Kohler M340+ Service And Parts Manual

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Page 1

Service and Parts

Automatic Transfer Switches

Models:

M340+

Logic:

Microprocessor

U.S.A. Plant ISO Registered

TP-5672 11/95d

Page 2

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 1-4.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. .

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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. Below are some general precautions relating to theoperation ofa transfer switch. This manual contains several types of safety precautions which are explained below. 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.

NOTE

Note communicates 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 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 generator set, be sure you understand the messages of these decals. Replace decals if missing or damaged.

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.

CAUTION

Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage if

the caution is ignored.

TP-5672 11/95

Safety Precautions and Instructions I

Page 4

Accidental Starting

WARNING

Accidental starting. Can cause severe injury or death.

Disconnect battery cables before working on generator set (negative lead first and reconnect it last).

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 reconnectitlast)to disable generator setbeforeworking 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.

II Safety Precautions and Instructions TP-5672 11/95

Page 5

Battery

WARNING

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. Relays in battery charger cause arcs or sparks.

Locate in a well-ventilated area. Keep explosive fumes away.

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. Alwayswear splash-proofsafety goggleswhen working around the battery. If battery electrolyte is splashed in the eyes or on skin, immediately flush the affected area for15 minutes withlargequantities of cleanwater. Seek immediatemedicalaidin the caseofeyecontact. Never addacidtoa battery once thebatteryhasbeen placed in service. This may result in hazardous spattering of electrolyte.

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. Alwayswear splash-proofsafety goggleswhen 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. Continue flushing with water until emergency help arrives Seek immediatemedicalaidin the caseofeyecontact. Never addacidtoa battery once thebatteryhasbeen placed in service. This may result in hazardous spattering of electrolyte.

Explosioncancause 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 batterycondition by shortingterminals 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.

TP-5672 11/95

Safety Precautions and Instructions III

Page 6

Hazardous Voltage/ Electrical Shock

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)

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. Whenever electricity is present, there is the

hazardofelectrocution. Openmaincircuitbreaker 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 oron wet ground, as the chance of electrocution is increased under such conditions.

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. 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!

(S340, R340, and R33 models only.)

Hazardous voltage can cause severe injury or

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)

IV Safety Precautions and Instructions TP-5672 11/95

death. To prevent the possibility of electrical shock, disconnect harness plug before installing any accessories involving connection to transformer assembly primary terminals on microprocessor logic models. Terminals are at line voltage!

Page 7

Hazardous voltage can cause severe injury or death. To prevent the possibility of electrical shock,

de-energize the normal power source to be connected to the transfer switch before makingany line or auxiliary connections.

Hazardous voltage can cause severe injury or death. De-energize bothnormal and emergencypower

sourcesbefore proceeding. Movegenerator set master switch 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 injury or death. Disconnect inner panel harness at in-line

connector. This will de-energize circuit board and logic circuitry, but allow transfer switch to continue to supply utility power to necessary lighting and equipment. Hazardousvoltage will exist ifanyaccessories mounted to inner panel are NOT wired through the inner panel harness and de-energized by in-line connector separation. Such accessories are at line voltage.

TP-5672 11/95

Safety Precautions and Instructions V

Page 8

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 unless it is securely bolted in place or stabilized.

VI Safety Precautions and Instructions TP-5672 11/95

Page 9

Notes

NOTE

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.

NOTE

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.

NOTE

A manual operator handle is provided on the transfer switch for maintenance purposes only. Return the transfer switch to the normal position. Remove manual operator handle (if used) and store it on the transfer switch in the placeprovided 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 thistransfer switch andconform with ULand CSAlisting requirements where specified. Do not use battery charger before reading instructions.

NOTE

Connect source and load phases as indicated by the markings and drawings. Improper connections may causeshortcircuitsand can causephase-sensitiveload devices to run in reverse or prevent load devices from functioning.

NOTE

Charger Damage! Connect battery charger only to a

batterywith thesame DC voltage as the battery charger output rating.

NOTE

Covertransferswitchduring installation to keepdirt,grit, metal drill chips, etc., out of components. Cover solenoid mechanism during installation. After installation, use manual operating handle to position contactor to ensure that it operates freely. Do not use a screwdriver to force contactor mechanism.

TP-5672 11/95

Safety Precautions and Instructions VII

Page 10

Introduction

This manual covers the operation, troubleshooting, repair,and service parts for the M340+ microprocessor logic controller.

Read through this manual and carefully follow all procedures and safety precautions to ensure proper transferswitchoperationandtoavoidbodilyinjury.Keep this manual with the transfer switchfor futurereference.

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 servicing to keep the switch in top condition.

All information found in this publication isbased on data availableat timeof printing. The manufacturerreserves 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. Available power conversion units and the related manual numbers are as follows:

Service/

Power Switch Device

Mechanically held or electrically held contactors

Molded-case circuit breakers or switch

Standard contactor, programmed transition, and Bypass-Isolation

Parts Manual

TP-5667

TP-5666

TP-5668

Service Assistance

For sales and service in the U.S.A. and Canada check the yellow pages of the telephone directory under the headingGENERATORS—ELECTRICfor anauthorized service distributor/dealer or call 1-800-544-2444.

KOHLER CO., Kohler, Wisconsin 53044 U.S.A. Phone: 920-565-3381 Fax: 920-459-1646 (U.S.A. Sales)

920-459-1614 (International)

To ensure supply of correct parts or information, make note of the following identification numbers in the spaces provided:

PART NUMBER AND SERIAL NUMBER

Part and serial numbers are provided on the nameplate attached to the transfer switch.

Part No.

Serial No.

TP-5672 11/95 Introduction i

Page 11

Notes

TP-5672 11/95Introduction ii

Page 12

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 source’s voltage has reached an acceptable level.

Upon normal source failure, the automatic transfer switchcontrollersignalsthe generator set(s)tostartand

Components of Switch

A typical automatic transfer switch includes the actual 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 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 thefront doorso its controls and indicatorsare 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.

transfer 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) is allowed to shut down.

TP-5672 11/95

1. Power Conversion Unit

2. Interface Panel

3. Logic Controller

Figure 1-1. Transfer Switch Components

Specifications 1-1

567111

Page 13

Normal (Utility)

Power

Emergency (Generator) Power

Generator

Start Generator

Power Switching Device

To Load

Figure 1-2. Basic Transfer Switch Block Diagram

Ratings

Anameplate is attachedtotheautomatic transfer switch enclosure. See Figure 1-3. The nameplate label includes a factory part number coded to provide characteristic and rating information that affects installationandoperation. Copy the partnumberinto the blank spaces provided in the introduction and then use the charts 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.

Interface

Logic

Controller

Automatic Transfer Switch

AUTOMATICTRANSFER SWITCH

PARTNO. ZCS-160341-0800

SERIAL NO. VOLTS PHASE HERTZ

KOHLER CO. KOHLER WISCONSIN 53044

567112

KOHLER

AMPS WIRES POLES

295232

Figure 1-3. Transfer Switch Nameplate

1-2 Specifications TP-5672 11/95

Page 14

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 accompanying chart.

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 chart explains the Kohler transfer switch part numbering code system. The sample part number shown is for a standard molded-case switch with M340+ 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.

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 B: Bypass

Type of Logic

5: M340+ 6: M340+ 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

SAMPLE PART NUMBER

MNS-566341-0080

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.

Figure 1-4. Transfer Switch Model Description

TP-5672 11/95

Specifications 1-3

Page 15

Specifications

The specifications listed below are for the M340+ logic controller. See the respective power switching device manual for its specifications.

Standard Features

D Normal source voltage sensing adjustable from

75% to 130% of normal for pickup and from 70% to 135% for dropout; provides monitoring line-to-line for all phases of 3-phase switches.

D TDNE (Time Delay Normal-to-Emergency)

adjustable 0 to 5 minutes.

D TDES (Time Delay Engine Start) adjustable from

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 minutes.

D LCD digital voltmeter. D LCD digital running time meter.

D LCD digital transfer counter. D LCD digital frequency meter. D Status panel with keypad data entry. D Area protection with override. D TDEC (Time Delay Engine Cooldown) adjustable

from 0 to 30 minutes.

D Generator engine start contacts. D Indicators for switch position—normal and

emergency.

D Indicators for source available—normal and

emergency.

D Lamp test switch, momentary. D Underfrequency sensing—one phase emergency

source only.

1-4 Specifications TP-5672 11/95

Page 16

Shunt-Jumper-Controlled Accessories

Enable or disable shunt-jumper-controlled accessories by altering socket JP1 on the main logic board. See Figure 1-5. All shunt-jumper features are disabled from thefactoryunlessthe function was ordered atthetimeof purchase. But features can be enabled after factory delivery by adding jumpers to the JP1 socket.

Main Logic Board

JP1

MANUAL

TIME

PLANT

VOLT/

PHASE

OFF

Figure 1-5. Logic Board Accessory Programming

Shunts

D Manual Override. Enabling manual override

allows automatic transfer to an available source when the connected source fails. Transfer time delays will be bypassed. Disabling manual override causes the logic board to wait for manual operation. The logic board will not automatically seek the available source.

D Inphase Monitor. Abnormal inrush currents from

switching between two live power sources can damage motors and related equipment. The purpose of the inphase monitor is to minimize abnormal inrush currents to equipment when the ATS transfers from one source to a new power source. The inphase monitor samples a single phase of one source and compares it to a single phase of the other source. When the two voltages are within the desired phase angle and approaching a zero phase angle difference, the inphase monitor signals the transfer switch to

OVRIDE DELAY EXER FREQ SEQUENCER MONITORIN-PHASE DELAYS

567215

operate. The transfer may be from utility to generator,from generator to generator,or utility to utility.

NOTE

This option is available only on contactor type, nonprogrammed transition switches. If the contactor 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 Rotation and Anti-Single Phasing. This

function provides source monitoring for both the normal and emergency sources. The feature includesphaserotation(A B C only)andanti-single phase protection. This option must be used in conjunction with accessory DD-05-K in order to provide source monitoring on the emergency side. Enable this accessory by installing the PHASE SEQUENCER jumper on the controller’s main logic board.

D Normal and Emergency Source Sensing. This

function provides overvoltage sensing on all phasesof the normalsource,over/underfrequency sensing on one phase of the normal source, overvoltage sensing on one phase of the emergency source, and overfrequency sensing on one phase of the emergency source. Enable this accessory by installing theVOLT/FREQjumper on the controller’s main logic board.

D Plant Exerciser. This function enables a no-load

plantexerciser.Userhasachoice of 7-day,14-day, or calendar-based exercise modes. Enable this accessory by installing the PLANT EXER jumper on the controller’s main logic board.

D Extended Time Delay. This function extends the

time delay to 99 minutes for TDNE, TDES, TDEN, TDOE, TDON, and TDEC. Enable this accessory by installing the TIME DELAY jumper on the controller’s main logic board.

D Off Position Time Delay. This function enables

the time delay during transfer when neither source is connected to the load. Enable this accessory by installing the OFF DELAYS jumper on the controller’s main logic board.

Optional Accessories

See Appendix C for details of optional accessories. The nameplate includes a list of the accessories selected. See Figure 1-3.

TP-5672 11/95

Specifications 1-5

Page 17

Section 2. Operation

Control Switches and Indicators

Various optional control switches and indicator lamps may be present on the transfer switch door depending

AUTO

TRANSFER

MANUAL

TRANSFER TO

EMERGENCY

MANUAL

TRANSFER TO

OFF

MANUAL

TRANSFER TO

NORMAL

MANUAL

TRANSFER

TEST SWITCH

NORMAL TEST

BYPASS

EMERGENCY TO

NORMAL TIME DELAY

BYPASS NORMAL

TO EMERGENCY

TIME DELAY

AUTO INHIBIT

Contactor Position Time Delays

Normal On EndEmergency

Source Available

Normal Emergency

· ·

System Status

Not In Automatic

· ·

Programming Mode Not in Off

Flashing, Local Steady,Remote

· ·

Plant Exerciser Load Shed Inphase Monitor Area Protection

· · · ·

Off

System Alert

Accessory Active

on the options chosen. See Figure 2-1 for LED, Switch, and Key locations.

Engine Start

Normal To Emergency

Emergency To Normal

Engine Cooldown

Off Position

Figure 2-1. Front Panel

LED Indicators

Contactor Position. LEDs indicate transfer switch

position—NORMAL (green), EMERGENCY (red), or OFF (yellow).

Source Available. LEDs indicate source with acceptable voltage and frequency—Normal (green) and/or Emergency (red).

System Status

Not in Automatic (red). LED flashes to indicate that

Test switch is actuated, or Auto/Manual switch is in the Manual position.

System Alert (red). LED flashes to indicate possible problem with contactor or logic operation. System alert will also flash if any fault signals are received from the generator set.

Programming Mode Not in Off (yellow). LED flashes to indicate that programming switch is in the LOCAL position. A steady, nonflashing light indicates that the programming switch is in the REMOTE position.

Operation 2-1TP-5672 11/95

Page 18

Time Delays

Engine Start (If emergency source is a generator set).

ON LED indicates that engine-start time delay is timing. ENDLED indicates thattheengine has been signaledto start.

Normal to Emergency. ON LED indicates that the normal-to-emergency time delay is timing. END LED indicates that the time delay has completed timing.

Emergency to Normal. ON LED indicates that the emergency to normal time delay is timing. END LED indicates that the time delay has completed timing.

transfer from emergency to normal and normal to emergency when sources are near synchronization.

NOTE

When a programmed transition switch is ordered, the inphase monitor option is disabled by the microprocessor.

Area Protection. Area protection LED indicates that the controller is in the area protection mode. The generator will be signaled to START and the contactor will transfer to the emergency positionand remain there while in area protection.

Engine Cooldown. ON LED indicates that the generator set engine cooldown timer is timing. END LED illuminates until the engine has shut down.

Off Position. ON LED indicates that the time delay off positionistiming. ENDLEDindicatesthatthetimedelay has completed timing.

Accessory Active

Plant Exerciser. Plant excerciser LED indicates that

the system is in the exerciser mode. LoadShed. LoadshedLEDindicates that programmed

load shedding is active. Inphase Monitor (availableon ZCtype powerswitches

only). Inphase monitor LED indicates that the sources are being monitored for phase relationship to allow inphase transfer. The inphase monitor will permit

Control Switches

Test Switch (Standard). Move the test switch to the

TEST position to simulate a normal source outage. Not-in-Automatic system status light will flash.

Bypass N-E Time Delay Pushbutton Switch (Option). If the bypass normal-to-emergency time

delay pushbutton is pressed when normal-to-emergency time delay is on, time delay will end.

Bypass E-N Time Delay Pushbutton Switch (Option). If the bypass normal-to-emergency time

delay pushbutton is pressed, when emergency-to-normal time delay is on, time delay will end.

Manual Transfer to Emergency Switch (Option).

When the transfer switch control is in the manual mode of operation and manual to emergency is required, press the manual transfer-to-emergency pushbutton to

Programming Mode Switch

NOTE

Theprogramming modeswitch keysshould bekept ina safe place to prevent unwanted tampering with the transfer switch control. 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 personal computer.

Off. Transfer switch status settings and power source may be monitored from the local LCD display or connected computers.

Local. Allows both status monitoring and setting of transfer switch control from the microprocessor’s LCD display and keypad.

cause the transfer switch to transfer to the emergency position.

Manual Transfer to Off Switch (Option). When the transfer switch control is in the manual mode of operation and manual to off is required, press the manual transfer-to-emergency pushbutton to cause the transfer switch to transfer to the off position.

Manual Transfer to Normal Switch (Option). When the transfer switch control is in the manual mode of operation and manual to normal is required, press the manual transfer-to-emergency pushbutton to cause the transfer switch to transfer to the normal position.

Auto/Inhibit Switch (Option). If the auto/inhibit switch is in the AUTO position, the transfer switch will operate normally. If the switch is in the Inhibit position, the transfer switch will not transfer under any conditions.

2-2 Operation TP-5672 11/95

Page 19

Sequence of Operation

This section describes the correct operation of a microprocessor-controlled transfer switch.

Sequence of Operation Standard Switch

When the Normal Source Fails

1. The source-available normal LED turns off.

2. The time-delay-engine-start ON LED illuminates to indicate the engine-start-time-delay is timing.

3. The time-delay-engine-start END LED illuminates to indicate the engine has been signaled to start.

4. The source-available emergency LED illuminates.

5. The time-delay normal-to-emergency ON LED illuminates to indicate the normal-to-emergency time delay is timing.

6. The time-delay normal-to-emergency END LED illuminates 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. The inphase monitor LED illuminates (if equipped with inphase monitor option on ZC type power switches only). The controller monitors the two voltagesto makesure theyare ata desiredphase angle and approaching zero phase angle difference.

9. The contactortransfers tothe emergency position after the load-shed time-before-transfer timer has completed timing. The contactor-position normal LED turns off and the contactor-position emergency LED illuminates. The inphase monitor LED turns off.

10. After the load-shed time-after-transfer timer has completed timing, the selected loads for the emergencysource are nowreturnedto the switch. The load-shed LED turns off (if equipped with load-shed option).

Operation 2-3TP-5672 11/95

Page 20

When the Normal Source Returns

1. The source-available, normal LED illuminates.

completed timing. The contactor-position emergency LED turns off and the contactor-position normal LED illuminates.

2. The time-delay emergency-to-normal ON LED illuminates to indicate the emergency-to-normal time delay is timing.

3. The time-delay emergency-to-normal END LED illuminates to indicate the time delay has completed timing.

4. 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).

5. The inphase monitor LED illuminates (if equipped with load-shed option).

6. The contactor transfers to the normal position after the load-shed time-before-transfer timer has

7. After the load-shed time-after-transfer timer has completed timing, the selected loads for the normal source are returned to the switch. The load-shed LED turns off (if equipped with load-shed options).

8. The time-delay engine-cooldown ON LED illuminates to indicate the generator set engine cooldown timer is timing.

9. The time-delay engine-cooldown END LED stays illuminated until the generator has shut down.

10. The source-available, emergency LED turns off.

2-4 Operation TP-5672 11/95

Page 21

Microprocessor-Controlled Transfer Logic

Standard Switch

Normal Source Failure

Time Delay Engine Start

Time Delay Normal-to-Emergency

Load Shed (all)—if equipped

Inphase Monitor—if equipped

Contactor Transfer to Emergency Position

Load Return (programmed sequence)—if equipped

Normal Source Return

Time Delay Emergency-to-Normal

Load Shed (all)—if equipped

Inphase Monitor—if equipped

Contactor Transfer to Normal Position

Load Return (programmed sequence)—if equipped

Time Delay Engine Cooldown

Operation 2-5TP-5672 11/95

Page 22

Sequence of Operation Programmed Transition Switch

When the Normal Source Fails

NOTE

When a programmed transition switch is ordered, the inphase monitor option is disabled by the microprocessor.

1. The source-available, normal LED turns off.

2. The time-delay-engine-start ON LED illuminates to indicate the engine-start-time-delay is timing.

3. The time-delay-engine-start END LED illuminates to indicate the engine has been signaled to start.

4. The source-available emergency LED illuminates after the generator is at rated voltage and frequency.

5. The time-delay normal-to-emergency ON LED illuminates to indicate the normal-to-emergency time delay is timing.

6. The time-delay normal-to-emergency END LED illuminates 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 load-shed time-before-transfer timerhas completed timing, the contactor transfers to the Off position. The contactor-position normal LED turns off and the contactor-position Off LED illuminates.

9. The time-delay-off-position ON LED illuminates to indicate the Off position time delay is timing.

10. The time-delay-off-position END LED illuminates to indicate the time delay has completed timing.

11. The contactor transfers to the emergency position. The contactor-position Off LED turns off and the contactor-position emergency LED illuminates.

12. After the load-shed time-after-transfer timer completes timing, the selected loads for the emergencysource arereturned to the switch. The load-shed LED turns off (if equipped with load-shed option).

2-6 Operation TP-5672 11/95

Page 23

When the Normal Source Returns

1. The source-available, normal LED illuminates.

2. The time-delay emergency-to-normal ON LED illuminates to indicate the emergency-to-normal time delay is timing.

3. The time-delay emergency-to-normal END LED illuminates to indicate the time delay has completed timing.

4. 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).

5. After the load-shed time-before-transfer timerhas completed timing, the contactor transfers to the Off position. The contactor-position emergency LED turns off and the contactor-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 the time delay has completed timing.

8. The contactor transfers to the normal position. The contactor-position OFF LED turns off and the contactor-position normal LED illuminates.

9. After the load-shed time-after-transfer timer has completed timing, the selected loads for the normal source are returned to the switch. The load-shed LED turns off (if equipped with load-shed option).

10. The time-delay-engine-cooldown ON LED illuminates to indicate the generator set engine cooldown timer is timing.

11. The time-delay-engine-cooldown END LED stays illuminated until the generator has shut down.

12. The source-available emergency LED turns off.

Operation 2-7TP-5672 11/95

Page 24

Microprocessor-Controlled Transfer Logic

Programmed Transition Switch

Normal Source Failure

Time Delay Engine Start

Time Delay Normal-to-Emergency

Load Shed (all)—if equipped

Contactor Transfer to Off Position

Time Delay Off-to-Emergency

Contactor Transfer to Emergency Position

Load Return (programmed sequence)—if equipped

Normal Source Return

Time Delay Emergency-to-Normal

Load Shed (all)—if equipped

Contactor Transfer to Off Position

Time Delay Off-to-Normal

Contactor Transfer to Normal Position

Load Return (programmed sequence)—if equipped

Time-Delay-Engine-Cooldown

2-8 Operation TP-5672 11/95

Page 25

To Disconnect The P1 Plug

1. If the transfer switch isin the normal position, open the emergency-source circuit breaker.

it is available, after a time delay. For immediate retransfer, open and then reclose the emergency-source circuit breaker. Place the generator set start switch in the AUTO position.

2. If the transfer switch is in the emergency position, open the normal-source circuit breaker.

3. Separate the in-line disconnect plug by grasping and squeezing the plug. Do NOT pull on the wires.

560423

Electrical Operation Test

Place the transfer switch in the NORMAL position. Use thefollowing procedureto check theelectrical operation of the automatic transfer switch:

1. Press andhold the testpushbutton for 15seconds. See Figure 2-1.

2. The generator set should start and run after the time delay engine start (TDES) completed timing.

3. The transfer switch will transfer to the emergency position. The transfer occurs after the normal-to-emergency time delay (TDNE) has completed timing.

4. Release the test pushbutton. The transfer switch retransfers to normal after the emergency-to-normal time delay.

5. Time delay engine cooldown (TDEC) allows the engineto continue running foranunloaded running time. The transfer switch TDEC will complete timing before any TDEC function in the generator set controller begins timing.

6. Close load circuit breaker(s) when loads may be safely energized.

Figure 2-2. In-Line Disconnect Plug

To Reconnect The P1 Plug

1 Engage the in-line disconnect plugby grasping the

connectors and pressing them together. See Figure 2-2.

2 If thetransfer switch isin the normalposition, place

thegenerator set startswitchin the AUTOposition. 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 willautomatically retransferto the normalsource, if

NOTE

Connecting the transfer switch in-line disconnect plugs(P1)togetherwhen the generator controller’s master switch is in the AUTO position causes the generator set to IMMEDIATELY start and run until the generator set controller’s cooldown timer completes timing.

This completes functional tests of the transfer switch. Leave the AUTO/MANUAL switch in the AUTO TRANSFER position.

Operation 2-9TP-5672 11/95

Page 26

Section 3. Troubleshooting Guide

For location of pushbuttons, switches, LEDs, and keys referred to in this section, see Figure 2-1. Refer to Figure 3-1 as a guide to troubleshooting problems with

Problem Refer to Section 4—Controller Troubleshooting

None of the LEDs are on and the LCD is blank Power to the system Pressing a key on the keypad does not supply the appropriate

response Every LED does not turn on and every character block on the LCD

does not blacken The normal source should be available but the Source-Available,

Normal LED is not on The emergency source should be available but the

Source-Available, Emergency LED is not on The Automatic/Test pushbutton is pressed, the Automatic/Inhibit

switch (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

The System-Status, System-Alert LED is flashing; check the LCD for a message

The LCD displays Auxiliary-Switch Fault or Double Auxiliary--Switch fault message

The LCD displays Transfer Hang error message Transfer hang error message The LCD displays Power-Down error message Power-down error message The LCD displays RAM or Memory error message RAM or memory error message The Programming-Mode-Not-In-Off LED is flashing Programming-mode-not-in-off The engine operates when it should not be operating Engine operates when it should not The engine should start Engine will not start One of the control options is not working (the control options

include the inphase monitor, source-phase-sequence, normal/emergency voltage/frequency sensing, plant exerciser, extended time delay,and manual override)

the microprocessor logic controller. Refer to Figure 3-2 as guide to troubleshooting problems with the microprocessor accessories.

Keypad and status panel

Source-available, normal error

Source-available, emergency error

System-status, not-in-automatic error

System-status, system-Alert error

Auxiliary-switch fault or double auxiliary-switch fault error message

Shunt-jumpered controlled options

TP-5672 11/95

Figure 3-1. Microprocessor logic controller troubleshooting chart

TroubleshootingGuide

3-1

Page 27

Problem Refer to Section 5—Accessory Troubleshooting

Controller will not sense three-phase emergency voltage Phase sequencer,accessory DD-05 The generator set does not start when the test switch is in the

Test switch, accessory DD-06 and DD-07

engine start position The generator set does not start when the test switch is in the test

Test switch, accessory DD-06 and DD-07

position The normal-to-emergency time delay pushbutton does not work Time delay override, accessory DD-08 The emergency-to-normal time delay pushbutton does not work Time delay override, accessory DD-08 The auxiliary dry contacts relay boards do not 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 emergency source does not work Manual operation switches, accessory DD-29 The manual transfer to normal source does not work Manual operation switches, accessory DD-29 The manual transfer to off does not work Manual operation switches, accessory DD-29 The auto/manual switch does not work in the manual position Manual operation switches, accessory DD-29 The auto/manual switch does not work in the auto position Manual operation switches, accessory DD-29 The load shed contacts do not work Load-shed contacts, accessory DD-35 Problems with remote communication exist Remote communication—RS/232 or RS/485, accessory

DD-51

Figure 3-2. Accessory troubleshooting chart

3-2 TroubleshootingGuide

TP-5672 11/95

Page 28

Section 4. Controller Troubleshooting

The following section will assist in solving common problems with the M340+ controller. Note any optional accessoriesthatmayhavebeenfurnishedonthisswitch

Is the LCD screen blank and no LEDs illuminated?

Is there 19 vac between terminals TB-AC1-NAS and TB-AC1-NCS of the power supply board?

Yes

Replace the power supply board.

Is a battery connected to terminals TB-DC1-29 and TB-DC1-34 of the power supply board?

Yes

Is there rated battery voltage between terminals TB-DC1-29 and TB-DC1-34 of the power supply board?

Check battery and wiring from battery to assembly for open of shorted leads.

Is an optional remote communications board installed?

Yes No

Is there 10 vdc between pin P2-13 of plug 2 and terminals TB-DC1-34 of the power supply board?

Is there normal source voltage between terminals TB-AC1-NA and TB-AC1-NC of the power supply board?

Is there 10 vdc between terminals TB-DC1-30 and TB-DC1-34 of the power supply board?

Replace the load-shed board.

and review their operation in section 5—Accessory Troubleshooting.

Yes

Is there from 12 to 30 vdc

Yes

Yes Yes

Yes

between terminals TB-DC1-23 and TD-DC1-34 of the power supply board?

Replace the logic board.

Yes

Troubleshooting complete.

Check the normal source and contactor-to-power supply board wiring harness for open or shorted leads.

Yes

Is there an optional load-shed board installed?

Disconnect the load-shed board.

Yes

Recheck the voltage at terminals TB-DC1-23 and TB-DC1-30 of the power supply board, and pin P2-13 of plug 2. Are the voltages correct?

Yes

Disconnect the communications board.

Recheck the voltage at terminals TB-DC1-23 and TB-DC1-30 of the power supply board, and pin P2-13 of plug 2. Are the voltages correct?

Replace the logic board.

TP-5672 11/95

Recheck the voltage at terminals TB-DC1-23 and TB-DC1-30 of the power supply board, and pin P2-13 of plug 2. Are the voltages correct?

Yes

Replace the remote communication board.

Yes

Replace the power supply board.

Figure 4-1. Troubleshooting—Power to the system

Yes

Recheck the voltage at terminals TB-DC1-23 and TB-DC1-30 of the power supply board, and pin P2-13 of plug 2. Are the voltages correct?

Disconnect the status panel board.

Disconnect the logic board.

Controller Troubleshooting

Yes

Replace the logic board.

4-1

Page 29

Power to the System

Ifthereisaproblemwiththelogicboard,thefirststepisto check the status panel. If no LEDs on the status panel are illuminated and the liquid crystal display (LCD) is blank, check the power to the system by performingthe following steps. See Figure 4-1 for the Power to the System troubleshooting flowchart. See Appendix B Figure B-4 for location of power supply board components referred to in this section. See Appendix B FigureB-6forlocationanddescriptionofP2ribboncable pins. See Appendix B Figure B-9 for location of main logic board components referred to in this section.

1. Using a voltmeter, connect one test lead to TB-AC1-NA. Connect the other test lead to TB-AC1-NC. If the voltmeter does not read the expected normal source voltage,check the normal sourceandthecontactor-to-assemblyharness,P1.

2. If thenormalsourcevoltageispresent,connectone test leadto TB-AC1-NAS and the other test leadto TB-AC1-NCS. If the voltmeter does not read approximately 19 volts AC, the secondary normal source voltage, check that the transformer is wired correctly. If the transformer is wired correctly and the voltmeter still does not read 19 volts AC, disconnect transformer secondary wires andretest transformer secondary voltage to determine if the transformer or the logic board assembly is at fault.

3. If boththenormalsourcevoltageandthesecondary normal source voltage are present, connect one test lead to TB-AC1-EA and the other test lead to TB-AC1-EC. If the voltmeter does not read the expected emergency source voltage, check the emergency source and the contactor-to-assembly harness, P1.

4. If theemergencysourcevoltageispresent,connect one test lead to TB-AC1-EAS and the other test leadtoTB-AC1-ECS.If thevoltmeterdoesnot read approximately19voltsAC,theexpectedsecondary emergency source voltage, check that the transformer is wired correctly. If the transformer is wiredcorrectly andthe voltmeter still doesnot read 19 volts AC, disconnect transformer secondary wires and retest transformer secondary voltage to determine if the transformer or the logic board assembly is at fault.

5. If the emergency source, normal source, and transformers are all working properly, and the batteryback-upoptionisused,connectthe positive testleadtoTB-DC1-29andthe negativetestleadto TB-DC1-34.If thevoltmeterdoesnot read between 12and30voltsDC,expectedbatteryvoltage,check the battery-to-assembly wires and the battery.

6. Connect the positive test lead to TB-DC1-23, and the negative test lead to TB-DC1-34. If the voltmeter does not read betweenapproximately12 and30voltsDC,checkifanaccessoryisconnected toTB-DC1-23.Ifthereisanaccessoryconnectedto TB-DC1-23,disconnectit. If the voltmeter stilldoes notread between12and30 voltsDC, performstep

NOTE

When taking a voltage or resistance measurement at a ribbon cable pin, do not disconnect the ribbon cable from the board. Use a needle point probe to take the readings from the holes on the top side of the ribbon cable connector.

7. Connect the positive test lead to P2-13, and the negative test lead to TB-DC1-34. If the voltmeter does not read approximately 10 volts DC, perform step 9. See Appendix B Figure 6 for location of P2 ribbon cable pins.

8. Connect the positive test lead to TB-DC1-30 and the negative test lead to TB-DC1-34. If the voltmeterdoesnotreadapproximately10voltsDC, perform step 9.

9. If eachofthemeasurementstakeninsteps6,7,and 8 was correct, this step may be skipped.

a. Disconnect the main logic board ribbon cable

from P2, and recheck the voltages in steps 6, 7, and8. If thevoltagereadings in steps 6,7, and8 are now correct, the main logic board is defective. Replace the logic board assembly.

b. If the logic board is equipped with a load shed

board, disconnect the load shed ribbon cable from P10 on the main logic board, and recheck the voltages in steps 6, 7, and 8. If the voltage readings in steps 6, 7, and 8 are now correct, replace the Load Shed board.

c. If the logic board is equipped with a remote

communications board, disconnect the remote communications ribbon cable from P12 on the main logic board, and recheck the voltages in steps6, 7, and 8. If thevoltagereadings in steps 6, 7, and 8 are now correct, replace the remote communications board.

d. Disconnect the status panel ribbon cable from

P4,andrecheckthevoltagesinsteps6,7, and8. If the voltage readings in steps 6, 7, and 8 are now correct, the status panel is defective. Replace the logic board assembly.

e. If the voltages measured in steps 6, 7, and 8

were never correct, replace the power supply board.

4-2 Controller Troubleshooting

TP-5672 11/95

Page 30

Keypad And Status Panel

For location of pushbuttons, switches, LEDs, and keys referred to in this section, see Figure 2-1.

1. Testthe keypadby pressinga keyandcheckingthe response.If theresponseiscorrect,repeatthisstep until satisfied that there is not a problem with the keypad. If the response is ever incorrect, the keypad is defective. Replace the logic board assembly.

2. Press the LAMP TEST key on the keypad.

3. If afterpressingtheLAMPTEST keysomeLEDson thedisplaypanelareon, butat leastoneLED isnot on, the status panel is defective. Replace the logic board assembly.

4. If after pressing the LAMP TEST key some of the character blocks on the LCD appear black, but at least one character block is not black, the status panel is defective. Replace the logic board assembly.

5. If after pressing the LAMP TEST key no LEDs are on, and the character blocks in the LCD are black, verify that there is power to the system by performing the steps outlinedin Section 4—Power To The System. Check the P2 and P4 ribboncable connections by performingthefollowingsteps. See Appendix B FigureB-9 for locationof ribboncables andotherpowersupplyboardcomponentsreferred to in this section.

a. Disconnect all power sources. b. Wait 30 seconds.

c. Being careful not to bend or break any of the

pins, remove both P2 and P4 ribbon cable connectors.

d. Inspect the pins on the P2 and P4 ribbon cable

connectors.

e. If pinsarebent,carefullybendthemback. Ifpins

are broken, replace the ribbon cable connector.

f. Carefully reconnect P2 and P4 ribbon cable

connector.

g. If the problem still exists,replacethe logic board

assembly.

560442

Figure 4-2. The M340+ LCD display during a lamp

test

TP-5672 11/95

Controller Troubleshooting

4-3

Page 31

If the normal source is available, but the source available normal LED is not illuminated. Check the trip point settings in index 6. See TP-5664 for programming information. Are the trip points programmed correctly?

Yes

Does the microprocessor display,in index 1, rated normal source voltages and frequency?

Correct the trip point settings in index 6. See TP-5664 for programming information.

Is the transfer switch wire with a phase

Yes

rotation of ABC?

Yes

Replace the logic board.

Calibrate the normal source voltage.

Yes

Does the voltage between terminals TB-AC1-NA and TB-AC1-NB and terminals TB-AC1-NB and TB-AC1-NC of the power supply board equal the rated voltage for the transfer switch?

Check the normal source voltage and the wiring harness from the contactor to power supply board for open or shorted leads.

Yes

Is the inphase sequence option installed?

Yes

Does the voltage between terminals TB-AC1-NC and TB-AC1-NA of the power supply board equal the rated voltage for the transfer switch?

Is 3-phase sensing used?

Check the normal source voltage and the wiring harness from the contactor to power supply board for open or shorted leads.

Is the voltage between pin P2-15 of

Yes

plug 2 and terminal TB-DC1-34 of the power supply board 1/25 of line voltage? See Appendix B Figure B-5.

Yes

Turn the generator set off. Jumper terminal TB-DC1-24 to TB-DC1-34 of the power supply board . Is the voltage between pin P2-15 of plug 2 and terminal TB-DC1-34 of the power supply board equal to 0 vac?

Replace the power supply board.

Yes

Is 3-phase sensing used?

Yes

Calibrate the controller’s normal source voltage.

Is the voltage between pin P2-18 of plug 2 and terminal TB-DC1-34 of the power supply board 1/25 of line voltage? See Appendix B Figure B-5.

Yes

Replace the power supply board.

Rewire the source for ABC phase rotation.

Figure 4-3. Troubleshooting—Source-available, normal error

Yes

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 the voltage between pin P2-17 of plug 2 and terminals TB-DC1-34 of the power supply board 1/25 of line voltage? See Appendix B Figure B-5.

Replace the power supply board.

Yes

Calibrate the controller’s normal source voltage.

4-4 Controller Troubleshooting

TP-5672 11/95

Page 32

For location of pushbuttons, switches, LEDs, and keys referred to in this section, see Figure 2-1.

This section covers the condition in which the normal source is available but the Source-Available, Normal LED is not on.

The first item to check is the trip-point settings. The trip-pointsettingscan be foundinIndex 6 inthe program menu. See Figure 4-4 for recommended trip-point settings.Thetrip-pointsdonotneedtoexactlymatchthe recommended trip-point settings for proper operation. However, if the trip-point settings in Index 6 are too high ortoo low,problemscouldoccur. Ifthe trip-pointsettings are too high or too low, correct them. Then enter normal source voltage and normal source frequency, and store the set points.

Next check Index 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 steps.

1. Check if the phase sequence option is installed. If thereisa jumperacrossJP1-5,thephasesequence option is installed.

2. If the phase sequence option is installed, press the MENU arrow down key to check the phase sequence in Index 1. Utility power must be phased ABC.

3. If the normal source is single-phase,verify inMenu Index 6 that single-phase sensing was selected. A single-phase source must be sensed as a single-phase source.

Trip Point Setting Limits

Overvoltage

Dropout

Overvoltage

Pickup

Undervoltage

Pickup

Undervoltage

Dropout

Overfrequency

Dropout

Overfrequency

Pickup

Underfrequency

Pickup

Underfrequency

Dropout

105% -- 135% 115%

100% -- 130% 110%

75% -- 100% 90%

70% -- 95% 85%

105% -- 135% 115%

100% -- 130% 110%

85% -- 100% 90%

80% -- 95% 85%

Normal Source

Factory Setting

Figure 4-4. Normal source voltage trip point

setting limits and factory settings

4. If the source is available, the phase sequencing is correct, the sensing is correct, and the Source-Available, NormalLED is still not on, check the P2 ribbon cable connector.

a. Remove all power sources. b. Wait for 30 seconds.

c. Makingsurenot to bendor breakanyofthepins,

remove the P2 ribbon cable connector.

d. Inspect the pins on the P2 ribbon cable

connector.

e. If any of the pins are bent, carefully bend them

back. If any of the pins are broken, the ribbon cableconnectorisdefective.Replacetheribbon cable connector.

f. Carefully, reconnect P2 ribboncable connector.

5. If the Source-Available, Normal LED is still not illuminated, the status panel is defective. Replace the logic board assembly. If a value in Index 1 is incorrect, see steps below.

TP-5672 11/95

Controller Troubleshooting

4-5

Page 33

Incorrect Normal Source Voltage And Frequency Values

See Appendix B, Figure B-9 for location of TB-AC1 and other power supply boardcomponents referredto inthis section.

1. If the system is single-phase, use a voltmeter to measure the normal source voltage by connecting onetest leadto TB-AC1-NA and theother test lead to TB-AC1-NC. Note the voltmeter reading.

2. If the system is three-phase, use a voltmeter to measure the normal source voltage by connecting onetest leadto TB-AC1-NA and theother test lead to TB-AC1-NB. Note the voltmeter reading. Connectone test leadto TB-AC1-NBand the other test lead to TB-AC1-NC. Note the voltmeter reading.

3. If the voltmeter did not display the normal source voltageinstep 1 or step 2, checkthe normalsource and the contactor-to-assembly harness, P1.

4. If the voltage reading(s) in step 1 or step 2 did not match the value(s) displayed in Index 1, check the powersupplyboardbyperformingthefollowingfour steps.

NOTE

a. Check the TestLED onthe powersupplyboard.

IftheTestLEDisnoton,installa jumperbetween TB-DC1-24 and TB-DC1-34. If the Test LED comesonwhenthejumperisinstalled,checkthe Automatic/Test pushbutton and the connected accessories.

b. Using a voltmeter, connect one test lead to

P2-15andtheothertestleadto TB-DC1-34.See Appendix B, FigureB-9 for locationof P2ribbon cable connector. The voltmeter should read approximately 1/25 of the line voltage. See Appendix B, Figure B-5 for values. Turn the generator off. See Appendix B, Figure B-9 for location of P2 ribbon cable pins.

c. Connect one test lead to P2-16 and the other to

TB-DC1-34. The voltmeter should read approximately 1/25 of the line voltage. See Appendix B, Figure B-5.

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 three-phase, connect one test

lead to P2-18 and the other to TB-DC1-34. The voltmeter should read approximately 1/25 of the line voltage. See Appendix B, Figure B-5.

f. Removepowerfrom thelogicboard.Disconnect

the P2 ribbon cable connector. Recheck the P2 pointsonthepowersupplyboardinsteps4a,4b, 4c, and 4d. If the voltage readings are now correct, either an accessory or the logic board main logic board is bad.

5. If any of the voltage readings in step four were incorrect, replace the power supply board. If all of the voltage readings in step four were correct, calibrate the normal source voltage.

Calibrate Logic Board Normal

Three-Phase Source Voltage

1. Press the Automatic/Test pushbutton to start the generatorand to transfer the loadto the generator.

2. Disconnect the incoming normal power to the transfer switch by removing the line fuses, the in-line disconnect plug, or the incoming circuit breaker.

3. Verify that the normalsource voltage is zero. Using a voltmeter connect one test lead to TB-AC1-NA and one test lead to TB-AC1-NC. The voltmeter shouldread 0 volts AC. Connect one voltmetertest lead to TB-AC1-NA and the other test lead to TB-AC1-NB.The voltmetershouldread0 voltsAC. Connectonevoltmeter test leadto TB-AC1-NBand the other test lead to TB-AC1-NC. The voltmeter should read 0 volts AC.

4. If the normal source is three-phase, it can be sensed as either single-phase or three-phase depending on what the application requires. In Menu Index 6 choose the appropriate sensing method: single-phase sensing or three-phase sensing.

NOTE

When calibrating either the normal source or emergency source, never auto-zero the source unless it is zero volts. If source voltage is present and the YES key is pressed and entered at the AUTO-ZERO message, the logicboard will always read the system voltage as zero volts.

5. Using the menu in Index 12, arrow down to N-AUTO-ZERO? and press the YES key and the ENTER key.

6. Observe the ENTRY ACCEPTED message on the LCD.

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7. When the message on the LCD again reads, N-AUTO-ZERO?,restorethenormalpowersource.

10. Press the RESET MENU key and then the ENTER key to store the set points.

8. If single-phase sensing is used, perform this step. PresstheMENUArrowDownkey so the LCDreads N-VOLT VAC. If the value displayed on the LCD after N-VOLT VAC is not between60% and 80% of the system voltage, replace the logic board assembly. If the value is between 60% and 80% of the system voltage, measure the normal system voltagebyconnectingone test leadofa voltmeterto TB-AC1-NAand theother test lead toTB-AC1-NC. Enter the measured value at the LCD message N-VOLT VAC. Press the ENTER key and observe the ENTRY ACCEPTED message on the LCD.

9. If three-phase sensing is used, perform this step. PresstheMENUArrowDownkey so the LCDreads N-PHA-C VAC. If the values displayedon theLCD after N-PH A-C VAC, N-PH A-B VAC,or N-PH B-C VAC are not between 60% and 80% of the system voltage, replace the logic board assembly. If the values are between 60% and 80% of the system voltage, measure and enter the normal system voltage by performing the next three steps.

a. Connect one test lead of a voltmeter to

TB-AC1-NA. Connect the other test lead to TB-AC1-NB. Enter the measured value at the LCD message N-PH A-B VAC. Press the ENTER key. Observe the ENTRY ACCEPTED message on the LCD. Press the MENU arrow down key.

b. Connect one test lead to TB-AC1-NB, and

connecttheothertestleadtoTB-AC1-NC.Enter the measuredvalue at the LCD message N-PH B-C VAC. Press the ENTER key. Observe the ENTRY ACCEPTED message on the LCD. Press the MENU arrow down key.

NOTE

If the system will not calibrate, replace the logic board assembly.

Calibrate Logic Board Normal

Single-Phase Source

NOTE

1. Using the menu in Index 12, arrow down to N-AUTO-ZERO?. Press the YES key and the ENTER key.

2. Observe the ENTRY ACCEPTED message on the LCD.

3. When the message on the LCD again reads, N-AUTO-ZERO?,restorethenormalpowersource.

4. Press the MENUArrowDownkeysotheLCDreads N-VOLT VAC. If the value displayed on the LCD after N-VOLT VAC is not between60% and 80% of the system voltage, replace the logic board assembly. If the value is between 60% and 80% of the system voltage, measure the normal system voltagebyconnectingone test leadofa voltmeterto TB-AC1-NAand theother test lead toTB-AC1-NC. Enter the measured value at the LCD message N-VOLT VAC. Press the ENTER key and observe the ENTRY ACCEPTED message on the LCD.

c. Connect one test lead to TB-AC1-NA, and

connecttheothertestleadtoTB-AC1-NC.Enter the measuredvalue at the LCD message N-PH A-C VAC. Press the ENTER key. Observe the ENTRY ACCEPTED message on the LCD. Press the MENU arrow down key.

TP-5672 11/95

5. Press the RESET MENU key and then the ENTER key to store the set points.

NOTE

If the system will not calibrate, replace the logic board assembly.

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Is the phase sequence option installed?

Is the phase sequence in index 2 A-B-C?

Rewire the source for a phase sequence of A-B-C in Index 2.

If the emergency source is available, but the source available emergency LED is not illuminated, check the trip point settings in index 7. Are the settings correct?

Yes

Does the microprocessor display, in index 2, rated emergency source voltages and frequency?

Is single-phase sensing used?

Yes

Are the pickup and

Yes

dropout settings correct in index 7?

Yes

No Replace the logic board.

Correct the trip point settings in index 7.

Correct the setpoints in Index 7.

NoYes

Measure the voltage between terminals TB-AC1-EB and

TB-AC1-EC of the power supply board; note results.

Yes

Does the voltage between terminals TB-AC1-EA and TB-AC1-EC of the power supply board equal the rated emergency voltage for the transfer switch?

Yes

Check the emergency source voltage and the wiring harness from the contactor to power supply board for open or shorted leads.

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.

Yes

Replace the power supply board.

Calibrate the emergency source voltage.

Figure 4-5. Troubleshooting—Source-available, emergency error

Is the voltage between pin

Yes No

P2-19 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 the voltage between pin P2-21 of Is 3-phase sensing used.

Yes

plug 2 and terminals TB-DC1-34 of

the power supply board 1/25 of rated

line voltage? See Appendix B Figure

B-5.

Replace the power supply board.

Calibrate the emergency source voltage.

Replace the power supply board.

Yes

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For location of pushbuttons, switches, LEDs, and keys referred to in this section, see Figure 2-1.

Thissectioncoverstheconditioninwhichtheemergency sourceisavailablebuttheSource-Available,Emergency LED is not on.

The first item to check is the trip-point settings. The trip-pointsettingscan be foundinIndex 7 inthe program menu. The recommended trip-point settings are in Figure 4-6. If the trip pointsin Index7 aretoo highor too low, changethem. Enter emergencysource voltageand emergency source frequency. Store the set points.

Emergency

Trip Point Setting Limits

Overvoltage

Dropout

Overvoltage

Pickup

Undervoltage

Pickup

Undervoltage

Dropout

Overfrequency

Dropout

Overfrequency

Pickup

Underfrequency

Pickup

Underfrequency

Dropout

105% -- 135% 115%

100% -- 130% 110%

75% -- 100% 90%

70% -- 95% 85%

105% -- 135% 115%

100% -- 130% 110%

85% -- 100% 90%

80% -- 95% 85%

Source Factory

Setting

Next check Index 2 of the program menu for correct emergencysourcevoltageand frequencyreading. If the valuesinIndex2arecorrect, performthefollowingsteps.

1. Check if the phase sequence option DD-05-K is installed. If accessory DD-05-K is installed and thereisa jumperacrossJP1-5,thephasesequence option is installed.

2. If the phase sequence option is installed, press the MENU arrow down key to check the phase sequencein Index 1. Emergency power must be phased ABC.

3. Check Menu Index 7 to verify proper sensing. A single phase source should use single phase sensing. If the source is three-phase and three phase sensing is desired, the three-phasesensing 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 phase sensingis correct,but the Source-Available,Emergency LED is still not on, the status panel is bad. Replace the logic board assembly.

If a valueinIndex2 is incorrect, performthesteps below.

Figure 4-6. Emergency source voltage trip point

Setting Limits And Factory Settings

Incorrect Emergency Source Voltage

and Frequency Values

1. Use a voltmeter to measurethe emergencysource voltage by connecting one test lead to TB-AC1-EA and the other test lead to TB-AC1-EC. Note the voltmeter reading. See Appendix B Figure B-9 for location of TB-AC1 and other power supply board components referred to in this section.

2. If the system is three-phase and three phase sensing or phase rotation is desired, the option DD-05-K must be installed. If it is installed, use a voltmeter to measure the emergency source voltage by connecting one test lead to TB-AC1-EA and the other test lead to TB-AC1-EB. Note the voltmeter reading. Connect one test lead to TB-AC1-EB and the othertest lead to TB-AC1-EC. Note the voltmeter reading.

the emergency source and the contactor to assembly harness, P1.

4. If the voltage reading(s) in step 1 or step 2 did not match the value(s) displayed in Index 2, check the power supply board by performing the following steps.

NOTE

See Appendix B Figure B-6 for location and description of P2 ribbon cable pins.

3. If the voltmeter did not display the expected emergencysourcevoltagein step1 orstep 2, check

TP-5672 11/95

a. Using a voltmeter, connect one test lead to

P2-19 and the other to TB-DC1-34. The

Controller Troubleshooting

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Page 37

voltmeter should read approximately 1/25 of the line voltage. See Appendix B, Figure B-5.

b. If the system is three-phase and the

three-phase-sensingoptionisinstalled,connect one test lead to P2-20 and the other to TB-DC1-34. The voltmeter should read approximately 1/25 of the line voltage. See Appendix B, Figure B-5.

c. If the system is three-phase and the

three-phase-sensingoptionisinstalled,connect one test lead to P2-21 and the other to TB-DC1-34. The voltmeter should read approximately 1/25 of the line voltage. See Appendix B, Figure B-5.

d. RemovePowerfromthelogicboard.Disconnect

the P2 ribbon cable connector. Recheck the P2 pointsonthepowersupplyboardinsteps4a,4b, and4c.If thevoltagereadingstakeninsteps4a, 4b, and 4c are now correct, either an accessory or the main logic board is bad.

5. If any of the voltage readings in step 4 were incorrect, replace the power supply board. If all of the voltage readings in step 4 were correct, calibratethelogicboardemergencysourcevoltage by performing the steps below.

Calibrate The Logic Board

Emergency

Source Voltage

1. Three-phases sources can be sensed as either three-phase or single-phase. However, to have three-phase sensing the three-phase-sensing option DD-05-K must be installed. If the three-phase sensing option is installed and three-phasesensing is desired chooseemergency three-phase sensing in Menu Index 7.

2. If the emergency source is single-phase, or the optionDD-05isnotinstalled,theemergencysource canonlybe sensed as single-phase.In Menu Index 7 choose single-phase sensing.

NOTE

When calibrating either the normal source or emergency source, never auto-zero the source unless it is zero volts. If source voltage is present, and the YES key is pressed and entered at the AUTO-ZERO message, the logicboard will always read the system voltage as zero volts.

3. Read this step completely before 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.

5. Press the ENTER key.

6. Observe the ENTRY ACCEPTED message on the LCD.

7. When the message on the LCD again reads, E-AUTO-ZERO?, reconnect the emergencypower source.

8. Press the MENU Arrow Down key.

Single-Phase Sensing

9. If single-phasesensingisused,performthis step. If the value displayed on the LCD after E-VOLT VAC isnotbetween60%and80% of thesystem voltage, replace the logic board assembly. If the value is between 60% and 80% of the system voltage, measure the emergency system voltage. Measure the emergency system voltage by connecting one test lead of a voltmeter toTB-AC1-EA. Connectthe other test leadto TB-AC1-EC. Enter the measured valueat the LCDmessageE-VOLTVAC. Press the ENTER key.

Three-Phase Sensing

10. If the emergency source is three phase and three-phase sensing is desired, the three-phase-sensing option DD-05-K must be installed. If the option is installed and three-phase sensing is used, perform this step. If the value displayed on the LCD after E-PH A-C VAC, E-PH A-B VAC, and E-PH B-C VAC is not between 60% and 80% of the system voltage, replace the logic board assembly. If the value is between 60% and 80% of the system voltage, measure the emergency system voltage by performing the following three steps.

a. Connect one test lead of a voltmeter to

TB-AC1-EA. Connect the other test lead to TB-AC1-EB. Enter the measured value at the LCD message E-PH A-B VAC. Press the ENTER key. Press the MENU arrow down key.

b. Connect one test lead to TB-AC1-EB, and

connecttheothertestleadtoTB-AC1-EC.Enter the measured value at the LCD message E-PH B-C VAC. Press the ENTER key. Press the MENU arrow down key.

c. Connect one test lead to TB-AC1-EA, and

connecttheothertestleadtoTB-AC1-EC.Enter the measured value at the LCD message E-PH A-C VAC. Press the ENTER key.

11. Press the RESET MENU key and then the ENTER key to store the setpoints.

NOTE

If the system will not calibrate, replace the logic board assembly.

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System-Status, Not-In-Automatic

Error

For location of pushbuttons, switches, LEDs, and keys referred to in this section, see Figure 2-1.

NOTE

Pressing the Automatic/Test pushbutton will cause the generator set to start and run.

The System-Status, Not-In-Automatic LED should flash if the Automatic/Test pushbutton is pressed, if the Automatic/Inhibitkeyswitch is inthe Inhibitposition,orif theAutomatic-Transfer/Manual-Transferkey switchisin theManualposition.If oneoftheseconditionsistrue,but the System-Status, Not-In-Automatic LED is not flashing, perform the following steps.

a. Press the LAMP TEST key. If the

System-Status, Not-In-AutomaticLED doesnot turn on, the status panel is defective. Replace the logic board assembly.

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

notflashing when P2-6 is grounded, remove the connectionfrom P2-6to TB-DC1-34, and check the P2 ribbon cable connection by performing the following steps.

d. Remove all power sources.

e. Wait for 30 seconds.

f. Makingsure not tobendorbreakanyofthepins,

remove the P2 ribbon cable connector.

g. Inspect the pins on the P2 ribbon cable

connector. Specifically check P2-6.

h. If any of the pins are bent, carefully bend them

back. If any of the pins are broken, the ribbon cableconnectorisdefective.Replacetheribbon cable connector.

i. Carefully reconnect P2 ribbon cable connector.

b. Connect TB-DC1-9 to TB-DC1-34. If the

System-Status, Not-In-Automatic LED is not flashing, connect P2-6 to TB-DC1-34. If the System-Status, Not-In-Automatic LED is now flashing, replace the power supply board. If the System-Status, Not-In-Automatic LED is not flashingwhenP2-6is grounded,perform step 4. SeeAppendixB,FigureB-9forlocationoftheP2 ribbon cable and other power supply board components referred to in this section. See Appendix B, Figure B-6 for location and

P2-6 P2-6

Main Logic Board

Figure 4-7. Wiring Diagram—System-status, not-in-automatic LED

12. If the System-Status, Not-In-Automatic LED is still not flashing, check the continuity of the P2 ribbon cable connector. Disconnect the P2 ribbon cable connector from both the power supply board and from the main logic board. Using an ohmmeter, placeone test leadon the powersupply board side of P2-6, and place the other test lead on the main logic board side of P2-6. If the resistance is high indicating a lack of continuity, replace the ribbon cable connector. If the resistance is low indicating continuity, replace the logic board assembly.

Power Supply Board

TB-DC1-9

560447

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System-Status, System-Alert

For location of pushbuttons, switches, LEDs, and keys referred to in this section, see Figure 2-1.

If the System-Status, System-Alert LED is flashing, check the LCD for an error message. If the System-Status, System-Alert LED is flashing, but no error message appears on the LCD, the status panel is defective. Replace the logic board assembly.

The following sections will cover the different error messages encountered when the System-Status, System-Alert LED is flashing.

Contactor Position Fault Error

Messages

3. While the contactor is in the EMERGENCY position, connect one test lead 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 ineither case was high, thereis an open circuit. Verify correct wiring.

5. Check the auxiliary switches on the contactor.

The following steps check proper operation of the controller.

6. Connect the positive leadof a 12-24 volt DC power sourcetoTB-DC1-29.Connectthenegativeleadof the power source to TB-DC1-34. See Appendix B Figure B-9 for locationof TB-DC1 and other power supplyboardcomponentsreferredtointhissection.

The auxiliary-switch (AUX-SWITCH) fault error occurs when the position of the contactor does not match the positionthatthe logiccontroller last placedthecontactor in.Thedoubleauxiliary-switch(DBLAUX-SW)faulterror occurs when two contactor positions are detected simultaneously. If either of these error messages appears on the LCD, perform the following steps. See Figure 4-8.

P1-14

Closed in Normal

P1-10

Closed in Emergency

P1-13

560448

Figure 4-8. Wiring Diagram—Auxiliary-switch fault

and double auxiliary-switch fault

error message

Check the continuity of the contactor by performing the following three steps:

1. Disconnect the 24-pin plug to the logic controller assembly.

2. While the contactor is in the NORMAL position, connect one test lead of an ohmmeter to the contactorsideofP1-12.Connecttheothertest lead to the contactor side of P1-4. Note the resistance.

7. Connect P1-12 to P1-4. Press the RESET MENU key. If the Contactor-Position, Normal LED is not on,oriftheSystem-Status,System-AlertLEDisstill on, replace the power supply board.

8. Connect P1-16 to P1-8. Press the RESET MENU key. If the Contactor-Position, Emergency LED is noton,orif theSystem-Status,System-AlertLEDis still on, replace the power supply board.

Transfer Hang Error Message

A Transfer Hangerroroccurs whenthe controller issues a transfer command, but a transfer is not detected.

If TRANSFER HANG ERROR appears on the LCD, check for a binding contactor and check the contactor bridge rectifier. See the Contactor Service Manual.

Power-Down Error Message

APOWER-DOWN ERROR indicatestherewasa loss of AC power for a period of time. If the POWER-DOWN ERRORmessagedoesnotappearregularlyontheLCD, press the RESET MENU key, and set the time and the date.Press theRESET MENUkey andthen theENTER key to store the setpoints. If the POWER-DOWN ERROR message does appear regularly on the LCD, perform the following two steps.

1. If the ambient temperature is less than 20 degrees Fahrenheit, install a battery backup on the logic board.

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WARNING

Sulfuric acid in batteries. Can cause severe injury or death.

Use protective goggles andclothes. Battery acidcan causepermanent damage toeyes, burnskin, andeat holes in clothing.

Sulfuric acid in batteriescan 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 whenworking around the battery. If battery electrolyte is splashed in the eyes or on skin, immediately flush the affected area for 15 minuteswithlargequantitiesof clean water. Seek immediatemedicalaidinthe case of eyecontact. Never addacidto abatteryonce the battery hasbeenplacedin service. This may result in hazardous spattering of electrolyte.

NOTE

a. Check the voltage at P2-13. Using a voltmeter,

connectthe positive test leadto P2-13.Connect the negative test lead to TB-DC1-34. See Appendix B, Figure B-6 for location and description of P2 ribbon cable pins. Carefully

remove the power source by disconnecting the in-linedisconnect plug.Leave the power source disconnected for six seconds. After six seconds note the voltmeter reading.

b. If the voltage is less than six volts, replace the

power supply board.

c. Ifthevoltageis greaterthansixvolts,replacethe

logic board assembly.

RAM Or Memory Error Message

If either a RAM ERROR or a MEMORY ERROR message appear on the LCD, power down the logic boardforatleast30seconds.Replacepowerto thelogic board. If either the RAM ERROR or MEMORY ERROR messagestillappearonthe LCD,the main logic boardis defective. Replace the logic board assembly.

Manual Transfer Message

The MANUAL TRANSFER message will appear on the LCD when a transfer to the emergency source or to the normal source is desired but the logic board is in the manual mode. When this message appears press the appropriatepushbutton:ManualTransfer-to-Emergency or Manual Transfer-to-Normal. If automatic transfer is desired instead of manual transfer, place the automatic/manual transfer switch in the automatic position.

Manual-to-Off Transfer Message

TheMANUAL TO OFF messagewill appear on the LCD when three conditionsare met: 1) The transfer switch is in either the emergency or normal position, 2) the logic controlleris inmanual mode, and 3) the off positiontime delayisenabled. When this messageappearspressthe MANUAL-TO-OFF pushbutton.

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TB-DC1-8

P2-7 P2-7

Fault LED

Power Supply Board

Figure 4-9. Wiring Diagram—Fault #1 or Fault #2 message

Fault #1 Or Fault #2 Message

The external fault function can be used to identify a problemwiththe emergencypowersystem, orasupport device of the emergency power system. A dry relay contactcanbeusedtosignala fault,suchasaTenRelay DryContact Kit, sold as anaccessorywith thegenerator set.

NOTE: The contact kit must be a dry contact, the logic controller supplies its own voltage source.

The fault messages are used to monitor accessory components. A faultmessageappearsontheLCDwhen an accessory is grounding the pin to which it is connected. See Figure 4-9.

1. If a FAULT#1 messageappearsonthe LCD, check TB-DC1-8.

a. If thereisan accessoryconnectedto TB-DC1-8,

disconnect the accessory. Press the RESET MENUkey.If themessagedisappears,thelogic board is performing correctly. The FAULT #1 messageiscausedbytheconnectedaccessory.

Main Logic Board

560449

b. If there is not an accessory connected to

TB-DC1-8, remove power from the logic board and disconnect the P2 ribbon cable connector from the power supply board. Using an ohmmeter, connectone test leadto P2-7 on the powersupplyboard.Connectthe other test lead to TB-DC1-34. If the resistance is low, replace thepowersupplyboard.If the resistance is high, replace the logic board assembly.

2. If a FAULT#2 messageappearsonthe LCD, check TB-DC1-11.

a. If there is an accessory connected to

TB-DC1-11, disconnect the accessory. If the message disappears, then the logic board is performing correctly.

b. If there is not an accessory connected to

TB-DC1-11, removepower from the logicboard and disconnect the P2 ribbon cable connector from the power supply board. Using an ohmmeter, connectone test leadto P2-8 on the powersupplyboard.Connectthe other test lead to TB-DC1-34. If the resistance is low, replace thepowersupplyboard.If the resistance is high, replace the logic board assembly.

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Programming Mode Not-In-Off

For location of pushbuttons, switches, LEDs, and keys referred to in this section, see Figure 2-1.

The Programming Mode Not-In-Off LED signals the status of the Programming-Mode key switch. The three programming modes are Remote, Off, and Local.When theProgramming-Modekeyis setto Localprogramming mode,theProgrammingMode Not-In-Off LED shouldbe flashing. When the Programming-Mode key is set to

Programming Mode Switch “New” style switch—green plastic body

Position Contacts Closure Remote 1-8 Off 1-3 Local 3-5

Programming Mode Switch “Old” style switch—blue plastic body

Position Contacts Closure Remote 7-6 Off 7-1 Local 1-3

Remote programming mode, the Programming Mode Not-In-Off 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 key switch for proper wiring and operation. If the problem still exists, replace the logic board assembly.

Programming Mode Keyswitch (”New” style)

Programming Mode Keyswitch (”Old” style)

TB3

Local

Remote

TB3

Local

Figure 4-10. Wiring Diagram—Programming Mode Keyswitch

Remote

5604410

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Engine Operates When it Should Not

If the engine continues to operate after the logic controller removes the start signal, check the power supply board Start LED and perform the following procedure.For locationof the StartLEDandotherpower supplyboardcomponents referred toin this section, see Figure 2-1.

1. If the Start LED is on, disconnect the engine from the contactor by removing wires number 3 and number 4 from the engine.

a. If theenginecontinuestorunwhenwires3and4

are disconnected from the engine, wait the period of time equal to the engine cooldown to ensure that the generator set is not just in the cooldown mode. If the engine continues to run, check the generator set and the generator set wiring.

b. If the engine stops running when wires 3 and 4

are disconnected from the engine, remove the P1 harness from the power supply board.

(1) If the engine continues to run when the P1

harness is disconnected, there is a contactor problem. See the Contactor Service Manual.

(2) If the engine stops running when the P1

harness is disconnected, reconnect the P1 wireharness.Checkthecontinuitybetween 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. If the resistance is high indicating lack of continuity, replace the powersupply board. If the resistanceis low indicating continuity, disconnect any accessoriesconnected to TB-DC1-21 or to TB-DC1-22. If the engine stops running after the accessories are disconnected, checktheaccessoriesbyreferringto Unit3. If the engine continues to run after the accessories are disconnected, replace the power supply board.

2. If the Start LED is off, check the voltage at TB-DC1-23. Using a voltmeter, connect one test leadto TB-DC1-23, andconnect the other test lead to TB-DC1-34. If the voltmeter does not read approximately 19 volts AC, see Section 4—Power To The System. If the voltmeter does read approximately 19 volts AC, connect P4-1 to TB-DC1-34.

a. If the Start LED still does not light when P4-1 is

grounded, replace the power supply board.

b. If the Start LED lights when P4-1 is grounded,

check the Normal-Source-Available LED. If the Normal-Source-AvailableLEDis on, replacethe logic board assembly. If the Normal-SourceAvailable LED is not on, see Source-Available Normal Error.

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Yes No

Is the start LED illuminated?

Disconnect the start terminals 3 and 4 on the power conversion unit. Does the generator set continue to run?

Yes

Check the generator set and generator set wiring.

Reconnect the start terminals 3 and 4 on the power conversion unit. Disconnect the 24 pin controller assembly plug, P24. Does the generator set continue to run?

Yes

Check the wiring harness from the transfer switch to the generator set for open or shorted leads.

Reconnect the 24 pin controller assembly plug, P24. Is there continuity between terminals TB-DC1-21 and TB-DC1-22 on the power supply board?

Is there 19 vac between terminals TB-DC1-23 and TB-DC1-34 of the power supply board?

Yes

See Power to the System troubleshooting chart.

Jumper pin P4-1 of plug 4 to terminal TB-DC1-34 of the power supply board. Does the start LED illuminate?

Replace the power supply board.

Is the normal source available LED illuminated?

Yes

Replace the logic board.

Yes

Replace the power supply board.

See Source Available Normal Error,troubleshooting chart.

Remove accessories that are connected to terminal TB-DC1-21 or TB-DC1-22 of the power supply board. Does the generator set continue to run?

Yes

Replace the power

supply board.

Check any accessories that are connected to terminals TB-DC1-21 or TB-DC1-22 of the power supply board for correct operation.

Figure 4-11. Troubleshooting—Engine operates when it should not.

TP-5672 11/95

Controller Troubleshooting

4-17

Page 45

Engine Will Not Start

If the engine will not operate, check the power supply boardSTARTLED and performthe followingprocedure. For location of the START LED and other power supply board components referred to in this section, see Appendix B, Figure B-10.

1. If the START LED is off, jumper engine start terminals 3 and 4 on the contactor assembly.

a. If the unit does not start when engine start

terminals 3 and 4 are jumpered, check the generator set and the generator set wiring.

b. If theunitstarts whentheenginestartterminals3

and4 arejumpered,removethejumperbetween engine start terminals 3 and 4. Jumper TB-DC1-21 and TB-DC1-22.

(1) If the engine starts 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-DC1-22andTB-DC1-31.Ifthereisnota jumper, add one. If the enginestill doesnot start when TB-DC1-21 and TB-DC1-22 are jumpered, replace the powersupply board.

NOTE

2. If the START LED is on, usinga voltmeter, connect thepositivetest leadto P4-1. Connect thenegative test lead to TB-DC1-34.

a. If the voltmeterreading is low (about 1 volt), the

status panel is defective. Replace the logic board assembly.

b. If the voltmeter reading is high (about 10 volts),

replace the power supply board.

4-18 Controller Troubleshooting

TP-5672 11/95

Page 46

Is the start LED illuminated?

NoYes

Is there 1 vdc between pin P4-1 of plug 4 and terminal TB-DC1-34 of the power supply board?

Yes

Replace the logic board.

Replace the power supply board.

Is there an accessory wired between terminals TB-DC1-22 and TB-DC1-31 of the power supply board

Yes

Jumper terminals 3 and 4 on the power conversion unit. Does the generator set start?

Check the generator set and the generator set wiring.

Remove the jumper between terminals 3 and 4. Jumper terminals TB-DC1-21 and TB-DC1-22 of the power supply board. Does the generator set start?

Is there a jumper between terminals TB-DC1-22 and TB-DC1-31 of the power supply board?

Jumper terminal TB-DC1-22 to terminal TB-DC1-31 of the power supply board together. Does the generator set start?

Yes

Check that the accessory is wired correctly. See Section 5 Accessories

Is there continuity between terminal TB-DC1-21 of the power supply board and pin P24-11 of plug P1?

Yes

Is there continuity between terminal TB-DC1-21 of the power supply board and pin P24-15 of plug P1?

Replace the power supply board.

Figure 4-12. Troubleshooting—Engine will not start.

Yes

Add a jumper between terminal TB-DC1-22 to terminal TB-DC1-31 of the power supply board.

Replace the power supply board.

Check the power conversion unit wiring for open or shorted leads.

TP-5672 11/95

Controller Troubleshooting

4-19

Page 47

Area Protection

Area Protection turns on the emergency source whena loss of normal power is expected because of an approaching storm or for some other reason. Area Protection allows the user to transfer to the emergency source.

If the Area-Protection LED is on and area protection is not active, perform the following steps.

1. Connect TB-DC1-6 to TB-DC1-34.

Is there a lead from TB-DC1-6 to TB-DC1-32, 33, or 34?

Replace logic board.

Is the Area Protection LED on?

Yes Yes

Check Engine Start Circuit.

2. If the Area-Protection LED does not turn off after groundingTB-DC1-6,connectP2-5toground.Ifthe Area-Protection LED does not turn off, replace the powersupplyboard.If theArea-ProtectionLEDstill doesnot turn off,replace the logicboardassembly.

3. If the Area-Protection LED does turn off after grounding TB-DC1-6, check the wiringfor an open circuit to TB-DC1-6 and the connection at TB-DC1-6.

Yes

Remove lead.

Is the Area Protection LED on?

Check Engine Start Circuit.

Install a lead from TB-DC1-6 to TB-DC1-32.

Figure 4-13. Troubleshooting—Area protection does not turn on

Is there a lead from TB-DC1-6 to TB-DC1-32, 33, or 34?

Replace logic board.

Yes

Is the Area Protection LED on?

Check Engine Start Circuit.

Figure 4-14. Troubleshooting—Area protection does not turn off

Yes

4-20 Controller Troubleshooting

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Page 48

Shunt Jumper-Controlled Options

Jumpersinstalledinthe shunt-jumpersocket JP1 on the main logic board control the following options.

D Extended Time Delays—DD-100-B D Plant Exerciser—DD-23-C, DD-23-D, and

DD-23-G

D Voltage/Frequency Sensing—DD-34-J D Phase Sequencer—DD-34-Z and DD-05-K D In-phase Monitor—DD-34-A D Off Delays

See Appendix B Figure B-9 to locate JP1. See Figure 4-15 to locate option shunt jumper locations on JP1. Programming Index 11 displays installed control options status as enabled or disabled. Figure 4-16 describes the options in Index 11.

To add/remove shunt-jumper controlled options:

1. Add/remove shunt-jumpers across the terminals nextto the name of the option on JP1 and shownin Figure 4-15. Do not remove the MANUAL OVERRIDE jumper.

3. Power down the controller by disconnecting the inline disconnect plug P1.

4. Waitaminimumof1 minutethenreconnectplugP1 to power up the controller.

5. Check Index 11. YES should appearonly 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

When the optionsare not locked the controller does not checkJP1uponpoweruptodetermineoptionstatus,but rather reads the setpoints stored before power was interrupted.

Main Logic Board

2. Go to Index 20 and press Menu Down and look for OPTIONS LOCK? NO. If the question does not appear, the options are locked. Go to step 3. Otherwise, lock the options:

a. Answer the question with YES then ENTER.

The controller briefly displays ENTRY ACCEPTED.

MANUAL

TIME

PLANT

VOLT/

PHASE

OFF

OVRIDE DELAY EXER FREQ SEQUENCER MONITORIN-PHASE

DELAYS

b. Press RESET MENU and then ENTER to store

the setpoints. The controller briefly displays STORE SET--POINTS. The optionswillremain locked when the controller powers back up the next time.

Control Option Description

INPHASE MON Shows Inphase Monitor enabled (Yes) or disabled (No). PHA SEQ/LOSS Shows Source-Phase-Sequence enabled (YES) or disabled (NO). (Transfer Switch contactor lug

connections must be properly phased ABC in order for the source to be acceptable).

NORM & EMER Shows sensing enabled (YES) or disabled (NO) of overvoltage, undervoltage, overfrequency,

underfrequency for both the normal source and the emergency source. PLANT EXER Shows generator set/system exerciser enabled (YES) or disabled (NO). TD EXTENDED Shows extended time delay enabled (YES) or disabled (NO). MAN OVERRIDE Shows manual override enabled (YES) or disabled (NO). Enabled manual override (YES) allows

automatic transfer to an available source when connected source fails. Transfer time delays will

be bypassed. Disabled manual override (NO) causes the logic board to wait for manual operation.

The logic board will not automatically seek available source. OFF DELAYS Shows time delay off to normal and off to emergency are enabled (YES) or disabled (NO).

Figure 4-15. Shunt-jumper socket JP1

560451

TP-5672 11/95

Figure 4-16. The installed control options as they appear on the LCD

Controller Troubleshooting

4-21

Page 49

Yes

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 setpoints before repeating powerdown/powerup sequence.

Does an entry appear in Index 20 that says OPTIONS LOCK? NO ?

Options are locked. Does OFF DELAYS not have a jumper and displays YES ?

Interrupt controller power supply by disconnecting the inline disconnect plug P1. Wait at least one minute. Reconnect P1. Does YES appear only after Index 11 listed options with jumpers on JP1?

Yes

Troubleshooting complete.Replace logic board.

Check Index 20. Is the switch type M GERIN MC ?

The OFF DELAYS are required and cannot be changed to NO.

Yes

Figure 4-17. Troubleshooting—YES appears in Index 11 when a jumper for that option is not installed

Yes

Does an entry appear in Index 20 that says OPTIONS LOCK? NO ?

Options are locked. Does OFF DELAYS have a jumper and displays NO ?

Yes

Check Index 20. Is the switch type ZENITH STD ?

Interrupt controller power supply by disconnecting the inline disconnect plug P1. Wait at least one minute. Reconnect P1. Does YES appear only after Index 11 listed options with jumpers on JP1?

Troubleshooting complete.

Remove the jumpers of the options that appears as NO in Index 11 and test for continuity. Is any jumper open?

Replace logic board. Replace open jumper.

Yes

Does INPHASE MONITOR

have a jumper and displays NO ?

Yes

Check Index 20. Is the switch type

Yes

ZENITH STD ?

IN-PHASE MONITOR not available on switches with an Off position

TD OFF not available on switches without an Off position

Yes

Figure 4-18. Troubleshooting—NO appears in Index 11 when a jumper for that option is installed

4-22 Controller Troubleshooting

TP-5672 11/95

Page 50

Inphase Monitor

Motors and related equipment can be damaged by abnormal inrush currents when switched between two livepowersources. ThepurposeoftheInphaseMonitor, DD-34-A, is to minimize abnormal inrush currents to equipment when the equipment is connected to a new power source. The Inphase Monitor samples a single phaseofonesourceandcomparesit toasinglephaseof another source. When the two voltages are within the desiredphase angle and approachingzero phaseangle difference, the Inphase Monitor signals the transfer switch to operate. The transfer may be from utility to generator, from generator to generator, or from utility to

NA NB NC EA EB EC LA

MANUAL

TIME PLANT VOLT/

PHASE

IN--PHASE

OFF

OVRIDE DELAY EXER FREQ SEQUENCER MONITOR

DELAYS

Programming Shunt (294634) must be installed to activate accessory

LC NAS NCS EAS ECS

utility. To enable this option, the IN-PHASE MONITOR jumper must be installed on the main logic board. See Figure 4-15.

NOTE

Thegeneratorsetshouldrun 0.5 Hzfasterthantheutility source. InphaseMonitor canbeenabledonlyontransfer switches with power conversion units without an Off position like ZENITH STD.

Figure 4-19shows a wiring diagram for this option. See Figure 4-20 for troubleshooting this option.

MICROCONTROLLER

TB--DC1TB--AC1

560458

Figure 4-19. Wiring Diagram—Inphase monitor, option DD-34-A

Is the In-phase Monitor jumper installed in JP1 on the logic board?

If a connected source fails partially (not all voltages on all phases below the undervoltage dropout setpoints) or after normal source restoration when connected to emergency, the ATS starts an automatic transfer sequence to the other source.

Does the In-phase Monitor LED light

1. After TDNE ends and before transfer to emergency or

2. After TDEN ends and before transfer to normal?

Replace logic board.

Figure 4-20. Troubleshooting—Inphase monitor, does not work

Yes

In Index 11 is Inphase

Yes

Monitor enabled?

Does the ATS transfer

Yes

to the other source in a few seconds and in phase?

Yes

In-phase monitor is working.

Rewire the phase rotation of the emergency source to match the normal source, or both to A-B-C when practical.

Replace logic board.

Install the In-phase Monitor jumper on JP1 and power down the controller for 1 minute mininum.

Troubleshoot shunt-jumper controlled options. See Figure 4-18.

Are the normal and emergency sources within 0.5 Hz?

Yes

Adjust the generator frequency 0.5 Hz faster than the normal source.

Do the emergency

and normal power sources have the

Yes

same phase rotation?

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Controller Troubleshooting

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Page 51

Source Monitors

The Source Monitor Phase Sequencer accessory DD-34-Zprovidessourcemonitoringforboth thenormal and emergency sources. The features include phase rotation and anti-single phasing protection. This option must be used in conjunction with DD-05-K in order to provide three-phase source monitoring on the emergencyside. Thisaccessoryneedstobeenabledby installing the PHASE SEQUENCER jumper on the main logic board. See Figure 4-15. A wiring diagram for this option is in Figure 4-21.

The Voltage/Frequency Sensing accessory, DD-34-J, provides source monitoring for both the normal and emergency sources. This accessory senses an overvoltage condition for all normal source phases, an over/underfrequency condition on one normal source phase,and anoverfrequencyand overvoltagecondition

NA NB NC EA EB EC LA LB

MANUAL

TIME

PLANT

VOLT/

PHASE

IN--PHASE

OFF

OVRIDE DELAY EXER FREQ SEQUENCER MONITOR DELAYS

NAS NCS EAS ECS

on one emergency source phase. This accessory 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 wiring diagram for this accessory is in Figure 4-22.

The three-phase emergency source sensing accessory DD-05-K provides source monitoring for the emergency source. The features includeoverfrequency sensing for one phase of the emergency source and over/undervoltage sensing for all three phases of the emergencysource. Thisaccessoryneedstobeenabled by installing the PHASE SEQUENCER jumper on the mainlogic board. See Figure 4-15. Figure 5-3 showsa wiring diagram for this option.

MICROCONTROLLER

TB--DC1TB--AC1

18 19 20

21 22 23 24 25 26 27 28 29 30

31 32 33 34

1 2 3

5 6 7 8 9

11 12 13 14 15 16

Programming shunt (294634) must be installed to activate accessory

Figure 4-21. Wiring Diagram—Source monitor phase sequence, option DD-34-Z

4-24 Controller Troubleshooting

560455

TP-5672 11/95

Page 52

MANUAL

TIME

PLANT

VOLT/

PHASE

IN--PHASE

OFF DELAYS

OVRIDE DELAY EXER FREQ SEQUENCER MONITOR

NA NB NC EA EB EC LA LB LC

NAS NCS EAS ECS

MICROCONTROLLER

TB--DC1TB--AC1

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

1 2 3

5 6 7 8 9

11 12 13 14 15 16

Programming shunt (294634)

must be installed to activate accessory

Figure 4-22. Wiring Diagram—Voltage/Frequency Sensing, option DD-34-J

Yes

Is option DD-05-K installed?

Yes

Is the Phase Sequencer jumper installed in JP1 on the logic board?

Yes

In Index 11 is Phase Sequencing enabled?

Yes

Does the controller sense only normal source three phase voltage and frequency?

Refer to Accessory DD-05-K Troubleshooting

560456

Install the Phase Sequencer jumper on JP1 and power down the controller for 1 minute mininum.

Troubleshoot shunt-jumper controlled options. See Figure 4-18.

In Index 1 and 2 are there readings for normal source three phase sensing?

Yes

Replace logic board.

Option is working.

Accessory DD-05-K is needed to monitor the emergency source three-phase voltage and frequency.

Figure 4-23. Troubleshooting—Source monitor phase sequencer does not work

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Controller Troubleshooting

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Page 53

Is the Volt/Freq jumper installed in JP1 on the logic board?

Yes

In Index 11 is Norm & Emer sensing enabled?

Yes

Install the Volt/Freq jumper on JP1 and power down the controller for 1 minute mininum.

Troubleshoot shunt-jumper controlled options. See Figure 4-18.

Is emergency source voltage available at the power conversion unit?

No power source is available.

Yes

Is the controller sensing the normal source only?

Yes

Is there normal source voltage available at the power conversion unit?

Yes

Is Index 1 displaying a voltage reading for the normal source?

Yes

Are the pickup and dropout set points correct in Index 6?

Yes

Replace logic board.

No power is available.

Refer to Section 4— Power To The System Troubleshooting.

Reset set points.

Is Index 2 displaying a voltage reading for the emergency source?

Refer to Power To The System Troubleshooting.

Yes

Are the pickup and dropout set points correct

Reset set points.

in Index 7?

Yes

Replace logic board.

Figure 4-24. Troubleshooting—Voltage and frequency sensing does not work

4-26 Controller Troubleshooting

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Page 54

Plant Exerciser

The Plant Exerciser is an accessory which periodically tests the emergency source for proper operation. To enable this option, the PLANT EXER jumper must be installed on the logic board. See Figure 4-15. The accessory is available in three different variations.

D DD-23-C. Allows test of the engine generator set

only. The generatorset will start and run under no load.

D DD-23-D. Allowsacompletetest of theemergency

source. The exerciser simulates a loss of normal power. The generator set starts and the transfer switch transfers the load to the generator set.

D DD-23-G. Allows the customer to choose between

DD-23-C and DD-23-D with a Load/No Load selector switch.

Option DD-23-C(no-load exerciser)and DD-23-D (load exerciser) are wired differently. In order to enable DD-23-D,TB-DC1-10 must be jumperedto TB-DC1-32. See Figure 3-1 or 3-2.

The plant exerciser is programmed in Index 8. The following information is needed to program the 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)

Entertheinformationandenabletheeventto operatethe plant exerciser.

If theplantexerciserisprogrammedandfunctioning,the Accessory Active, Plant Exerciser LED lights whenever the plant exerciser is operating.

The Plant Exerciser uses three different modes.

D 7 Day. The timer looks at only 7 days at one time D 14 Day. The timer looks at 14 days at a time D Calendar. The timer looks at a true calendar for

each month.

SeeFigure 4-27throughFigure 4-30fortroubleshooting flowcharts for these options.

TB--AC1

NA NB NC EA EB EC

LC NAS NCS EAS ECS

DD-23-C DD-23-D

MICROCONTROLLER

TB--DC1

25 26

MANUAL

TIME PLANT VOLT/

PHASE

IN--PHASE

OFF

OVRIDE DELAY EXER FREQ SEQUENCER MONITOR DELAYS

TB--AC1

NA NB NC EA EB EC

LC NAS NCS EAS ECS

Programming shunt (294634) must be installed

MICROCONTROLLER

TB--DC1

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Jumper

1 2 3 4 5 6 7 8 9

11 12 13 14 15 16

TP-5672 11/95

Figure 4-25. Wiring Diagram—Plant exerciser, option DD-23-C and DD-23-D

Controller Troubleshooting

560452

4-27

Page 55

EXERCISOR SELECT

S11

1 — 2

MANUAL

TIME PLANT VOLT/

PHASE

IN--PHASE

OFF

W/LOAD

NO LOAD

OVRIDE DELAY EXER FREQ SEQUENCER MONITOR DELAYS

Programming shunt (294634)

must be installed to activate accessory

TB--AC1

NA NB NC EA EB EC LA LB

LC NAS NCS EAS

ECS

MICROCONTROLLER

TB--DC1

18 19 20

21 22 23 24

28 29 30 31 32 33 34

1 2 3 4

5 6

11 12 13 14 15 16

110

S11

Figure 4-26. Wiring Diagram—Plant exerciser, option DD-23-G

Troubleshoot shunt-jumper controlled options. See Figure 4-18.

Place a jumper across terminals 21 and 31 on TB-DC1 of the power supply board. Does the generator set start?

Yes

Do pins 11 and 15 on plug P2 short when the plant exerciser is active?

Yes

Replace logic board.

Replace the ribbon cable between plugs P2 and P3

In Index 11 is Plant

Exerciser enabled?

Is the Plant Exer jumper

Yes

installed in JP1 on the logic

board?

Yes

Do pins 11 and 15 on plug

Yes No

P3 short when the plant exerciser is active?

Place a jumper across start terminals 3 and 4 on the power conversion unit. Does the generator set start?

Yes

Check the engine start circuit for an open circuit.

Replace the wiring harness between TB-DC1 and the power conversion unit.

132

Install the Plant Exer jumper on JP1 and power down the controller for 1 minute mininum.

Is the plant exerciser programmed correctly in index 8? See TP-5664 for programming information.

Yes

Replace logic board.

Reprogram the plant exerciser. Refer to TP-5664 for programming instructions.

560453

Figure 4-27. Troubleshooting—Accessory 23-C, plant exerciser, does not work

4-28 Controller Troubleshooting

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Page 56

Troubleshoot shunt-jumper controlled options. See Figure 4-18.

Yes

In Index 11 is Plant

Exerciser enabled?

Is the Plant Exer jumper installed in JP1 on the logic board?

Yes

Is there a jumper from terminals TB-DC1-10 to TB-DC1-32 on the power supply board?

Yes

Install the Plant Exer jumper on JP1 and power down the controller for 1 minute mininum.

Install jumper lead between terminals TB-DC1-10 and TB-DC1-32 of the power supply board.

Place a jumper across terminals 21 and 31 on TB-DC1 of the power supply board. Does the generator set start?

Yes

Do pins 11 and 15 on plug P2 short when the plant exerciser is active?

Yes

Replace the logic board.

Replace the ribbon cable between plugs P2 and P3.

Figure 4-28. Troubleshooting—Accessory 23-D, plant exerciser does not work

Yes

Do pins 11 and 15 on plug P3 short when the plant exerciser is active?

Place a jumper across the start terminals 3 and 4 on the power conversion unit. Does the generator set start?

Yes

Check engine start circuit for an open circuit.

Replace the wiring harness between TB-DC1 and the power conversion unit.

Is the plant exerciser programmed correctly in index 8? See TP-5664 for programming information.

Yes

Replace the logic board.

Reprogram the plant exerciser. Refer to TP-5664 for programming instructions.

TP-5672 11/95

Controller Troubleshooting

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Page 57

Install the Plant Exer jumper on JP1 and power down the controller for 1 minute mininum.

Is the Plant Exer jumper

installed in JP1 on the logic board?

Yes

In Index 11 is Plant Exerciser enabled?

Troubleshoot

shunt-jumper controlled options. See Figure 4-18.

Is the Load/No Load selector switch in the NO LOAD position?

Check for continuity between terminals TB-DC1-10 and TB-DC1-32 of the power supply

Yes

board. Is there continuity?

Is there continuity across the Load/No Load selector switch when it is in the NO LOAD position?

Remove the leads from terminals TB-DC1-10 and TB-DC1-32 of the power supply board. Is there continuity from terminals TB-DC1-10 to TB-DC1-32 of the power supply board?

Replace the leads from terminals TB-DC1-10 and TB-DC1-32 of the power supply board.

Yes

Replace the Load/No Load selector switch.

Yes

Replace the logic board.

Place a jumper across terminals 21 and 31 on TB-DC1 of the power supply board. Does the generator set start?

Yes

Place the Load/No Load selector switch into the NO LOAD position.

Do pins 11 and 15 on plug P3 short when the plant exerciser is active?

Yes

Is the plant exerciser programmed correctly in index 8? See TP-5664 for programming information.

Yes

Replace the logic board.

Reprogram the plant exerciser. Refer to TP-5664 for programming instructions.

Do pins 11 and 15 on plug P2 short when the plant exerciser is active?

start terminals 3 and 4 on the power conversion unit. Does the generator set start?

Yes

Place a jumper across the

Replace the logic board.

Check the engine start

circuit for an open circuit.

Replace the ribbon cable between plugs P2 and P3.

Replace the wiring harness between TB-DC1 and the power conversion unit.

Figure 4-29. Troubleshooting—Accessory 23-G, plant exerciser, does not work (unloaded exercise)

4-30 Controller Troubleshooting

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Page 58

Troubleshoot shunt-jumper controlled options. See Figure 4-18.

Yes

In Index 11 is the Plant

Exerciser enabled?

Is the Plant Exer jumper installed in JP1 on the logic board?

Yes

Install the Plant Exer jumper on JP1 and power down the controller for 1 minute mininum.

Place the Load/No Load selector switch into the LOAD position.

Replace the Load/No Load selector switch.

Place a jumper across terminals 21 and 31 on TB-DC1 of the power supply board. Does the

Yes

generator set start?

Do pins 11 and 15 on plug P2 short when the plant exerciser is active?

Yes

Is the Load/No Load

selector switch in the LOAD position?

Yes

Is there continuity across the Load/No Load selector switch ?

Do pins 11 and 15 on plug P3 short when the

Yes

plant exerciser is active?

Place a jumper across the start terminals 3 and 4 on the power conversion unit. Does the generator set start?

Yes

TB-DC1-10 to the Load/No Load selector switch. Is there continuity?

Replace the lead from TB-DC1-10 to the Load/No Load selector switch.

Check for continuity from terminal TB-DC1-32 of the

Check for continuity from

power supply board to the Load/No Load selector switch. Is there continuity?

Replace the lead from terminal TB-DC1-32 of the power supply board to the Load/No Load selector switch .

Is the plant exerciser programmed correctly in index 8? See TP-5664 for programming information.

Yes

Replace the logic board.

Yes

Check the engine start circuit for an open circuit.

Reprogram the plant exerciser. Refer to TP-5664 for programming instructions.

Replace the ribbon cable between plugs P2 and P3.

Replace the wiring harness between terminal TB-DC1 of the power supply board and the power conversion unit.

Figure 4-30. Troubleshooting—Accessory 23-G, plant exerciser, does not work (loaded exercise)

TP-5672 11/95

Controller Troubleshooting

4-31

Page 59

Time Delays

D DD-100-B. This accessoryallowsalltime delaysto

be adjusted from 0 to 99 minutes.

TimeDelayaccessoryDD-100-Bincreasesallofthetime delays up to 99 minutes. The time delays are used for transfer from normal to emergency, transfer from emergency to normal, engine start, engine cooldown, and load-shed sequence. The TIME DELAY jumper

Is the Time Delay jumper installed in JP1 socket on the logic board?

In Index 11 are TD Extended enabled?

In Index 5 can TDES, TDEN,

Replace logic board.

TDOE, TDON and TDEC be adjusted to 99 minutes?

must be installedon themainlogicboardto increasethe adjustable range of standard time delays up to 99 minutes. See Figure 4-15. To extend TDES time delays an external 12-32 vdc power supply is required. See Figure 4-15. Timedelays are adjustable from either the front panel keypad or from a remote computer. See Figure 4-31 for a troubleshooting chart for this option.

Yes

Install the Time Delay jumper for on JP1 and power down the controller for 1 minute mininum.

Troubleshoot shunt-jumper controlled options. See Figure 4-18.

Connect an external DC power supply between TB-DC1-29 and TD-DC1-32?

Figure 4-31. Troubleshooting—Extended time delays do not work

Is there an external DC power

supply connected between TB-DC1-29 and TD-DC1-32?

Yes

Option is working.

4-32 Controller Troubleshooting

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Page 60

Manual Override

It isimportantthat theMANUALOVRIDE jumperalways beinplaceonthemainlogicboard. SeeFigure 4-15. Do not remove it!

Is the Manual Ovride jumper installed in JP1 socket on the logic board?

Yes

In Index 11is Manual Override enabled?

Yes

Replace logic board.

Yes

Is the auto/manual switch in the auto position?

Place the auto/manual switch in the auto position.

See Figure 4-32 for a troubleshooting flowchart for this option.

Install the Manual Ovride jumper on JP1 and power down the controller for 1 minute mininum.

Troubleshoot shunt-jumper controlled options. See Figure 4-18.

Figure 4-32. Troubleshooting—Switch does not automatically transfer

TP-5672 11/95

Controller Troubleshooting

4-33

Page 61

Off Delays

The Off position time delay allows an off position power conversionunit to stop for a definedperiodof time in the offposition. A uniquetimedelaycanbe programmedfor an off-to-normal transfer and an off-to-emergency transfer. Thisoff delay can beused toallow motor loads to come to rest before being reenergized. The OFF DELAYS jumper must be installed on the logic board. See Figure 4-15. Off delays cannot be enabled on a switch type that does not have an Off position like ZENITH STD andthejumperhasnoeffect. On allpower

conversionunits with anOff position except the MM and MN,theoffdelayscanbeset to zero. On theMM andMN power conversion units the minimum off delay is one second.

If the Off Delays jumper is not installed, install the Off Delay jumper on JP1 and power downthe controller for 1 minute minimum.

If the jumperis installed, checkIndex 11to see if the Off Delaysoptionisenabled. If notenabled,seeFigure 4-18 to troubleshoot shunt-jumper controlled options.

4-34 Controller Troubleshooting

TP-5672 11/95

Page 62

Section 5. Accessory Troubleshooting

This section contains a brief description, wiring diagrams, and troubleshooting flowcharts for many of the logic board accessories.

Refer to Appendix C for a comprehensive list of

Options with

DD- Prefix

23-C Plant Exerciser X X 34-A Inphase Monitor X X 34-J Voltage Sensing X X 34-Z Phase Rotation X X 100-B Extended Time Delays X X X X

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 Position Test Switch X X X X 07-D Four Position Test Switch X X X X 08-C E-to-N Time Delay Override Switch X 08-D N-to-E Time Delay Override Switch X 23-D Plant Exerciser X X X X 23-G Plant Exerciser X X X X 24-XX-A,B Battery Charger X 29-P Manual Transfer--Both Directions X X 29-R Manual Transfer--Both Directions, Key X X 29-S Manual Transfer--E-to-N X 29-T Manual Transfer--E-to-N, Key X 29-U Manual Transfer--Both Directions with

Auto/Manual switch

29-V Manual Transfer--Both Directions with

Auto/Manual Switch, Key

29-W Manual Transfer--E-to-N with

Auto/Manual Switch

29-X Manual Transfer--E-to-N with

Auto/Manual Switch, Key

35-N Load Shed X X

Option Description

Shunt Jumper-Controlled Options

Other Options

commonly used accessories. See Figure 5-1 for the relationship between the

microprocessormainfunctionsandtheaffectthatcertain accessories can have on those functions.

Transfer

Normal to

Emergency

X X

Accessory Affects

Transfer

Emergency

to Normal

Engine Start

Engine

Shutdown

TP-5672 11/95

Figure 5-1. Accessory Troubleshooting Grid

Accessory Troubleshooting

5-1

Page 63

Optional Accessories

Three-Phase Emergency Source Sensing Accessory, DD-05-K

The three-phase emergency source sensing accessory DD-05-K provides source monitoring for the emergency source. The accessory includes over/undervoltage

Enable three-phase sensing in index 7. See TP-5664 for programming information

Is there emergency source line-to-line voltage between terminals EA and EB, EA and EC, and EB and EC on the three-phase sensing accessory circuit board? See Figure 5-3 for location of circuit board)

Replace the three-phase accessory circuit board.

In Index 7 of the microprocessor menu is three-phase emergency source sensing enabled?

Yes

In Index 11 of the microprocessor menu is phase sequence enabled?

Yes

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 source line-to-line voltage between pins 6 and 7 of plug P15?

Yes

Is there 1/25 of the emergency source line-to-line voltage between pins 6 and 8 of plug P15?

sensing for all three phases of the emergency source. Refer to Figure 5-2 for the troubleshooting flowchart.

Refer to shunt-jumpered control options troubleshooting.

Is there emergency source line-to-line voltage between EA and EB, EA and EC, and EB and EC at terminals EA, EB, and EC on TB-AC1?

Yes

Replace the leads from TB-AC1 to the three-phase accessory circuit board.

The emergency source is not available.

Replace the three-phase accessory circuit board.

Yes

Refer to Power Supply to Main Logic Board troubleshooting.

Figure 5-2. Troubleshooting—Controller will not sense three-phase emergency voltage

5-2 Accessory Troubleshooting

Yes

Check the ribbon cable for bent or broken pins and for continuity between connectors. Is the ribbon cable free of defects?

Replace the ribbon cable between P15 on the three-phase accessory circuit board and P14 on the power supply board.

TP-5672 11/95

Page 64

NB NC EA EB EC LA LB

BLUE STRIPE TO

SLOTTED SIDE

OF DIPSOCKET

NAS NCS EAS ECS

MICROCONTROLLER

RIBBON CABLE

294638

PCBASSY C--294493

TB--DC1TB--AC1

LOT NO.

MANUAL

TIME PLANT VOLT/

PHASE

IN--PHASE

OFF

OVRIDE DELAY EXER FREQ SEQUENCER MONITOR DELAYS

Programming Shunt (294634)

must be installed to activate accessor

Figure 5-3. Wiring Diagram—Three-phase emergency source sensing, Option DD-05-K

560457

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Accessory Troubleshooting

5-3

Page 65

Test Switches

RefertoFigure 5-4for wiringdiagramfortheTestswitch. Refer to Figure 5-5 through Figure 5-10 for the troubleshooting flowcharts.

Description Of The Automatic/Test

Switch Accessories

The two-position test switch is described below:

D DD-06-F. Momentary, key-operated Automatic/

Test switch simulates a normal source failure.

The system operates automatically with switch in the automaticposition. The test position simulates a normal source failure.

The three-position test switches are described below:

D DD-06-N. Momentary Test/Automatic/Engine-

Start switch

D DD-06-P. Momentary, key-operated Test/

Automatic/Engine-Start switch

The system operates automatically with switch in the automaticposition. The test position simulates a normal source failure. The engine-start position starts the generator set.

The four-position test switch is described below:

D DD-07-D. Maintained rotary style

Test/Automatic/Off/Engine-Start switch.

The system operates automatically with switch in the automaticposition. The test position simulates a normal source failure. The off position prevents transfer switch operation. Theengine-startpositionstarts the generator set.

NOTE

When taking a voltage or resistance measurement at a ribboncablepin,do not disconnect the ribbon cablefrom theboard. Use aneedlepointprobeto take the readings from the holes on the top side of the ribbon cable connector.

2. If the power supply board Test LED turns on when the Automatic/Test pushbutton is pressed, check the Not-In-Automatic LED. If the Not-In-Automatic LED does not turn on when the Automatic/Test pushbutton is pressed, connect TB-DC1-9 to TB-DC1-34.

a. If the Not-In-Automatic LED does not turn on

when TB-DC1-9 is grounded, check the P2 ribbon cable connection by performing the following steps.

(1) Disconnect TB-DC1-9 from TB-DC1-34. (2) Remove all power sources. (3) Wait for 30 seconds. (4) Makingsure not to bend or break any of the

pins,removetheP2ribboncableconnector.

(5) Inspect the pins on the P2 ribbon cable

connector.

(6) If any of the pins are bent, carefully bend

themback.If anyofthe pinsare broken, the ribbon cable connector is defective. Replace the ribbon cable.

(7) Carefully reconnect P2 ribbon cable

connector.

Troubleshooting The Automatic/Test

Switch Accessory

NOTE

Pressing the Automatic/Test pushbutton causes the generator set to start and run.

Press the Automatic/Test pushbutton for 15 seconds.

1. If the power supply board Test LED does not illuminate,connectTB-DC1-24toTB-DC1-34.Ifthe Test LEDilluminateswhenTB-DC1-24isgrounded, checktheAutomatic/Testpushbuttonandthewiring from the Automatic/Test pushbutton to the power supply board. If the Test LED does not illuminate when TB-DC1-24 is grounded, replace the power supply board.

5-4 Accessory Troubleshooting

(8) If the Not-In-Automatic LED still does not

turn on when TB-DC1-9 is grounded, replace the logic board assembly.

b. If the Not-In-Automatic LED turns on when

TB-DC1-9 is grounded but not when the Automatic/Test pushbutton is pressed, check the Automatic/Test pushbutton and the wiring from the Automatic/Test pushbutton to the power supply board.

3. If the power supply board Test LED and the Not-In-Automatic LED both turn on when the Automatic/Test pushbutton is pressed, but the engine does not start, check the power supply board Start LED. If the Start LED is not on, see Section 4, Engine Will Not Start. If the Start LED does come on, replace the power supply board.

TP-5672 11/95

Page 66

NA NB NC EA EB EC LA LB

LC NAS NCS EAS ECS

MICROCONTROLLER

S1--6

S1--3

S1--2 134

121S1--5 122

124

Wire Code Example

Device Name

S10--13—201

Device Terminal Number

TB--DC1TB--AC1

Wire Number

S1--1109

TBDC1--9

TBDC1--34 134

TBDC1--21

TBDC1--22

109

121

122

1--2 3--4 5--6

5 61 2

TEST SWITCH

ENG.

START

124 TBDC1--24

TESTAUTO

5604516

Figure 5-4. Wiring Diagram—Test switches, Options DD-06-N, -P, -R, -T

Refer to the engine start troubleshooting flowchart.

Replace the lead from terminal TB-DC1-21 on the power supply board to the test switch.

Place a jumper between terminals TB-DC1-21 and TB-DC1-31 on the power supply board. Does the generator set start?

Yes

Place a jumper between terminals TB-DC1-21 and TB-DC1-22 on the power supply board. Does the generator set start?

Yes

Is there continuity between terminal TB-DC1-21 and terminal 5 of the test switch?

Yes

Is there continuity between terminal TB-DC1-22 and terminal 6 of the test switch?

Yes

Replace the test switch.

Is there a jumper between terminals TB-DC1-22 and TB-DC1-31 on the power supply board?

Yes

Replace the jumper between terminals TB-DC1-22 and TB-DC1-31 on the power supply board.

Install a jumper between terminals TB-DC1-22 and TB-DC1-31 on the power supply board.

Replace the lead from terminal TB-DC1-22 on the power supply board to the test switch.

Figure 5-5. Troubleshooting—Test switches, Options DD-06-N, -P switch does not start the generator set

when switch is in the engine start position

TP-5672 11/95

Accessory Troubleshooting

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Page 67

Does the generator set start when the test switch is in the TEST position?

Yes

Option is functioning properly.

Replace the logic board.

Replace the lead from terminal TB-DC1-34 on the power supply board to the test switch.

Does the Not-In-Automatic LED illuminate when the test button is pressed?

Yes

Place a jumper between terminals TB-DC1-9 and TB-DC1-34 on the power supply board. Does the Not-In-Automatic LED illuminate?

Is there continuity between terminal TB-DC1-34 on the power supply board and terminal 4 of the test switch?

Yes

Is there continuity from terminal 2 to terminal 4 of the test switch?

Yes

Replace the test switch.

Yes

Place a jumper between terminals TB-DC1-21 and TB-DC1-31 on the power supply board. Does the

Yes

generator set start?

Replace the logic board.

Is there continuity between

Yes

terminal TB--DC1--9 on the power supply board and terminal 1 of the test switch?

Yes

Replace the lead from terminal TB-DC1-9 on the power supply board to the test switch.

Replace the jumper between terminals 2 and 4 of the test switch.

Is there continuity between terminals TB-DC1-24 and TB-DC1-34 of the power supply board when the test button is pressed?

Is there continuity between terminal TB-DC1-24 on the power supply board and terminal 3 of the test switch?

Refer to the engine start troubleshooting flowchart.

Is there continuity between terminal TB-DC1-34 on the power supply board and terminal 4 of the test switch?

Yes

Replace the lead from terminal TB-DC1-34 on the power supply board to the test switch.

Yes

Replace the test switch.

Replace the lead from terminal TB-DC1-24 on the power supply board to the test switch.

Figure 5-6. Troubleshooting—Test switches, Options DD-06-N, -P switch does not start the generator

setwhen the test switch is in the Test position

5-6 Accessory Troubleshooting

TP-5672 11/95

Page 68

Place a jumper between terminals TB-DC1-21 and TB-DC1-31 of the power supply board. Does the generator set start?

Refer to the Engine Start Troubleshooting Flowchart.

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 to the test switch.

Yes

Place a jumper between terminals TB-DC1-21 to TB-DC1-22 of the power supply board. Does the generator set start when the test switch is in the Engine Start position?

Yes

Is there continuity between terminal TB-DC1-21 on the power supply board and terminal 7 of the test switch?

Yes

Is there continuity between terminal TB-DC1-22 on the power supply board and terminal 9 of the test switch?

Yes

Is there continuity between terminal TB-DC1-31 on the power supply board and terminal 10 of the test switch?

Is there a jumper between terminal 8 and terminal 9 of the test switch?

Yes

Replace the jumper between terminal 8 and terminal 9 of the test switch.

Install a jumper between terminal 8 and terminal 9 of the test switch.

Replace the lead from terminal

Yes TB-DC1-31 on the power supply board to the test switch.

Replace the test switch.

Figure 5-7. Troubleshooting—Test switches, Option DD-07-D switch does not start the generator set when

in the engine start position

TP-5672 11/95

Accessory Troubleshooting

5-7

Page 69

Does the generator set start when the test switch is in the Test position?

Is there continuity between terminals TB-DC1-24 and TB-DC1-34 on the power supply board when the test button is pressed?

Place a jumper between terminals TB-DC1-21 to TB-DC1-31 on the power supply board. Does the generator set start?

Yes

Refer to the engine start troubleshooting flowchart.

Refer to Figure 5-7 troubleshooting flowchart

Is there 10 vdc at terminal TB-DC1-30 on the power supply board?

Yes

Is there 10 vdc at terminal TB-DC1-25 on the power

supply board when the test switch is in the test position?

Yes

Is there continuity between terminal TB-DC1-24 on the power supply board and terminal 3 of the test switch?

Yes

Is there continuity between terminal TB-DC1-34 on the power supply board and terminal 4 of the test switch?

Yes

Replace the lead from terminal TB-DC1-34 on the power supply board to the test switch.

Replace the lead from terminal TB-DC1-24 on the power supply board to the test switch.

Replace the power supply board.

Does the Not-In-Automatic LED illuminate when the test switch is in the test position?

Yes

Replace the test switch.

Is there continuity between terminal TB-DC1-9 on the power supply board and terminal 1 of the test switch?

Replace the lead from terminal TB-DC1-9 on the power supply board to the test switch.

Is there continuity between terminal TB-DC1-34 on the

power supply 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.

Yes

YesNo

Yes

Place a jumper between terminals TB-DC1-9 and TB-DC1-34 on the power supply board. Does the Not-In-Automatic LED illuminate?

Replace the logic board.

Is there continuity between terminal 2 to terminal 4 of the test switch?

Replace the jumper between terminal 2 to terminal 4 of the

Option is functioning properly

Yes

Replace the test switch.

test switch.

Figure 5-8. Troubleshooting—Test switches, Option DD-07-D switch does go into Test mode

5-8 Accessory Troubleshooting

TP-5672 11/95

Page 70

Is there continuity between terminals TB-DC1-24 and TB-DC1-34 on the power supply board?

Yes

Replace the test switch.

Is there continuity between terminals TB-DC1-25 and TB-DC1-30 on the power supply board?

Is there continuity between terminals TB-DC1-21 and TB-DC1-22 on the power supply board?

Is there continuity between terminals TB-DC1-22 and TB-DC1-31 on the power supply board?

Replace the logic board.

Yes

Replace the test switch.

Figure 5-9. Troubleshooting—Transfer switch operates when Option DD-07-D test switch is in the Off

position

Is there 10 vdc at terminal TB-DC1-30 on the power supply board?

Yes

Replace 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?

Yes

Is there continuity between terminals TB-DC1-22 and TB-DC1-31 on the power supply board?

Is there continuity between terminal TB-DC1-22 on the power supply board and terminal 9 on the test switch?

Yes

Is there continuity between terminals TB-DC1-31 on the power supply board and terminal 10 on the test switch?

Yes

Replace the test switch

Yes

Refer to controller troubleshooting in section 4

Replace the lead from terminal TB-DC1-22 on the power supply board to the test switch

Replace the lead from terminal TB-DC1-31 on the power supply board to the test switch

Replace the test switch

Figure 5-10. Troubleshooting—Transfer switch will not operate when Option DD-07-D test switch is in the

Auto position

TP-5672 11/95

Accessory Troubleshooting

5-9

Page 71

Time Delay Override Accessory

The Time Delay Override Accessory allows the user to manually override the emergency-to-normal or normal-to-emergency time delay. When the pushbutton is pressed the corresponding transfer occurs immediately. The two different Time Delay Override accessories are listed below.

D DD-08-C. Emergency to normal time delay

override pushbutton

D DD-08-D. Normal to emergency time delay

override pushbutton

Wiring diagrams for these two accessories are in Figure 5-11 and Figure 5-12. Refer to Figure 5-13 and Figure 5-14 for troubleshooting flowcharts.

Troubleshooting The Bypass

Normal-To-Emergency Time Delay

Pushbutton

This section covers the steps to take to verify that the Bypass Normal-to-Emergency Time Delay pushbutton will override the normal-to-emergency time delay.

NOTE

make sure that the emergency source is available. Initiate a normal-to-emergency time delay by removing the normal source, and then press the Bypass Normal-to- Emergency Time Delay pushbutton.

If afterpressing the Bypass Normal-to-EmergencyTime Delaypushbuttonthenormal-to-emergencytimedelayis not bypassed, connect TB-DC1-3 to TB-DC1-34.

1. If grounding TB-DC1-3 causes the normal-toemergency time delay to be bypassed but the Bypass Normal-to-Emergency Time Delay pushbutton is not operating, check the Bypass Normal-to-Emergency TimeDelay pushbutton and the wiring to the Bypass Normal-to-Emergency Time Delay pushbutton.

2. If after grounding TB-DC1-3 the normal-toemergency time delay is not bypassed, check the continuity between P2-3 and TB-DC1-3.

a. Remove power from the logic board. b. Disconnect the P2 ribbon cable connector from

the power supply board.

Pressing the Bypass Normal-to-Emergency Time Delay pushbutton causes the generator set to start and run.

First ensure through the software that a minumum 5-second normal-to-emergency time delay is set. Next,

MICROCONTROLLER

NA NB NC EA EB EC

Wire Code Example

Device Name

S10--13—201

Device Terminal Number

Wire Number

LC NAS NCS EAS ECS

S2--3 133

c. Using an ohmmeter, connect one test lead to

P2-3 on the power supply board. Connect the other test lead to TB-DC1-3. If there is an open circuit, replace the power supply board. If the resistance is low, the main logic board is bad. Replace the logic board assembly.

TB--DC1TB--AC1

104

S2--4

TBDC1--33

TBDC1--4 104

133

5604519

Figure 5-11. Wiring Diagram—Time Delay Override, Option DD-08-C

5-10 Accessory Troubleshooting

TP-5672 11/95

Page 72

MICROCONTROLLER

Wire Code Example

Device Name

S10--13—201

Device Terminal Number

Wire Number

TB--AC1

NA NB NC

EC LA LB

LC NAS NCS EAS ECS

Figure 5-12. Wiring Diagram—Time Delay Override, Option DD-08-D

Troubleshooting The Bypass

Emergency-To-Normal Time Delay

Pushbutton

This section covers the steps to take to verify that pressingthe BypassEmergency-To-Normal Time Delay pushbutton will override the emergency-to-normal time delay.

First ensure through the software that a 10 second emergency-to-normal time delay is set. While the emergency source is being used, initiate an emergency-to-normaltimedelaybyrestoringthenormal source. Then press the Bypass Emergency-to-Normal Time Delay pushbutton.

If afterpressing the Bypass Emergency-to-NormalTime Delaypushbuttontheemergency-to-normaltimedelayis not bypassed, connect TB-DC1-4 to TB-DC1-34.

S3--3 133

TB--DC1

S3--4103

TBDC1--3

133TBDC1--33

103

5604520

1. If grounding TB-DC1-4 causes the emergency-tonormal time delay to be bypassed but the Bypass Emergency-to-Normal Time Delay pushbutton is not operating, check the Bypass EmergencyTo-Normal TimeDelaypushbuttonandthewiringto the Bypass Emergency-To-Normal Time Delay pushbutton.

2. If after grounding TB-DC1-4 the emergency-tonormal time delay is not bypassed, check the continuity between P2-4 and TB-DC1-4.

a. Remove power from the logic board. b. Disconnect the P2 ribbon cable connector from

the power supply board.

c. Using an ohmmeter, connect one test lead to

P2-4 on the power supply board. Connect the other test lead to TB-DC1-4. If there is an open circuit, replace the power supply board. If the resistance is low, the main logic board is bad. Replace the logic board assembly.

TP-5672 11/95

Accessory Troubleshooting

5-11

Page 73

Is the emergency power source available?

Yes

Emergency source must be present to bypass the time delay normal-to-emergency.

Yes

Replace the ribbon cable between P2 on the power supply board and P3 on the logic board.

Replace the power supply board.

Is there a TDNE time delay set in Index 5 of the microprocessor program?

Yes

Place a jumper between terminals TB-DC1-3 and TB-DC1-33 on the power supply board. Does the switch transfer to the emergency source?

Disconnect the in-line plug to remove power from the logic board. Remove the ribbon cable between P2 on the power supply board and P3 on the logic board. Check the ribbon cable for any open or shorted leads. Are there any open or shorted leads?

Is there continuity between pin P2-3 on the ribbon cable and TB-DC1-3 on the power supply board?

Yes

Program a TDNE time

delay in index 5 of the microprocessor program.

Yes

Is there continuity between terminal TB-DC1-3 on the power supply board and terminal 3 on the bypass switch?

Replace the lead from terminal TB-DC1-3 on the power supply board to the bypass switch.

Is there continuity between terminal TB-DC1-33 on the power supply board and terminal 4 on the test switch?

Yes

Replace the logic board.

Replace the bypass switch.

Replace the lead from terminal TB-DC1-33 on the power supply board to the bypass switch.

Figure 5-13. Troubleshooting—Option DD-08-C, Normal-to-emergency time delay pushbutton does not

work

5-12 Accessory Troubleshooting

TP-5672 11/95

Page 74

Is the normal source available

Yes

Normal source must be present to bypass the time delay emergency-to-normal.

Yes

Replace the ribbon cable between P2 on the power supply board and P3 on the logic board.

Replace the power supply board.

Is there a TDEN time delay set in Index 5 of the microprocessor program?

Yes

Place a jumper between terminals TB-DC1-4 and TB-DC1-33 on the power supply board. Does the switch transfer to the normal source?

Is there continuity between pin P2-4 on the ribbon cable and TB-DC1-4 on the power supply board?

Yes

Replace the logic board.

delay in index 5 of the microprocessor program.

Yes

Is there continuity between terminal TB-DC1-4 on the power supply board and terminal 3 on the bypass switch?

Replace the lead from terminal TB-DC1-4 on the power supply board to the bypass switch

Is there continuity between terminal TB-DC1-33 on the power supply board and terminal 4 on the test switch?

Yes

Program a TDEN time

Replace the bypass switch

Yes

Replace the lead from terminal TB-DC1-33 on the power supply board to the bypass switch.

Figure 5-14. Troubleshooting—Option DD-08-D, Emergency-to-normal time delay pushbutton does not

work

TP-5672 11/95

Accessory Troubleshooting

5-13

Page 75

Preferred Source Switch

Preferred source switch option DD-10-D provides a meansto select whichof two generatorsets will beused

TB--AC1

NA NB NC

EB EC

LA LB

LC NAS NCS

EAS

ECS

MICROCONTROLLER

TB--DC1--23--123

DCK--K1--118

2FU--BK--123

DCK--2--132

PSS--4--134

2FU

SPLICE

BK R

TB--DC1

18 19 20 21 22 23 24 25 26

27 28

TB--DC1--18--118 TB--DC1--32--132

whentheemergencysourcefails. See Figure 5-15for a wiring diagram for DD-10-D.

PSS

503

1 2 3 4

5 6 7 8 9

PSS--3--106

K1 2 42A

DCK

To Gen. 1

Engine Start

3A 4A

502

504

1 2

501

5 6

500

1--2 3--4 5--6

134--TBDC1--34

NCNC

106--TBDC1--6

GEN1 GEN2

PREFERRED

SOURCE

G2G1PSS

Wire Code Example

Device Name

S10--13—201

Device Terminal Number

Emergency Source Available

Contacts Shown De-energized

Wire Number

To Gen. 2

Engine Start

3 4

Contactor

Figure 5-15. Wiring Diagram—Preferred source switch, Option DD-10-D

321383

5-14 Accessory Troubleshooting

TP-5672 11/95

Page 76

Relay Auxiliary Dry Contacts

Auxiliary Dry Contacts option DD-14-G provides ten contactsfor remote indication.The contactsare ratedat 10 amperes and125 volts AC. This accessory indicates normal and emergency contactor positions, normal and emergency source availability, control not in automatic,

NA NB NC EA EB EC LA LB LC NAS NCS EAS ECS

4FU

TBDC1--23--123

SPLICE

Wire Code Example

Device Name

S10--13—201

SPLICE

BK R

Wire Number

Device Terminal Number

142--DCK--42A

programmodenot in off,and system alert.DD-14-Gcan be fitted to a transfer switch alone or with up to two additional auxiliary dry contact accessories. Figure 5-16 contains a wiring diagram for DD-14-G.

K10 K9 K8 K7 K6 K5 K4 K3 K2 K1 2 42A

TB--DC1TB--AC1

DCK

K10

101--DCK--K9

114--DCK--K10

ATS not in auto

Program switch “not in off”

System alarm

Emergency position

Normal position

Emergency available

Normal available

MICROCONTROLLER

DCK--K3--118 DCK--K7--119

4FU--BK--123

DCK--K1--126 DCK--K6--127 DCK--K5--128

DCK--2--132

TBDC1--14--114

TBDC1--1--101

TBDC1--19--119 TBDC1--27--127 TBDC1--28--128

TBDC1--18--118 TBDC1--26--126

TBDC1--32--132

4FU--R--142

J J

TP-5672 11/95

Shown De-energized

Figure 5-16. Wiring Diagram—Option DD-14-G, Auxiliary Dry Contacts

Accessory Troubleshooting

5604521

5-15

Page 77

Additional auxiliary dry contact accessories are describedbelow. Wiring diagrams for these accessories are in Figure 5-17 to Figure 5-24. Refer to Figure 5-25 for the troubleshooting flowchart.

D DD-14-H. Single-contactkitfor remote indication.

This option is rated for 10 amps and for 120 volts AC. It is used to indicate the normal contactor position.

D DD-14-J. Single-contact kit for remote indication.

This option is rated for 10 amps and for 120 volts AC. It is used to indicate the emergency contactor position.

D DD-14-K. Single-contactkit forremoteindication.

This option is rated for 10 amps and for 120 volts AC. It is used to indicatenormal source availability.

D DD-14-L. Single-contact kit for remote indication.

This option is rated for 10 amps and for 120 volts AC. It is used to indicate emergency source availability.

D DD-14-M. Single-contactkitforremoteindication.

This option is rated for 10 amps and for 120 volts AC. It is used to indicate whether the Automatic/Manual selector switch is not in the Automatic position.

D DD-14-N. Single-contactkitfor remote indication.

This option is rated for 10 amps and for 120 volts AC. It is used to indicatewhether the programming mode switch is not in the Off position.

D DD-14-P. Single-contact kit for remote indication.

This option is rated for 10 amps and for 120 volts AC. It is used to indicate a system alert condition.

D DD-14-R. Single-contactkitfor remote indication.

This option is rated for 10 amps and for 120 volts AC. It is used for load bank control. Relay energizes whenthe plant exersieris active andthe contractor does not transfer.

TB--AC1

NA NB NC

EB EC

LA LB

LC NAS NCS

EAS

ECS

MICROCONTROLLER

2FU--BK--123

DCK--K1--128

DCK--2--132

Wire Code Example

Device Name

Wire Number

S10--13—201

Device Terminal Number

TB--DC1

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

1 2 3 4 5 6 7 8 9

11 12 13 14 15 16

TB--DC1--23--123

TB--DC1--28--128 TB--DC1--32--132

2FU--R--306

SPLICE

2FU

BK R

K1 2 42A

DCK

306--DCK--42A

C NC NO

Contacts Shown De-energized

5604522

Figure 5-17. Wiring Diagram—Option DD-14-H, Auxiliary dry contacts

5-16 Accessory Troubleshooting

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Wire Code Example

Device Name

S10--13—201

Device Terminal Number

NA NB

NC EA EB EC LA LB

LC NAS NCS EAS ECS

MICROCONTROLLER

2FU--BK--123

DCK--K1--127

DCK--2--132

TB--DC1TB--AC1

TB--DC1--23--123

TB--DC1--27--127 TB--DC1--32--132

2FU--R--306

Contacts Shown De-energized

Wire Number

Figure 5-18. Wiring Diagram—Option DD-14-J, Auxiliary dry contacts

SPLICE

2FU

K1 2 42A

DCK

306--DCK--42A

C NC NO

RBK

5604523

Wire Code Example

Device Name

S10--13—201

Device Terminal Number

NA NB NC

EB EC

LC NAS NCS EAS ECS

MICROCONTROLLER

2FU--BK--123

DCK--K1--126

DCK--2--132

TB--DC1TB--AC1

TB--DC1--23--123

TB--DC1--26--126 TB--DC1--32--132

2FU--R--306

Contacts Shown De-energized

Wire Number

Figure 5-19. Wiring Diagram—Option DD-14-K, Auxiliary dry contacts

SPLICE

2FU

BK R

K1 2 42A

DCK

306--DCK--42A

C NC NO

5604524

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Page 79

Wire Code Example

Device Name

S10--13—201

Device Terminal Number

TB--AC1

NA NB NC EA EB EC LA LB

LC NAS NCS EAS ECS

Wire Number

MICROCONTROLLER

DCK--K1--118

2FU--BK--123

DCK--2--132

TB--DC1

21 22 23 24 25 26 27 28

29 30

31 32 33 34

1 2 3 4 5 6 7 8 9

11 12 13 14 15 16

TB--DC1--23--123

TB--DC1--18--118 TB--DC1--32--132

2FU--R--306

SPLICE

Contacts Shown De-energized

Figure 5-20. Wiring Diagram—Option DD-14-L, Auxiliary dry contacts

2FU

BK R

K1 2 42A

DCK

306--DCK--42A

C NC NO

5604525

Wire Code Example

Device Name

S10--13—201

Device Terminal Number

TB--DC1TB--AC1

TB--DC1--23--123

114--DCK--K1

TB--DC1--14--114 TB--DC1--32--132

SPLICE

2FU--R--306

NA NB NC EA EB EC

LC NAS NCS EAS ECS

MICROCONTROLLER

2FU--BK--123

DCK--2--132

Contacts Shown De-energized

Wire Number

Figure 5-21. Wiring Diagram—Option DD-14-M, Auxiliary dry contacts

2FU

BK R

K1 2 42A

DCK

306--DCK--42A

C NC NO

5604526

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Wire Code Example

Device Name

S10--13—201

Device Terminal Number

TB--AC1

NA NB NC EA EB EC

LC NAS NCS EAS ECS

Wire Number

MICROCONTROLLER

2FU--BK--123

DCK--2--132

TB--DC1

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

1 2 3 4 5 6 7 8

11 12 13 14 15 16

101--DCK--K1

TB--DC1--23--123

TB--DC1--1--101

TB--DC1--32--132

2FU--R--306

SPLICE

Contacts Shown De-energized

Figure 5-22. Wiring Diagram—Option DD-14-N, Auxiliary dry contacts

2FU

BK R

K1 2 42A

DCK

306--DCK--42A

C NC NO

5604527

Wire Code Example

Device Name

S10--13—201

Device Terminal Number

TB--AC1

NA NB NC EA EB EC LA LB

LC NAS NCS EAS ECS

MICROCONTROLLER

DCK--K1--119

2FU--BK--123

DCK--2--132

TB--DC1

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

1 2 3 4 5 6 7 8 9

11 12 13 14

TB--DC1--23--123

TB--DC1--19--119 TB--DC1--32--132

2FU--R--306

SPLICE

Contacts Shown De-energized

Wire Number

Figure 5-23. Wiring Diagram—Option DD-14-P, Auxiliary dry contacts

2FU

BK R

K1 2 42A

DCK

306--DCK--42A

C NC NO

5604528

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Page 81

Wire Code Example

Device Name

S10--13—201

Device Terminal Number

TB--DC1TB--AC1

105--DCK--K1

TB--DC1--23--123

TB--DC1--5--105

TB--DC1--32--132

2FU--R--306

Contacts Shown De-energized

NA NB NC EA EB EC

LC NAS NCS EAS ECS

Wire Number

MICROCONTROLLER

2FU--BK--123

DCK--2--132

Figure 5-24. Wiring Diagram—Option DD-14-R, Auxiliary dry contacts

SPLICE

K1 2 42A

2FU

RBK

DCK

306--DCK--42A

5604529

5-20 Accessory Troubleshooting

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Yes

Is there 12 to 32 vdc between terminals 42A(+) and 2(--) on the relay board?

Is there continuity between terminal TB-DC1-32 on the power supply board and terminal 2 on the relay board?

Replace wire from terminal TB-DC1-32 on the power supply board to terminal 2 on the relay board.

Does the terminal become grounded at TB-DC1 when the event is active? Refer to Figure 1a for leads and functions of each contact.

Yes

Replace the leads to the relay board.

Replace the logic board.

Yes

Is the inline fuse between terminal 42A on the relay board and terminal TB-DC1-23 on the power supply board blown?

Replace fuse.

Replace the leads from terminal TB-DC1-23 on the power supply board to terminal 42A on the relay board.

Yes

Is there 12 to 32 vdc between terminals TB-DC1-23(+) and TB-DC1-32(--)on the power supply board?

Is there 19 vac between terminals TB-AC1-NAS and TB-AC1-NCS or TB-AC1-EAS to TB-AC1-ECS on the power supply 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 power supply board terminals?

Yes

Sources not available.

Yes

Replace the power supply board.

Figure 5-25. Troubleshooting—Option DD-14, Auxiliary dry contacts relay boards do not operate

Make sure that the function you are testing is available, i.e., ATS Not-In-Auto relay K10. For this relay to be

Terminal number for

ten-relay board

K1 K1 Normal Source Available TB-DC1-32 K2 K1 Normal Source Available TB-DC1-26 K3 K1 Emergency Source Available TB-DC1-18 K4 K1 Emergency Source Available TB-DC1-18 K5 K1 Contactor in the Normal position TB-DC1-28 K6 K1 Contactor in the Emergency position TB-DC1-27 K7 K1 System Alarm TB-DC1-19 K8 K1 System Alarm TB-DC1-19 K9 K1 Program switch not in the Off position TB-DC1-1

K10 K1 Test switch not in the Auto position TB-DC1-14

Terminal number for

single-relay boards

energized the Test switch must not be in the Auto position.

Description Terminal Number

Figure 5-26. Option DD-14 Terminal Description

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Main Shaft Auxiliary Dry Contacts

One main shaft auxiliary dry contact, option DD-15-A,is supplied standard on 600 volt class transfer switches. DD-15-Aismountedon thetransfer switch. The location of the auxiliarycontacts varies accordingto the ampere size and type of power conversion unit. One set of auxiliary contacts is closed when the transfer switch is connectedtothe normalsource.One set is closedwhen the transfer switch is connected to the emergency source. Refer to the power conversion unit service

manual for troubleshooting. Additional accessory DD-15 contacts available are

described below.

D DD-15-E. This accessory has one additional

contact which is closed when the transfer switch is connected to the normal source.

D DD-15-F. This accessory has one additional

contact which is closed when the transfer switch is connected to the emergency source.

5-22 Accessory Troubleshooting

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Meters

Option 18 providesan analog meter to measure various parameters including voltage, current, and frequency. Figure 5-27 contains a wiring diagram for option DD-18-G. Figure 5-33 contains a troubleshooting flowchart for option DD-18-G. Figure 1b through Figure 5-32contain wiring diagrams for option DD-18-J.

MICROCONTROLLERTB--AC1 TB--DC1

T4--W

T4--BK

204

206

Wire Code Example

S10--13—201

NA NB NC EA EB EC LA LB

LC NAS NCS EAS ECS

Device Name

Wire Number

Device Terminal

Number

21 22 23 24 25 26 27 28

29 30

31 32 33 34

Troubleshooting flowcharts for option DD-18-J begin with Figure 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.

1 2 3 4

11 12 13 14 15 16

3FU--BK FM--2

3FU--R 308

T4--BL 407

307 (R)

407 (BL)

3FU

BK R

204 (W) 206 (BK)

PRIMARYSECONDARY

SPLICESPLICE

308 FM--1307T4--R

TBAC1--EA

TBAC1--EC

5604533

Figure 5-27. Wiring Diagram—Option DD-18-G, Analog frequency meter

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Figure 5-28. Wiring Diagram—Option DD-18-J, Analog Volt and Amp Meter

295385

5-24 Accessory Troubleshooting

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Figure 5-29. Wiring Diagram—Option DD-18-J, Analog Volt and Amp Meter

295386

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Page 87

Figure 5-30. Wiring Diagram—Option DD-18-J, Analog Volt and Amp Meter

295387

5-26 Accessory Troubleshooting

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Figure 5-31. Wiring Diagram—Option DD-18-J, Analog Volt and Amp Meter

295388

TP-5672 11/95

Figure 5-32. Wiring Diagram—Option DD-18-J, Analog Volt and Amp Meter

Accessory Troubleshooting

295388

5-27

Page 89

Is the emergency source available?

Accessory 18-G only displays emergency source frequency.

Is there rated line-to-line voltage at the primary

No No

windings of the transformer?

Replace the leads from terminals TB-AC1-EA and TB-AC1-EC of the power supply board to the transformer.

Is there 120 vac at the

secondary winding of the transformer?

Replace the transformer.

Yes

Is there rated line-to-line emergency source voltage between terminals TB-AC1-EA and TB-AC1-EC of the power supply board?

Yes

Is there a transformer wired between terminal TB-AC1-EA of the power supply board and the frequency meter?

Yes

Refer to Source-Available, Emergency Error Troubleshooting.

Is there rated line-to-line voltage between the two frequency meter terminals?

Yes

Is the in-line fuse between terminal TB-AC1-EA of the power supply board and the frequency meter blown?

Yes

Replace the frequency meter.

Replace the leads between the transformer and the frequency meter.

Is there 120 vac between the

Yes

two frequency meter terminals?

Replace the frequency meter.

Replace the leads between the transformer and the frequency meter.

Figure 5-33. Troubleshooting—Option DD-18-G, Meter will not display frequency

Is the in-line fuse between the secondary side of the transformer and the frequency meter blown?

Yes

Replace the fuse between the secondary side of the transformer and the frequency meter.

Replace the fuse between terminal TB-AC1-EA of the power supply board and the frequency meter.

5-28 Accessory Troubleshooting

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Use the following table to find the troubleshooting flowchart for Option DD-18-J Current and Voltage meters. Locate the DD-18-J accessory that is used on your transfer switch in the left column. The flowchart numberfor troubleshootingthe voltmeter is in the center column and the flowchart for troubleshooting the ammeter is in the right column.

Options

with

DD-18-

Prefix JA1 Figure 5-36 Figure 5-37 JA2 Figure 5-40 to Figure 5-45 Figure 5-46 JA3 Figure 5-36 Figure 5-37 JA4 Figure 5-38 Figure 5-39 JA5 Figure 5-40 to Figure 5-45 Figure 5-46 JA8 Figure 5-47 to Figure 5-52 Figure 5-46 JA9 Figure 5-47 to Figure 5-52 Figure 5-46 JA10 Figure 5-47 to Figure 5-52 Figure 5-46 JB1 Figure 5-36 Figure 5-37 JB2 Figure 5-40 to Figure 5-45 Figure 5-46 JB3 Figure 5-36 Figure 5-37 JB4 Figure 5-38 Figure 5-39 JB5 Figure 5-40 to Figure 5-45 Figure 5-46 JB6 Figure 5-47 to Figure 5-52 Figure 5-46 JB8 Figure 5-47 to Figure 5-52 Figure 5-46 JB9 Figure 5-47 to Figure 5-52 Figure 5-46 JB10 Figure 5-47 to Figure 5-52 Figure 5-46 JC1 Figure 5-36 Figure 5-37 JC2 Figure 5-40 to Figure 5-45 Figure 5-46 JC3 Figure 5-36 Figure 5-37 JC4 Figure 5-38 Figure 5-39 JC5 Figure 5-40 to Figure 5-45 Figure 5-46 JC8 Figure 5-47 to Figure 5-52 Figure 5-46 JC9 Figure 5-47 to Figure 5-52 Figure 5-46 JC10 Figure 5-47 to Figure 5-52 Figure 5-46 JD1 Figure 5-36 Figure 5-37 JD2 Figure 5-40 to Figure 5-45 Figure 5-46 JD3 Figure 5-36 Figure 5-37 JD4 Figure 5-38 Figure 5-39

Voltmeter Troubleshooting

Ammeter

Troubleshooting

Flowchart

Figure 5-34. Option DD-18, analog meters troubleshooting table

Option 18-JXXX, analog meters

JA1-5, JA8-10 30-5 JB1-6, JB8-10 75-5 JC1-5, JC8-10 100-5 JD1-5, JD8-10 150-5 JE1-5, JE8-10 300-5 JF1-6, JF8-10 400-5 JG1-5, JG8-10 600-5 JH1-5, JH8-10 800-5

Figure 5-35. Transformer Turn Ratio

Options

with

DD-18-

Prefix 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 Figure 5-46 JE1 Figure 5-36 Figure 5-37 JE2 Figure 5-40 to Figure 5-45 Figure 5-46 JE3 Figure 5-36 Figure 5-37 JE4 Figure 5-38 Figure 5-39 JE5 Figure 5-40 to Figure 5-45 Figure 5-46 JE8 Figure 5-47 to Figure 5-52 Figure 5-46 JE9 Figure 5-47 to Figure 5-52 Figure 5-46 JE10 Figure 5-47 to Figure 5-52 Figure 5-46 JF1 Figure 5-36 Figure 5-37 JF2 Figure 5-40 to Figure 5-45 Figure 5-46 JF3 Figure 5-36 Figure 5-37 JF4 Figure 5-38 Figure 5-39 JF5 Figure 5-40 to Figure 5-45 Figure 5-46 JF6 Figure 5-47 to Figure 5-52 Figure 5-46 JF8 Figure 5-47 to Figure 5-52 Figure 5-46 JF9 Figure 5-47 to Figure 5-52 Figure 5-46 JF10 Figure 5-47 to Figure 5-52 Figure 5-46 JG1 Figure 5-36 Figure 5-37 JG2 Figure 5-40 to Figure 5-45 Figure 5-46 JG3 Figure 5-36 Figure 5-37 JG4 Figure 5-38 Figure 5-39 JG5 Figure 5-40 to Figure 5-45 Figure 5-46 JG8 Figure 5-47 to Figure 5-52 Figure 5-46 JG9 Figure 5-47 to Figure 5-52 Figure 5-46 JG10 Figure 5-47 to Figure 5-52 Figure 5-46 JH1 Figure 5-36 Figure 5-37 JH2 Figure 5-40 to Figure 5-45 Figure 5-46 JH3 Figure 5-36 Figure 5-37 JH4 Figure 5-38 Figure 5-39 JH5 Figure 5-40 to Figure 5-45 Figure 5-46 JH6 Figure 5-47 to Figure 5-52 Figure 5-46 JH8 Figure 5-47 to Figure 5-52 Figure 5-46 JH9 Figure 5-47 to Figure 5-52 Figure 5-46 JH10 Figure 5-47 to Figure 5-52 Figure 5-46

Turn ratio of transformer

Voltmeter Troubleshooting

Ammeter

Troubleshooting

Flowchart

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Page 91

Does the voltmeter read only the Normal source voltage?

Yes

No No

Refer to Power to the System Troubleshooting.

Replace the leads from terminals TB-AC1-NA and TB-AC1-NB of the power supply board to the source selector switch.

Move the source selector switch to the NORM. NA-NB L1 position.

Is there rated line-to-line voltage between terminals TB-AC1-NA and TB-AC1-NB of the power supply board?

Yes

Is there rated line-to-line voltage between terminals 32 and 42 of the source selector switch?

Yes

Is the source selector switch in the NORM. NA-NB L1 position?

Yes

Is there rated line-to-line voltage between terminals 31 and 41 of the source selector switch?

Is there rated line-to-line voltage between terminals TB-AC1-EA and TB-AC1-EC of the power supply board?

Yes

Is there rated line-to-line voltage between terminals 38 and 48 of the source selector switch?

Yes

Is the source selector switch in the EMERG. EA-EB position?

Yes

Is there rated line-to-line voltage between terminals 31 and 41 of the source selector switch?

Refer to Power to the System Troubleshooting.

Replace the leads from terminals TB-AC1-EA and TB-AC1-EC of the power supply board to the source selector switch.

Move the source selector switch to the EMERG. EA-EB position.

Replace the source selector switch.

Yes Yes

Replace the voltmeter.

Replace the fuse between terminal 31 of the source selector switch and the voltmeter.

Figure 5-36. Troubleshooting—Option DD-18-J, Voltmeter is not functioning

Yes

Is there rated line-to-line voltage between the two terminals of the voltmeter?

Is the fuse between terminal 31 of the source selector switch and the voltmeter blown?

Yes

Replace the leads from terminals 31 and 41 of the source selector switch to the voltmeter.

Yes

Is there rated line-to-line voltage between the two terminals of the voltmeter?

Is the fuse between terminal 31 of the source selector switch and the voltmeter blown?

Yes

Replace the fuse between terminal 31 of the source selector switch and the voltmeter.

Replace the source selector switch.

Replace the voltmeter.

Replace the lead from terminals 31 and 41 on the source selector switch to the voltmeter.

5-30 Accessory Troubleshooting

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NOTE: The ammeter reads load currents. The source

selectorswitchmust beintheNORM. NA-NBL1 position to read the load current.

Yes

Is the current between terminals 12 and 21 of the source selector switch correct? Refer to Figure 5-35 for the proper turn ratio of the current transformer.

Replace the source selector switch.

Replace the ammeter.

Figure 5-37. Troubleshooting—Option DD-18-J, Ammeter is not functioning

Is the current between terminals 11 and 21 of the source selector switch correct?

Refer to Figure 5-35 for the proper turn ratio of the current transformer.

Yes

Is the current between the terminal

Yes

of the ammeter correct? Refer to Figure 5-35 for the proper turn ratio of the current transformer.

Replace the leads from the source selector switch to the ammeter.

Are the leads from the current transformer to the source selector switch open or shorted?

Yes

Replace the current transformers.

Replace the leads from the current transformer to the source selector switch.

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Page 93

Does the voltmeter display only the emergency source?

Yes

No No

Refer to Power to the System Troubleshooting.

Replace the leads from terminals TB-AC1-NA and TB-AC1-NC of the power supply board to the source selector switch.

Move the source selector switch to the NORM. NA-NB L1 position.

Is there rated line-to-line voltage between terminals TB-AC1-NA and TB-AC1-NC of the power supply board?

Yes

Is there rated line-to-line voltage between terminals 32 and 42 of the source selector switch?

Yes

Is the source selector switch in the NORM. NA-NB L1 position?

Yes

Is there rated line-to-line voltage between terminals 31 and 41 of the source selector switch?

Is there rated line-to-line voltage between terminals TB-AC1-EA and TB-AC1-EC of the power supply board?

Yes

Is there rated line-to-line voltage between terminals 38 and 48 of the source selector switch?

Yes

Is the source selector switch in the EMERG. EA-EB position?

Yes

Is there rated line-to-line voltage between terminals 31 and 41 of the source selector switch?

Refer to Power to the System Troubleshooting.

Replace the leads from terminals TB-AC1-EA and TB-AC1-EC of the power supply board to the source selector switch.

Move the source selector switch to the EMERG. EA-EB position.

Replace the source selector switch.

Yes Yes

Replace the voltmeter.

Replace the fuse between terminal 31 of the source selector switch and the voltmeter.

Figure 5-38. Troubleshooting—Option DD-18-J, Voltmeter is not functioning

Yes

Is there rated line-to-line voltage between the two terminals of the voltmeter?

Is the fuse between terminal 31 of the source selector switch and the voltmeter blown?

Yes

Replace the leads from terminals 31 and 41 of the source selector switch to the voltmeter.

Yes

Is there rated line-to-line voltage between the two terminals of the voltmeter?

Is the fuse between terminal 31 of the source selector switch and the voltmeter blown?

Yes

Replace the fuse between terminal 31 of the source selector switch and the voltmeter.

Replace the source selector switch.

Replace the voltmeter.

Replace the lead from terminals 31 and 41 on the source selector switch to the voltmeter.

5-32 Accessory Troubleshooting

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NOTE: Theammeterreadstheloadcurrent.Thesource

selectorswitchmust beintheNORM. NA-NBL1 or L2 position to read the load current.

Is the ratio of current that L1 is using between terminals 12 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 L1 is using between terminals 11 and 21 of the source selector switch correct? Refer to Figure 5-35 for the proper

turn ratio of the current transformer.

Replace the source selector switch.

Is the correct amount of current load L1 is using between the

two terminals of the ammeter?

Replace the ammeter.

Replace the leads from source selector switch to the ammeter.

Yes

Does the ammeter display load currents for L1 only?

Yes

Are the leads from CT1 current transformer to the source selector switch open or shorted?

Yes

Replace the current transformers.

Replace the leads from the current transformer to the source selector switch.

Is the amount of current that L2 is using between terminals 11 and 21 of the source selector switch correct? Refer to Figure 5-35 for the proper

turn ratio of the current transformer.

Replace the source selector switch.

Is the amount of current that L2 is using between the terminals of the ammeter correct? Refer to

Replace the ammeter.

Figure 5-35 for the proper turn ratio of the current transformer.

Replace the leads from source selector switch to the ammeter.

Figure 5-39. Troubleshooting—Option DD-18-J, Ammeter is not functioning

Yes

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

Are the leads from CT2

current transformer to the source selector switch open or shorted?

Replace the leads from the current transformer to the source selector switch.

Yes

Replace the current transformers.

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Replace the leads from terminals TB-AC1-NA and TB-AC1-NB of the power supply board to the source selector switch.

Is there rated line-to-line voltage between terminals TB-AC1-NA and TB-AC1-NB of the power supply board?

Yes

Is there rated line-to-line voltage between terminals

32 and 42 of the source selector switch?

Yes

Refer to Power to the System Troubleshooting.

Is the source selector switch in the NORM. NA-NB L1 position?

Yes

Replace the source selector switch.

Is there rated line-to-line voltage between terminals

31 and 41 of the source selector switch?

Move the source selector switch to the NORM. NA-NB L1 position.

Yes

Is there rated line-to-line voltage between the two terminals of the voltmeter?

Replace the voltmeter.

Replace the lead from terminals 31 and 41 of the source selector switch to the voltmeter.

Is the fuse between terminal 31 of the source selector switch and the voltmeter blown?

YesNo

Replace the fuse between terminal 31 of the source selector switch and the voltmeter.

Figure 5-40. Troubleshooting—Option DD-18-J, Voltmeter does not read NA-NB voltage

5-34 Accessory Troubleshooting

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Is there rated line-to-line voltage between terminals TB-AC1-NB and TB-AC1-NC of the power supply board?

Yes

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.

Replace the source selector switch.

Is there rated line-to-line voltage between terminals 33 and 43 of the source

selector switch?

Yes

Is there rated line-to-line voltage between terminals 31 and 41 of the source selector switch?

Is the source selector switch in the NORM. NB-NC L2 position?

Yes

Move the source selector switch to the NORM. NA-NB L1 position.

Yes

Is there rated line-to-line voltage between the two

terminals of the voltmeter?

Replace the voltmeter.

Replace the lead from terminals 31 and 41 of the source selector switch to the voltmeter.

Is the fuse between terminal 31 of the source selector switch and the voltmeter blown?

YesNo

Replace the fuse between terminal 31 of the source selector switch and the voltmeter.

Figure 5-41. Troubleshooting—Option DD-18-J, Voltmeter does not read NB-NC voltage

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Page 97

Is there rated line-to-line voltage between terminals TB-AC1-NA and TB-AC1-NC of the power supply board?

Replace the leads from terminals TB-AC1-NA and TB-AC1-NC of the power supply board to the source selector switch.

Replace the source selector switch.

Is there rated line-to-line voltage between terminals

32 and 42 of the source selector switch?

Is the source selector switch in the NORM. NA-NC L3 position?

Is there rated line-to-line voltage between terminals

31 and 41 of the source selector switch?

Is there rated line-to-line voltage between the two terminals of the voltmeter?

Yes

Refer to Power to the System Troubleshooting.

Move the source selector switch to the NORM. NA-NC L3 position.

Replace the voltmeter.

Replace the lead from terminals 31 and 41 of the source selector switch to the voltmeter.

Is the fuse between terminal 31 of the source selector switch and the voltmeter blown?

YesNo

Replace the fuse between terminal 31 of the source selector switch and the voltmeter.

Figure 5-42. Troubleshooting—Option DD-18-J, Voltmeter does not read NA-NC voltage

5-36 Accessory Troubleshooting

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Page 98

Is there rated line-to-line voltage between terminals TB-AC1-EA and TB-AC1-EB of the power supply board?

Replace the leads from terminals TB-AC1-EA and TB-AC1-EB of the power supply board to the source selector switch.

Replace the source selector switch.

Is there rated line-to-line voltage between terminals

32 and 42 of the source selector switch?

Is the source selector switch in the EMERG. EA-EB position?

Is there rated line-to-line voltage between terminals

31 and 41 of the source selector switch?

Is there rated line-to-line voltage between the two terminals of the voltmeter?

Yes

Refer to Power to the System Troubleshooting.

Move the source selector switch to the EMERG. EA-EB position.

Replace the voltmeter.

Replace the lead from terminals 31 and 41 of the source selector switch to the voltmeter.

Is the fuse between terminal 31 of the source selector switch and the voltmeter blown?

YesNo

Replace the fuse between terminal 31 of the source selector switch and the voltmeter.

Figure 5-43. Troubleshooting—Option DD-18-J, Voltmeter does not read EA-EB voltage

TP-5672 11/95

Accessory Troubleshooting

5-37

Page 99

Is there rated line-to-line voltage between terminals TB-AC1-EB and TB-AC1-EC of the power supply board?

Replace the leads from terminals TB-AC1-EB and TB-AC1-EC of the power supply board to the source selector switch.

Replace the source selector switch.

Is there rated line-to-line voltage between terminals

32 and 42 of the source selector switch?

Is the source selector switch in the EMERG. NB-NC position?

Is there rated line-to-line voltage between terminals

31 and 41 of the source selector switch?

Is there rated line-to-line voltage between the two terminals of the voltmeter?

Yes

Refer to Power to the System Troubleshooting.

Move the source selector switch to the EMERG. EB-EC position.

Replace the voltmeter.

Replace the lead from terminals 31 and 41 of the source selector switch to the voltmeter.

Is the fuse between terminal 31 of the source selector switch and the voltmeter blown?

YesNo

Replace the fuse between terminal 31 of the source selector switch and the voltmeter.

Figure 5-44. Troubleshooting—Option DD-18-J, Voltmeter does not read EB-EC voltage

5-38 Accessory Troubleshooting

TP-5672 11/95

Page 100

Is there rated line-to-line voltage between terminals TB-AC1-EA and TB-AC1-EC of the power supply board?

Replace the leads from terminals TB-AC1-EB and TB-AC1-EC of the power supply board to the source selector switch.

Replace the source selector switch.

Is there rated line-to-line voltage between terminals

32 and 42 of the source selector switch?

Is the source selector switch in the EMERG. NB-NC position?

Is there rated line-to-line voltage between terminals

31 and 41 of the source selector switch?

Is there rated line-to-line voltage between the two terminals of the voltmeter?

Yes

Refer to Power to the System Troubleshooting.

Move the source selector switch to the EMERG. EB-EC position.

Replace the voltmeter.

Replace the lead from terminals 31 and 41 of the source selector switch to the voltmeter.

Is the fuse between terminal 31 of the source selector switch and the voltmeter blown?

YesNo

Replace the fuse between terminal 31 of the source selector switch and the voltmeter.

Figure 5-45. Troubleshooting—Option DD-18-J, Voltmeter does not read EA-EC voltage

TP-5672 11/95

Accessory Troubleshooting

5-39

Kohler M340+ Service And Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual