of the power supply board. Does the generator set start? Refer to the Engine Start Troubleshooting Flowchart. Place a jumper between terminals TB-DC1-21 to TB-DC1-22 of the power supply board. Does the generator set start when the test switch is in the Engine Start position? Is there a jumper between...
  • Page 69 Does the generator set Is there continuity between terminals TB-DC1-24 start when the test switch and TB-DC1-34 on the power supply board when is in the Test position? the test button is pressed? Place a jumper between terminals Is there continuity between terminal TB-DC1-21 to TB-DC1-31 on the TB-DC1-24 on the power supply board power supply board.
  • Page 70 Is there continuity between terminals TB-DC1-24 Replace the test switch. and TB-DC1-34 on the power supply board? Is there continuity between terminals TB-DC1-25 Replace the test switch. and TB-DC1-30 on the power supply board? Is there continuity between terminals TB-DC1-21 Replace the test switch.

  • Page 71: Time Delay Override Option

    Time Delay Override Accessory The Time Delay Override Accessory allows the user to make sure that the emergency source is available. manually override emergency-to-normal Initiate a normal-to-emergency time delay by removing normal-to-emergency time delay. When the pushbutton the normal source, and then press the Bypass pressed corresponding transfer...
  • Page 72 MICROCONTROLLER TB--AC1 TB--DC1 S3--4 Wire Code Example Device Name TBDC1--33 Wire Number TBDC1--3 S10--13— 201 Device Terminal Number S3--3 5604520 Figure 5-12. Wiring Diagram— Time Delay Override, Option DD-08-D Troubleshooting The Bypass 1. If grounding TB-DC1-4 causes the emergency-to- normal time delay to be bypassed but the Bypass Emergency-To-Normal Time Delay Emergency-to-Normal Time Delay pushbutton is Pushbutton...
  • Page 73 Emergency source must be Is the emergency power present to bypass the time source available? delay normal-to-emergency. Program a TDNE time Is there a TDNE time delay delay in index 5 of the set in Index 5 of the microprocessor program. microprocessor program? Place a jumper between terminals TB-DC1-3 and TB-DC1-33 on the...
  • Page 74 Normal source must be Is the normal source present to bypass the time available delay emergency-to-normal. Is there a TDEN time delay Program a TDEN time set in Index 5 of the delay in index 5 of the microprocessor program? microprocessor program.

  • Page 75: Preferred Source Switch

    Preferred Source Switch Preferred source switch option DD-10-D provides a when the emergency source fails. See Figure 5-15 for a means to select which of two generator sets will be used wiring diagram for DD-10-D. MICROCONTROLLER 134--TBDC1--34 TB--AC1 TB--DC1 106--TBDC1--6 DCK--K1--118 PSS--3--106 2FU--BK--123...

  • Page 76: Relay Auxiliary Dry Contacts

    Relay Auxiliary Dry Contacts Auxiliary Dry Contacts option DD-14-G provides ten program mode not in off, and system alert. DD-14-G can contacts for remote indication. The contacts are rated at be fitted to a transfer switch alone or with up to two 10 amperes and 125 volts AC.
  • Page 77 Additional auxiliary dry contact accessories are D DD-14-M. Single-contact kit for remote indication. This option is rated for 10 amps and for 120 volts described below. Wiring diagrams for these accessories used indicate whether are in Figure 5-17 to Figure 5-24. Refer to Figure 5-25 Automatic/Manual selector switch is not in the for the troubleshooting flowchart.
  • Page 78 MICROCONTROLLER TB--AC1 TB--DC1 2FU--BK--123 DCK--K1--127 SPLICE TB--DC1--23--123 306--DCK--42A DCK--2--132 TB--DC1--27--127 TB--DC1--32--132 2FU--R--306 Wire Code Example Contacts Shown De-energized Device Name Wire Number S10--13— 201 Device Terminal Number 5604523 Figure 5-18. Wiring Diagram— Option DD-14-J, Auxiliary dry contacts MICROCONTROLLER TB--AC1 TB--DC1 2FU--BK--123 SPLICE 306--DCK--42A...
  • Page 79 MICROCONTROLLER TB--AC1 TB--DC1 DCK--K1--118 2FU--BK--123 SPLICE 306--DCK--42A TB--DC1--23--123 DCK--2--132 TB--DC1--18--118 TB--DC1--32--132 2FU--R--306 Wire Code Example Device Name Contacts Shown De-energized Wire Number S10--13— 201 Device Terminal Number 5604525 Figure 5-20. Wiring Diagram— Option DD-14-L, Auxiliary dry contacts MICROCONTROLLER TB--AC1 TB--DC1 2FU--BK--123 SPLICE TB--DC1--23--123...
  • Page 80 MICROCONTROLLER TB--AC1 TB--DC1 101--DCK--K1 2FU--BK--123 SPLICE TB--DC1--23--123 306--DCK--42A DCK--2--132 TB--DC1--1--101 TB--DC1--32--132 2FU--R--306 Wire Code Example Device Name Contacts Shown De-energized Wire Number S10--13— 201 Device Terminal Number 5604527 Figure 5-22. Wiring Diagram— Option DD-14-N, Auxiliary dry contacts MICROCONTROLLER TB--AC1 TB--DC1 DCK--K1--119 2FU--BK--123 SPLICE...
  • Page 81 TB--AC1 MICROCONTROLLER TB--DC1 105--DCK--K1 2FU--BK--123 SPLICE TB--DC1--23--123 306--DCK--42A DCK--2--132 TB--DC1--5--105 TB--DC1--32--132 2FU--R--306 Wire Code Example Device Name Contacts Shown De-energized Wire Number S10--13— 201 Device Terminal Number 5604529 Figure 5-24. Wiring Diagram— Option DD-14-R, Auxiliary dry contacts 5-20 Accessory Troubleshooting TP-5672 11/95...
  • Page 82 Is there 12 to 32 vdc between terminals 42A(+) and 2(--) on the relay board? Is there continuity between Is there 12 to 32 vdc between terminal TB-DC1-32 on the power terminals TB-DC1-23(+) and supply board and terminal 2 on TB-DC1-32(--) on the power the relay board? supply board?

  • Page 83: Main Shaft Auxiliary Dry Contacts

    Main Shaft Auxiliary Dry Contacts One main shaft auxiliary dry contact, option DD-15-A, is manual for troubleshooting. supplied standard on 600 volt class transfer switches. Additional accessory DD-15 contacts available are DD-15-A is mounted on the transfer switch. The location described below.

  • Page 84: Meters

    Meters Option 18 provides an analog meter to measure various Troubleshooting flowcharts for option DD-18-J begin parameters including voltage, current, and frequency. with Figure 5-36 and conclude with Figure 5-52. Figure 5-27 contains a wiring diagram for option D DD-18-G. Analog frequency meter with fuse. DD-18-G.
  • Page 85 295385 Figure 5-28. Wiring Diagram— Option DD-18-J, Analog Volt and Amp Meter 5-24 Accessory Troubleshooting TP-5672 11/95...
  • Page 86 295386 Figure 5-29. Wiring Diagram— Option DD-18-J, Analog Volt and Amp Meter TP-5672 11/95 5-25 Accessory Troubleshooting...
  • Page 87 295387 Figure 5-30. Wiring Diagram— Option DD-18-J, Analog Volt and Amp Meter 5-26 Accessory Troubleshooting TP-5672 11/95...
  • Page 88 295388 Figure 5-31. Wiring Diagram— Option DD-18-J, Analog Volt and Amp Meter 295388 Figure 5-32. Wiring Diagram— Option DD-18-J, Analog Volt and Amp Meter TP-5672 11/95 5-27 Accessory Troubleshooting...
  • Page 89 Is the emergency source available? Accessory 18-G only displays emergency source frequency. Is there rated line-to-line emergency source voltage between terminals TB-AC1-EA and TB-AC1-EC of the power supply board? Refer to Source-Available, Emergency Error Troubleshooting. Is there a transformer wired between terminal TB-AC1-EA of the power supply board and the frequency meter?
  • Page 90 Use the following table to find the troubleshooting Options with Ammeter flowchart for Option DD-18-J Current and Voltage Troubleshooting DD-18- meters. Locate the DD-18-J accessory that is used on Flowchart Prefix Voltmeter Troubleshooting your transfer switch in the left column. The flowchart Figure 5-40 to Figure 5-45 Figure 5-46 number for troubleshooting the voltmeter is in the center...
  • Page 91 Does the voltmeter read only the Normal source voltage? Is there rated line-to-line Is there rated line-to-line voltage between terminals voltage between terminals TB-AC1-NA and TB-AC1-NB TB-AC1-EA and TB-AC1-EC of the power supply board? of the power supply board? Refer to Power to the Refer to Power to the System Troubleshooting.
  • Page 92 NOTE: The ammeter reads load currents. The source selector switch must be in the NORM. NA-NB L1 position to read the load current. Is the current between terminals 12 and 21 of the source selector switch correct? Refer to Figure 5-35 for the proper turn ratio of the current transformer.
  • Page 93 Does the voltmeter display only the emergency source? Is there rated line-to-line Is there rated line-to-line voltage between terminals voltage between terminals TB-AC1-NA and TB-AC1-NC TB-AC1-EA and TB-AC1-EC of the power supply board? of the power supply board? Refer to Power to the Refer to Power to the System Troubleshooting.
  • Page 94 NOTE: The ammeter reads the load current. The source selector switch must be in the NORM. NA-NB L1 or L2 position to read the load current. Does the ammeter display load currents for L1 only? Is the ratio of current that L1 is using Are the leads from CT1 between terminals 12 and 21 of the current transformer to...
  • Page 95 Is there rated line-to-line voltage between terminals TB-AC1-NA and TB-AC1-NB of the power supply board? Refer to Power to the System Troubleshooting. Replace the leads from Is there rated line-to-line terminals TB-AC1-NA and Is the source selector switch voltage between terminals TB-AC1-NB of the power in the NORM.
  • Page 96 Is there rated line-to-line voltage between terminals TB-AC1-NB and TB-AC1-NC of the power supply board? Refer to Power to the System Troubleshooting. Is there rated line-to-line Replace the leads from Is the source selector switch voltage between terminals terminals TB-AC1-NB and in the NORM.
  • Page 97 Is there rated line-to-line voltage between terminals TB-AC1-NA and TB-AC1-NC of the power supply board? Refer to Power to the System Troubleshooting. Replace the leads from Is there rated line-to-line terminals TB-AC1-NA and voltage between terminals TB-AC1-NC of the power 32 and 42 of the source supply board to the source selector switch?
  • Page 98 Is there rated line-to-line voltage between terminals TB-AC1-EA and TB-AC1-EB of the power supply board? Refer to Power to the System Troubleshooting. Replace the leads from Is there rated line-to-line terminals TB-AC1-EA and voltage between terminals TB-AC1-EB of the power 32 and 42 of the source supply board to the source selector switch?
  • Page 99 Is there rated line-to-line voltage between terminals TB-AC1-EB and TB-AC1-EC of the power supply board? Refer to Power to the System Troubleshooting. Replace the leads from Is there rated line-to-line terminals TB-AC1-EB and voltage between terminals TB-AC1-EC of the power 32 and 42 of the source supply board to the source selector switch?
  • Page 100 Is there rated line-to-line voltage between terminals TB-AC1-EA and TB-AC1-EC of the power supply board? Refer to Power to the System Troubleshooting. Replace the leads from Is there rated line-to-line terminals TB-AC1-EB and voltage between terminals TB-AC1-EC of the power 32 and 42 of the source supply board to the source selector switch?
  • Page 101 NOTE: The ammeter reads load currents. The Source selector switch must be in the NORM. NA-NB, NB-NC, or NA-NC to read loads L1, L2, or L3. Is the correct current for load L1 between terminal 12,13, or 14 and 21 of the source selector switch? Refer to Figure 5-35 for the proper turn ratio of the current transformer.
  • Page 102 Is there rated line-to-line voltage between terminals TB-AC1-NA and TB-AC1-NB of the power supply board? Refer to Power to the System Troubleshooting. Replace the leads from Is there rated line-to-line voltage terminals TB-AC1-NA and TB-AC1-NB of the power between terminals 32 and 42 of the source selector switch? supply board to the source selector switch.
  • Page 103 Is there rated line-to-line voltage between terminals TB-AC1-NB and TB-AC1-NC of the power supply board? Refer to Power to the System Troubleshooting. Replace the leads from Is there rated line-to-line voltage terminals TB-AC1-NB and TB-AC1-NC of the power between terminals 33 and 43 of the source selector switch? supply board to the source selector switch.
  • Page 104 Is there rated line-to-line voltage between terminals TB-AC1-NA and TB-AC1-NC of the power supply board? Refer to Power to the System Troubleshooting. Replace the leads from Is there rated line-to-line voltage terminals TB-AC1-NA and TB-AC1-NC of the power between terminals 34 and 44 of the source selector switch? supply board to the source selector switch.
  • Page 105 Is there rated line-to-line voltage between terminals TB-AC1-EA and TB-AC1-EB of the power supply board? Refer to Power to the System Troubleshooting. Replace the leads from Is there rated line-to-line voltage terminals TB-AC1-EA and TB-AC1-EB of the power between terminals 38 and 48 of the source selector switch? supply board to the source selector switch.
  • Page 106 Is there rated line-to-line voltage between terminals TB-AC1-EB and TB-AC1-EC of the power supply board? Refer to Power to the System Troubleshooting. Replace the leads from Is there rated line-to-line voltage terminals TB-AC1-EB and TB-AC1-EC of the power between terminals 37 and 47 of the source selector switch? supply board to the source selector switch.
  • Page 107 Is there rated line-to-line voltage between terminals TB-AC1-EA and TB-AC1-EC of the power supply board? Refer to Power to the System Troubleshooting. Replace the leads from Is there rated line-to-line voltage terminals TB-AC1-EA and TB-AC1-EC of the power between terminals 36 and 46 of the source selector switch? supply board to the source selector switch.

  • Page 108: Battery Charger

    Battery Charger Option DD-24 is an automatic adjustable float battery WARNING charger. The battery charger is mounted below the main circuit board on the enclosure door. The automatic battery charger is designed to charge and maintain lead-acid and nickel-cadmium automotive-type batteries in a fully charged state without manual intervention.
  • Page 109 WIRING DIAGRAM AMMETER OUTPUT 6 AMP ORANGE BLUE RED/BLUE OR RED/YELLOW VIOLET ORANGE POWER TRANSFORMER INPUT 1 AMP— 12 V 1.5 AMP— 24 V CONTROL BOARD BLK/YEL TERMINAL BLK/RED BLOCK GND. BLK/WHT SCHEMATIC POWER ORANGE ORANGE VIOLET CONTROL BOARD BLUE AMMETER RED/BLUE RED/YELLOW...
  • Page 110 WIRING DIAGRAM AMMETER OUTPUT 6 AMP ORANGE BLUE RED/BLUE OR RED/YELLOW VIOLET ORANGE POWER TRANSFORMER INPUT 0.5 AMP— 12 V CONTROL 1 AMP— 24 V BOARD TERMINAL BLOCK GND. SCHEMATIC CONTROL ORANGE VIOLET ORANGE POWER BOARD BLUE AMMETER RED/BLUE RED/YELLOW DC OUTPUT TRANS.
  • Page 111 AMMETER WIRING DIAGRAM OUTPUT 6 AMP ORANGE BLUE RED/BLUE OR RED/YELLOW VIOLET POWER ORANGE TRANSFORMER INPUT 0.5 AMP— 12 V CONTROL 1 AMP— 24 V BOARD BLK/YEL BLK/ GND. BLK/WHT TERMINAL BLOCK SCHEMATIC CONTROL ORANGE VIOLET ORANGE POWER BOARD AMMETER BLUE RED/BLUE RED/YELLOW...
  • Page 112 WIRING DIAGRAM AMMETER OUTPUT 6 AMP ORANGE BLUE RED/BLUE OR RED/YELLOW VIOLET ORANGE POWER TRANSFORMER INPUT 0.3 AMP— 12 V CONTROL 0.5 AMP— 24 V BOARD TERMINAL BLOCK GND. BLK/WHT SCHEMATIC CONTROL ORANGE VIOLET ORANGE POWER BOARD BLUE AMMETER RED/BLUE RED/YELLOW DC OUTPUT TRANS.
  • Page 113 AMMETER WIRING DIAGRAM OUTPUT 6 AMP ORANGE BLUE RED/BLUE OR RED/YELLOW VIOLET POWER ORANGE TRANSFORMER INPUT 0.2 AMP— 12 V CONTROL 0.4 AMP— 24 V BOARD TERMINAL BLOCK GND. BLK/WHT SCHEMATIC POWER CONTROL ORANGE VIOLET ORANGE BOARD AMMETER RED/BLUE BLUE RED/YELLOW DC OUTPUT TRANS.
  • Page 114 MICROCONTROLLER TB--AC1 TB--DC1 BC--AC1 BC--AC2 Battery Charger Wire Code Example Device Name Wire Number S10--13— 201 Device Terminal Number TBAC1--LA D.C. To Battery 5604534 TBAC1--LC Figure 5-59. Wiring Diagram— Option DD-24-A and DD-24-B, Battery charger Turn off the AC supply to the Check the battery charger connections to the battery charge.

  • Page 115: Manual Operation Switches

    Manual Operation Switches Description of the Manual Troubleshooting the Standard Power Conversion Unit Operation Switches Automatic-Transfer/Manual-Transfer Switch The accessory DD-29 allows manual operation of the If the Automatic-Transfer/Manual-Transfer switch is in transfer switch. DD-29 includes an override circuit which the Manual position, the following events will occur. will cause the transfer switch to automatically transfer to the alternate power source if the connected source fails.
  • Page 116 Troubleshooting the Off Position When the Automatic-Transfer/Manual-Transfer key switch is in the Manual position, the Not-In-Automatic Automatic-Transfer/Manual-Transfer Key LED illuminates. When the system is in the Manual mode Switch and is waiting to be transferred to a new power source If the Automatic-Transfer/Manual-Transfer key switch is after all the time-delays have completed timing, the in the Manual position, the following events occur.
  • Page 117 When the Automatic-Transfer/Manual-Transfer key If the P2 ribbon cable connection is good, connect P2-24 switch is in the Manual position, the Not-In-Automatic to TB-DC1-34. If the System-Status, System-Alert LED LED illuminates. When the system is in the Manual mode illuminates when P2-24 is grounded, but does not and is waiting to be transferred to a new power source illuminate when TB-DC1-20 is grounded, replace the after all the time delays have completed timing, the...
  • Page 118 Troubleshooting The Manual Troubleshooting The Manual Transfer-To-Normal Source Pushbutton Transfer-To-Off Pushbutton If the Manual Transfer-to-Normal Source pushbutton is If the Manual Transfer-to-Off pushbutton is not not operating, connect TB-DC1-2 to TB-DC1-34. operating, connect TB-DC1-12 to TB-DC1-34. 1. If grounding TB-DC1-2 causes a transfer to the 1.
  • Page 119 MICROCONTROLLER TB--AC1 TB--DC1 S7-3 TBDC1--2 TBDC1--34 Wire Code Example Device Name S7-4 Wire Number S10--13— 201 Device Terminal Number 5604538 Figure 5-62. Wiring Diagram— Option DD-29-S and DD-29-T, Manual operation switches TBDC1--20 TBDC1--9 MICROCONTROLLER TB--AC1 TB--DC1 NO NO S6-4 TBDC1--34 S7-3 S5-1 TBDC1--7...
  • Page 120 MICROCONTROLLER TB--AC1 TB--DC1 TBDC1--20 TBDC1--9 NO NO S7-3 S7--4 TBDC1--34 S5-1 TBDC1--2 S5-4 S5--2 S5-3 Wire Code Example Device Name Wire Number S10--13— 201 Device Terminal Number 5604540 Figure 5-64. Wiring Diagram— Option DD-29-W and DD-29-X, Manual operation switches Place a jumper between terminals TB-DC1-7 and TB-DC1-34 of the power supply board.
  • Page 121 Place a jumper between terminals TB-DC1-2 and TB-DC1-34 of the power supply board. Does the generator set start and transfer to the emergency source? Is there continuity between terminal Disconnect the in-line plug. Remove the TB-DC1-2 of the power supply board and ribbon cable between plug P2 of the power terminal 3 of the manual transfer switch? supply board and plug P3 on the logic...
  • Page 122 Is the auto/manual switch Place the auto/manual switch in the MANUAL position? in the MANUAL position. Place a jumper between terminals TB-DC1-20 and TB-DC1-34 of the power supply board. Does the generator set start and transfer to the emergency source? Is there continuity between terminal Disconnect the in-line plug.
  • Page 123 Is the auto/manual switch Place the auto/manual switch in the AUTO position? in the AUTO position. Is there continuity between terminals TB-DC1-20 and TB-DC1-34 of the power supply board? Remove the leads from terminals TB-DC1-20 and Disconnect the in-line plug. Remove the TB-DC1-34 of the power supply board from the ribbon cable between plug P2 of the power auto/manual switch.

  • Page 124: Load Shedding Contacts

    Load-Shedding Contacts The load-shedding contacts accessory, DD-35-N, allows The time delays before transfer and the sequence the user to control the number of loads as well as the interval time delays are individually adjustable. Settings which loads will receive power. This accessory can may be made from the front panel keypad or from a remote computer.
  • Page 125 Is there between 12 and 30 vdc between terminals TD-DC1-23 and TB-DC1-34 of the power supply board? Replace the power supply board. Is there between 12 and 30 vdc between pins P11-8 and P11-2 of plug P11? Is there between 12 and 30 vdc between pins P17-1 and P17-9 of plug P17? Replace the load-shed...

  • Page 126: Remote Communication- Rs/232 Or Rs/485

    Remote Communication— RS/232 Or RS/485 For location of pushbuttons, switches, LEDs, and keys Return to the Remote Control submenu. At the referred to in this section, see Figure 2-1. REMOTE message press the MENU Arrow Right key. The LCD should read SYS ID. Press up to six D DD-51-A.
  • Page 127 LOCKED. Press the YES key and then the ENTER 2. If the voltmeter reads approximately five volts DC, key. check the voltage at P13-7 on the Remote Communication board. Using a voltmeter, connect 7. Press the RESET MENU key, and then press the the positive test lead to P13-7.
  • Page 128 Remove modem from the transfer switch and verify that it is operating properly. (Refer to modem operation manual from the manufacturer of the modem) Is the modem operating correctly? Replace the modem. Connect a PC directly to the communication interface board and try to communicate with the transfer switch.

  • Page 129: Section 6. Service Parts

    Section 6. Service Parts Introduction Using Parts Lists Finding Parts Information Use this section to locate and identify service parts for the models of the automatic transfer switches that use 1. Determine the parts needed. microprocessor logic. The part numbers of the Example: The micro-controller assembly needs automatic transfer switches covered by the parts listed to be replaced.

  • Page 130: Inner Panel

    Inner Panel BW-295000 Figure 6-1. Micropocessor inner panel assembly TP-5672 11/95 6-2 Service Parts...
  • Page 131 BW-295000 Figure 6-2. Micro-controller assembly Description Description Item Qty. Variation Part No. Item Qty. Variation Part No. Micro-controller assembly 346061 Logic to power conversion Figure 6-4 Logic to interface harness unit harness Figure 6-4 Guard 294860 Contact Assembly 298049 Decal, hazardous voltage 294328 Block, contact 294651...
  • Page 132 Item 8. Logic/Interface to Switch Item 2. Power Conversion Amps Switch Description Logic to Interface Unit TES, TLS 25-180 standard and programmed transition 320957 321089 265-400 standard and programmed transition 320960 321327 MNS, MMS 40-160 standard and programmed transition 320957 321313 250-4000 standard and programmed transition...

  • Page 133: Accessories

    M340+ Accessories Time Delay Auxiliary Contacts— Relay Accessory Description Part Number Accessory Description Part Number 02-F Relay, Time Delay 295974 14-C Relay 295254 Socket, Relay 295034 Tab, Identification 201620-157 Source Monitors Clamp, Relay Hold Down 295189 Accessory Description Part Number 14-D Relay 295254...

  • Page 134: Meters

    Accessories Meters Accessory Description Part Number 18-JA5 Insulink (2) X-367-3 Accessory Description Part Number Fuse, 2 Amp 239049 18-GA Insulink (3) X-367-3 Switch, Selector 283638 Fuse, 2 Amp 239049 Nameplate 294704 Meter, Frequency 295069 Voltmeter, AC 295011 Transformer (2) 295019 18-GB Insulink (3) X-367-3...
  • Page 135 Meters (continued) Accessory Description Part Number 18-JC5 Insulink X-367-3 Accessory Description Part Number Fuse, 2 Amp 239049 18-JB5 Insulink (2) X-367-3 Transformer (3) 246885 Fuse, 2 Amp 239049 Switch, Selector 283638 Transformer (3) 246884 Nameplate 295342 Switch, Selector 283638 Ammeter 295338 Nameplate 295342...
  • Page 136 Meters (continued) Accessory Description Part Number 18-JE8 Insulink X-367-3 Accessory Description Part Number Fuse, 2 Amp 239049 18-JD8 Insulink X-367-3 Transformer 246889 Fuse, 2 Amp 239049 Switch, Selector 283638 Transformer 246886 Nameplate 295343 Switch, Selector 283638 Ammeter 295339 Nameplate 295343 Voltmeter 295014 Ammeter...
  • Page 137 Meters (continued) Accessory Description Part Number 18-JG8 Insulink X-367-3 Accessory Description Part Number Fuse, 2 Amp 239049 18-JF8 Insulink X-367-3 Transformer 295302 Fuse, 2 Amp 239049 Switch, Selector 283638 Transformer 248874 Nameplate 295343 Switch, Selector 283638 Ammeter 295339 Nameplate 295343 Voltmeter 295014 Ammeter...
  • Page 138 Meters (continued) 18-JM2 Insulink X-367-3 Fuse, 2 Amp 239049 Accessory Description Part Number Switch, Selector 283638 Nameplate 295342 18-JH9 Insulink X-367-3 Ammeter 282960 Fuse, 2 Amp 239049 Voltmeter 295011 Transformer 295302 Transformer (3) 291548 Switch, Selector 283638 Nameplate 295342 18-JM9 Insulink X-367-3 Ammeter...

  • Page 139: Plant Exercisers

    Plant Exercisers Accessory Description Part Number 23-VC Clock, Time 294541 Accessory Description Part Number Transformer 295355 23-TA Clock, Time 294541 Switch, Selector 295322 23-TB Clock, Time 294541 23-VC3 Clock, Time 294541 Transformer 295354 Transformer 295355 23-TC Clock, Time 294541 Switch, Operator 298039 Transformer 295355...

  • Page 140: Battery Chargers

    Battery Chargers Manual Switch Operation Accessory Description Part Number Accessory Description Part Number 24-60A Charger Assembly, Battery A-294236 29-P Switch, Pushbutton (2) 294653 Fuse, 6.0 amp 226520 Contact Assembly (2) 298049 Fuse, 0.2 amp 226527 29-R Switch, 2 Position (2) 294656 Decal 294688...

  • Page 141: Appendix A. Glossary Of Abbreviations

    Appendix A. Glossary of Abbreviations Abbreviations are used throughout this manual. abbreviated form. The commonly used abbreviations Normally they will appear in the text in complete form are shown below. Some items may not apply to this with the abbreviation following in parentheses the first application.
  • Page 142 Abbreviation Description Abbreviation Description International Standards Organization National Standard taper pipe thread joule, joules per general use Japanese Industry Standard not required kilogram, kilograms overcrank kg/cm kilograms per square centimeter outside diameter kilogram meter(s) original equipment manufacturer kilojoules (btu cal) overspeed kilometer, kilometers oversize...

  • Page 143: Appendix B. General Controller Information

    Appendix B General Controller Information TB-DC1 Terminal Input/ TB-DC1 TB-DC1 Output* Terminal Name Terminal Description OUTPUT Programming-Mode-Not- If the programming-mode key is not in the off position, terminal In-Off 1 is grounded. INPUT Manual Transfer If terminal 2 is grounded, a manual-transfer-to-normal-source to Normal occurs.
  • Page 144 TB-DC1 Terminal Input/ TB-DC1 TB-DC1 Output* Terminal Name Terminal Description OUTPUT Emergency Source If the emergency source is available, terminal 18 is grounded. OUTPUT System Alert If there is a system-status system alert, terminal 19 is grounded. INPUT Automatic/Manual If terminal 20 is grounded, the logic board is in the manual mode.
  • Page 145 TB-AC1 TB-AC1 Label Terminal Name Terminal Name Normal Phase A Normal Phase A voltage is connected from the P1-5 contactor to terminal NA through P1-5. Normal Phase B Normal Phase B voltage is connected from the P1-1 contactor to terminal NB through P1-1. Normal Phase C Normal Phase C voltage is connected from the P1-2...
  • Page 146 Emergency P1-J1 Contactor-transformer Pin Names Source Factory Setting Normal Phase B. Trip Point Settings Limits Normal Phase C. Overvoltage Dropout 115%-135% 115% Overvoltage Normal contactor position auxiliary contact Pickup 110%-130% 110% common. Undervoltage Normal Phase A. Pickup 75%-100% Undervoltage Dropout 70%-95% Overfrequency Emergency contactor position auxiliary contact...
  • Page 147 5604B6 1. Manual transfer to emergency, input 16. Normal phase AC inphase monitor 2. Manual transfer to normal, input 17. Normal phase BC 3. Normal to emergency time-delay bypass, input 18. Normal phase AB 4. Emergency to normal time-delay bypass, input 19.
  • Page 148 TDOE TDON TDON TDOE Shown with no power present in normal position. ADV-5900 Figure B-8. Logic board schematic diagram TP-5672 11/95 B-6 Appendices...
  • Page 149 (NR) (TDON) (ER) (TDOE) ADV-5900 Figure B-9. Logic board schematic diagram TP-5672 11/95 Appendices...
  • Page 150 P24--16 LOT NO. PCB ASSY A--320788 P24--12 P24--11 P24--5 TEST START P24--1 P24--2 P24--21 P24--17 P24--13 P24--23 P24--24 P24--15 P24--8 P24--4 MAX. AMB. TEMP 150%%DF A-320788 1. TB-DC1 4. TB-AC1 2. P14 accessory ribbon cable connector 5. P2 main logic board ribbon cable connector 3.
  • Page 151 A-320790 1. P3 power supply board ribbon cable connector 4. P12 remote communications ribbon cable connector 2. P6 status panel ribbon cable connector 5. JP1 3. P10 load--shed buffer ribbon cable connector Figure B-11. Main logic board TP-5672 11/95 Appendices...

  • Page 152: Appendix C. Commonly Used Accessories

    APPENDIX C Commonly Used Accessories Standard Accessories Optional Accessories Controller contains a CMOS microprocessor and nonvolatile Source Monitors, Emergency memory. DD-05-K Overfrequency sensing, 1-phase, over/undervoltage sensing 3-phase, phase rotation Microprocessor provides digital accuracy for time-delay, and anti-single-phasing protection source-transfer, and generator set exerciser intervals. Two-Position Test Switch Controller is protected against EMI, voltage transients, ESD, shock, vibration, and other hostile environments per U.S.A.,...
  • Page 153 Battery Charger Remote Communication DD-24-XX A Solid State, 2-amp. float, 12 volt DD-51-A ATS RS-485 Port adapter board for direct or LAN connection DD-24-XX B Solid State, 2-amp. float, 24 volt DD-51-B ATS RS-232 Port adapter board for modem XX-Same voltage code as the automatic transfer switch connection Manual Switch Operation with Override Circuit PA-320798...
  • Page 154 Fax 920-459-1646 (U.S.A. Sales), Fax 920-459-1614 (International) For the nearest sales and service outlet in U.S.A. and Canada Phone 1-800-544-2444 KohlerrPower Systems Asia Pacific Headquarters TP-5672 11/95d 7 Jurong Pier Road Singapore 619159 E Kohler Co., 1995. All rights reserved. Phone (65)264-6422, Fax (65)264-6455...

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