Kohler PA-320751, PA-320743, PA-320742, PA-320748, PA-320747 Operation And Installation Instructions Manual

Operation and

Installation Instructions

Automatic Battery Chargers

Kits:

PA-320741

P

A-320741-SD through P

through P

A-320764 and

A-320764-SD

TT-855 12/93b

Table of Contents

SUBJECT PAGE SUBJECT PAGE

Safety Precautions and Instructions 1.
Introduction 4
Specifications 5
Installing Charger 8.

Mount Charger 9.
Ouput Connections 9.
Input Connections 9.

Disconnecting Charger 11.
Battery Charger Operation 12.

Charging Lead-Acid Batteries 12.
Checking Specific Gravity 14.
Charging Nickel-Cadmium Batteries 14.

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Charger Voltage Adjustment 15.
Charger and Battery Maintenance 15.

Troubleshooting 16
Standard Accessories 17.

Current Limiting 17.
Reverse Polarity Protection 17.
Automatic Float Operation 17.
Temperature Compensation 17.
AC Input Fuse 17.
DC Output Fuse 17.
Power On Lamp 17.

Wiring Diagrams 18.
Parts Lists 24.

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-855 12/93

T

able of Contents

iTT

Safety Precautions and Instructions

A generator set, like any other electro-mechanical
device, can pose potential dangers to life and limb if
improperly maintained or imprudently operated. The
best way to prevent accidents is to be aware of the
potential dangers and to always use good common
sense. In the interest of safety, some general
precautions
follow. Keep these in mind. This manual contains
several
below.

relating the to operating of a generator set

types of safety precautions

which are explained

CAUTION

Caution

will

damage if the warning is ignored.

Note
maintenance information that is important but not
hazard-related.

is

used to indicate the presence of a hazard that

or

can

is used

cause

to notify people of installation, operation, or

minor

personal injury or property

NOTE

DANGER

Danger is used to indicate the presence of a hazard that

will

cause

property damage if the warning is ignored.

Warning is used to indicate the presence of a hazard
that
substantial property damage if the warning is ignored.

severe

WARNING

can

cause

personal injury, death, or substantial

severe

personal injury, death, or

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).

Safety decals are affixed to the generator set in
prominent places to advise the operator or service
technician of potentially hazardous situations. The
decals are reproduced here to improve operator
recognition and thereby increase decal effectiveness.
For

a further
the accompanying safety precautions. Before
operating or servicing the generator set, be sure you
understand the message of these decals. Replace
decals if missing or damaged.

Accidental starting can cause severe injury or
death. Turn generator master switch to OFF position,

disconnect power to battery charger, and remove
battery cables (remove negative lead first and
reconnect
on any equipment connected to generator. The
generator set can be started by automatic transfer
switch or remote start/stop switch unless these
precautions are followed.

explanation of decal information, reference

it last) to disable generator set before working

-855 12/93

Safety Precautions

1TT

Hazardous Voltage/Electrical Shock

WARNING

Hazardous voltage.
Can cause severe injury or death.

Do not operate generator set without all guards
and electrical enclosures in place.

Hazardous voltage can cause severe injury or
death. De-energize both normal and emergency power

sources before proceeding. Move generator 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. Keep everyone away from the set and take

precautions to prevent unqualified personnel from
tampering.
only by qualified technicians. Wiring should be
inspected at the recommended interval shown in the
service schedule—replace leads that are frayed or in
poor condition. Do not operate electrical equipment
when standing in water, on wet ground, or when your
hands are wet.

Have the set and electrical circuits serviced

Moving rotor.

Hazardous voltage can cause severe injury or
death. Electrical shock may occur if battery charger is

not properly grounded. Connect battery charger
enclosure
an alternative, run an equipment-grounding conductor
with circuit conductors and connect to
equipment-grounding terminal or lead on battery
charger. Battery charger installation should be
performed
comply with all local codes and ordinances.

to ground of a permanent wiring

as prescribed in equipment manual and must

system. As

(Applies to Optional Battery Charger.)

Hazardous voltage can cause severe injury or
death. Improper reconnection may damage charger

and

battery(ies), and

Installation must be done by a qualified electrician.

create an electrical shock hazard.

(Applies to Optional Battery Charger.)

Hazardous voltage can cause severe injury or
death. Short circuits can cause bodily injury and/or

equipment damage. Do not contact electrical
connections
made.
cause short circuits.

with tools or jewelry while adjustments are

Remove wristwatch, rings, and jewelry that can

2 TT

Safety Precautions

-855 12/93

Battery

WARNING

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

Use protective goggles and clothes. Can cause
permanent
in clothing.

Sulfuric
death. Sulfuric acid in battery can cause permanent

damage to eyes, burn skin, and eat holes in clothing.
Always
around the battery. If battery electrolyte
the

eyes or

for

15 minutes with large quantities of clean water
case of eye contact, seek immediate medical aid. Never
add acid to a battery once
service.
electrolyte.

damage to eyes, burn skin, and eat holes

acid in batteries

wear splash-proof safety goggles when working

on skin, immediately flush the af

Doing so may result in

can cause severe injury or

is splashed in

fected area

. In

the

battery has been placed in

hazardous spattering of

the

Explosion can cause severe injury or death. Battery

gases

can cause an explosion. Do not smoke or permit
flame or spark to occur near a battery at any time,
particularly
terminals
sparks that could cause an explosion. Remove
wristwatch,
battery. Never connect negative (–) battery cable to
positive (+) connection terminal of starter solenoid. Do
not

test battery condition by shorting terminals together
or sparks could ignite battery gases or fuel vapors. Any
compartment containing batteries must be well
ventilated to prevent accumulation of explosive gases.
To avoid sparks, do not disturb battery charger
connections
turn charger off before disconnecting battery
connections. When disconnecting battery, remove
negative lead first and reconnect it last.

when it is being charged. A

with tools,

rings, and any other jewelry before handling

while battery is being charged and always

etc. to prevent burns and to prevent

void contacting

NOTES

NOTE

Charge only LEAD-ACID or NICKEL-CADMIUM
batteries with battery charger.

NOTE

Split lock washers may be supplied with some kits. If
split lock washers are supplied with kit, their use is
optional.

(use with kits only)

NOTE

HARDWARE DAMAGE! Engine and generator may

make use of both American Standard and metric
hardware. Be sure to use the correct size tools to
prevent rounding of bolt heads and nuts.

-855 12/93

Safety Precautions

3TT

Introduction

This TT includes the following kits:
PA-320741 through P

PA-320741-SD through PA-320764-SD
This manual contains important safety and operating

instructions for automatic 2-amp battery chargers.
Before using the battery charger, read all instructions
and cautionary instructions on (1) battery charger, (2)
battery, and (3) product using battery. Keep these
instructions

The battery chargers are designed for various AC
voltage,
follows:

in mind when operating the battery charger

50- or 60-Hz input, and capable of charging as

A-320764 and

12-Volt Charger Lead-Acid Battery (6-cell)
24-Volt Charger Lead-Acid Battery (12-cell)

Determine input voltage and type of battery(ies) to be
charged. Make any necessary modifications before
using charger.

Grounding Instructions—Connect the battery
charger
or an equipment-grounding conductor with circuit

.

conductors and connect it to equipment-grounding
terminal or lead on battery charger. Connections to
battery charger should comply with all local codes and
ordinances.

to a

grounded, metal, permanent wiring system

4 TT

Introduction

-855 12/93

Specifications

The automatic battery charger is designed to charge
and maintain lead-acid and nickel-cadmium
automotive-type batteries in a fully charged state
without any manual intervention. The charger output
provided by the power transformer is controlled by the
circuit board. The control board provides the charger
with current-limiting, AC line compensation,
reverse-polarity protection, ambient-temperature
compensation, and constant voltage charging mode.

1 2 3 4

DC

AMPERES

0

AC INPUT
120V 50/60HZ .68A
DC OUTPUT
12V 2A

321

POWER

ON

DC

OUTPUT

6A

VOLT.

ADJ.

AC

INPUT

1A

The control circuit board continuously monitors the
battery and load conditions to maintain the battery’s
proper

state of charge. Refer to Figure 1 for component
identification. The chargers are factory adjusted to
maintain the battery at the proper float voltages. The
12-volt

charger will

maintain a lead-acid (6-cell) battery
with no adjustment required. The 24-volt charger will
maintain

a lead-acid (12-cell) battery with no adjustment

required.

5

294241-B

1. DC

Ammeter

2.

DC Output Fuse

3.

“Power On” Lamp

4. Transformer

GRD

AC

AC + –

678

5.

6.

7. T

8.

Figure 1. Battery Charger Components

Main Circuit Board Assembly
AC Input Fuse

erminal Block

Ground T

erminal (AC)

A-294226-A

P1

-855 12/93

Specifications

5TT

Battery Charger Kits Selection Table

e

e

e

e

Volts Input Voltage

led

e

12 24

Descriptions
T

ransfer Switch Accessory No.
Battery Charger Kit No. *
T

ransfer Switch Accessory No.
Battery Charger Kit No. *

* SA

TS model transfer switches have an -SD suffix. EXAMPLE: P

Descriptions
T

ransfer Switch Accessory No.
Battery Charger Kit No. *
T

ransfer Switch Accessory No.
Battery Charger Kit No. *

* SA

TS+ model transfer switches have an -SD suf

Loos

Install

X X KA-24-62A KA-24-64A KA-24-63A KA-24-60A KA-24-68A KA-24-71A

X X PA-320741 PA-320747 PA-320745 PA-320751 PA-320743 PA-320749

X X KA-24-62B KA-24-64B KA-24-63B KA-24-60B KA-24-68B KA-24-71B

X X PA-320742 PA-320748 PA-320746 PA-320752 PA-320744 PA-320750

Figure 2. Battery Chargers for S340 Model Transfer Switch

Volts Input Voltage

led

e

Loos

12 24

Install

X X DA-24-62A DA-24-64A DA-24-63A DA-24-60A DA-24-68A DA-24-71A

X X PA-320741 PA-320747 PA-320745 PA-320751 PA-320743 PA-320749

X X DA-24-62B DA-24-64B DA-24-63B DA-24-60B DA-24-68B DA-24-71B

X X PA-320742 PA-320748 PA-320746 PA-320752 PA-320744 PA-320750

fix. EXAMPLE: P

120 V

50/60 Hz

120 V

50/60 Hz

240 V

50/60 Hz

A-320741-SD

240 V

50/60 Hz

A-320741-SD

220 V

50/60 Hz

220 V

50/60 Hz

480/600 V

50/60 Hz

480/600 V

50/60 Hz

208 V

50/60 Hz

208 V

50/60 Hz

380/416 V

50/60 Hz

380/416 V

50/60 Hz

Figure 3. Battery Chargers for S340+ Model Transfer Switch

Volts Input Voltage

led

e

Loos

12 24

Descriptions
T

ransfer Switch Accessory No.
Battery Charger Kit No. *
T

ransfer Switch Accessory No.
Battery Charger Kit No. *

* MA

TS model transfer switches have an -SD suffix. EXAMPLE: P

Install

X X KD-24-62A KD-24-64A KD-24-63A KD-24-60A KD-24-68A KD-24-71A

X X PA-320753 PA-320759 PA-320757 PA-320763 PA-320755 PA-320755

X X KD-24-62B KD-24-64B KD-24-63B KD-24-60B KD-24-68B KD-24-71B

X X PA-320754 PA-320760 PA-320758 PA-320764 PA-320756 PA-320756

Figure 4. Battery Chargers for M340 Model Transfer Switch

120 V

50/60 Hz

240 V

50/60 Hz

A-320741-SD

220 V

50/60 Hz

480/600 V

50/60 Hz

208 V

50/60 Hz

380/416 V

50/60 Hz

6 TT

Specifications

-855 12/93

e

e

e

e

Descriptions
T

ransfer Switch Accessory No.
Battery Charger Kit No. *
T

ransfer Switch Accessory No.
Battery Charger Kit No. *

* MA

TS+ model transfer switches have an -SD suf

Loos

X X PA-320753 PA-320759 PA-320757 PA-320763 PA-320755 PA-320761

X X PA-320754 PA-320760 PA-320758 PA-320764 PA-320756 PA-320762

Figure 5. Battery Chargers for M340+ Model Transfer Switch

e

Descriptions
T

ransfer Switch Accessory No.
Battery Charger Kit No.
T

ransfer Switch Accessory No.
Battery Charger Kit No.

Loos

X X ––– ––– ––– ––– ––– –––

X X ––– ––– ––– ––– ––– –––

Figure 6. Battery Chargers for R33 Model Transfer Switch

Volts Input Voltage

led

12 24

Install

X X DD-24-62A DD-24-64A DD-24-63A DD-24-60A DD-24-68A DD-24-71A

X X DD-24-62B DD-24-64B DD-24-63B DD-24-60B DD-24-68B DD-24-71B

fix. EXAMPLE: P

Volts Input Voltage

led

12 24

Install

X X ––– KD-24-64A KD-24-63A ––– ––– –––

X X ––– KD-24-64B KD-24-63B ––– ––– –––

120 V

50/60 Hz

120 V

50/60 Hz

240 V

50/60 Hz

A-320741-SD

240 V

50/60 Hz

220 V

50/60 Hz

220 V

50/60 Hz

480/600 V

50/60 Hz

480/600 V

50/60 Hz

208 V

50/60 Hz

208 V

50/60 Hz

380/416 V

50/60 Hz

380/416 V

50/60 Hz

Descriptions
Primary Circuit

Protection
Secondary Circuit

Protection
Output Level

Preset at Factory

120 V

50/60 Hz

1 Amp 12 V

1.5 Amp 24 V

Figure 7. Battery Charger Specifications

240 V

50/60 Hz

0.5 Amp 12 V
1 Amp 24 V

12-V

olt Charger—13.2 V

24- V

olt Charger—26.4 V

Input Voltage

220 V

50/60 Hz

0.5 Amp 12 V
1 Amp 24 V

6 Amp Slo-Blo

480/600 V

50/60 Hz

0.2 Amp 12 V

0.4 Amp 24 V

208 V

50/60 Hz

0.5 Amp 12 V
1 Amp 24 V

olt, 2 Amp Current Limiting

olt, 2 Amp Current Limiting

380/416 V

50/60 Hz

0.3 Amp 12 V

0.5 Amp 24 V

-855 12/93

Specifications

7TT

Installing Charger

WARNING

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

Use protective goggles and clothes. Can cause
permanent
in clothing.

damage to eyes, burn skin, and eat holes

NOTE

CHARGER

a battery with the same DC voltage as the battery
charger output rating.

DAMAGE!

Connect battery

charger only to

WARNING

Sulfuric
death. Sulfuric acid in battery can cause permanent

damage to eyes, burn skin, and eat holes in clothing.
Always
around the battery. If battery electrolyte
the
for
case of eye contact, seek immediate medical aid. Never
add acid to a battery once
service.
electrolyte.

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 master switch to OFF position,

disconnect power to battery charger, and remove
battery cables (remove negative lead first and
reconnect
on any equipment connected to generator. The
generator set can be started by automatic transfer
switch or remote start/stop switch unless these
precautions are followed.

acid in batteries

wear splash-proof safety goggles when working

eyes or

15 minutes with large quantities of clean water

on skin, immediately flush the af

Doing so may result in

WARNING

it last) to disable generator set before working

can cause severe injury or

is splashed in

fected area

. In

the

battery has been placed in

hazardous spattering of

the

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.

Explosion

gases
flame or spark to occur near a battery at any time,
particularly
terminals
sparks that could cause an explosion. Remove
wristwatch,
battery. Never connect negative (–) battery cable to
positive (+) connection terminal of starter solenoid. Do
not

test battery condition by shorting terminals together
or sparks could ignite battery gases or fuel vapors. Any
compartment containing batteries must be well
ventilated to prevent accumulation of explosive gases.
To avoid sparks, do not disturb battery charger
connections
turn charger off before disconnecting battery
connections. When disconnecting battery, remove
negative lead first and reconnect it last.

can cause severe injury or death. Battery

can cause an explosion. Do not smoke or permit

when it is being charged. A

with tools,

rings, and any other jewelry before handling

while battery is being charged and always

etc. to prevent burns and to prevent

void contacting

8 TT

Installation

-855 12/93

Mount Charger

1. Move generator master switch to OFF position.
Disconnect battery cables, negative lead first.
Open circuit breaker of AC power source to be
applied.

2. Turn automatic transfer switch selector to OFF
position.

3. Open automatic transfer switch enclosure.

Output Connections

NOTE

For

DC

connections use stranded copper wire, 600 V
105_C vinyl plastic insulation UL style 1015, CSA
TEW.

1. Due to the variety of generator installations,
battery cables are not provided. To make battery
connections, cut red (+) 10-gauge stranded wire
to proper length and strip insulation from both
ends. To one end of wire attach a post-type
connector. Route other end of battery cable and
connect
DC terminal block. See
block lock screw to secure battery cable. Repeat

to output positive (+) terminal on

Figure 8. T

ighten terminal

charger

olt,

type

4. Install four captive nuts (298811) in the transfer
switch

inner panel and install battery charger

Figure 8.

5. The battery charger is factory set to maintain the
proper

output for the battery voltage for which it is

rated. No customer adjustments are required.

procedure
connect black wire to output negative (–)
on DC terminal

2. Connect
terminal and black charger lead(s) to battery
negative (–) terminal.

Grounding Instructions—This
be connected to a grounded, metal, permanent wiring
system.
be run with circuit conductors and connected to
equipment-grounding terminal on battery charger.
Connections to battery charger should comply with all
local codes and ordinances.

An equipment-grounding conductor could

with black (–) 10-gauge stranded wire;

block

and secure with lock screw

red charger lead(s) to battery positive

battery charger should

. See

terminal

(+)

also

.

Input Connections

1. Connect
source as indicated by nameplate or transfer
switch wiring diagram.

the correct voltage, 50/60 Hz, AC power

2. Turn AC power on. Power On lamp will light and
ammeter will show charging current.

-855 12/93

Installation

9TT

1. Battery

Charger Assembly (see parts lists)

Figure 8. Battery Charger Installation—Solid-State Transfer Switch

2.

Captive Nuts (29881

1) qty

1

2

BW-29500-B294241-B

. 4

10 TT

Installation

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