Kohler MMS Guide

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

Table of ContentsTP-5670 9/94
Table of Contents
SUBJECT PAGE SUBJECT PAGE
Safety Precautions and Instructions I........
Introduction i..............................
List of Related Manuals i.....................
Service Assistance i........................
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 1-5..............................
Standard Features 1-5........................
Optional Features 1-5........................
Section 2. Operation 2-1......................
Control Switches and Indicators 2-1..............
Sequence of Operation 2-2......................
Normal Source Failure 2-2....................
Normal Source Restoration 2-2................
Main Circuit Board Voltage Adjustments 2-4.......
To Disconnect The P1 Plug 2-4................
To Reconnect The P1 Plug 2-4.................
Voltage Checks 2-5............................
Electrical Operation Test 2-6...................
Section 3. Circuit Board Adjustment 3-1.......
Main Circuit Board Jumper Wire Configuration 3-2.
Main Circuit Board Voltage Adjustment 3-2........
Normal Source 3-2.............................
For Single-Phase Monitoring 3-3.................
For Three-Phase Monitoring 3-3.................
Emergency Source 3-3.........................
Section 4. Controller Troubleshooting 4-1.....
General Troubleshooting Information 4-1..........
Logic Board Troubleshooting 4-1.................
Interface Relay Board Troubleshooting 4-3........
Section 5. Accessory Troubleshooting 5-1.....
Optional Features Troubleshooting 5-2............
Accessories 23-P: 7-Day, Solid-State Exercise
Timer 5-2................................
Specifications 5-2............................
Adjustment 5-2..............................
Troubleshooting 5-5..........................
Accessory 24-XX-A,B Battery Charger 5-6.......
Specifications 5-6............................
Features 5-6................................
To Disconnect Charger (When Replacing or
Servicing Battery) 5-8.......................
Battery Charger Operation 5-8.................
Charger Voltage Adjustment 5-9...............
Charger and Battery Maintenance 5-9..........
Troubleshooting 5-9..........................
Battery Charger Wiring Diagrams 5-10...........
Accessory DA-26 5-16..........................
Troubleshooting 5-16..........................
Section 6. Wiring Diagrams 6-1................
Section 7. Service Parts 7-1...................
Inner Panel 7-1................................
Accessories 7-3...............................
Plant Exercisers 7-3..........................
Battery Chargers 7-3.........................
Three-Phase Sensing 7-3.....................
Appendix A. Glossary of Abbreviations A-1....

Safety Precautions and Instructions I
TP-5670 9/94
Safety Precautions and Instructions
A transfer switch, like any other electromechanical
device, can pose potential dangers to life and limb if
improperly maintained or imprudently operated. The
best way to prevent accidents is to be aware of the
potential dangers and to always use good common
sense. In the interest of safety, some general
precautions relating to operating of a transfer switch
follow. Below are some general precautions relating to
the operation of a transfer switch. SAVE THESE
INSTRUCTIONS.
DANGER
Danger indicates the presence of a hazard that will
cause severe personal injury, death, or substantial
property damage if the danger is ignored.
WARNING
Warning indicates the presence of a hazard that can
cause severe personal injury, death, or substantial
property damage if the warning is ignored.
CAUTION
Caution indicates the presence of a 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
hazard related.

II Safety Precautions and Instructions TP-5670 9/94
Accidental Starting
Accidental starting.
Can cause severe injury or death.
Disconnect battery cables before working on
generator set (negative lead first and reconnect it
last).
WARNING
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
reconnect it last) to disable generator set before working
on any equipment connected to generator set. The
generator set can be started by automatic transfer
switch or remote start/stop switch unless these
precautions are followed.
Battery
Sulfuric acid in batteries.
Can cause severe injury or death.
Use protective goggles and clothes. Battery acid can
cause permanent damage to eyes, burn skin, and eat
holes in clothing.
WARNING
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 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. Sparks
could ignite battery gases or fuel vapors. Ventilate any
compartment containing batteries to prevent
accumulation of explosive gases. To avoid sparks, do
not disturb battery charger connections while battery is
being changed. Always turn battery charger off before
disconnecting battery connections. Remove negative
lead first and reconnect it last when disconnecting
battery.

Safety Precautions and Instructions III
TP-5670 9/94
Hazardous Voltage/
Electrical Shock
600 Volt and Above
DANGER
Hazardous voltage.
Will cause severe injury or death.
Do not open enclosure until all power sources are
disconnected.
(600 Volt and above)
DANGER
Hazardous voltage.
Will cause severe injury or death.
Disconnect power sources before servicing.
Barrier must be installed after adjustments,
maintenance, or servicing.
(600 Volt and above)
Under 600 Volt
WARNING
Hazardous voltage.
Can cause severe injury or death.
Disconnect power sources before servicing.
Barrier must be installed after adjustments,
maintenance, or servicing.
(under 600 Volt)
WARNING
Hazardous voltage.
Can cause severe injury or death.
Do not open enclosure until all power sources are
disconnected.
(under 600 Volt)
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.
Hazardous voltage can cause severe injury or
death. Keep unauthorized persons away from the
generator set and take precautions to prevent
unqualified personnel from tampering with the transfer
switch. Have the generator set and electrical circuits
serviced only by qualified technicians. Wiring should be
inspected at the recommended interval shown in the
service schedule—replace leads that are frayed or in
poor condition. Do not operate electrical when standing
in water or on wet ground.
Hazardous voltage can cause severe injury or
death. To prevent the possibility of electrical shock,
disconnect harness plug before installing any
accessories involving connection to transformer
assembly primary terminals 76, 77, 78, and 79.
Terminals are at line voltage!
Hazardous voltage can cause severe injury or
death. To prevent the possibility of electrical shock,
deenergize the normal power source to be connected to
the transfer switch before making any line or auxiliary
connections.
Hazardous voltage can cause severe injury or
death. Disconnect inner panel harness at in-line
connector. This will deenergize circuit board and logic
circuitry, but allow transfer switch to continue to supply
utility power to necessary lighting and equipment.
Hazardous voltage will exist if any accessories mounted
to inner panel are NOT wired through the inner panel
harness and deenergized by in-line connector
separation. Such accessories are at line voltage.

IV Safety Precautions and Instructions TP-5670 9/94
Notes
Charge only lead-acid or nickel-cadmium batteries with
battery charger.
Charger Damage! Connect battery charger only to a
battery with the same DC voltage as the battery charger
output rating.
Hardware Damage! Transfer switch may use both
American standard and metric hardware. Use the
correct size tools to prevent rounding of bolt heads and
nuts.
When replacing hardware, do not substitute with
inferior grade hardware. Screws and nuts are
available in different hardness ratings. American
Standard hardware uses a series of markings and
metric hardware uses a numeric system to indicate
hardness. Check markings on bolt head and nuts for
identification.

TP-5670 9/94 Introduction i
Introduction
This manual covers the operation, troubleshooting,
repair, and service parts for the E33+ solid-state logic
controller.
Read through this manual and carefully follow all
procedures and safety precautions to ensure proper
transfer switch operation and to avoid bodily injury. Keep
this manual with the transfer switch for future reference.
Service requirements are minimal but are very
important to the safe and reliable operation of the
transfer switch; therefore, inspect associated parts
often. It is recommended that an authorized service
distributor perform required service to keep the switch in
top condition.
All information found in this publication is based on data
available at time of printing. The manufacturer reserves
the right to make changes to this literature and the
products represented at any time without notice and
without incurring obligation.
List of Related Manuals
The logic controller covered in this manual is part of a
family of related devices. Separate service 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 automatic
transfer switch. There are three types of power
conversion units and each type is covered in a separate
service and parts manual. To be complete, the logic
controller service and parts manual must be
accompanied by a copy of the service and parts manual
for the power conversion unit used in that automatic
transfer switch. The power conversion service and
parts manual contains all of the wiring diagrams and
schematics for each of the logic controllers. Available
power conversion units and the related manual
numbers are as follows:
Models (Power Switching Device)
Service/
Parts Manual
MMS/MNS (molded case circuit breaker or
switch 40 to 4000 amp) TP-5666
TES/TLS (electrically and mechanically held
contactors 40 to 400 amp) TP-5667
ZCS/ZCB (contactor or bypass isolation
switch 150 to 3000 amp) TP-5668
MMT/MNT (molded case circuit breaker or
switch 40 to 1250 amp) TP-5973
Service Assistance
For service or information, consult the yellow pages of
the telephone directory under the heading
GENERATORS—ELECTRIC for the Authorized Kohler
Service Distributor/Dealer.
KOHLER CO., Kohler, Wisconsin 53044
Phone [phone]
Fax [phone] (North American Sales)
920-459-1614 (International Sales)
For Sales and Service in U.S.A. and Canada
Phone [phone]
In communications regarding the automatic transfer
switch, please include the PART and SERIAL numbers
provided on the nameplate attached to the transfer
switch. Enter the numbers in the spaces provided
below. This information will enable the authorized
Kohler service distributor/dealer to supply the correct
part or information for your particular model.
Part No. ____________________________________
Serial No. ___________________________________

TP-5670 9/94ii Introduction
Notes

1
TP-5670 9/94 Specifications 1-1
Section 1. Specifications
Purpose of Switch
An Automatic Transfer Switch (ATS) is a device used for
transferring critical electrical loads from a normal
(preferred) source of electrical power to an emergency
(standby) source. This transfer occurs automatically
when the normal source voltage fails, or is substantially
reduced, and the emergency sources voltage has
reached an acceptable level.
Upon normal source failure, the automatic transfer
switch controller signals the generator set(s) to start,
and transfers to the emergency source. The automatic
transfer switch controller continuously senses for an
acceptable normal source and will retransfer the load to
the normal source after it has been restored to an
acceptable level. After retransfer of the load, the
generator set start signal is removed and the generator
set(s) are allowed to shut down.
Components of Switch
A typical automatic transfer switch includes the power
switching device and the logic controller to perform
power monitoring and transfer sequencing tasks. See
Figure 1-1. An interface board is also included to match
the standard controller inputs/outputs to the levels
required by a specific switching device.
The three functional units that make up the automatic
transfer switch are mounted in an enclosure with a
hinged front door. The controller mounts on the back of
the front door so its controls and indicators are available
to an operator. A signal cable, with in-line connectors to
facilitate component replacement and door removal,
connects the controller to the interface board and the
switching devices.
12
3321159
1. Switching Device
2. Interface Panel
3. Logic Controller
Figure 1-1. Transfer Switch Components

1-2 Specifications TP-5670 9/94
Interface
Power
Switching
Device
To Load
Automatic Transfer Switch
Logic
Controller
Normal
(Utility)
Power
Emergency (Generator) Power Generator
Start
Generator
565812
Figure 1-2. Basic Transfer Switch Block Diagram
Ratings
A nameplate is attached to the automatic transfer switch
enclosure. See Figure 1-3. The nameplate label
includes a factory part number coded to provide
characteristic and rating information that affects
installation and operation. Copy the part number into
the blank spaces provided in Figure 1-4 and then use
the tables in Figure 1-4 to interpret the part number.
NOTE
Also copy the part number and serial number from the
nameplate into the spaces provided in the Service
Assistance Section of the Introduction for use when
requesting service or parts.
KOHLER
AUTOMATIC TRANSFER SWITCH
PART NO. MMS-266341-0080
SERIAL NO.
VOLTS
PHASE
HERTZ
KOHLER CO. KOHLER WISCONSIN 53044
AMPS
WIRES
POLES
295232
600
3
60
800
4
3
Figure 1-3. Transfer Switch Nameplate