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Kohler MMS Service And Parts

Kohler MMS Service And Parts

Automatic transfer switches
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Service and Parts
Automatic Transfer Switches
Models:
MMS/MNS
TES/TLS
ZCS/ZCB
Electrical Controls:
E33+ Solid-State
U.S.A. Plant ISO Registered
TP-5670
9/94b

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  • Page 1 Service and Parts Automatic Transfer Switches Models: MMS/MNS TES/TLS ZCS/ZCB Electrical Controls: E33+ Solid-State U.S.A. Plant ISO Registered TP-5670 9/94b...

  • Page 2: Table Of Contents

    Table of Contents SUBJECT PAGE SUBJECT PAGE Safety Precautions and Instructions ..Section 4. Controller Troubleshooting ..Introduction ......General Troubleshooting Information .

  • Page 3: Safety Precautions And Instructions

    Safety Precautions and Instructions A transfer switch, like any other electromechanical device, can pose potential dangers to life and limb if WARNING improperly maintained or imprudently operated. The best way to prevent accidents is to be aware of the Warning indicates the presence of a hazard that can potential dangers and to always use good common cause severe personal injury, death, or substantial sense.
  • Page 4 Accidental Starting Battery WARNING WARNING Accidental starting. Sulfuric acid in batteries. Can cause severe injury or death. Can cause severe injury or death. Disconnect battery cables before working on Use protective goggles and clothes. Battery acid can generator set (negative lead first and reconnect it cause permanent damage to eyes, burn skin, and eat last).
  • Page 5 Hazardous Voltage/ WARNING Electrical Shock 600 Volt and Above Hazardous voltage. DANGER Can cause severe injury or death. Do not open enclosure until all power sources are disconnected. (under 600 Volt) Hazardous voltage. Hazardous voltage can cause severe injury or Will cause severe injury or death.
  • Page 6 Notes When replacing hardware, do not substitute with inferior grade hardware. Screws and nuts are Charge only lead-acid or nickel-cadmium batteries with available in different hardness ratings. American battery charger. Standard hardware uses a series of markings and metric hardware uses a numeric system to indicate Charger Damage! Connect battery charger only to a hardness.

  • Page 7: Introduction

    Service/ Models (Power Switching Device) Parts Manual products represented at any time without notice and MMS/MNS (molded case circuit breaker or without incurring obligation. TP-5666 switch 40 to 4000 amp) TES/TLS (electrically and mechanically held...
  • Page 8 Notes ii Introduction TP-5670 9/94...

  • Page 9: Section 1. Specifications

    Section 1. Specifications Purpose of Switch An Automatic Transfer Switch (ATS) is a device used for and transfers 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 10: Ratings

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

  • Page 11: Interpreting A Transfer Switch Part Number

    Kohler Part Number Key SAMPLE PART NUMBER This key explains the Kohler transfer switch part number system. The sample part number shown is for a standard molded-case switch with E33+ logic rated at 480 volts, 60 hertz, 3-phase, 3-pole, and 4 wires in a NEMA 1 enclosure with an MMS-266341-0080 amperage rating of 80 amperes.

  • Page 12: Specifications

    Specifications D The test switch simulates a normal source failure. The specifications listed herein are for the E33+ logic controller. See the respective power switching device D Lamps illuminate to indicate normal or emergency manual for its specifications. source switch position. D Lamps Standard Features illuminate...

  • Page 13: Section 2. Operation

    Section 2. Operation Control Switches and Indicators Various optional control switches and indicator lamps TRANSFER SWITCH POSITION may be present on the transfer switch door. NORMAL EMERGENCY identification of switches and indicators and an explanation of their function, refer to Figure 2-1 and the following descriptions.

  • Page 14: Sequence Of Operation

    Sequence of Operation Normal Source Failure the preset pickup point (90%) on all phases before the circuit will accept the normal source again. Load transfer to the emergency source automatically When the normal source is accepted by the voltage begins when the voltage sensing circuit detects reduced sensing circuit the K2 relay is energized.
  • Page 15 E.V. FREQ BPEN VOLT N/CA VOLT CONT NORM N/AB CONT VOLT CONT N/BC VOLT +12UF TEST SOURCE ACCEPTABLE POSITION EMERGENCY NORMAL EMERGENCY NORMAL EMERGENCY NORMAL EMERGENCY NORMAL A-320717-A 1. Time Delay Engine Start (TDES) Relay 4. Normal Source Acceptable Relay (K2) 2.

  • Page 16: Main Circuit Board Voltage Adjustments

    Main Circuit Board Voltage Adjustments The main circuit board contains a normal source retransfer, open then reclose undervoltage circuit. The voltage values are factory set emergency-source circuit breaker. Place the and should not need adjustment. Single phase sensing generator set start switch in the AUTO position. is fixed at 70% dropout and 90% pickup.

  • Page 17: Voltage Checks

    Voltage Checks NOTE Hazardous voltage can cause severe injury or death. Disconnect inner panel harness at in-line Perform voltage checks in the order given to avoid connector. This will deenergize circuit board and logic damaging the switch. circuitry, but allow transfer switch to continue to supply utility power to necessary lighting and equipment.

  • Page 18: Electrical Operation Test

    7. If the emergency source is not at rated voltage, 11. The transfer switch will transfer to the emergency adjust the generator voltage regulator following the position. The transfer will occur after the generator set manufacturer’s instructions. The Normal-to-Emergency Time Delay (TDNE) relay automatic transfer switch will respond only to rated times out.

  • Page 19: Section 3. Circuit Board Adjustment

    Section 3. Circuit Board Adjustment E.V. FREQ BPEN VOLT N/CA VOLT CONT NORM N/AB CONT VOLT CONT N/BC VOLT +12UF TEST SOURCE ACCEPTABLE POSITION EMERGENCY NORMAL EMERGENCY NORMAL EMERGENCY NORMAL EMERGENCY NORMAL A-320717-A 1. R42 6. Jumper 4 2. R29 7.

  • Page 20: Main Circuit Board Jumper Wire Configuration

    Main Circuit Board Voltage WARNING Adjustment The E33+ logic board has five pots used to adjust the voltage and frequency pickup points. See Figure 3-3 for a list of the pots and their functions. Hazardous voltage. Can cause severe injury or death. Adjustment Disconnect power sources before servicing.

  • Page 21: For Single-Phase Monitoring

    For Single-Phase Monitoring Emergency Source 1. Turn pot R17 completely counterclockwise. The E33+ logic board Figure 3-1 contains an emergency source undervoltage circuit. The voltage 2. Set the adjustable voltage supply to 90% of rated values are factory-set and should not need adjustment voltage and 100% of rated frequency.
  • Page 22 Notes 3-4 Main Circuit Board Adjustments TP-5670 9/94...

  • Page 23: Section 4. Controller Troubleshooting

    Section 4. Controller Troubleshooting General Troubleshooting Information 1. Contactor must be in the normal position to allow 3. Terminal TB1-6 on the logic board (contactor the generation of an engine start signal. common) provides a ground connection to the contactor’s auxiliary switch (used for switch 2.
  • Page 24 Generator runs, but transfer switch does not transfer load to the emergency source during power failure or with the test switch depressed. Step Test Procedure Yes Action No Action Does LED1 illuminate when the generator set Proceed to step B2 Proceed to step B4 is running? With a frequency meter check the frequency at...

  • Page 25: Interface Relay Board Troubleshooting

    Interface Relay Board Troubleshooting NOTE Before using the following troubleshooting procedure, complete the logic board troubleshooting flowchart procedures. Transfer switch will not transfer to emergency. Step Test Procedure Yes Action No Action Is the voltage at the emergency transformers Proceed to step A2 Proceed to step A10 correct? See Figure 4-2 and Figure 4-3.
  • Page 26 Transfer switch will not transfer to normal. NOTE Before using the following troubleshooting procedure, complete the logic board troubleshooting flowchart procedures. Step Test Procedure Yes Action No Action Is the voltage at the emergency transformers Proceed to step B2 Proceed to step B10 correct? See Figure 4-2 and Figure 4-3.

  • Page 27: Section 5. Accessory Troubleshooting

    Section 5. Accessory Troubleshooting Hazardous voltage can cause severe injury or 600 Volt and Above death. Whenever electricity is present, there is the hazard of electrocution. Open main circuit breaker on all DANGER power sources before servicing equipment. Electrically ground the generator set and electrical circuits when in use.

  • Page 28: Optional Features Troubleshooting

    Optional Features Troubleshooting Accessories 23-P: 7-Day, Adjustment Solid-State Exercise Timer See Figure 5-2 for operational information. Remove the transparent timer cover when making adjustments. Accessory 23-P signals the generator set to run Replace the cover when adjustment is complete. unloaded for the set time period. Timer does not simulate a normal source failure.
  • Page 29 Daylight Savings Time Adjustment 7. Now set periods 2, 3, and 4 of the same weekday using the same procedure, if required. If a semiannual time change applies in the area, use the override/cancel this function and go to another following procedure to conveniently set the hour without weekday, press the d button until the required having to completely reset the timer.
  • Page 30 4. To change the number of vacation/holidays, press 4. When all changes are complete, press . The and hold h while pressing each time until the timer is now set to function as programmed. desired number of vacation/holidays is displayed. Vacation/Holiday Setting Temporary Program Override The Vacation/Holiday Setting suspends the automatic...

  • Page 31: Troubleshooting

    294623-A Figure 5-3. Timer Connection Schematic Troubleshooting Plant Exerciser does not function correctly Step Test Procedure Yes Action No Action Is there rated line-to-line voltage between Proceed to A2 Source voltage is not terminals 76 and 77 on terminal block TB-6? available.

  • Page 32: Accessory 24-Xx-A,B Battery Charger

    Accessory 24-XX-A,B Battery Features Charger Current Limiting Specifications The battery charger is protected from overload by its current-limiting circuitry. This circuitry continuously The automatic battery charger is designed to maintain monitors the charger output current and is set to limit the lead-acid automotive-type batteries in a fully charged current to 2 amps from full load to short circuit.
  • Page 33 Power On Lamp Accidental starting can cause severe injury or death. Turn generator set master switch to OFF The Power On lamp is connected across the power position, disconnect power to battery charger, and transformer’s primary winding and indicates when AC remove battery cables (remove negative lead first and power is present.

  • Page 34: To Disconnect Charger (When Replacing Or Servicing Battery)

    294623-B BW-29500-B Figure 5-5. Battery Charger Location on Inner Panel—Solid-State Transfer Switch To Disconnect Charger 2. Check the fluid level in each cell. If fluid level is low, add distilled water until fluid level is full. (No (When Replacing maintenance is required for maintenance-free or Servicing Battery) batteries.) When using a dry-charge battery, give the battery a conditioning charge immediately...

  • Page 35: Charger Voltage Adjustment

    D Charging rate tapers to zero. As a battery Charger Float Current becomes charged, battery voltage Voltage Voltage Limit (Amps) approaches the control voltage setting. The 13.2 ammeter needle may fluctuate, indicating a continuous supply of pulsating current that 26.4 automatically keeps the battery charged.

  • Page 36: Battery Charger Wiring Diagrams

    Battery Charger Wiring Diagrams WIRING DIAGRAM AMMETER OUTPUT 6 AMP ORANGE BLUE RED/BLUE OR RED/YELLOW VIOLET ORANGE POWER TRANSFORMER INPUT 1 AMP—12 V B- - 1.5 AMP—24 V CONTROL BOARD BLK/YEL TERMINAL BLK/RED BLOCK BLK/WHT GND. SCHEMATIC POWER ORANGE VIOLET ORANGE CONTROL BOARD...
  • Page 37 AMMETER WIRING DIAGRAM OUTPUT 6 AMP ORANGE BLUE RED/BLUE OR RED/YELLOW VIOLET POWER ORANGE TRANSFORMER INPUT 0.5 AMP—12 V B- - 1 AMP—24 V CONTROL BOARD GND. TERMINAL BLOCK SCHEMATIC ORANGE ORANGE CONTROL VIOLET POWER BOARD BLUE RED/BLUE AMMETER B- - RED/YELLOW DC OUTPUT TRANS.
  • Page 38 WIRING DIAGRAM AMMETER OUTPUT 6 AMP ORANGE BLUE RED/BLUE OR RED/YELLOW VIOLET ORANGE POWER TRANSFORMER INPUT 0.5 AMP—12 V CONTROL B- - 1 AMP—24 V BOARD TERMINAL BLOCK GND. SCHEMATIC ORANGE ORANGE CONTROL VIOLET POWER BOARD BLUE RED/BLUE AMMETER B- - RED/YELLOW DC OUTPUT TRANS.
  • Page 39 AMMETER WIRING DIAGRAM OUTPUT 6 AMP ORANGE BLUE RED/BLUE OR RED/YELLOW VIOLET POWER ORANGE TRANSFORMER INPUT 0.5 AMP—12 V B- - CONTROL 1 AMP—24 V BOARD BLK/YEL BLK/ GND. BLK/WHT TERMINAL BLOCK SCHEMATIC CONTROL ORANGE ORANGE VIOLET POWER BOARD AMMETER BLUE RED/BLUE B- -...
  • Page 40 WIRING DIAGRAM AMMETER OUTPUT 6 AMP ORANGE BLUE RED/BLUE OR RED/YELLOW VIOLET ORANGE POWER TRANSFORMER INPUT 0.3 AMP—12 V CONTROL B- - 0.5 AMP—24 V BOARD TERMINAL BLOCK GND. BLK/WHT SCHEMATIC ORANGE CONTROL ORANGE VIOLET POWER BOARD BLUE AMMETER RED/BLUE B- - RED/YELLOW DC OUTPUT...
  • Page 41 AMMETER WIRING DIAGRAM OUTPUT 6 AMP ORANGE BLUE RED/BLUE OR RED/YELLOW VIOLET POWER ORANGE TRANSFORMER INPUT 0.2 AMP—12 V CONTROL B- - 0.4 AMP—24 V BOARD TERMINAL BLOCK GND. BLK/WHT SCHEMATIC CONTROL POWER ORANGE ORANGE VIOLET BOARD RED/BLUE BLUE AMMETER B- - RED/YELLOW DC OUTPUT...

  • Page 42: Accessory Da-26

    Accessory DA-26 Accessory DA-26 senses normal source three phase voltage directly from the power conversion unit. A harness connects the optional circuit board to the P3 PCB ASSY A-- 320938 connector on the main logic board. See Figure 5-7 for wiring connections.
  • Page 43 Between pins Pin Number Voltage Continuity P-15 1 to 2 NA to NB 1 to 3 NA to NC 2 to 3 NB to NC Figure 5-8. Normal Source Voltage Pin Number Voltage 4 to 7 1/25 of NA to NB 8 to 9 1/25 of NB to NC Figure 5-9.
  • Page 44 Notes 5-18 Accessories TP-5670 9/94...

  • Page 45: Section 6. Wiring Diagrams

    Section 6. Wiring Diagrams Diagram or Drawing Drawing Number Page Generator/ATS Interconnect 1-Phase, 2 Wire ......ADV-5262 Generator/ATS Interconnect 1-Phase, 3 Wire .

  • Page 46: Generator/Ats Interconnect 1-Phase, 2 Wire

    ADV-5262 Generator/ATS Interconnect 1-Phase, 2 Wire Wiring Diagrams 6-2 TP-5670 9/94...

  • Page 47: Generator/Ats Interconnect 1-Phase, 3 Wire

    ADV-5263 Generator/ATS Interconnect, 1-Phase, 3 Wire TP-5670 9/94 Wiring Diagrams 6-3...

  • Page 48: Generator/Ats Interconnect 3-Phase, 3 Or 4 Wire

    ADV-5264 Generator/ATS Interconnect, 3-Phase, 3 or 4 Wire Wiring Diagrams 6-4 TP-5670 9/94...

  • Page 49: 1-Phase Ats Transformer

    BLUE BLK/WHT RED/BL BLACK BLK/WHT BLUE RED/BL BLACK 56126-3 1-Phase ATS Transformer 567123-P Accessory DA-23-P TP-5670 9/94 Wiring Diagrams 6-5...
  • Page 50 Notes Wiring Diagrams 6-6 TP-5670 9/94...

  • Page 51: Section 7. Service Parts

    Section 7. Service Parts Inner Panel Optional 3 Phase Sensing Circuit Board N-320000-A Item Qty. Description Part No. Item Qty. Description Part No. Light, rectangular 320827 Guard 321017 Decal (outside of door) 321159 Decal 295261 Switch, Toggle (momentary) 295068 Decal 294328 Switch, Toggle (maintained) 268015...
  • Page 52 TES, TLS 25-180 amp standard and programmed transition 320959 321120 25-180 amp standard and programmed transition 320961 321281 MNS, MMS 40-160 amp standard and programmed transition 320959 321175 250-1200 amp standard and programmed transition 320961 321163 1600-4000 amp standard and programmed transition...

  • Page 53: Accessories

    Accessories NOTE Battery Chargers Refer to the nameplate for a list of installed accessories. Accessory Description Part Number 24-60A Charger Assembly, Battery A-294236 Plant Exercisers Fuse, 6.0 amp 226520 Fuse, 0.2 amp 226527 Accessory Description Part Number 24-60B Charger Assembly, Battery A-294237 Fuse, 6.0 amp 226520...
  • Page 54 Notes 7-4 Service Parts TP-5670 9/94...

  • Page 55: 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 56 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 57 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 Kohlerr Power Systems Asia Pacific Headquarters TP-5670 9/94b 7 Jurong Pier Road Singapore 619159 E Kohler Co., 1994, 2000. All rights reserved. Phone (65)264-6422, Fax (65)264-6455...

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