Automatic Transfer Switch - Norwall · Automatic Transfer Switch Operation and Installation Model: RXT 100--400 Amp Automatic Transfer Switches For use with Kohlerr Model …

Automatic Transfer Switch

Operation andInstallation

Model:

RXT100--400 Amp Automatic Transfer Switches

For use with Kohlerr Model RESA, RESAL, or RCL generator setsequipped with RDC2 or DC2 generator/transfer switch controllers

TP-6807 12/11a

TP-6807 12/112

Product Identification Information

Product identification numbers determine service parts.Record the product identification numbers in the spacesbelow immediately after unpacking the products so thatthe numbers are readily available for future reference.Record field-installed kit numbers after installing thekits.

Transfer Switch Identification Numbers

Record the product identification numbers from thetransfer switch nameplate.

Model Designation

Serial Number

Table of Contents

TP-6807 12/11 Table of Contents 3

Product Identification Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Precautions and Instructions 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Nameplate 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Model Designation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Assistance 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 1 Description 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1 Transfer Switch Description 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2 Service Entrance Models 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3 Load Centers 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4 Controller Interface Board 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5 Optional LED Indicator Panel 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2 Installation 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1 Introduction 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2 Receipt of Unit 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.1 Inspection 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2.2 Storage 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2.3 Unpacking 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2.4 Lifting 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 Installation 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4 Manual Operation Check 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.1 Manual Operation Procedure 1 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4.2 Manual Operation Procedure 2 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5 Electrical Wiring 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.1 Load Center Circuit Breakers 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.2 AC Power Connections 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.3 Neutral Connection 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.4 Neutral Bonding Jumper, Service Entrance Models 17. . . . . . . . . . . . . . . . .2.5.5 Engine Start Function 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.6 Interface Module Connection 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.7 Optional Load Control Connection 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.8 Accessory Module Connections 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6 Test and Exercise 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7 Warranty Registration 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 3 Operation 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1 Model RXT Transfer Switch Operation 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2 Source Availability 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3 ATS Control Sequence of Operation 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4 Time Delays 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.5 Load Control Time Delay 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 4 Service Disconnect, SE Model 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1 Service Disconnect Procedure 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2 Source Circuit Breaker Reset 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents, continued

TP-6807 12/11Table of Contents4

Section 5 Scheduled Maintenance 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1 Introduction 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2 Testing 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.1 Weekly Generator Set Exercise 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2.2 Monthly Automatic Control System Test 26. . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Inspection and Service 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3.1 General Inspection 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3.2 Other Inspections and Service 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 Service Schedule 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 6 Diagrams and Drawings 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A Abbreviations 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TP-6807 12/11 5Safety Precautions and Instructions

Safety Precautions and Instructions

IMPORTANTSAFETY INSTRUCTIONS.Electromechanical equipment,including generator sets, transferswitches, switchgear, and accessories,can cause bodily harm and poselife-threatening danger whenimproperly installed, operated, ormaintained. To prevent accidents beaware of potential dangers and actsafely. Read and follow all safetyprecautions and instructions. SAVETHESE INSTRUCTIONS.

Thismanual has several types of safetyprecautions and instructions: Danger,Warning, Caution, and Notice.

DANGER

Danger indicates the presence of ahazard that will cause severepersonal injury, death, orsubstantialproperty damage.

WARNING

Warning indicates the presence of ahazard that can cause severepersonal injury, death, orsubstantialproperty damage.

CAUTION

Caution indicates the presence of ahazard that will or can cause minorpersonal injury or property damage.

NOTICENotice communicates installation,operation, or maintenance informationthat is safety related but not hazardrelated.

Safety decals affixed to the equipmentin prominent places alert the operatoror service technician to potentialhazards and explain how to act safely.The decals are shown throughout thispublication to improve operatorrecognition. Replace missing ordamaged decals.

Accidental Starting

Accidental starting.Can cause severe injury or death.

Disconnect the battery cables beforeworking on the generator set.Remove the negative (--) lead firstwhen disconnecting the battery.Reconnect the negative (--) lead lastwhen reconnecting the battery.

WARNING

Disabling the generator set.Accidental starting can causesevere injury or death. Beforeworking on the generator set orequipment connected to the set,disable the generator set as follows:(1) Press the generator set off/resetbutton to shut down the generator set.(2) Disconnect the power to the batterycharger, if equipped. (3) Remove thebattery cables, negative (--) lead first.Reconnect the negative (--) lead lastwhen reconnecting the battery. Followthese precautions to prevent thestarting of the generator set by theremote start/stop switch.

Hazardous Voltage/Moving Parts

Hazardous voltage.Will cause severe injury or death.

Disconnect all power sources beforeopening the enclosure.

DANGER


Only authorized personnel shouldopen the enclosure.

DANGER


This equipment must be installed andserviced by qualified electricalpersonnel.

DANGER

Grounding electrical equipment.Hazardous voltage can causesevere injury or death. Electrocutionis possible whenever electricity ispresent. Ensure you comply with allapplicable codes and standards.Electrically ground the generator set,transfer switch, and related equipmentand electrical circuits. Turn off themaincircuit breakers of all power sourcesbefore servicing the equipment. Nevercontact electrical leads or applianceswhen standing in water or on wetground because these conditionsincrease the risk of electrocution.

Short circuits. Hazardousvoltage/current can cause severeinjury or death. Short circuits cancause bodily injury and/or equipmentdamage. Do not contact electricalconnections with tools or jewelry whilemaking adjustments or repairs.Remove all jewelry before servicing theequipment.

Making line or auxiliaryconnections. Hazardous voltagecan cause severe injury or death. Toprevent electrical shock deenergize thenormal power source before makingany line or auxiliary connections.

TP-6807 12/116 Safety Precautions and Instructions

Servicing the transfer switch.Hazardous voltage can causesevere injuryor death. Deenergizeallpower sources before servicing. Turnoff the main circuit breakers of alltransfer switch power sources anddisable all generator sets as follows:(1) Move all generator set mastercontroller switches to theOFFposition.(2) Disconnect power to all batterychargers. (3) Disconnect all batterycables, negative (--) leads first.Reconnect negative (--) leads lastwhenreconnecting the battery cables afterservicing. Follow these precautions toprevent the starting of generator setsby an automatic transfer switch, remotestart/stop switch, or engine startcommand from a remote computer.Before servicing any componentsinside the enclosure: (1) Remove alljewelry. (2) Stand on a dry, approvedelectrically insulated mat. (3) Testcircuits with a voltmeter to verify thatthey are deenergized.

Heavy Equipment

Unbalanced weight.Improper lifting can cause severeinjury or death and equipmentdamage.

Use adequate lifting capacity.Never leave the transfer switchstanding upright unless it is securelybolted in place or stabilized.

WARNING

NoticeNOTICE

Foreign material contamination.Cover the transfer switch duringinstallation to keep dirt, grit, metal drillchips, and other debris out of thecomponents. Cover the solenoidmechanism during installation. Afterinstallation, use the manual operatinghandle to cycle the contactor to verifythat it operates freely. Do not use ascrewdriver to force the contactormechanism.

NOTICEElectrostatic discharge damage.Electrostatic discharge (ESD)damages electronic circuit boards.Prevent electrostatic dischargedamage by wearing an approvedgrounding wrist strap when handlingelectronic circuit boards or integratedcircuits. An approved grounding wriststrap provides a high resistance (about1 megohm), not a direct short, toground.

TP-6807 12/11 7Introduction

Introduction

This manual provides operation and installationinstructions for Kohlerr Model RXT automatic transferswitches. See Figure 1 for typical Model RXT transferswitches.

Model RXT transfer switches operate only with Kohlerrgenerator sets equipped with the RDC2 or DC2generator/transfer switch controller. See Figure 2 forcontroller identification.

Information in this publication represents data availableat the time of print. Kohler Co. reserves the right tochange this literature and the products representedwithout notice and without any obligation or liabilitywhatsoever.

Read this manual and carefully follow all proceduresand safety precautions to ensure proper equipmentoperation and to avoid bodily injury. Readand follow theSafety Precautions and Instructions section at thebeginning of this manual. Keep this manual with theequipment for future reference.

The equipment service requirements are very importantto safe and efficient operation. Inspect parts often andperform required service at the prescribed intervals.Obtain service from an authorized service distributor/dealer to keep equipment in top condition.

Figure 1 Typical Model RXT Transfer Switches(shown with optional status indicators)

GM77569

RDC2 DC2

Figure 2 RDC2 and DC2 Generator/Transfer SwitchControllers (provided with and mounted onthe generator set)

TP-6807 12/118 Introduction

Nameplate

A nameplate attached to the inside of the enclosurecover or on the upper right side wall includes a modeldesignation, a serial number, ratings, and otherinformation about the transfer switch. See Figure 3.

Check the transfer switch model number from thetransfer switch nameplate and verify that it matches themodel shown on the front cover of this manual beforeproceeding with installation.

Copy the model designation, serial number, andaccessory information from thenameplate to thespacesprovided in the Product Identification Informationsection located inside the front cover of this manual foruse when requesting service or parts.

Model Designation

Figure 4 explains the model designation.

TRANSFER SWITCH

GM21291-E

1

2

3

1. Model designation2. Serial number3. Factory-installed accessory numbers

MATERIAL

FOR EMERGENCY SYSTEMSTRANSFER SWITCH

TYPE ENCLOSUREMFG. DATE

POLESWIRESAMPS

HERTZ

BAR CODE

PHASEVOLTS

SERIAL NO.MODEL

ACCESSORIES:

FOR EMERGENCY SYSTEMSLISTED

R

Figure 3 Typical Transfer Switch Nameplate

ModelRXT: Kohler Automatic Transfer Switch

ControlsJ: Interface for RDC2/DC2 Controller

Number of Poles/Wires

Enclosure

ConnectionsA: No load centerB: With load center (100 amp single-phase only)ASE: Service entrance rated

C: 208 Volts/60 Hz (3-phase only)F: 240 Volts/60 HzM: 480 Volts/60 Hz (3-phase only)

Voltage/Frequency

N: 2-pole, 3-wire, solid neutral (120/240 V only)T: 3-pole, 4-wire, solid neutralV: 4-pole, 4-wire, switched neutral

C: NEMA 3R

Model Controls Voltage Poles Enclosure Current Rating Connections

Current Rating: Numbers indicate the current ratingof the switch in amperes:

Record the transfer switch model designation in the boxes. The transfer switch model designation defines ratings ancharacteristics as explained below.

Sample Model Designation: RXT-JFNC-0200A

01000150

02000300

0400

Figure 4 Model Designation

TP-6807 12/11 9Service Assistance

Service Assistance

For professional advice on generator set powerrequirementsandconscientiousservice, pleasecontactyour nearest Kohler distributor or dealer.

D Consult the Yellow Pages under the headingGenerators—Electric.

D Visit the Kohler Power Systems website atKOHLERPower.com.

D Lookat the labels and stickers on yourKohler productor review the appropriate literature or documentsincluded with the product.

D Call toll free in the US and Canada 1-800-544-2444.

D Outside theUSandCanada, call the nearest regionaloffice.

Headquarters Europe, Middle East, Africa(EMEA)Kohler Power Systems Netherlands B.V.Kristallaan 14761 ZC ZevenbergenThe NetherlandsPhone: (31) 168 331630Fax: (31) 168 331631

Asia PacificPower Systems Asia Pacific Regional OfficeSingapore, Republic of SingaporePhone: (65) 6264-6422Fax: (65) 6264-6455

ChinaNorth China Regional Office, BeijingPhone: (86) 10 6518 7950

(86) 10 6518 7951(86) 10 6518 7952

Fax: (86) 10 6518 7955

East China Regional Office, ShanghaiPhone: (86) 21 6288 0500Fax: (86) 21 6288 0550

India, Bangladesh, Sri LankaIndia Regional OfficeBangalore, IndiaPhone: (91) 80 3366208

(91) 80 3366231Fax: (91) 80 3315972

Japan, KoreaNorth Asia Regional OfficeTokyo, JapanPhone: (813) 3440-4515Fax: (813) 3440-2727

Latin AmericaLatin America Regional OfficeLakeland, Florida, USAPhone: (863) 619-7568Fax: (863) 701-7131

TP-6807 12/1110 Service Assistance

Notes

TP-6807 12/11 11Section 1 Description

Section 1 Description

1.1 Transfer Switch Description

An automatic transfer switch (ATS) transfers electricalloads from a normal source of electrical power to anemergency source when the normal source voltage orfrequency falls below an acceptable level. The normalsource is typically utility power. The emergency sourceis usually a generator set.

Model RXT transfer switches must be connected to agenerator set equipped with the Kohlerr RDC2 or DC2generator/transfer switch controller. Applicablegenerator set models are listed in the Introduction.

Voltage sensing data from the ATS is continuouslytransmitted to theRDC2/DC2 controller mounted on thegenerator set. When the normal source fails, theRDC2/DC2 controller signals the emergency sourcegenerator set to start. When the emergency sourcereaches acceptable levels and stabilizes, the ATStransfers the electrical load to the emergency source.

The RDC2/DC2 controller signals the ATS to transferthe load back when the normal source returns andstabilizes.

Figure 1-1 shows a typical installation block diagram.

PowerSwitchingDevice

To Load

Automatic Transfer Switch

InterfaceBoard

Normal(Utility)Power

Emergency(Generator)Power

Generator

TP-6751

ElectricalControls

Figure 1-1 Typical ATS Block Diagram

Service Entrance Model

Load Center Model Standard Model

Figure 1-2 Selected Transfer Switches(covers removed)

1.2 Service Entrance Models

Serviceentrancemodelsuseacircuit breaker toprovidethe service disconnect for the utility source. A serviceentrance model is shown in Figure 1-2.

1.3 Load Centers

ModelRXT100amp transfer switchesareavailablewitha built-in load center. A model with a built-in load centeris shown in Figure 1-2. Models without load centersrequire the installation of a separate load panel.

TP-6807 12/1112 Section 1 Description

Loads. The transfer switch can be connected to supplyall of the electrical loads in the home, or only theessential loads such as the furnace, refrigerator, wellpump, and selected light circuits. Identify the essentialcircuits that must be supplied during a power outage.Verify that the generator set and transfer switch areadequately rated to supply all of the selected loads.

Circuit breakers. Because the size and number ofcircuit breakers required will vary with each application,circuit breakers are not providedwith the transfer switchload center.

Determine the circuits that will be connected to thetransfer switch (essential loads). Identify the breakersfor those circuits in the main distribution panel.

The ATS load center requires Square D type QObreakers. If the main distribution panel uses the sametype of breakers, the breakers can be moved from themain panel to the load center. Otherwise, obtain newSquareD typeQOcircuit breakers. For each circuit, therating of the load center circuit breaker must match therating of the existing breaker in the main panel.

Up to 8 tandem breakers can be used. Use Square Dtype QOT tandem breakers.

Verify that the total rating for all of the breakers used inthe load center doesnot exceed the ratingof the transferswitch.

1.4 Controller Interface Board

All ATS control functions are performed by theRDC2/DC2controllermounted on the generator set andcommunicated through the interface board. Thecontroller interface board sends voltage sensing data totheRDC2/DC2controller and receives transfer and loadcontrol signals from the RDC2/DC2 controller.

1.5 Optional LED Indicator Panel

A user interface panel that contains status-indicatingLEDs is available. See Figure 1-3. Source availableLEDs light to indicate that the utility and/or generatorsources are available. The utility or generator sourcesupplying load LED lights to show which source isconnected to the building load (i.e. contactor position,normal or emergency).

If the status indicator is purchased as a loose kit (notfactory-installed), refer to the installation instructionsprovided with the kit, TT-1585.

1

GM78649

1. Utility power available2. Utility source supplying load3. Generator source supplying load4. Generator power available

2

3

4

Figure 1-3 LED Indicators

TP-6807 12/11 13Section 2 Installation

Section 2 Installation

2.1 Introduction

Kohlerr transfer switches are shipped factory-wired,factory-tested, and ready for installation. Have theequipment installed only by trained and qualifiedpersonnel, and verify that the installation complies withapplicable codes and standards. Protect the switchagainst damage before and during installation.

2.2 Receipt of Unit

2.2.1 Inspection

At the time of delivery, inspect the packaging and thetransfer switch for signs of shipping damage. Unpackthe transfer switch as soon as possible and inspect theexterior and interior for shipping damage. If damageand/or rough handling is evident, immediately file adamage claim with the transportation company.

2.2.2 Storage

Store the transfer switch in its protective packing untilfinal installation. Protect the transfer switch at all timesfrommoisture, construction grit, andmetal chips. Avoidstorage in cold or damp areas where moisture couldcondense on the unit. See Figure 2-1 for acceptablestorage temperatures.

Item Specification

StorageTemperature

--40C to 85C (--40F to 185F)

OperatingTemperature

--20C to 70C (--4F to 158F)

Humidity 5% to 95% noncondensing

Altitude 0 to 3050 m (10000 ft.) without derating

Figure 2-1 Environmental Specifications

2.2.3 Unpacking

Allow the equipment to warm to room temperature for atleast 24 hours before unpacking to preventcondensation on the electrical apparatus. Use carewhen unpacking to avoid damaging transfer switchcomponents. Use a vacuum cleaner or a dry cloth toremove dirt and packing material that may haveaccumulated in the transfer switch or any of itscomponents.

Note: Do not use compressed air to clean the switch.Cleaning with compressed air can cause debristo lodge in the components and damage theswitch.

2.2.4 Lifting

Unbalanced weight.Improper lifting can cause severeinjury or death and equipmentdamage.

Use adequate lifting capacity.Never leave the transfer switchstanding upright unless it is securelybolted in place or stabilized.

WARNING

See Figure 2-2 or the dimensional drawing for theweight of the transfer switch. Use a spreader bar to liftthe transfer switch. Attach the bar only to theenclosure’s mounting holes or lifting brackets; do not liftthe unit any other way. Close and latch the enclosuredoor before moving the unit.

Amps Description Weight, kg (lb.) [

100

Single phase 7 (14)

With load center 8.2 (18)

Three phase 14 (30)

Service Entrance 10 (22)

150 Service Entrance 12 (26)

200

Single phase 7 (15)

Three phase 14 (30)


300 Service Entrance 46 (100)

400

Single phase 36 (80)

3-Pole/208--240 Volts 41 (90)

3-Pole/480 Volts 59 (130)

4-Pole 59 (130)


Figure 2-2 Approximate Weights(ATS without packaging)

TP-6807 12/1114 Section 2 Installation

2.3 Installation

NOTICEForeign material contamination. Cover the transfer switchduring installation to keep dirt, grit, metal drill chips, and otherdebris out of the components. Cover the solenoidmechanismduring installation. After installation, use themanual operatinghandle to cycle the contactor to verify that it operates freely.Do not use a screwdriver to force the contactor mechanism.

NOTICEThe transfer switch may use both American Standard andmetric hardware. Use the correct size tools to preventrounding of the bolt heads and nuts.

Check the system voltage and frequency. Comparethe voltage and frequency shown on the transfer switchnameplate to the source voltage and frequency. Do notinstall the transfer switch if the voltage and frequencyare different from the normal (utility) source voltage andfrequency or the emergency source voltage andfrequency shown on the generator set nameplate.

Plan the installation. Use the dimensions given on theenclosure dimension (ADV) drawings in Section 6.Select amounting site that complies with local electricalcode restrictions for the enclosure type. Mount thetransfer switch as close to the load and power sourcesas possible. Allow adequate space to open theenclosure and service the switch.

NEMA3Renclosures. To remove the enclosure’s frontpanel, support the panel while removing the screws.

Pull the bottom of the panel out and down until the topclears the enclosure. Remove the inner panel to accessthe transfer switch components.

NEMA3Renclosures have locking tabs at the bottomoftheenclosureand thedoor. While theenclosure isopen,turn the locking tab out so that the door can be lockedwith a padlock after installation is complete.

Wall mounting. Mount the transfer switch to a wall orother rigid vertical supporting structure. Refer to thedimension drawings in Section 6 for hole locations. Useshims to plumb the enclosure.

Cover or remove the transfer switch’s internalcomponents to protect them from drill chips or debrisduring installation. Use a vacuum cleaner to removedebris from the enclosure.

Note: Do not use compressed air to clean the switch.Cleaning with compressed air can cause debristo lodge in the components and cause damage.

Tighten themounting screws to 2.9 Nm (26 in. lb.) whenreinstalling the components.

Clearanceholes through the backof eachenclosureareprovided for mounting. The mounting holes on NEMA3R enclosures have gaskets to seal out moisture. Usewashers with the mounting screws to protect thegaskets.


2.4 Manual Operation Check



DANGER

Check the manual operation before energizing thetransfer switch. Verify that the contactor operatessmoothly without binding. Do not place the transferswitch into service if the contactor does not operatesmoothly.

After checking the manual operation, place thecontactor in the Normal (utility) position.

See Figure 2-3 to identify the manual operationprocedure for your transfer switch.

ATS Procedure Figure

100--200 amps, 1-phase 2.4.1 Figure 2-4

100--200 amps, 3-phase 2.4.2 Figure 2-6

300 amps, 1-phase

2.4.1 Figure 2-5400 amps, 1-phase

400 amps, 3-phase, 3-pole,208--240 Volts

400 amps, 3-phase,3-pole/480 Volt and 4-pole

2.4.2 Figure 2-7

Figure 2-3 Manual Operation Procedure Guide

2.4.1 Manual Operation Procedure 1

Note: Nevermanually operate the transfer switchwhenthe power is connected. Disconnect both powersources before manually operating the switch.

1. 100-200 amp switches: These switches have anattached handle as shown in Figure 2-4.400 amp switches: Slide the detachable handle ora wrench over the shaft. See Figure 2-5.

2. Move the handle up to place the transfer switch inthe Normal Source position or down to place thecontactor in the Emergency Source position. SeeFigure 2-4 or Figure 2-5.

3. 400ampswitches: Remove thedetachablehandleor wrench.

4 3

78

CN

CE

NL1 NL2

EL2EL1

SCN

C

NO

NC

SCE

C

NC

NO

1

1. Handle (not detachable)

Figure 2-4 Manual Operation, 100 -- 200 AmpSingle-Phase Switches

1

GM80139

1. Shaft (attach handle or wrench here)

Figure 2-5 Manual Operation, 300--400 Amp Single-Phase and 208--240 Volt Switches

2.4.2 Manual Operation Procedure 2

Note: Never use themaintenancehandle to transfer theload with the power connected. Disconnect bothpower sources before manually operating theswitch.

1. If the transfer switch is equipped with amaintenance handle, remove the handle from itsstorage location inside the enclosure. SeeFigure 2-7.

2. Insert the maintenance handle or a tool (such as ascrewdriver) into the hole in the shaft on the left


side of the operator as shown in Figure 2-6 orFigure 2-7.

3. Move the maintenance handle (or tool) up or downasshown tomanually operate the transfer switch. Itshould operate smoothly without any binding. If itdoes not, check for shipping damage orconstruction debris.

4. Return the transfer switch to the Normal position.

5. Remove the maintenance handle and return it to thestorage location.

1. Insert handle or tool here for manual operation

GM78867

1

Figure 2-6 Manual Operation, 100--200 Amp3-Phase Switches

tp6225

1

2

1. Handle storage location2. Insert handle here for manual operation

Figure 2-7 Manual Operation, 400 Amp 3-PhaseSwitches

2.5 Electrical Wiring

Refer to the connection diagrams on the transfer switchenclosure door and the wiring diagrams in Section 6during installation.

All wiring must comply with applicable national, state,and local electrical codes. Use separate conduit for ACpower wiring and low-voltage DC, control, andcommunication system wiring.



DANGER

Making line or auxiliary connections. Hazardous voltagecan cause severe injury or death. To prevent electricalshock deenergize the normal power source beforemaking anyline or auxiliary connections.

Grounding electrical equipment. Hazardous voltage cancause severe injury or death. Electrocution is possiblewhenever electricity is present. Ensure you comply with allapplicable codes and standards. Electrically ground thegenerator set and related equipment and electrical circuits.Turn off the main circuit breakers of all power sources beforeservicing the equipment. Never contact electrical leads orappliances when standing in water or on wet ground becausethese conditions increase the risk of electrocution.

2.5.1 Load Center Circuit Breakers

The 100 amp Model RXT transfer switch is availablewith a built-in load center with room for up to 16single-pole circuit breakers. Up to 8 tandem breakerscan be used for a maximum of 24 circuits.

The load center usesSquareD typeQOorQOT tandembreakers. In an essential load application, the breakerscan be moved from the main panel to the load center ifthe main distribution panel uses the same type ofbreakers. Otherwise, obtain and install new Square Dtype QO circuit breakers. The rating of the load centercircuit breaker must match the rating of the existingbreaker in the main panel for each circuit. If circuitbreakers are removed from the load panel, install coverplates over the vacant positions. Cover plates can beobtained from a local Square D supplier.

Verify that the total rating for all breakersused in the loadcenter does not exceed the rating of the transfer switch.


2.5.2 AC Power Connections

Determine the cable size. Refer to the ADV drawingsin Section 6 or the transfer switch specification sheet todetermine the cable size required for the transfer switch.Make sure the lugsprovided are suitable for usewith thecables being installed.

Conduit. Use separate conduit for AC power wiringand low-voltage DC, control, and communicationsystemwiring. Watertight conduit hubsmaybe requiredfor outdoor use.

Select the proper cable clamp or use other approvedmethods for securing the cable or conduit to theenclosure.

Source and load connections. Clean cables with awire brush to remove surface oxides before connectingthem to the terminals. Apply joint compound to theconnections of any aluminum conductors.

Refer to the connection diagrams on the transfer switchenclosure door and the wiring diagrams in Section 6.The connection points on the transfer switch contactorare labelled Normal, Emergency, and Load. Connectthe utility power toNormal. Connect the generator set toEmergency.

Single phase. For single-phase models, connect to Aand C.

Three phase. For three-phase models, be sure tofollow the phase markings (A, B, C, and N).

Note: Connect the sourceand loadphasesas indicatedby the markings and drawings to prevent shortcircuits and to prevent phase-sensitive devicesfrom malfunctioning or operating in reverse.

Serviceentrancemodels. Connect theutility source tothe lugs on the normal source disconnect circuitbreakers as shown in the service entrance switchwiringdiagram in Section 6.

Verify that all connections are consistent with drawingsbefore tightening the lugs. Tighten all cable lugconnections to the torque values shown on the label onthe switch. Carefully wipe off any excess jointcompound after tightening the terminal lugs.

On models with built-in load centers, the load lugs arefactory-wired to the load center. Connect the load leadsto the circuits in the load center and tighten theconnections. Check the labels on the breakers for thetightening torques.

2.5.3 Neutral Connection

Connect the neutral from the main panel to the neutrallug in the ATS enclosure.

Ground the system according to NEC and local codes.

2.5.4 Neutral Bonding Jumper, ServiceEntrance Models

The transfer switch is shipped with theneutral-to-ground jumper installed. For non-serviceentranceapplications, disconnect theneutral-to-groundbonding jumper. See the transfer switch dimensiondrawing.

2.5.5 Engine Start Function

Theengine start function is controlledby theRDC2/DC2controller on the generator set. There are no enginestart terminals on the Model RXT ATS.


2.5.6 Interface Module Connection

The interface module must be connected to a Kohlerrgenerator set equipped with the RDC2 or DC2controller. The generator set is typically equippedwith afield-connection terminal block. See the generator setInstallationManual for the location of the terminal block.

Note: This document gives connection information forone Model RXT transfer switch connected to agenerator set equipped with an RDC2 or DC2controller. If additional accessory modules suchas a programmable interface module (PIM) or aload control module (LCM) are connected, referto the generator set installation manual for cablerequirements and connection instructions.

See Figure 2-8 and Figure 2-9. Use 20 AWG Belden#9402, 8723, or equivalent shielded, twisted-pair cableto connect P10-1 through P10-4 on the controllerinterface module to the generator set terminal blockconnectionsA,B,PWR,andCOM. Themaximumcablelength is 61 meters (200 ft.).

Alternatively, 12--14AWGwire can be used for thePWRand COM connections only. If 12--14 AWGwire is usedfor thePWRandCOMconnections, themaximumcablelength is 152 m (500 ft.) if one Model RXT transferswitch and no accessory modules are connected to thegenerator set.

Note: Connections 3 and 4 on the generator set are notused with the Model RXT transfer switch.

Terminal Block Connection Designation Description Wire Size

P10

P10-1 A Communication Line 20 AWG shielded twisted-pair,Belden 9402, 8723, or equivalentP10-2 B Communication Line

P10-3 PWR 12 VDC 20 AWG shielded twisted-pair Belden 9402or 12--14 AWG wireP10-4 COM 12 VDC

Figure 2-8 Controller Interface Connections

1. Communication cable Belden #9402 or equivalent 20 AWG shielded, twisted-pair cable

Interface Board on the ModelRXT Transfer Switch

Note: Generator set terminal block connections 3 and 4 areNOT USED with the Model RXT ATS.

RXT

Leave one end of each cable shield disconnected.

If accessory modules are connected in series, connectthe cable shields as shown below and refer to thegenerator set installation manual.

Generator Set

COM

PWR

B

A

Connect one end of each cable shield toGROUND at the generator set.

RXT

COM

PWR

B

A

1

GND

Generator Set Terminal Block TB1.See the generator set manuals for location.Check the decal on the generator set for terminalblock connections.

A

B

COM

PWR

3

4

TB1

Figure 2-9 Interface Module Connection to Generator Set Field-Connection Terminal Block


2.5.7 Optional Load Control Connection

Connector P11 on the interface module provides aconnection point for optional load control circuits. Theload control contact provides a delayed contact closuretoallowstartupof selected loads5minutesafter transferto the emergency power source (generator set). Usethis contact to delay startup of equipment with largemotor-starting loads such as air conditioners.

See Figure 2-10 for the location of load controlconnector P11. See Figure 2-11 for contact ratings,connection, and wire size information.

Note: An optional load control module is available forgenerator sets equipped with the RDC2 or DC2controller. The load control module allowsmanagement of up to six separate loads (twoHVAC thermostat connections and four othernon-essential loads). SeeTT-1574, LoadControlModule Instructions.

1. ATS/generator set interface connection P102. Load control connection P113. Factory connections

1GM806632

3

Figure 2-10 Interface Module Connections

2.5.8 Accessory Module Connections

For connection of the optional load control module(LCM)or programmable interfacemodule (PIM), refer tothe instructions provided with the modules and to thegenerator set installation manual.

2.6 Test and ExerciseRefer to the generator set Operation Manual forinstructions to test the power system operation and toset theRDC2orDC2 controller for weekly exercise runsto keep the power system in good operating condition.

2.7 Warranty Registration

Startup Notification Form. The Startup NotificationForm covers all equipment in the standby system.Complete the Startup Notification Form and register theequipment in the Kohler online warranty system within60 days of the initial startup date. Standby systems notregistered within 60 days of startup are automaticallyregistered using the manufacturer’s ship date as thestartup date.

Terminal Block Connection Designation Description Contact Rating Wire Size

P11P11-1 LC1

Load Control Output10 A @ 250 VAC1 A @ 30 VDC #12--18 AWG

P11-2 LC2

Figure 2-11 Load Control Contact P11 Connections


Notes

TP-6807 12/11 21Section 3 Operation

Section 3 Operation

3.1 Model RXT Transfer SwitchOperation

The Model RXT transfer switch must be connected to agenerator set equipped with the RDC2 or DC2controller. The RDC2/DC2 generator set/transferswitch controller manages automatic transfer switch(ATS) functions when connected to a Kohlerr ModelRXT transfer switch through the ATS interface board.The controller receives voltage sensing data from theModel RXT ATS and operates the generator set andtransfer switch to provide standby power when utilitypower is lost.

See the generator set operation manual for:

D ATS status screens and configuration menus.

D Information about loaded exercise.

3.2 Source Availability

The Model RXT transfer switch supplies voltagesensing data to the RDC2 or DC2 controller through theATS interface board. If the source voltage falls belowthe undervoltage dropout setting, the source isconsidered to have failed. See Figure 3-1.

Voltage Sensing Parameter Setting

Accuracy ±5%Undervoltage Dropout 90% of Pickup

Undervoltage Pickup 90% of Nominal

Figure 3-1 Voltage Sensing Parameters

3.3 ATS Control Sequence ofOperation

See Figure 3-2 for time delay settings.

Preferred Source Fails:

1. The load control contact opens.

2. The engine start time delay times out.

3. The generator set is signaled to start.

4. The generator starts and the emergency sourcebecomes available.

5. The normal-to-emergency time delay times out.

6. The transfer switch transfers to the emergencysource.

7. The load control contact time delay times out.

8. The load control contact closes.

Normal Source Returns:

1. The emergency-to-normal time delay times out.

2. The contactor transfers to the normal source.

3. The engine cooldown time delay times out.

4. The generator is signaled to stop.

TP-6807 12/1122 Section 3 Operation

3.4 Time Delays

Time delays are factory-set to the values shown inFigure 3-2. An authorized distributor/dealer can adjusttime delays using a personal computer and KohlerrSiteTecht software.

Time delays described in this section operate onlywhenthe RDC2 or DC2 generator set controller is connectedto a Kohlerr Model RXT transfer switch.

The engine start and load transfer time delays preventengine start and load transfer caused by brief variationsin the utility power source.

3.5 Load Control Time Delay

The load control time delay allows delayed starting oflarge motor loads (such as air conditioners), preventingsimultaneous starting of large motors after transfer tothe generator set. The load control time delay is fixed at5 minutes. It is not adjustable.

The load must be connected to the load control outputon the interface board of theModel RXT transfer switch.See the transfer switch operation and installationmanual for connection instructions.

Note: A separate load control module (LCM) thatprovides four power relays and two HVAC relaysis available for generator sets equipped with theRDC2 or DC2 controller. See LCM SpecificationSheet G6-120 for more information.

Time Delay Setting Description

Engine Start 3 seconds Time delay after utility source is lost until the engine start cycle begins.Guards against starting the generator set because of a brief change inthe utility source.

Transfer, Normal to Emergency 3 seconds Time delay after emergency source becomes available until transfer toemergency source.

Transfer, Emergency to Normal 2 minutes Time delay after the utility source returns until transfer back to normal.Ensures that the the utility source is stable before transferring from theemergency source.

Load Control 5 minutes Allows delayed connection of selected loads to the generator set.Prevents simultaneous starting of large motors after transfer to theemergency source. Recommended for delayed starting of airconditioners.

Figure 3-2 Time Delays

TP-6807 12/11 23Section 4 Service Disconnect, SE Model

Section 4 Service Disconnect, SE Model

Note: This section applies only to service entrancemodel transfer switches, which are identifiedwiththe letters ASE at the end of the modeldesignation.


This equipment must be installed andserviced by qualified electricalpersonnel.

DANGER

4.1 Service Disconnect Procedure

Use the following procedure to disconnect the utilitysource on service entrance model transfer switches.

Note: Power is still present on the input side of the utilitysource circuit breaker after this procedure.

1. Prevent the emergency generator set fromstarting:

a. Press the OFF button on the generator setcontroller.

b. Disconnect power to the generator set batterycharger.

c. Disconnect the generator set engine startingbattery, negative (--) lead first.

2. On the transfer switch, remove the outer enclosuredoor only.

3. Move the utility source circuit breaker to the OFFposition.

Note: Power is still present on the input side of theutility source circuit breaker. Do not removethe protective barrier around the utilitysource connection lugs.

4. To lock out the transfer switch, replace the outerdoor and attach a padlock to the hasp.

4.2 Source Circuit Breaker Reset

The utility source circuit breaker can trip due to anovercurrent condition. Identify and correct the cause ofthe overcurrent condition before resetting the circuitbreaker. Contact a local distributor/dealer for service ifnecessary.

When the circuit breaker trips, the handle moves to anintermediate position. To reset a tripped circuit breaker,move the handle to the extreme OFF position and thento the ON position.

1

GM80015

1. Normal/utility circuit breaker2. Padlock hasp

2

Figure 4-1 Service Entrance Model, Door Removed

TP-6807 12/1124 Section 4 Service Disconnect, SE Model

Notes

TP-6807 12/11 25Section 5 Scheduled Maintenance

Section 5 Scheduled Maintenance

5.1 Introduction

Regular preventive maintenance ensures safe andreliable operation and extends the life of the transferswitch. Preventive maintenance includes periodictesting, cleaning, inspection, and replacement of wornor missing components. Section 5.4 contains a serviceschedule for recommended maintenance tasks.

A local authorized distributor/dealer can providecomplete preventive maintenance and service to keepthe transfer switch in top condition. Unless otherwisespecified, havemaintenanceor serviceperformedbyanauthorized distributor/dealer in accordance with allapplicable codes and standards. See the ServiceAssistance section in this manual for how to locate alocal distributor/dealer.

Keep records of all maintenance or service.

Replace all barriers and close and lock the enclosuredooraftermaintenanceor serviceandbefore reapplyingpower.

Accidental starting.Can cause severe injury or death.

Disconnect the battery cables beforeworking on the generator set.Remove the negative (--) lead firstwhen disconnecting the battery.Reconnect the negative (--) lead lastwhen reconnecting the battery.

WARNING

Disabling the generator set. Accidental starting cancause severe injury or death. Before working on thegenerator set or equipment connected to the set, disable thegenerator set as follows: (1) Press the generator set off/resetbutton to shut down the generator set. (2) Disconnect thepower to the battery charger, if equipped. (3) Remove thebattery cables, negative (--) lead first. Reconnect the negative(--) lead last when reconnecting the battery. Follow theseprecautions to prevent the starting of the generator set by theremote start/stop switch.



DANGER


Only authorized personnel shouldopen the enclosure.

DANGER

Hazardous voltage.Can cause severe injury or death.

Operate the generator set only whenall guards and electrical enclosuresare in place.

Moving parts.

WARNING

Grounding the transfer switch. Hazardous voltage cancause severe injury or death. Electrocution is possiblewhenever electricity is present. Open main circuit breakers ofall power sources before servicing equipment. Configure theinstallation to electrically ground the transfer switch andrelated equipment and electrical circuits to comply withapplicable codes and standards. Never contact electricalleads or appliances when standing in water or on wet ground,as the chance of electrocution increases under suchconditions.

TP-6807 12/1126 Section 5 Scheduled Maintenance

Servicing the transfer switch. Hazardous voltage cancause severe injury or death. Deenergize all power sourcesbefore servicing. Turn off the main circuit breakers of alltransfer switch power sources and disable all generator setsas follows: (1) Move all generator set master controllerswitches to the OFF position. (2) Disconnect power to allbattery chargers. (3) Disconnect all battery cables, negative(--) leads first. Reconnect negative (--) leads last whenreconnecting the battery cables after servicing. Follow theseprecautions to prevent the starting of generator sets by anautomatic transfer switch, remote start/stop switch, or enginestart command from a remote computer. Before servicing anycomponents inside the enclosure: (1) Remove all jewelry. (2)Stand on a dry, approved electrically insulated mat. (3) Testcircuits with a voltmeter to verify that they are deenergized.

Short circuits. Hazardous voltage/current can causesevere injury or death. Short circuits can cause bodily injuryand/or equipment damage. Do not contact electricalconnections with tools or jewelry while making adjustments orrepairs. Remove all jewelry before servicing the equipment.

NOTICEThe transfer switch may use both American Standard andmetric hardware. Use the correct size tools to preventrounding of the bolt heads and nuts.

NOTICEElectrostatic discharge damage. Electrostatic discharge(ESD) damages electronic circuit boards. Preventelectrostatic discharge damage by wearing an approvedgrounding wrist strap when handling electronic circuit boardsor integrated circuits. An approved grounding wrist strapprovides a high resistance (about 1 megohm), not a directshort, to ground.

Screws and nuts are available in different hardnessratings. To indicate hardness, American Standardhardware uses a series of markings and metrichardware uses a numeric system. Check the markingson the bolt heads and nuts for identification.

5.2 Testing

5.2.1 Weekly Generator Set ExerciseUse the exerciser or a manual test to start and run thegenerator set under load once a week to maximize thereliability of the emergency power system.

5.2.2 Monthly Automatic ControlSystem Test

Test the transfer switch’s automatic control systemmonthly. Refer to the RDC2/DC2 controller operationmanual for the test procedure.

D Verify that the expected sequence of operationsoccurs as the switch transfers the load to theemergency source when a preferred source failureoccurs or is simulated.

D Watch and listen for signs of excessive noise orvibration during operation.

D After the switch transfers the load to the standbysource, end the test and verify that the expectedsequence of operations occurs as the transfer switchretransfers to the preferred source.

5.3 Inspection and Service

Contact an authorized distributor/dealer to inspect andservice the transfer switch annually and also when anywear, damage, deterioration, or malfunction of thetransfer switch or its components is evident orsuspected.

5.3.1 General InspectionExternal Inspection. Keep the transfer switch cleanand in good condition by performing a weekly generalexternal inspection of the transfer switch. Check for anycondition of vibration, leakage, excessive temperature,contamination, or deterioration. Remove accumulationsof dirt, dust, and other contaminants from the transferswitch’s external components or enclosure with avacuum cleaner or by wiping with a dry cloth or brush.

Note: Do not use compressed air to clean the transferswitch because it can cause debris to lodge in thecomponents and damage the switch.

Tighten loose external hardware. Replace worn, missing,or broken external components with manufacturer-recommended replacement parts. Contact anauthorized distributor/dealer for specific partinformation and ordering.

Internal Inspection. Disconnect all power sources,open the transfer switch enclosure door, and inspectinternal components monthly or when any conditionnoticed during anexternal inspectionmayhaveaffectedinternal components.

Contact an authorized distributor/dealer to inspect andservice the transfer switch if any of the followingconditions are found inside the transfer switch.

D Accumulations of dirt, dust, moisture, or othercontaminants.

D Signs of corrosion.

D Worn, missing, or broken components.

D Loose hardware.

D Wire or cable insulation deterioration, cuts, orabrasion.

TP-6807 12/11 27Section 5 Scheduled Maintenance

D Signs of overheating or loose connections:discoloration of metal, melted plastic, or a burningodor.

D Other evidence of wear, damage, deterioration, ormalfunction of the transfer switch or its components.

If the application does not allow a power interruption forthe time required for the internal inspection, have anauthorized distributor/dealer perform the internalinspection.

5.3.2 Other Inspections and ServiceHave an authorized distributor/dealer performscheduled maintenance, service, and othermaintenance that ensures the safe and reliable

operation of the transfer switch. See Section 5.4,Service Schedule, for the recommended maintenanceitems and service intervals.

Have an authorized distributor/dealer repair or replacedamaged or worn internal components withmanufacturer-recommended replacement parts.

5.4 Service Schedule

Follow the service schedule in Figure 5-1 for therecommended service intervals. Have all serviceperformedbyanauthorized distributor/dealer except foractivities designated by an X, which may be performedby the switch operator.

System Component or ProcedureSee

SectionVisuallyInspect Check

Adjust,Repair,Replace Clean Test Frequency

Electrical System

Check for signs of overheating or loose connections:discoloration of metal, melted plastic, or a burning odor 5.3.1 X X Y

Check the contactor’s external operating mechanismfor cleanliness; clean and relubricate if dirty * 5.3.1 X

D (cleanand lube) Y

Inspect wiring insulation for deterioration, cuts, orabrasion. Repair or replace deteriorated or damagedwiring

5.3.1 X D D Y

Tighten control and power wiring connections tospecifications 2.5 D D Y

Check the transfer switch’s main power switchingcontacts’ condition; clean or replace the main contactsor replace the contactor assembly as necessary

S/M D D D Y

General Equipment Condition

Inspect the outside of the transfer switch for any signsof excessive vibration, leakage, high temperature,contamination, or deterioration *

5.3 X X M

Check that all external hardware is in place, tightened,and not badly worn 5.3 X X X M

Inspect the inside of transfer switch for any signs ofexcessive vibration, leakage, high temperature,contamination, or deterioration *

5.3 D D D Y

Check that all internal hardware is in place, tightened,and not badly worn 5.3 X D D Y

* Service more frequently if the transfer switch is operated in dusty or dirty areas.

See Section: Read these sections carefully for additional information before attempting maintenance or service.Visually Inspect: Examine these items visually.Check: Requires physical contact with or movement of system components, or the use of nonvisual indications.Adjust, Repair, Replace: Includes tightening hardware and lubricating the mechanism. May require replacement of componentsdepending upon the severity of the problem.Clean: Remove accumulations of dirt and contaminants from external transfer switch’s components or enclosure with a vacuum cleaner orby wiping with a dry cloth or brush. Do not use compressed air to clean the switch because it can cause debris to lodge in the componentsand cause damage.Test: May require tools, equipment, or training available only through an authorized distributor/dealer.

Symbols used in the chart:X=The transfer switch operator can perform these tasks.D=Authorized distributor/dealer must perform these tasks.W=WeeklyM=Monthly

Q=QuarterlyS=Semiannually (every six months)Y=Yearly (annually)W/D=Wiring diagram

Figure 5-1 Service Schedule

TP-6807 12/1128 Section 5 Scheduled Maintenance

Notes

TP-6807 12/11 29Section 6 Diagrams and Drawings

Section 6 Diagrams and Drawings

Diagram or Drawing Drawing Number Page

Single-Phase

Enclosure Dimension Drawings100--200 Amp Single-Phase

Sheet 1 ADV-8190 1 of 2 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Sheet 2 ADV-8190 2 of 2 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100 Amp Single-Phase with Load Center ADV-8197 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400 Amp Single-Phase ADV-8193 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Diagrams100--400 Amp Single-Phase GM80663 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 Amp Single-Phase with Load Center GM80675 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Schematic Diagrams100--400 Amp Single-Phase GM80664 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 Amp Single-Phase with Load Center GM80676 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Entrance

Enclosure Dimension Drawings100--200 Amp Single-Phase Service Entrance

Sheet 1 ADV-8192 1 of 3 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Sheet 2 ADV-8192 2 of 3 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Sheet 3 ADV-8192 3 of 3 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

300--400 Amp Single-Phase Service Entrance SwitchSheet 1 ADV-8196 1 of 2 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Sheet 2 ADV-8196 2 of 2 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Diagrams100--400 Amp Service Entrance GM80665 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Schematic Diagrams100--400 Amp Service Entrance GM80666 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three-Phase

Enclosure Dimension Drawings100--200 Amp Standard, Three-Phase, 3- and 4-Pole ADV-8191 32. . . . . . . . . . . . . . . . . . .400 Amp Standard, Three-Phase, 3-pole 208--240 V ADV-8194 37. . . . . . . . . . . . . . . . . . .400 Amp Standard, Three-Phase, 4-pole and 3-Pole/480 V ADV-8195 38. . . . . . . . . . . . . .

Wiring Diagrams100--200 Amp Standard, Three-Phase, 3- and 4-Pole GM80667 46. . . . . . . . . . . . . . . . . . .400 Amp Standard, Three-Phase, 3-pole 208--240 V GM80669 48. . . . . . . . . . . . . . . . . . .400 Amp Standard, Three-Phase, 4-pole and 3-Pole/480 V GM80671 50. . . . . . . . . . . . . .

Schematic Diagrams100--200 Amp Standard, Three-Phase, 3- and 4-Pole GM80668 47. . . . . . . . . . . . . . . . . . .400 Amp Standard, Three-Phase, 3-pole 208--240 V GM80670 49. . . . . . . . . . . . . . . . . . .400 Amp Standard, Three-Phase, 4-pole and 3-Pole/480 V GM80672 51. . . . . . . . . . . . . .

TP-6807 12/1130 Section 5 Diagrams and Drawings

Figure 6-1 Enclosure Dimensions, 100--200 Amp Single-Phase, ADV-8190, Sheet 1 of 2


Figure 6-2 Enclosure Dimensions, 100--200 Amp Single-Phase, ADV-8190, Sheet 2 of 2


Figure 6-3 Enclosure Dimensions, 100--200 Amp Three-Phase, 3- and 4-Pole, ADV-8191


Figure 6-4 Enclosure Dimensions, 100--200 Amp Single-Phase, Service Entrance, ADV-8192, Sheet 1 of 3






Figure 6-7 Enclosure Dimensions, 400 Amp Single-Phase, ADV-8193


Figure 6-8 Enclosure Dimensions, 400 Amp Three-Phase, 3-Pole/208--240 Volts, ADV-8194


Figure 6-9 Enclosure Dimensions, 400 Amp Three-Phase, 3-Pole/480 Volt and 4-Pole, ADV-8195


Figure 6-10 Enclosure Dimensions, 400 Amp Single-Phase, Service Entrance, ADV-8196, Sheet 1 of 2


Figure 6-11 Enclosure Dimensions, 400 Amp Single-Phase, Service Entrance, ADV-8196, Sheet 2 of 2


Figure 6-12 Enclosure Dimensions, 100 Amp Single-Phase with Load Center, ADV-8197


Figure 6-13 Wiring Diagram, 100--400 Amp Single-Phase, GM80663


Figure 6-14 Schematic Diagram, 100--400 Amp Single-Phase, GM80664


Figure 6-15 Wiring Diagram, 100--400 Amp Service Entrance, GM80665


Figure 6-16 Schematic Diagram, 100--400 Amp Service Entrance, GM80666


Figure 6-17 Wiring Diagram, 100--200 Amp Three-Phase, 3- and 4-Pole, GM80667


Figure 6-18 Schematic Diagram, 100--200 Amp Three-Phase, 3- and 4-Pole, GM80668


Figure 6-19 Wiring Diagram, 400 Amp Three-Phase, 3-Pole/208--240 Volts, GM80669


Figure 6-20 Schematic Diagram, 400 Amp Three-Phase, 3-Pole/208--240 Volts, GM80670


Figure 6-21 Wiring Diagram, 400 Amp Three-Phase, 3-Pole/480 Volts and 4-Pole, GM80671


Figure 6-22 Schematic Diagram, 400 Amp Three-Phase, 3-Pole/480 Volts and 4-Pole, GM80672


Figure 6-23 Wiring Diagram, 100 Amp Single-Phase with Load Center, GM80675


Figure 6-24 Schematic Diagram, 100 Amp Single-Phase with Load Center, GM80676


Notes

TP-6807 12/11 Appendix 55

Appendix A Abbreviations

The following list contains abbreviations that may appear in this publication.

A, amp ampereABDC after bottom dead centerAC alternating currentA/D analog to digitalADC advanced digital control;

analog to digital converteradj. adjust, adjustmentADV advertising dimensional

drawingAh amp-hourAHWT anticipatory high water

temperatureAISI American Iron and Steel

InstituteALOP anticipatory low oil pressurealt. alternatorAl aluminumANSI American National Standards

Institute (formerly AmericanStandards Association, ASA)

AO anticipatory onlyAPDC Air Pollution Control DistrictAPI American Petroleum Instituteapprox. approximate, approximatelyAQMD Air Quality Management DistrictAR as required, as requestedAS as supplied, as stated, as

suggestedASE American Society of EngineersASME American Society of

Mechanical Engineersassy. assemblyASTM American Society for Testing

MaterialsATDC after top dead centerATS automatic transfer switchauto. automaticaux. auxiliaryavg. averageAVR automatic voltage regulatorAWG American Wire GaugeAWM appliance wiring materialbat. batteryBBDC before bottom dead centerBC battery charger, battery

chargingBCA battery charging alternatorBCI Battery Council InternationalBDC before dead centerBHP brake horsepowerblk. black (paint color), block

(engine)blk. htr. block heaterBMEP brake mean effective pressurebps bits per secondbr. brassBTDC before top dead centerBtu British thermal unitBtu/min. British thermal units per minuteC Celsius, centigradecal. calorieCAN controller area networkCARB California Air Resources BoardCB circuit breakercc cubic centimeterCCA cold cranking ampsccw. counterclockwiseCEC Canadian Electrical Codecert. certificate, certification, certifiedcfh cubic feet per hour

cfm cubic feet per minuteCG center of gravityCID cubic inch displacementCL centerlinecm centimeterCMOS complementary metal oxide

substrate (semiconductor)cogen. cogenerationcom communications (port)coml commercialComl/Rec Commercial/Recreationalconn. connectioncont. continuedCPVC chlorinated polyvinyl chloridecrit. criticalCRT cathode ray tubeCSA Canadian Standards

AssociationCT current transformerCu coppercUL Canadian Underwriter’s

LaboratoriesCUL Canadian Underwriter’s

Laboratoriescu. in. cubic inchcw. clockwiseCWC city water-cooledcyl. cylinderD/A digital to analogDAC digital to analog converterdB decibeldB(A) decibel (A weighted)DC direct currentDCR direct current resistancedeg., degreedept. departmentDFMEA Design Failure Mode and

Effects Analysisdia. diameterDI/EO dual inlet/end outletDIN Deutsches Institut fur Normung

e. V. (also Deutsche IndustrieNormenausschuss)

DIP dual inline packageDPDT double-pole, double-throwDPST double-pole, single-throwDS disconnect switchDVR digital voltage regulatorE, emer. emergency (power source)ECM electronic control module,

engine control moduleEDI electronic data interchangeEFR emergency frequency relaye.g. for example (exempli gratia)EG electronic governorEGSA Electrical Generating Systems

AssociationEIA Electronic Industries

AssociationEI/EO end inlet/end outletEMI electromagnetic interferenceemiss. emissioneng. engineEPA Environmental Protection

AgencyEPS emergency power systemER emergency relayES engineering special,

engineered specialESD electrostatic discharge

est. estimatedE-Stop emergency stopetc. et cetera (and so forth)exh. exhaustext. externalF Fahrenheit, femalefglass. fiberglassFHM flat head machine (screw)fl. oz. fluid ounceflex. flexiblefreq. frequencyFS full scaleft. foot, feetft. lb. foot pounds (torque)ft./min. feet per minuteftp file transfer protocolg gramga. gauge (meters, wire size)gal. gallongen. generatorgenset generator setGFI ground fault interrupter

GND, groundgov. governorgph gallons per hourgpm gallons per minutegr. grade, grossGRD equipment groundgr. wt. gross weightH x W x D height by width by depthHC hex capHCHT high cylinder head temperatureHD heavy dutyHET high exhaust temp., high

engine temp.hex hexagonHg mercury (element)HH hex headHHC hex head capHP horsepowerhr. hourHS heat shrinkhsg. housingHVAC heating, ventilation, and air

conditioningHWT high water temperatureHz hertz (cycles per second)IC integrated circuitID inside diameter, identificationIEC International Electrotechnical

CommissionIEEE Institute of Electrical and

Electronics EngineersIMS improved motor startingin. inchin. H2O inches of waterin. Hg inches of mercuryin. lb. inch poundsInc. incorporatedind. industrialint. internalint./ext. internal/externalI/O input/outputIP iron pipeISO International Organization for

StandardizationJ jouleJIS Japanese Industry Standard

TP-6807 12/1156 Appendix

k kilo (1000)K kelvinkA kiloampereKB kilobyte (210 bytes)KBus Kohler communication protocolkg kilogramkg/cm2 kilograms per square

centimeterkgm kilogram-meterkg/m3 kilograms per cubic meterkHz kilohertzkJ kilojoulekm kilometerkOhm, k kilo-ohmkPa kilopascalkph kilometers per hourkV kilovoltkVA kilovolt amperekVAR kilovolt ampere reactivekW kilowattkWh kilowatt-hourkWm kilowatt mechanicalkWth kilowatt-thermalL literLAN local area networkL x W x H length by width by heightlb. pound, poundslbm/ft3 pounds mass per cubic feetLCB line circuit breakerLCD liquid crystal displayld. shd. load shedLED light emitting diodeLph liters per hourLpm liters per minuteLOP low oil pressureLP liquefied petroleumLPG liquefied petroleum gasLS left sideLwa sound power level, A weightedLWL low water levelLWT low water temperaturem meter, milli (1/1000)M mega (106 when used with SI

units), malem3 cubic meterm3/hr. cubic meters per hourm3/min. cubic meters per minutemA milliampereman. manualmax. maximumMB megabyte (220 bytes)MCCB molded-case circuit breakerMCM one thousand circular milsmeggar megohmmeterMHz megahertzmi. milemil one one-thousandth of an inchmin. minimum, minutemisc. miscellaneousMJ megajoulemJ millijoulemm millimetermOhm, mmilliohmMOhm, MmegohmMOV metal oxide varistorMPa megapascalmpg miles per gallonmph miles per hourMS military standardms millisecondm/sec. meters per secondMTBF mean time between failure

MTBO mean time between overhaulsmtg. mountingMTU Motoren-und Turbinen-UnionMW megawattmW milliwattF microfaradN, norm. normal (power source)NA not available, not applicablenat. gas natural gasNBS National Bureau of StandardsNC normally closedNEC National Electrical CodeNEMA National Electrical

Manufacturers AssociationNFPA National Fire Protection

AssociationNm newton meterNO normally openno., nos. number, numbersNPS National Pipe, StraightNPSC National Pipe, Straight-couplingNPT National Standard taper pipe

thread per general useNPTF National Pipe, Taper-FineNR not required, normal relayns nanosecondOC overcrankOD outside diameterOEM original equipment

manufacturerOF overfrequencyopt. option, optionalOS oversize, overspeedOSHA Occupational Safety and Health

AdministrationOV overvoltageoz. ouncep., pp. page, pagesPC personal computerPCB printed circuit boardpF picofaradPF power factorph., phasePHC Phillipsr head Crimptiter

(screw)PHH Phillipsr hex head (screw)PHM pan head machine (screw)PLC programmable logic controlPMG permanent magnet generatorpot potentiometer, potentialppm parts per millionPROM programmable read-only

memorypsi pounds per square inchpsig pounds per square inch gaugept. pintPTC positive temperature coefficientPTO power takeoffPVC polyvinyl chlorideqt. quart, quartsqty. quantityR replacement (emergency)

power sourcerad. radiator, radiusRAM random access memoryRDO relay driver outputref. referencerem. remoteRes/Coml Residential/CommercialRFI radio frequency interferenceRH round headRHM round head machine (screw)rly. relay

rms root mean squarernd. roundROM read only memoryrot. rotate, rotatingrpm revolutions per minuteRS right sideRTU remote terminal unitRTV room temperature vulcanizationRW read/writeSAE Society of Automotive

Engineersscfm standard cubic feet per minuteSCR silicon controlled rectifiers, sec. secondSI Systeme international d’unites,

International System of UnitsSI/EO side in/end outsil. silencerSN serial numberSNMP simple network management

protocolSPDT single-pole, double-throwSPST single-pole, single-throwspec specificationspecs specification(s)sq. squaresq. cm square centimetersq. in. square inchSS stainless steelstd. standardstl. steeltach. tachometerTD time delayTDC top dead centerTDEC time delay engine cooldownTDEN time delay emergency to

normalTDES time delay engine startTDNE time delay normal to

emergencyTDOE time delay off to emergencyTDON time delay off to normaltemp. temperatureterm. terminalTHD total harmonic distortionTIF telephone influence factorTIR total indicator readingtol. toleranceturbo. turbochargertyp. typical (same in multiple

locations)UF underfrequencyUHF ultrahigh frequencyUL Underwriter’s Laboratories, Inc.UNC unified coarse thread (was NC)UNF unified fine thread (was NF)univ. universalUS undersize, underspeedUV ultraviolet, undervoltageV voltVAC volts alternating currentVAR voltampere reactiveVDC volts direct currentVFD vacuum fluorescent displayVGA video graphics adapterVHF very high frequencyW wattWCR withstand and closing ratingw/ withw/o withoutwt. weightxfmr transformer

TP-6807 12/11 57

Notes

TP-6807 12/1158

Notes

E 2011 by Kohler Co. All rights reserved.

TP-6807 12/11a

KOHLER CO. Kohler, Wisconsin 53044Phone 920-457-4441, Fax 920-459-1646For the nearest sales/service outlet in theUS and Canada, phone 1-800-544-2444KOHLERPower.com

Kohler Power SystemsAsia Pacific Headquarters7 Jurong Pier RoadSingapore 619159Phone (65) 6264-6422, Fax (65) 6264-6455

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