Kohler M340+ Service And Parts Manual Download Page 2

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Table of Contents

SUBJECT

PAGE

SUBJECT

PAGE

Safety Precautions and Instructions

. . . . . . . . . . .

Introduction

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

List of Related Manuals

. . . . . . . . . . . . . . . . . . . . . . . .

Service Assistance

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 1. Specifications

1-1

. . . . . . . . . . . . . . . . . . .

Purpose of Switch

1-1

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Components of Switch

1-1

. . . . . . . . . . . . . . . . . . . . . . .

Ratings

1-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Interpreting a Transfer Switch Part Number

1-3

. . . . .

Specifications

1-4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standard Features

1-4

. . . . . . . . . . . . . . . . . . . . . . .

Shunt-Jumper-Controlled Accessories

1-5

. . . . . .

Optional Features

1-5

. . . . . . . . . . . . . . . . . . . . . . . .

Section 2. Operation

2-1

. . . . . . . . . . . . . . . . . . . . . . .

LED Indicators

2-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Switches and Indicators

2-2

. . . . . . . . . . . . . . .

Sequence of Operation

2-3

. . . . . . . . . . . . . . . . . . . . . . .

Normal Source Failure

2-3

. . . . . . . . . . . . . . . . . . . .

Normal Source Restoration

2-4

. . . . . . . . . . . . . . .

Sequence of Operation Programmed Transition

2-6

Normal Source Failure

2-6

. . . . . . . . . . . . . . . . . . . .

Normal Source Restoration

2-7

. . . . . . . . . . . . . . .

To Disconnect The P1 Plug

2-9

. . . . . . . . . . . . . . . . . . .

Electrical Operation Test

2-9

. . . . . . . . . . . . . . . . . . . . .

Section 3. Troubleshooting Guide

3-1

. . . . . . . . . .

Section 4. Controller Troubleshooting

4-1

. . . . . .

Power to the System

4-2

. . . . . . . . . . . . . . . . . . . . . . . . .

Keypad And Status Panel

4-3

. . . . . . . . . . . . . . . . . . . .

Normal Source Voltage and Frequency

4-6

. . . . . . . . .

Emergency Source Voltage and Frequency

4-9

. . . . .

System-Status, Not-In-Automatic Error

4-11

. . . . . . . .

System-Status, System-Alert

4-12

. . . . . . . . . . . . . . . .

Contactor Position Fault Error Messages

4-12

. . . . . .

Transfer Hang Error Message

4-12

. . . . . . . . . . . . . . . .

Power-Down Error Message

4-12

. . . . . . . . . . . . . . . . .

RAM Or Memory Error Message

4-13

. . . . . . . . . . . . .

Manual Transfer Message

4-13

. . . . . . . . . . . . . . . . . . .

Manual-to-Off Transfer Message

4-13

. . . . . . . . . . . . .

Fault #1 Or Fault #2 Message

4-14

. . . . . . . . . . . . . . . .

Programming Mode Not-In-Off

4-15

. . . . . . . . . . . . . . .

Engine Operates When it Should Not

4-16

. . . . . . . . .

Engine Will Not Start

4-18

. . . . . . . . . . . . . . . . . . . . . . . .

Area Protection

4-20

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shunt Jumper-Controlled Options

4-21

. . . . . . . . . . . . .

Inphase Monitor

4-23

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Source Monitors

4-24

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Plant Exerciser

4-27

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Time Delays

4-32

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Override

4-33

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Off Delays

4-34

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 5. Accessory Troubleshooting

5-1

. . . . . .

Optional Accessories

5-2

. . . . . . . . . . . . . . . . . . . . . . . .

Emergency Source Three-Phase Phase Option

5-2

Test Switches

5-4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Time Delay Override Option

5-10

. . . . . . . . . . . . . . . . .

Preferred Source Switch

5-14

. . . . . . . . . . . . . . . . . . . .

Relay Auxiliary Dry Contacts

5-15

. . . . . . . . . . . . . . . . .

Main Shaft Auxiliary Dry Contacts

5-22

. . . . . . . . . . . .

Meters

5-23

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Charger

5-47

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Operation Switches

5-54

. . . . . . . . . . . . . . . . . .

Load Shedding Contacts

5-63

. . . . . . . . . . . . . . . . . . . .

Remote Communication— RS/232 Or RS/485

5-65

. .

Section 6. Service Parts

6-1

. . . . . . . . . . . . . . . . . . . .

Introduction

6-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inner Panel

6-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessories

6-5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Time Delay

6-5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Source monitors

6-5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test Switches

6-5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Time Delay Override Switches

6-5

. . . . . . . . . . . . . . . .

Preferred-Source Switches

6-5

. . . . . . . . . . . . . . . . . . .

Auxiliary Contacts— Relay

6-5

. . . . . . . . . . . . . . . . . . . .

Auxiliary Contacts— Main Shaft

6-5

. . . . . . . . . . . . . . . .

Meters

6-6

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Plant Exercisers

6-11

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Chargers

6-11

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Source Monitors— Normal and Emergency

6-12

. . . .

Load-Shed Contacts

6-12

. . . . . . . . . . . . . . . . . . . . . . . .

Time Delays

6-12

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A. Glossary of Abbreviations

A-1

. . . . .

Appendix B. General Controller Information B-1

Appendix C. Commonly Used Accessories

C-1

. .

Summary of Contents for M340+

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

Page 2: ...y Error Message 4 13 Manual Transfer Message 4 13 Manual to Off Transfer Message 4 13 Fault 1 Or Fault 2 Message 4 14 Programming Mode Not In Off 4 15 Engine Operates When it Should Not 4 16 Engine Wi...

Page 3: ...hazard that will or can cause minor personal injury or property damage if the caution is ignored NOTE Note communicates installation operation or maintenance information that is important but not haza...

Page 4: ...NING Accidental starting can cause severe injury or death Turn generator set master switch to OFF position disconnect power to battery charger and remove battery cables remove negative lead first and...

Page 5: ...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 Cont...

Page 6: ...efore servicing equipment Electrically ground the generator set and electrical circuits when in use Never come into contact with electrical leads or appliances when standing in water or on wet ground...

Page 7: ...itch on controller to OFF position and disconnect battery negative before working on transfer switch Turn the transfer switch selector switch to the OFF position Hazardous voltage can cause severe inj...

Page 8: ...11 95 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 unles...

Page 9: ...ed when service is completed NOTE Perform voltage checks in the order given to avoid damaging the switch NOTE These battery chargers are designed strictly for use in this transfer switch and conform w...

Page 10: ...vice and parts manuals are available for each group within the overall family Be sure this manual is the correct manual for the automatic transfer switch A power conversion unit is included in each au...

Page 11: ...TP 5672 11 95 Introduction ii Notes...

Page 12: ...ter retransfer of the load the generator set start signal is removed and the generator set s is allowed to shut down Components of Switch A typical automatic transfer switch includes the actual power...

Page 13: ...provide characteristic and rating information that affects installation and operation Copy the part number into the blank spaces provided in the introduction and then use the charts in Figure 1 4 to...

Page 14: ...E PART NUMBER Classification of Power Switch M Switch or Circuit Breaker T Electrically Mechanically Held Z Contactor Style Type of Power Switch C Contactor E Electrically Held Contactor L Mechanicall...

Page 15: ...m 0 to 6 seconds D TDEN Time Delay Emergency to Normal adjustable 0 to 30 minutes D Program Transition Center off time delay during transfer with neither source connected to the load Adjustable 0 to 2...

Page 16: ...actor is not of this type then the controller will not allow this option to be enabled Enable this accessory by installing the INPHASE MONITOR jumper on the controller s main logic board D Phase Rotat...

Page 17: ...TRANSFER TO EMERGENCY BYPASS EMERGENCY TO NORMAL TIME DELAY MANUAL TRANSFER TO OFF BYPASS NORMAL TO EMERGENCY TIME DELAY AUTO INHIBIT Figure 2 1 Front Panel LED Indicators Contactor Position LEDs ind...

Page 18: ...ol Do not leave the programming switch in the LOCAL position with the transfer switch unattended Remote Allows both status monitoring and setting of the transfer switch controls by a connected persona...

Page 19: ...icate the time delay has completed timing 7 The load shed LED illuminates at the same time all loads to be shed are disconnected from the switch if equipped with load shed option 8 The inphase monitor...

Page 20: ...equipped with load shed option 6 The contactor transfers to the normal position after the load shed time before transfer timer has completed timing The contactor position emergency LED turns off and...

Page 21: ...ncy Load Shed all if equipped Inphase Monitor if equipped Contactor Transfer to Emergency Position Normal Source Return Load Return programmed sequence if equipped Time Delay Emergency to Normal Load...

Page 22: ...s to indicate the time delay has completed timing 7 The load shed LED illuminates at the same time all loads to be shed are disconnected from the switch if equipped with load shed option 8 After the l...

Page 23: ...ontactor position Off LED illuminates 6 The time delay off position ON LED illuminates to indicate the off position time delay is timing 7 The time delay off position END LED illuminates to indicate t...

Page 24: ...ed Contactor Transfer to Off Position Contactor Transfer to Emergency Position Normal Source Return Load Return programmed sequence if equipped Time Delay Emergency to Normal Load Shed all if equipped...

Page 25: ...ace the transfer switch in the NORMAL position Use the following procedure to check the electrical operation of the automatic transfer switch 1 Press and hold the test pushbutton for 15 seconds See Fi...

Page 26: ...option DD 09 is set to Inhibit or the Automatic Transfer key switch option DD 29 is set to manual but the System Status Not In Automatic LED is not flashing System status not in automatic error The Sy...

Page 27: ...operate Relay auxiliary dry contacts accessory DD 14 The analog meters are not working Meters accessory DD 18 The battery charger is not working Battery charger accessory DD 24 The manual transfer to...

Page 28: ...B DC1 30 and TB DC1 34 of the power supply board Is there an optional load shed board installed Recheck the voltage at terminals TB DC1 23 and TB DC1 30 of the power supply board and pin P2 13 of plug...

Page 29: ...ansformers are all working properly and the battery back up option is used connect the positive test lead to TB DC1 29 and the negative test lead to TB DC1 34 If the voltmeter does not read between 12...

Page 30: ...black the status panel is defective Replace the logic board assembly 560442 Figure 4 2 The M340 LCD display during a lamp test 5 If after pressing the LAMP TEST key no LEDs are on and the character b...

Page 31: ...l TB DC1 34 of the power supply board equal to 0 vac Is the voltage between pin P2 16 of plug 2 and terminal TB DC1 34 of the power supply board 1 25 of line voltage See Appendix B Figure B 5 Is 3 pha...

Page 32: ...1 in the program menu for correct normal source voltage and frequency reading If the voltage and frequency values in Index 1 match the voltage and frequency values in Index 6 perform the following ste...

Page 33: ...d If the system is three phase connect one test lead to P2 17 and the other to TB DC1 34 The voltmeter should read approximately 1 25 of the line voltage See Appendix B Figure B 5 e If the system is t...

Page 34: ...AC Press the ENTER key Observe the ENTRY ACCEPTED message on the LCD Press the MENU arrow down key c Connect one test lead to TB AC1 NA and connect the other test lead to TB AC1 NC Enter the measured...

Page 35: ...of rated line voltage See Appendix B Figure B 5 Is the voltage between pin P2 20 of plug 2 and terminal TB DC1 34 of the power supply board 1 25 of rated line voltage See Appendix B Figure B 5 Is 3 ph...

Page 36: ...ng option DD 05 K must be installed If this option is not installed single phase sensing must be used If the source is available the values in Index 2 are correct the phase sequence is correct and the...

Page 37: ...efore performing it Using the menu in Index 12 of the program menu press the YES key when the E AUTO ZERO message appears Do not press the ENTER key afterwards 4 Disconnect the emergency power source...

Page 38: ...igure B 6 for location and description of P2 ribbon cable pins See Figure 4 7 for the System Status Not In Automatic LED wiring diagram c If the System Status Not In Automatic LED is not flashing when...

Page 39: ...of an ohmmeter to the contactor side of P1 16 Connect the other test lead to the contactor side of P1 8 Note the resistance 4 If the resistance in either case was high there is an open circuit Verify...

Page 40: ...on cable pins Carefully remove the power source by disconnecting the in line disconnect plug Leave the power source disconnected for six seconds After six seconds note the voltmeter reading b If the v...

Page 41: ...e message disappears the logic board is performing correctly The FAULT 1 message is caused by the connected accessory b If there is not an accessory connected to TB DC1 8 remove power from the logic b...

Page 42: ...f LED should be on steadily When the Programming Mode key is set to Off the Programming Mode Not In Off LED should be off See Figure 4 10 If any of these cases are not true check the Programming Mode...

Page 43: ...harness is disconnected reconnect the P1 wire harness Check the continuity between TB DC1 22 and TB DC1 21 Using an ohmmeter connect one test lead to TB DC1 22 Connect the other test lead to TB DC1 21...

Page 44: ...rd Does the generator set continue to run Is there 19 vac between terminals TB DC1 23 and TB DC1 34 of the power supply board Jumper pin P4 1 of plug 4 to terminal TB DC1 34 of the power supply board...

Page 45: ...rts when TB DC1 21 and TB DC1 22 are jumpered replace the power supply board 2 If the engine does not start when TB DC1 21 and TB DC1 22 are jumpered check if there is a jumper between TB DC1 22 and T...

Page 46: ...rd together Does the generator set start Is there an accessory wired between terminals TB DC1 22 and TB DC1 31 of the power supply board Is there continuity between terminal TB DC1 21 of the power sup...

Page 47: ...oard If the Area Protection LED still does not turn off replace the logic board assembly 3 If the Area Protection LED does turn off after grounding TB DC1 6 check the wiring for an open circuit to TB...

Page 48: ...r 5 Check Index 11 YES should appear only after the Index 11 listing of all options with installed shunt jumpers To troubleshoot shunt jumper controlled options see Figure 4 17 or Figure 4 18 NOTE Whe...

Page 49: ...y 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 press RESET MENU then ENTER to store the setpo...

Page 50: ...LC NAS NCS EAS ECS MICROCONTROLLER MANUAL TIME PLANT VOLT PHASE IN PHASE OVRIDE DELAY EXER FREQ SEQUENCER MONITOR Programming Shunt 294634 560458 OFF DELAYS must be installed to activate accessory Fi...

Page 51: ...essory is enabled by installing the VOLT FREQ jumper on the main logic board See Figure 4 15 See Appendix B Figure B 4 for the emergency source voltage trip point setting limits and factory settings A...

Page 52: ...Sequencer jumper installed in JP1 on the logic board Does the controller sense only normal source three phase voltage and frequency Is option DD 05 K installed Refer to Accessory DD 05 K Troubleshoot...

Page 53: ...d dropout set points correct in Index 6 Reset set points Replace logic board Is emergency source voltage available at the power conversion unit No power source is available Refer to Power To The Syste...

Page 54: ...plant exerciser D Start time D Day of the week D Run time in hours and minutes D Week of the month Calendar Mode Only Enter the information and enable the event to operate the plant exerciser If the p...

Page 55: ...21 and 31 on TB DC1 of the power supply board Does the generator set start Do pins 11 and 15 on plug P2 short when the plant exerciser is active Is the plant exerciser programmed correctly in index 8...

Page 56: ...set start Install jumper lead between terminals TB DC1 10 and TB DC1 32 of the power supply board Replace the logic board Replace the ribbon cable between plugs P2 and P3 Replace the logic board Repro...

Page 57: ...nd 4 on the power conversion unit Does the generator set start Replace the Load No Load selector switch Remove the leads from terminals TB DC1 10 and TB DC1 32 of the power supply board Is there conti...

Page 58: ...r set start Is the plant exerciser programmed correctly in index 8 See TP 5664 for programming information Replace the logic board Reprogram the plant exerciser Refer to TP 5664 for programming instru...

Page 59: ...pply is required See Figure 4 15 Time delays are adjustable from either the front panel keypad or from a remote computer See Figure 4 31 for a troubleshooting chart for this option No Yes No No Yes Ye...

Page 60: ...s Yes Is the auto manual switch in the auto position Place the auto manual switch in the auto position Is the Manual Ovride jumper installed in JP1 socket on the logic board Replace logic board No No...

Page 61: ...gic board See Figure 4 15 Off delays cannot be enabled on a switch type that does not have an Off position like ZENITH STD and the jumper has no effect On all power conversion units with an Off positi...

Page 62: ...Phase Rotation X X 100 B Extended Time Delays X X X X Other Options 05 K Emergency Source Sensing X X X 06 F Two Position Test Switch X X X X 06 N Three Position Test Switch X X X X 06 P Three Positi...

Page 63: ...ard See Figure 5 3 for location of circuit board Remove the ribbon cable between plug P15 on the three phase accessory circuit board and P14 on the power supply board Is there 1 25 of the emergency so...

Page 64: ...26 25 24 23 22 21 20 19 18 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 17 MICROCONTROLLER TB DC1 TB AC1 ECS EAS NCS NAS LC LB LA EC EB EA NC NB NA RIBBON CABLE BLUE STRIPE TO SLOTTED SIDE 294638 OF DIPSOC...

Page 65: ...to the power supply board If the Test LED does not illuminate when TB DC1 24 is grounded replace the power supply board NOTE When taking a voltage or resistance measurement at a ribbon cable pin do no...

Page 66: ...erminals TB DC1 21 and TB DC1 22 on the power supply board Does the generator set start Refer to the engine start troubleshooting flowchart Is there a jumper between terminals TB DC1 22 and TB DC1 31...

Page 67: ...rd to the test switch Is there continuity between terminal TB DC1 9 on the power supply board and terminal 1 of the test switch Yes Is there continuity between terminals TB DC1 24 and TB DC1 34 of the...

Page 68: ...supply board and terminal 9 of the test switch Replace the lead from terminal TB DC1 21 on the power supply board to the test switch Replace the lead from terminal TB DC1 22 on the power supply board...

Page 69: ...board and terminal 4 of the test switch Replace the lead from terminal TB DC1 34 on the power supply board to the test switch Is there continuity between terminal 2 to terminal 4 of the test switch R...

Page 70: ...n the power supply board Is there 10 vdc at terminal TB DC1 25 on the power supply board when the test switch is in the AUTO position Is there continuity between terminals TB DC1 22 and TB DC1 31 on t...

Page 71: ...ce and then press the Bypass Normal to Emergency Time Delay pushbutton If after pressing the Bypass Normal to Emergency Time Delay pushbutton the normal to emergency time delayis not bypassed connect...

Page 72: ...storing the normal source Then press the Bypass Emergency to Normal Time Delay pushbutton If after pressing the Bypass Emergency to Normal Time Delay pushbutton the emergency to normal time delayis no...

Page 73: ...k the ribbon cable for any open or shorted leads Are there any open or shorted leads Replace the ribbon cable between P2 on the power supply board and P3 on the logic board Is there continuity between...

Page 74: ...C1 33 on the power supply board Does the switch transfer to the normal source Normal source must be present to bypass the time delay emergency to normal Program a TDEN time delay in index 5 of the mic...

Page 75: ...132 TB DC1 MICROCONTROLLER TB AC1 ECS EAS NCS NAS LC LB LA EC EB EA NC NB NA 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 17 Wire Code Example S10 13 201 D...

Page 76: ...rm System alarm Emergency position Normal position Emergency available Emergency available Normal available Normal available 114 DCK K10 101 DCK K9 Shown De energized 4FU R 142 TBDC1 32 132 TBDC1 26 1...

Page 77: ...20 volts AC It is used to indicate whether the Automatic Manual selector switch is not in the Automatic position D DD 14 N Single contact kit for remote indication This option is rated for 10 amps and...

Page 78: ...evice Terminal Number 5604523 Contacts Shown De energized Figure 5 18 Wiring Diagram Option DD 14 J Auxiliary dry contacts TB DC1 23 123 SPLICE BK R 306 DCK 42A 2FU TB DC1 26 126 TB DC1 32 132 2FU R 3...

Page 79: ...evice Terminal Number Contacts Shown De energized 5604525 Figure 5 20 Wiring Diagram Option DD 14 L Auxiliary dry contacts TB DC1 23 123 SPLICE BK R 306 DCK 42A 2FU 2FU R 306 TB DC1 32 132 TB DC1 14 1...

Page 80: ...vice Terminal Number Contacts Shown De energized 5604527 Figure 5 22 Wiring Diagram Option DD 14 N Auxiliary dry contacts TB DC1 23 123 SPLICE BK R 2FU 306 DCK 42A TB DC1 19 119 TB DC1 32 132 2FU R 30...

Page 81: ...TB DC1 TB AC1 105 DCK K1 ECS EAS NCS NAS LC LB LA EC EB EA NC NB NA 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 17 DCK K1 2 42A K1 C NC NO Wire Code Examp...

Page 82: ...er supply board to terminal 42A on the relay board Replace power supply board Is there rated line to line voltage between terminals TB AC1 NA and TB AC1 NC or terminals TB AC1 EA and TB AC1 EC on the...

Page 83: ...iary contacts is closed when the transfer switch is connected to the normal source One set is closed when the transfer switch is connected to the emergency source Refer to the power conversion unit se...

Page 84: ...igure 5 36 and conclude with Figure 5 52 D DD 18 G Analog frequency meter with fuse D DD 18 J Analog voltmeter and ammeter with fuses T4 BK T4 W 206 204 3FU R 308 T4 BL 407 FM 2 1 FM 2 3FU BK 407 BL 3...

Page 85: ...5 24 Accessory Troubleshooting TP 5672 11 95 295385 Figure 5 28 Wiring Diagram Option DD 18 J Analog Volt and Amp Meter...

Page 86: ...5 25 Accessory Troubleshooting TP 5672 11 95 295386 Figure 5 29 Wiring Diagram Option DD 18 J Analog Volt and Amp Meter...

Page 87: ...5 26 Accessory Troubleshooting TP 5672 11 95 295387 Figure 5 30 Wiring Diagram Option DD 18 J Analog Volt and Amp Meter...

Page 88: ...5 27 Accessory Troubleshooting TP 5672 11 95 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...

Page 89: ...rated line to line voltage between the two frequency meter terminals Is the in line fuse between terminal TB AC1 EA of the power supply board and the frequency meter blown Accessory 18 G only displays...

Page 90: ...g Ammeter Troubleshooting Flowchart JD5 Figure 5 40 to Figure 5 45 Figure 5 46 JD8 Figure 5 47 to Figure 5 52 Figure 5 46 JD9 Figure 5 47 to Figure 5 52 Figure 5 46 JD10 Figure 5 47 to Figure 5 52 Fig...

Page 91: ...tch Replace the source selector switch Is there rated line to line voltage between the two terminals of the voltmeter Replace the voltmeter Is the fuse between terminal 31 of the source selector switc...

Page 92: ...tor switch correct Refer to Figure 5 35 for the proper turn ratio of the current transformer Are the leads from the current transformer to the source selector switch open or shorted Is the current bet...

Page 93: ...ch Replace the source selector switch Is there rated line to line voltage between the two terminals of the voltmeter Replace the voltmeter Is the fuse between terminal 31 of the source selector switch...

Page 94: ...n terminals 13 and 21 of the source selector switch correct Refer to Figure 5 35 for the proper turn ratio of the current transformer Is the amount of current that L2 is using between terminals 11 and...

Page 95: ...ge between the two terminals of the voltmeter Is the fuse between terminal 31 of the source selector switch and the voltmeter blown Refer to Power to the System Troubleshooting Replace the leads from...

Page 96: ...lector switch and the voltmeter blown Refer to Power to the System Troubleshooting Replace the leads from terminals TB AC1 NB and TB AC1 NC of the power supply board to the source selector switch Move...

Page 97: ...oltage between the two terminals of the voltmeter Is the fuse between terminal 31 of the source selector switch and the voltmeter blown Refer to Power to the System Troubleshooting Replace the leads f...

Page 98: ...oltage between the two terminals of the voltmeter Is the fuse between terminal 31 of the source selector switch and the voltmeter blown Refer to Power to the System Troubleshooting Replace the leads f...

Page 99: ...oltage between the two terminals of the voltmeter Is the fuse between terminal 31 of the source selector switch and the voltmeter blown Refer to Power to the System Troubleshooting Replace the leads f...

Page 100: ...oltage between the two terminals of the voltmeter Is the fuse between terminal 31 of the source selector switch and the voltmeter blown Refer to Power to the System Troubleshooting Replace the leads f...

Page 101: ...L1 between terminal 11 and 21 of the source selector switch Refer to Figure 5 35 for the proper turn ratio of the current transformer Are the leads from the current transformer to the source selector...

Page 102: ...between the two terminals of the voltmeter Remove the resistor from the circuit and measure its resistance Is the resistance 2500 ohms 10 Is the fuse between the transformer and the voltmeter blown R...

Page 103: ...between the two terminals of the voltmeter Remove the resistor from the circuit and measure its resistance Is the resistance 2500 ohms 10 Is the fuse between the transformer and the voltmeter blown R...

Page 104: ...between the two terminals of the voltmeter Remove the resistor from the circuit and measure its resistance Is the resistance 2500 ohms 10 Is the fuse between the transformer and the voltmeter blown R...

Page 105: ...between the two terminals of the voltmeter Remove the resistor from the circuit and measure its resistance Is the resistance 2500 ohms 10 Is the fuse between the transformer and the voltmeter blown R...

Page 106: ...between the two terminals of the voltmeter Remove the resistor from the circuit and measure its resistance Is the resistance 2500 ohms 10 Is the fuse between the transformer and the voltmeter blown R...

Page 107: ...between the two terminals of the voltmeter Remove the resistor from the circuit and measure its resistance Is the resistance 2500 ohms 10 Is the fuse between the transformer and the voltmeter blown R...

Page 108: ...out adjustment Refer to Figure 5 54 through Figure 5 58 for wiring diagrams See Figure 5 59 for battery charger connection and Figure 5 60 for the troubleshooting table Sulfuric acid in batteries Can...

Page 109: ...RANGE DC A B RED ON AC CT AC YEL B RED AMMETER TERMINAL BLOCK BLK TRANSFORMER DC OUTPUT 6 AMP AMMETER AC INPUT 1 AMP 12 V TRANS AC AC BLK YEL BLK RED WHT BLK WHT BLK RED RED BLK CONTROL BOARD YEL YEL...

Page 110: ...L AMMETER BLK WHT AC AC BLK RED RED BLK ORANGE VIOLET ORANGE RED GND RED BLUE OR RED YELLOW B B POWER ON AC CT AC ON TRANSFORMER YEL B BLUE DC A TERMINAL BLOCK CONTROL BOARD TERMINAL BLOCK CONTROL BOA...

Page 111: ...LUE RED BLUE OR RED YELLOW ORANGE VIOLET GND RED ORANGE B B AC CT AC ON BLK RED BLK WHT WHT BLK RED BLK BLK YEL TRANSFORMER TRANS AMMETER POWER ON POWER ON DC A TERMINAL BLOCK CONTROL BOARD TERMINAL B...

Page 112: ...UT 6 AMP AC INPUT 0 3 AMP 12 V RED BLK AC AMMETER BLK AC 380 BLK BLK WHT WHT RED RED YEL YEL BLK 416 BLUE RED BLUE OR RED YELLOW ORANGE VIOLET ORANGE GND RED B B AC CT AC ON TRANSFORMER AMMETER POWER...

Page 113: ...AMMETER WHT AC 480 RED RED BLK YEL YEL BLUE RED BLUE OR RED YELLOW ORANGE VIOLET ORANGE GND RED B B AC CT AC ON BLK AC DC OUTPUT 6 AMP AC INPUT 0 2 AMP 12 V BLK BLK WHT 600 TRANSFORMER AMMETER POWER...

Page 114: ...polarity correct Turn off the AC supply to the battery charge Are the battery terminals clean and tight Is there rated line to line voltage at the AC input terminals of the battery charger Is there ra...

Page 115: ...utomatic Transfer Manual Transfer Switch If the Automatic Transfer Manual Transfer switch is in the Manual position the following events will occur When the normal source fails 1 The Source Available...

Page 116: ...e System Status System Alert LED does not illuminate when P2 24 is grounded Replace the logic board assembly Troubleshooting the Off Position Automatic Transfer Manual Transfer Key Switch If the Autom...

Page 117: ...e ribbon cable connector 6 Carefully reconnect P2 ribbon cable connector If the P2 ribbon cable connection is good connect P2 24 to TB DC1 34 If the System Status System Alert LED illuminates when P2...

Page 118: ...n is not operating connect TB DC1 12 to TB DC1 34 1 If grounding TB DC1 12 causes a transfer to the off position when the system is in the Manual mode and is waiting to be transferred to the off posit...

Page 119: ...Diagram Option DD 29 S and DD 29 T Manual operation switches 294662 102 134 MICROCONTROLLER TB DC1 TB AC1 17 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34...

Page 120: ...r supply board and terminal 3 of the manual transfer switch Disconnect the in line plug Remove the ribbon cable between plug P2 of the power supply board and plug P3 on the logic board Check the ribbo...

Page 121: ...oard Replace the logic board Figure 5 66 Troubleshooting Option DD 29 P and DD 29 R Manual transfer to normal source does not work No No Yes Yes Yes Yes Yes No No No Place a jumper between terminals T...

Page 122: ...erminal TB DC1 20 of the power supply board to the auto manual switch Replace the ribbon cable between plug P2 of the power supply board and plug P3 on the logic board Is there continuity between term...

Page 123: ...n cable between plug P2 of the power supply board and plug P3 on the logic board Remove the leads TB DC1 20 and TB DC1 34 from TB DC1 terminal strip Is there continuity between leads that were connect...

Page 124: ...delays before transfer and the sequence interval time delays are individually adjustable Settings may be made from the front panel keypad or from a remote computer The first relay to energize is K1 an...

Page 125: ...5 vdc between pins P11 1 and P11 5 of plug P11 Replace the load shed circuit board Check the continuity of the ribbon cable between plugs P10 and P11 Does the cable have any open leads or bent or bro...

Page 126: ...E message press the MENU Arrow Right key The LCD should read SYS ID Press up to six digit keys and ENTER to create a password for the transfer switch Make sure that the ID entered at the keypad is the...

Page 127: ...at P13 7 on the Remote Communication board Using a voltmeter connect the positive test lead to P13 7 Connect the negative test lead to P13 6 The voltmeter should read approximately ten volts DC a If t...

Page 128: ...5 vdc between pins 1 and 6 of plug P12 on the logic board Replace the ribbon cable between the communications board and the logic board Replace the logic board Is there 10 vdc between pins 7 and 6 of...

Page 129: ...is manual for the name and number of the service and parts manual for the applicable power conversion unit Using Parts Lists Finding Parts Information 1 Determine the parts needed Example The micro co...

Page 130: ...TP 5672 11 95 6 2 Service Parts Inner Panel BW 295000 1 3 4 5 6 P18 12345678 A A 2 8 7 Figure 6 1 Micropocessor inner panel assembly...

Page 131: ...1 Pannel inner 294741 7 2 Transformers See Figure 6 3 8 1 Logic to power conversion unit harness See Figure 6 4 9 1 Guard 294860 10 1 Decal hazardous voltage 294328 11 1 Decal This transfer 294523 12...

Page 132: ...ogrammed transition 320960 321326 ZCS 150 4000 standard and programmed transition 320960 321089 ZCB 100 400 standard 321456 321460 100 400 programmed transition 321456 321457 600 1200 standard and pro...

Page 133: ...art Number 10 D Fuse Lamp Block Contact Block Contact Switch Operator Contact Assembly 239179 294651 294652 298039 298047 Auxiliary Contacts Relay Accessory Description Part Number 14 C Relay Socket R...

Page 134: ...meter AC Transformer 2 Ammeter X 367 4 X 367 3 239049 294701 294703 295011 295019 295336 Accessory Description Part Number 18 JA5 Insulink 2 Fuse 2 Amp Switch Selector Nameplate Voltmeter AC Transform...

Page 135: ...8 295011 18 JC4 Insulink Fuse 2 Amp Transformer 2 Switch Selector Nameplate Ammeter Voltmeter X 367 3 239049 246885 283638 295341 295338 295011 Accessory Description Part Number 18 JC5 Insulink Fuse 2...

Page 136: ...367 3 239049 246889 283638 295342 295339 295011 Accessory Description Part Number 18 JE8 Insulink Fuse 2 Amp Transformer Switch Selector Nameplate Ammeter Voltmeter Transformer Resistor X 367 3 239049...

Page 137: ...9049 297148 283638 295342 295339 295011 Accessory Description Part Number 18 JG8 Insulink Fuse 2 Amp Transformer Switch Selector Nameplate Ammeter Voltmeter Transformer Resistor X 367 3 239049 295302...

Page 138: ...er Transformer 3 X 367 3 239049 283638 295342 282959 295011 291547 18 JL9 Insulink Fuse 2 Amp Transformer Switch Selector Nameplate Ammeter Voltmeter Transformer 3 Resistor X 367 3 239049 295302 28363...

Page 139: ...95354 295322 23 VB3 Clock Time Transformer Switch Operator Block Contact Block Contact Contact Assembly 294541 295354 298039 298051 298052 298054 Accessory Description Part Number 23 VC Clock Time Tra...

Page 140: ...mp Fuse 0 3 amp A 294234 226520 226526 24 73B Charger Assembly Battery Fuse 6 0 amp Fuse 0 5 amp A 294235 226520 294552 Manual Switch Operation Accessory Description Part Number 29 P Switch Pushbutton...

Page 141: ...DC before top dead center Btu British thermal unit _ C Celsius degree cc cubic centimeter CCA cold cranking amps CEC Canadian Electrical Code cfh cubic feet per hour cfm cubic feet per minute CID cubi...

Page 142: ...l Manufacturers Association NFPA National Fire Protection Association Nm Newton meter s N O normally open no nos number numbers NPT National Standard taper pipe thread per general use N R not required...

Page 143: ...protection mode is active 7 INPUT Manual Transfer to Emergency If terminal 7 is grounded a manual transfer to emergency occurs 8 INPUT Fault 1 If terminal 8 is grounded the fault 1 message appears on...

Page 144: ...erminal 24 energizes the test relay which simulates a normal source failure 25 INPUT Normal Relay Emergency Relay Off to Normal Relay Off to Emergency Relay Terminal 25 supplies 10 volts DC to the tra...

Page 145: ...mergency Phase C P1 13 Emergency Phase C voltage is connected from the contactor to terminal EC through P1 13 LA Load Phase A P1 23 Contactor load voltage Phase A from P1 23 LB N A N A LC Load Phase C...

Page 146: ...sensing 18 N A 19 N A 20 N A 21 Emergency Phase A 22 N A 23 Load Phase A 24 Load Phase C Figure B 3 P1 J1 contactor to power supply board harness pin numbers and pin names Trip Point Setting Limits Em...

Page 147: ...osition input 23 Emergency Contactor Position Input 24 Automatic manual input 25 13 DC volts load shed relays 26 N A 27 Load shed dry contact board gound 28 Ground 29 Ribbon cable connector notch Figu...

Page 148: ...B 6 Appendices TP 5672 11 95 ADV 5900 Shown with no power present in normal position TDOE TDON TDOE TDON Figure B 8 Logic board schematic diagram...

Page 149: ...B 7 Appendices TP 5672 11 95 ADV 5900 K1 K2 K4 K3 TDOE TDON NR ER Figure B 9 Logic board schematic diagram...

Page 150: ...LC LA EC EB EA NC NB NA P24 8 P24 4 P24 15 P24 16 P24 12 P24 11 P24 5 P24 1 P24 2 P24 21 P24 17 P24 13 P24 23 P24 24 P24 MAX AMB TEMP 150 DF 1 5 4 6 3 A 320788 1 TB DC1 2 P14 accessory ribbon cable co...

Page 151: ...4 5 A 320790 1 P3 power supply board ribbon cable connector 2 P6 status panel ribbon cable connector 3 P10 load shed buffer ribbon cable connector 4 P12 remote communications ribbon cable connector 5...

Page 152: ...sensing all phases over underfrequency sensing for one phase on normal source and overvoltage frequency sensing one phase on emergency source DD 34 Z Phase rotation and anti single phasing protection...

Page 153: ...from one to nine isolated form C contacts before adj 0 60 sec and after adj 0 5 sec switch transfer in either direction The contacts can be transferred in a block or sequentially in either direction T...

Page 154: ...3381 Web site www kohlergenerators com 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 Syste...

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