Kohler PA-320741 Operation And Installation Instructions Manual Download Page 1

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Operation and

Installation Instructions

TT-855 12/93b

Automatic Battery Chargers

Kits:

PA-320741 through PA-320764 and

PA-320741-SD through PA-320764-SD

Summary of Contents for PA-320741

Page 1: ...Operation and Installation Instructions TT 855 12 93b Automatic Battery Chargers Kits PA 320741 through PA 320764 and PA 320741 SD through PA 320764 SD ...

Page 2: ...Charger 11 Battery Charger Operation 12 Charging Lead Acid Batteries 12 Checking Specific Gravity 14 Charging Nickel Cadmium Batteries 14 Charger Voltage Adjustment 15 Charger and Battery Maintenance 15 Troubleshooting 16 Standard Accessories 17 Current Limiting 17 Reverse Polarity Protection 17 Automatic Float Operation 17 Temperature Compensation 17 AC Input Fuse 17 DC Output Fuse 17 Power On La...

Page 3: ...d NOTE Note is used to notify people of installation operation or maintenance information that is important but not hazard related Safety decals are affixed to the generator set in prominent places to advise the operator or service technician of potentially hazardous situations The decals are reproduced here to improve operator recognition and thereby increase decal effectiveness For a further exp...

Page 4: ...rate electrical equipment when standing in water on wet ground or when your hands are wet Hazardous voltage can cause severe injury or death Electrical shock may occur if battery charger is not properly grounded Connect battery charger enclosure to ground of a permanent wiring system As an alternative run an equipment grounding conductor with circuit conductors and connect to equipment grounding t...

Page 5: ...n it is being charged Avoid contacting terminals with tools etc to prevent burns and to prevent sparks that could cause an explosion Remove wristwatch rings and any other jewelry before handling battery Never connect negative battery cable to positive connection terminal of starter solenoid Do not test battery condition by shorting terminals together or sparks could ignite battery gases or fuel va...

Page 6: ...he battery charger The battery chargers are designed for various AC voltage 50 or 60 Hz input and capable of charging as follows 12 Volt Charger Lead Acid Battery 6 cell 24 Volt Charger Lead Acid Battery 12 cell Determine input voltage and type of battery ies to be charged Make any necessary modifications before using charger Grounding Instructions Connect the battery charger to a grounded metal p...

Page 7: ...itors the battery and load conditions to maintain the battery s proper state of charge Refer to Figure 1 for component identification The chargers are factory adjusted to maintain the battery at the proper float voltages The 12 volt charger will maintain a lead acid 6 cell battery with no adjustment required The 24 volt charger will maintain a lead acid 12 cell battery with no adjustment required ...

Page 8: ...X X DA 24 62A DA 24 64A DA 24 63A DA 24 60A DA 24 68A DA 24 71A Battery Charger Kit No X X PA 320741 PA 320747 PA 320745 PA 320751 PA 320743 PA 320749 Transfer Switch Accessory No X X DA 24 62B DA 24 64B DA 24 63B DA 24 60B DA 24 68B DA 24 71B Battery Charger Kit No X X PA 320742 PA 320748 PA 320746 PA 320752 PA 320744 PA 320750 SATS model transfer switches have an SD suffix EXAMPLE PA 320741 SD F...

Page 9: ...d Volts Input Voltage Descriptions Loose Install 12 24 120 V 50 60 Hz 240 V 50 60 Hz 220 V 50 60 Hz 480 600 V 50 60 Hz 208 V 50 60 Hz 380 416 V 50 60 Hz Transfer Switch Accessory No X X KD 24 64A KD 24 63A Battery Charger Kit No X X Transfer Switch Accessory No X X KD 24 64B KD 24 63B Battery Charger Kit No X X Figure 6 Battery Chargers for R33 Model Transfer Switch Input Voltage Descriptions 120 ...

Page 10: ...before working on any equipment connected to generator The generator set can be started by automatic transfer switch or remote start stop switch unless these precautions are followed NOTE CHARGER DAMAGE Connect battery charger only to a battery with the same DC voltage as the battery charger output rating WARNING Explosion Can cause severe injury or death Relays in battery charger cause arcs or sp...

Page 11: ...p insulation from both ends To one end of wire attach a post type connector Route other end of battery cable and connect to output positive terminal on charger DC terminal block See Figure 8 Tighten terminal block lock screw to secure battery cable Repeat procedure with black 10 gauge stranded wire connect black wire to output negative terminal on DC terminal block and secure with lock screw 2 Con...

Page 12: ...10 TT 855 12 93 Installation BW 29500 B 294241 B 1 2 1 Battery Charger Assembly see parts lists 2 Captive Nuts 298811 qty 4 Figure 8 Battery Charger Installation Solid State Transfer Switch ...

Page 13: ...injury or death Use protective goggles and clothes Can cause permanent damage to eyes burn skin and eat holes in clothing 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 Always wear splash proof safety goggles when working around the battery If battery electrolyte is splashed in the eyes or ...

Page 14: ...battery charger cause arcs or sparks Locate in a well ventilated area Keep explosive fumes away Explosion can cause severe injury or death Battery gases can cause an explosion Do not smoke or permit flame or spark to occur near a battery at any time particularly when it is being charged Avoid contacting terminals with tools etc to prevent burns and to prevent sparks that could cause an explosion R...

Page 15: ...285 at an electrolyte temperature of 80_F 26 7_C This hydrometer reading indicates a battery that is in good condition Bubbles appear at the surface of the battery fluid This indicates a battery that is 80 to 85 charged Vigorous bubbling occurs when the battery is near full charge D As a battery becomes charged and the battery voltage approaches the control voltage setting the charging rate will t...

Page 16: ... 0 65 6 71 1 15 6 032 030 028 026 024 022 020 018 016 014 012 010 008 006 004 002 0 002 004 006 008 010 012 014 016 018 020 022 024 026 028 _C _F EXAMPLE NO 1 Temperature below 80_F 26 7_C Hydrometer Reading 1 250 Acid Temperature 20_F 6 7_C Subtract 024 Sp Gravity Corrected Sp Gravity is 1 226 EXAMPLE NO 2 Temperature above 80_F 26 7_C Hydrometer Reading 1 235 Acid Temperature 100_F 37 8_C Add 00...

Page 17: ...t be done by a qualified electrician Applies to Optional Battery Charger Hazardous voltage can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while adjustments are made Remove wristwatch rings and jewelry that can cause short circuits WARNING Sulfuric acid in batteries Can cause severe injury o...

Page 18: ...3 Check for AC at the charger terminal strip 4 Check AC input and DC output fuses 5 Check secondary voltage at transformer 24 volts across secondary with 12 volts to center tap 6 With AC supply disconnected check DC output lead connections from circuit board to DC output terminal block Needle Remains at 2 Amps Indefinitely 1 Battery charger not matched to battery voltage 2 Battery may be severely ...

Page 19: ...until AC input power is lost or the current required to maintain the battery at the float voltage setting exceeds 2 amps Temperature Compensation The charger will provide temperature compensation of 2 mV _C per cell over the ambient temperature range of 40_C 40_F to 60_C 140_F This feature will automatically adjust the float voltage setting to prevent the battery from being overcharged at high amb...

Page 20: ...ORANGE ORANGE 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 WHT BLUE RED BLUE OR RED YELLOW ORANGE VIOLET ORANGE GND RED POWER ON B B AC CT AC ON TERMINAL BLOCK CONTROL BOARD 1 5 AMP 24 V 1 AMP 12 V 1 5 AMP 24 V Figure 10 Wiring Diagram Schematic 120 V...

Page 21: ...BLK BLK RED RED BLK YEL YEL BLUE RED BLUE OR RED YELLOW AC AC ORANGE VIOLET ORANGE GND RED POWER ON B B AC CT AC ON BLK POWER ON BLUE RED YEL VIOLET ORANGE ORANGE DC A B RED ON AC CT AC YEL B TRANSFORMER BLK TERMINAL BLOCK CONTROL BOARD TERMINAL BLOCK CONTROL BOARD RED BLUE OR RED YELLOW 1 AMP 24 V 0 5 AMP 12 V 1 AMP 24 V Figure 11 Wiring Diagram Schematic 208 Volt Battery Charger ...

Page 22: ...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 BOARD RED BLUE OR RED YELLOW DC OUTPUT 6 AMP AC INPUT 0 5 AMP 12 V AC INPUT DC OUTPUT 6 AMP 1 AMP 24 V 0 5 AMP 12 V 1 AMP 24 V Figure 12 Wiring Diagram Schematic 220 Volt Battery Charger ...

Page 23: ...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 BLOCK CONTROL BOARD RED BLUE OR RED YELLOW BLK RED DC OUTPUT 6 AMP AC INPUT 0 5 AMP 12 V AC INPUT DC OUTPUT 6 AMP 1 AMP 24 V 0 5 AMP 12 V 1 AMP 24 V Figure 13 Wiring Diagram Schematic 240 Volt Battery ...

Page 24: ...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 ON POWER ON DC A TERMINAL BLOCK CONTROL BOARD TERMINAL BLOCK CONTROL BOARD RED BLUE OR RED YELLOW 0 5 AMP 24 V 0 3 AMP 12 V 0 5 AMP 24 V Figure 14 Wiring Diagram Schematic 380 416 Volt Battery Charger...

Page 25: ... 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 ON POWER ON DC A TERMINAL BLOCK CONTROL BOARD TERMINAL BLOCK CONTROL BOARD RED BLUE OR RED YELLOW 0 4 AMP 24 V 0 2 AMP 12 V 0 4 AMP 24 V Figure 15 Wiring Diagram Schematic 480 600 Volt Battery Charger...

Page 26: ... X 367 3 Insulink Terminal 1 X 367 4 Terminal 1 X 431 25 Terminal 2 X 431 29 Terminal 3 X 431 30 Screw 6 32 x 0 875 in 2 X 49 3 Screw 8 32 x 0 500 in 4 X 51 15 Screw 8 32 x 0 625 in 1 X 51 53 Spacer fiber 4 X 712 13 Fuse 1 226520 Fuse 1 226525 Holder fuse 2 238426 Ammeter 1 293278 Transformer 1 293279 Strip terminal 1 293281 Lamp 1 293655 Cover terminal block 1 294214 Box silkscreen 1 294241 Decal...

Page 27: ...67 3 Insulink Terminal 1 X 367 4 Terminal 1 X 431 25 Terminal 2 X 431 29 Terminal 3 X 431 30 Screw 6 32 x 0 875 in 2 X 49 3 Screw 8 32 x 0 500 in 4 X 51 15 Screw 8 32 x 0 625 in 1 X 51 53 Spacer fiber 4 X 712 13 Fuse 1 226520 Holder fuse 2 238426 Fuse 1 5 amp 1 291207 Ammeter 1 293278 Transformer 1 293279 Strip terminal 1 293281 Lamp 1 293655 Cover terminal block 1 294214 Box silkscreen 1 294242 D...

Page 28: ...X 431 25 Terminal 2 X 431 29 Terminal 3 X 431 30 Terminal 1 X 431 46 Screw 6 32 x 0 875 in 2 X 49 3 Screw 8 32 x 0 500 in 4 X 51 15 Screw 8 32 x 0 625 in 1 X 51 53 Spacer fiber 4 X 712 13 Fuse 1 226520 Fuse 1 226521 Holder fuse 2 238426 Ammeter 1 293278 Strip terminal 1 293281 Lamp 1 293655 Transformer 1 293659 Cover terminal block 1 294214 Box silkscreen 1 294243 Decal barrier 1 294742 Retainer 4...

Page 29: ...X 431 25 Terminal 2 X 431 29 Terminal 3 X 431 30 Terminal 1 X 431 46 Screw 6 32 x 0 875 in 2 X 49 3 Screw 8 32 x 0 500 in 4 X 51 15 Screw 8 32 x 0 625 in 1 X 51 53 Spacer fiber 4 X 712 13 Fuse 1 226520 Fuse 1 226521 Holder fuse 2 238426 Ammeter 1 293278 Strip terminal 1 293281 Lamp 1 293655 Cover terminal block 1 294214 Box silkscreen 1 294245 Decal barrier 1 294742 Retainer 4 294759 Transformer 1...

Page 30: ...X 431 25 Terminal 2 X 431 29 Terminal 3 X 431 30 Terminal 1 X 431 46 Screw 6 32 x 0 875 in 2 X 49 3 Screw 8 32 x 0 500 in 4 X 51 15 Screw 8 32 x 0 625 in 1 X 51 53 Spacer fiber 4 X 712 13 Fuse 1 226520 Fuse 1 226525 Holder fuse 1 238426 Ammeter 1 293278 Strip terminal 1 293281 Lamp 1 293655 Cover terminal block 1 294214 Box silkscreen 1 294246 Decal barrier 1 294742 Retainer 4 294759 Transformer 1...

Page 31: ... 3 Terminal 1 X 431 25 Terminal 2 X 431 29 Terminal 3 X 431 30 Terminal 1 X 431 46 Screw 6 32 x 0 875 in 2 X 49 3 Screw 8 32 x 0 500 in 4 X 51 15 Screw 8 32 x 0 625 in 1 X 51 53 Spacer fiber 4 X 712 13 Fuse 1 226520 Fuse 1 226521 Holder fuse 2 238426 Ammeter 1 293278 Transformer 1 293279 Strip terminal 1 293281 Lamp 1 293655 Cover terminal block 1 294214 Box silkscreen 1 294247 Decal barrier 1 294...

Page 32: ... 3 Terminal 1 X 431 25 Terminal 2 X 431 29 Terminal 3 X 431 30 Terminal 1 X 431 46 Screw 6 32 x 0 875 in 2 X 49 3 Screw 8 32 x 0 500 in 4 X 51 15 Screw 8 32 x 0 625 in 1 X 51 53 Spacer fiber 4 X 712 13 Fuse 1 226520 Fuse 1 226525 Holder fuse 2 238426 Ammeter 1 293278 Transformer 1 293279 Strip terminal 1 293281 Lamp 1 293655 Cover terminal block 1 294214 Box silkscreen 1 294248 Decal barrier 1 294...

Page 33: ...Terminal 2 X 431 29 Terminal 3 X 431 30 Terminal 2 X 431 46 Screw 6 32 x 0 875 in 2 X 49 3 Screw 8 32 x 0 500 in 4 X 51 15 Screw 8 32 x 0 625 in 1 X 51 53 Spacer fiber 4 X 712 13 Fuse 1 226520 Fuse 1 226526 Holder fuse 1 238426 Ammeter 1 293278 Holder fuse 1 293652 Strip terminal 1 293653 Lamp 1 293655 Cover terminal block 1 294215 Box silkscreen 1 294249 Decal barrier 1 294742 Retainer 4 294759 T...

Page 34: ...Terminal 2 X 431 29 Terminal 3 X 431 30 Terminal 2 X 431 46 Screw 6 32 x 0 875 in 2 X 49 3 Screw 8 32 x 0 500 in 4 X 51 15 Screw 8 32 x 0 625 in 1 X 51 53 Spacer fiber 4 X 712 13 Fuse 1 226520 Holder fuse 1 238426 Ammeter 1 293278 Holder fuse 1 293652 Strip terminal 1 293653 Lamp 1 293655 Cover terminal block 1 294215 Box silkscreen 1 294250 Fuse 1 294552 Decal barrier 1 294742 Retainer 4 294759 T...

Page 35: ...Terminal 2 X 431 29 Terminal 3 X 431 30 Terminal 2 X 431 46 Screw 6 32 x 0 875 in 2 X 49 3 Screw 8 32 x 0 500 in 4 X 51 15 Screw 8 32 x 0 625 in 1 X 51 53 Spacer fiber 4 X 712 13 Fuse 1 226520 Fuse 1 226527 Holder fuse 1 238426 Ammeter 1 293278 Transformer 1 293649 Holder fuse 1 293652 Strip terminal 1 293653 Lamp 1 293655 Cover terminal block 1 294215 Box silkscreen 1 294251 Decal barrier 1 29474...

Page 36: ...Terminal 2 X 431 29 Terminal 3 X 431 30 Terminal 2 X 431 46 Screw 6 32 x 0 875 in 2 X 49 3 Screw 8 32 x 0 500 in 4 X 51 15 Screw 8 32 x 0 625 in 1 X 51 53 Spacer fiber 4 X 712 13 Fuse 1 226520 Fuse 1 226528 Holder fuse 1 238426 Ammeter 1 293278 Transformer 1 293649 Holder fuse 1 293652 Strip terminal 1 293653 Lamp 1 293655 Cover terminal block 1 294215 Box silkscreen 1 294252 Decal barrier 1 29474...

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