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

1
TP-5670 9/94 Specifications 1-3
Interpreting a Transfer Switch Part Number
Record the transfer switch part number in the boxes below. The transfer switch part number defines
characteristics and ratings as explained in the following key.
Type of Switch Type of Logic Voltage & Frequency Number of Poles Number of Wires Type of Enclosure Amperage Rating Code
Kohler Part Number Key
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
amperage rating of 80 amperes.
SAMPLE 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: Mechanically Held Contactor
M: Molded-Case Circuit Breaker
N: Molded-Case Switch (no protection)
Type of Switch
S: Standard
Type of Logic
2: E33+
4: E33+ with programmed transition
Voltage Code
60: 600 Volt, 60 Hz 66: 480 Volt, 60 Hz
62: 120 Volt, 60 Hz 68: 208 Volt, 60 Hz
63: 220 Volt, 50 Hz 71: 380 Volt, 50/60 Hz
64: 240 Volt, 60 Hz
Number of Poles
2: 2 pole, 1 phase (MM_, MN_, TE_, TL_, devices
will be supplied with 3 poles)
3: 3 pole, 3 phase
6: 4 pole, fully rated switched poles
(no overlapping neutral)
Number of Wires
2: 2 wire
3: 3 wire
4: 4 wire
Enclosure
1: NEMA type 1
Amperes
Available sizes vary with the type of switch.
MMS-266341-0080
56641
Figure 1-4. Model Number Description

1-4 Specifications TP-5670 9/94
Specifications
The specifications listed herein are for the E33+ logic
controller. See the respective power switching device
manual for its specifications.
Standard Features
DTransfer switch uses proven solid-state
technology.
DNormal source single-phase voltage sensing is
fixed at 70% for dropout and 90% for pickup.
DAll printed circuit boards are conformal coated for
environmental protection.
DEmergency source single-phase sensing is fixed at
85% of rated voltage and 95% of rated frequency.
DTDEN (Time Delay Emergency to Normal) is fixed
at 5 minutes.
DTDES (Time Delay on Engine Start) is fixed at 3.0
seconds.
DThe test switch simulates a normal source failure.
DLamps illuminate to indicate normal or emergency
source switch position.
DLamps illuminate to indicate normal and
emergency source availability.
DAutomatic and inhibit transfer positions are
provided.
DEngine start contacts are provided.
Optional Features
See Section 5. Accessories for details of optional
features selected.
DPlant exerciser—7 day no load
DSolid state, 2-amp float, 12 volt
DSolid state, 2-amp float, 24 volt
D3-phase sensing—normal source

2
TP-5670 9/94 Operation 2-1
Section 2. Operation
Control Switches and Indicators
AVAILABLE AVAILABLE
SOURCE
EMERGENCYNORMAL
TRANSFER SWITCH POSITION
NORMAL
SOURCE
EMERGENCY
POSITION.
RETURN SWITCH TO AUTO
AFTER TEST IS COMPLETED
CAUTION:
PUSH TO TEST
WARNING
WORKING ON THIS SWITCH
SUPPLY SOURCES BEFORE
OR BURNS, DISCONNECT ALL
TO INSURE AGAINST SHOCK
321159
1
2
3
4
5
Figure 2-1. Transfer Switch Control Switches &
Indicators
Various optional control switches and indicator lamps
may be present on the transfer switch door. For
identification of switches and indicators and an
explanation of their function, refer to Figure 2-1 and the
following descriptions.
1. Normal Transfer Switch Position Lamp (green):
Lamp illuminates to indicate that the load is
connected to the normal source.
2. Normal Source Available Lamp (white): Lamp
illuminates to indicate presence of normal source
voltage.
3. Emergency Transfer Switch Position Lamp
(red): Lamp illuminates to indicate that load is
connected to the emergency source.
4. Emergency Source Available Lamp (white):
Lamp illuminates to indicate presence of
emergency source voltage.
5. Test Switch: Normal position allows automatic
transfer switch operation. Test position signals
generator set to start.

2-2 Operation TP-5670 9/94
Sequence of Operation
Normal Source Failure
Load transfer to the emergency source automatically
begins when the voltage sensing circuit detects reduced
voltage or total loss of the normal source. Relay K2,
located on the main logic circuit board, will de-energize
whenever the voltage level falls below the preset
dropout point (70%) of line voltage. See Figure 2-3.
The time delay engine start relay (TDES) begins its
engine start timing cycle as the K2 relay deenergizes.
The TDES relay is located on the main logic panel. See
Figure 2-3. Standard time delay is factory set at 3.0
seconds. TDES relay is a time delay on dropout to
override momentary outages. This delay prevents
nuisance starting of the generator set. If the normal
source voltage returns above the voltage dropout
setting before the time delay expires the K2 and TDES
energize causing the timing cycle to reset to zero.
TDES relay deenergizes after the time delay and signals
the generator set to start. The emergency voltage and
frequency circuits monitor the emergency source. The
K1 relay will energize when the emergency source
voltage and frequency reach the pickup points (85%
voltage and 95% frequency). See Figure 2-3. If the
emergency source is immediately available, the sensing
circuits will accept immediately.
When the emergency source is acceptable, the
emergency relay (ER) relay is energized. The ER relay
will cause immediate transfer to the emergency source
or cause the opening of the normal source and/or a
transfer to the emergency source after a time delay
(TDOE) if the switch is equipped with an optional
program transition function. See Figure 2-1.
When the ER relay or the TDOE relay (if equipped)
energizes the switch transfers load to the emergency
source. The transfer switch is now supplying the load
from the emergency source and will remain in this
position until the normal source is restored.
Normal Source Restoration
Load transfer to the normal source automatically begins
when the voltage sensing circuit detects restoration of
the normal source. The voltage level must rise above
the preset pickup point (90%) on all phases before the
circuit will accept the normal source again.
When the normal source is accepted by the voltage
sensing circuit the K2 relay is energized. After a time
delay period (TDEN) the NR relay energizes. This time
delay ensures that the normal source has stabilized
before reconnection of vital loads. An optional program
transition will stop the transition in the off position for an
adjustable time (TDON). If the emergency source fails
during this timing cycle the K1 relay drops out and the
load is immediately transferred to the normal source if
acceptable.
The K1 relay energizes and after the TDEN delay the NR
relay energizes. The ER relay is dropped out. The
switch transfers load back to the normal source. The
transfer switch is in the normal position.
The logic circuitry energizes the TDES relay, which
signals the generator set to shut down. All circuits are
reset for any future normal source failure.
Normal Source Failure
Time Delay Engine Start
Time Delay Normal-to-Emergency
Contactor Transfer to Emergency Position
Normal Source Return
Time Delay Emergency-to-Normal
Contactor Transfer to Normal Position
Time Delay Engine Cooldown
567022
Figure 2-2. Logic Board Operation

2
TP-5670 9/94 Operation 2-3
A-320717-A
1 2 3 4 5 6 7 8 9 10 11 1 2
REF
TB2
EMERGENCY NORMAL EMERGENCY NORMAL
NCCNONCCNONCCNONCCNO
12
11
10
9
8
7
6
5
4
3
2
1
121110987654321
PCB ASSY A--320717
LOT NO.
ACC
E.V.
FREQ
E
JP1
JP2
VOLT
N/CA
VOLT
N/BC
JP3
JP4
JP5
EMERGENCY NORMAL EMERGENCY NORMAL
SOURCE ACCEPTABLE POSITION
T
R
A
T
S
E
N
I
G
N
E
VOLT
N/AB
VOLT
EBPEN
ES3
ES4
CONT
NORM
CONT
EM
CONT
COM
ER1
NR1
+12UF
TEST
GND
1
2345
6
1. Time Delay Engine Start (TDES) Relay
2. Normal Position Relay (K5)
3. Emergency Position Relay (K3)
4. Normal Source Acceptable Relay (K2)
5. Emergency Source Acceptable Relay (K1)
6. Optional 3-Phase Sensing Connection
Figure 2-3. Main Logic Circuit Board
PCB ASSY A--320687 LOT NO.
A-320687-
1
4
2
3
1. NR Relay
2. TDON Relay
3. TDOE Relay
4. ER Relay
Figure 2-4. Interface Circuit Board

2-4 Operation TP-5670 9/94
Main Circuit Board Voltage Adjustments
The main circuit board contains a normal source
undervoltage circuit. The voltage values are factory set
and should not need adjustment. Single phase sensing
is fixed at 70% dropout and 90% pickup. Three phase
sensing on normal requires an optional accessory. See
Section 5.
Single phase sensing on the emergency source is fixed
at 85% voltage and 95% frequency.
To Disconnect The P1 Plug
1. If the transfer switch is in the normal position, place
the generator set start switch in the OFF position,
and then open the emergency-source circuit
breaker.
2. If the transfer switch is in the emergency position,
open the normal-source circuit breaker and place
the generator set start switch in the TEST position.
3. Separate the in-line disconnect plug by grasping
and squeezing the plug. Do NOT pull on the wires.
SeeFigure2-5.
To Reconnect The P1 Plug
1. Engage the in-line disconnect plug by grasping the
connectors and pressing together.
2. If the transfer switch is in the normal position, place
the generator set start switch in the AUTO position,
and then close the emergency-source circuit
breaker.
3. If the transfer switch is in the emergency position,
close the normal-source circuit breaker. The load
will automatically retransfer after a time delay to the
normal source, if available. For immediate
retransfer, open and then reclose the
emergency-source circuit breaker. Place the
generator set start switch in the AUTO position.
1
56622
1. In-Line Disconnect Plug (P1)
Figure 2-5. In-line Disconnect Plug

2
TP-5670 9/94 Operation 2-5
Voltage Checks
NOTE
Perform voltage checks in the order given to avoid
damaging the switch.
DANGER
Hazardous voltage.
Will cause severe injury or death.
Do not open enclosure until all power sources are
disconnected.
(600 Volt and above)
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
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)
Hazardous voltage can cause severe injury or
death. Whenever electricity is present, there is the
hazard of electrocution. Open main circuit breaker on all
power sources before 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, as
the chance of electrocution is increased under such
conditions.
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.
Safety decals are affixed to the transfer switch in
prominent places to advise the operator or service
technician of potential hazards. The decals are
reproduced here to improve operator recognition. For a
further explanation of decal information, refer to the
safety precautions throughout this manual. Before
operating or servicing the transfer switch, be sure you
understand the messages of these decals. Replace
decals if missing or damaged.
Read and understand all instructions on installation
drawings and labels affixed to the switch. Note any
optional accessories that have been furnished with the
switch and review their operation.
Check the transfer switch nameplate for rated voltage.
The voltage should be the same as normal and
emergency line voltage and emergency line voltage.
1. Verify power is off then separate the power switch
device control in-line disconnect plug (P1) if not
already done. See Figure 2-5.
2. Close the normal source line circuit breaker.
3. Use an accurate voltmeter to check for rated
voltage phase-to-phase and phase-to-neutral
voltages. Check phase rotation at the power
switching device’s normal-source terminals.
4. Close the emergency source line circuit breaker.
5. Manually start the generator set using the engine
control switch on the generator set controller.
6. Use an accurate voltmeter to check for rated
voltage phase-to-phase and phase-to-neutral
voltages. Check phase rotation at the contactor’s
emergency-source terminals.

2-6 Operation TP-5670 9/94
7. If the emergency source is not at rated voltage,
adjust the generator voltage regulator following the
generator set manufacturer’s instructions. The
automatic transfer switch will respond only to rated
voltage and frequency specified on the nameplate.
Check phase rotation; it should be the same as that
of the normal source.
8. Shut down the generator set using the engine
control switch on the generator set controller.
Remove the normal source and reconnect the
power switch device control in-line disconnect
plugs. See Figure 2-5. Wait until the time delay
engine cooldown (TDEC, if equipped) has
completed timing per the factory setting. After the
TDEC has completed timing, the generator set
controller’s engine control switch can be placed in
the AUTO position.
Electrical Operation Test
9. Place the transfer switch in the Normal position.
The following procedure will check the electrical
operation of the automatic transfer switch.
10. Place the Test switch (if so equipped) in the TEST
position. See Figure 2-1. The generator set will
start and run after the Time Delay Engine Start
(TDES) relay times out.
11. The transfer switch will transfer to the emergency
position. The transfer will occur after the
Normal-to-Emergency Time Delay (TDNE) relay
times out.
12. Move the door-mounted test switch back to the
normal position. The transfer switch will retransfer
to normal after the emergency-to-normal time
delay relay times out.
13. Time Delay Engine Cooldown (TDEC) allows the
engine to continue running without load for an
additional period. The transfer switch TDEC will
complete timing before any TDEC function in the
generator set controller begins timing.
14. Close load circuit breaker(s) when loads may be
energized.
NOTE
If you connect the transfer switch in-line disconnect
plugs (P1) together while the generator controller’s
master switch in the AUTO position, the generator
set will IMMEDIATELY start and run until the
generator set controller’s cooldown timer has
completed timing.
This completes functional tests of the transfer switch.
Place the generator set starting control in the automatic
position.

3
TP-5670 9/94 Main Circuit Board Adjustments 3-1
Section 3. Circuit Board Adjustment
A-320717-A
1 2 3 4 5 6 7 8 9 10 11 1 2
REF
TB2
EMERGENCY NORMAL EMERGENCY NORMAL
NCCNONCCNONCCNONCCNO
12
11
10
9
8
7
6
5
4
3
2
1
121110987654321
PCB ASSY A--320717
LOT NO.
ACC
E.V.
FREQ
E
JP1
JP2
VOLT
N/CA
VOLT
N/BC
JP3
JP4
JP5
EMERGENCY NORMAL EMERGENCY NORMAL
SOURCE ACCEPTABLE POSITION
T
R
A
T
S
E
N
I
G
N
E
VOLT
N/AB
VOLT
EBPEN
ES3
ES4
CONT
NORM
CONT
EM
CONT
COM
ER1
NR1
+12UF
TEST
GND
1
2
3
4
5
7
6
8
9
10
1. R42
2. R29
3. R17
4. R34
5. R37
6. Jumper 4
7. Jumper 3
8. Jumper 5
9. Jumper 2
10. Jumper 1
Figure 3-1. Main Logic Circuit Board

3-2 Main Circuit Board Adjustments TP-5670 9/94
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)
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.
Main Circuit Board Jumper Wire
Configuration
The E33+ logic board uses five jumpers to configure the
voltage range and number of phases sensed on the
normal source. See Figure 3-2 for a list of the jumper
numbers and their functions.
Jumper
Numbers Jumper Installed Jumper Removed
Jumpers
1-4
Calibrated for a
voltage from 0 to
240 volts
Calibrated for a
voltage from 241
to 600 volts
Jumper 5 Configured for
single phase
sensing
Configured for
three phase
sensing
Figure 3-2. Main Circuit Board Jumper Wire
Configuration
Main Circuit Board Voltage
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.
Adjustment
Potentiometers Function Adjusted
R17 Normal source voltage
adjustment (A--C)
R34 Normal source voltage
adjustment (A--B)
R37 Normal source voltage
adjustment (B--C)
R29 Emergency source voltage
adjustment (A--C)
R42 Emergency source
frequency adjustment
Figure 3-3. Main Circuit Board Voltage Adjustment
Normal Source
The E33+ logic board See Figure 3-1 contains a normal
source undervoltage circuit that is fixed at 70% dropout
and 90% pickup. The voltage values are factory-set and
should not need adjustment unless the voltage rating of
the switch has changed. The following steps explain the
procedure for adjusting the pickup voltage.
NOTE
Use a variable AC power supply or generator set to
establish the voltage and frequency needed to calibrate
the logic board. Refer to Figure 3-2 for jumper
configuration.
1. Turn the normal and emergency source circuit
breakers off.
2. Disconnect the normal, emergency, and load
cables from the transfer switch.
3. Connect the adjustable voltage source to the
transfer switch normal terminals. The voltage
source must have the same frequency rating as the
transfer switch.
4. Check jumpers 1--4 for the correct voltage range
configuration. Refer to Figure 3-2.
5. Check jumper five to see if single- or three-phase
monitoring is selected. Refer to Figure 3-2.