Operation and Installation Automatic Transfer Switch Model: RDT 100--400 Amp Automatic Transfer Switches 100 and 200 Amp Automatic Transfer Switches with Load Centers 200 and 400 Amp Service Entrance Rated Transfer Switches Electrical Controls: MPACt 500 TP-6345 9/13j
Product Identification Information Product identification numbers determine service parts. Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference. Record field-installed kit numbers after installing the kits. Transfer Switch Identification Numbers Record the product identification numbers from the transfer switch nameplate.
Table of Contents Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nameplate . .
Table of Contents, continued Section 4 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Accessory Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.1 Audible Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.2 EAM Connection (P13) . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely. Read and follow all safety precautions and instructions. SAVE THESE INSTRUCTIONS.
Servicing the transfer switch. Hazardous voltage can cause severe injury or death. Deenergize all power sources before servicing. Turn off the main circuit breakers of all transfer switch power sources and disable all generator sets as follows: (1) Move all generator set master controller switches to the OFF position. (2) Disconnect power to all battery chargers. (3) Disconnect all battery cables, negative (--) leads first.
Introduction This manual provides operation and installation instructions for Kohler Model RDT automatic transfer switches with MPACr 500 electrical controls. Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this literature and the products represented without notice and without any obligation or liability whatsoever.
Model Code Record the transfer switch model designation in the boxes below. The transfer switch model designation defines characteristics and ratings as explained in the accompanying chart. Model MechanismTransition Controls Voltage Poles Enclosure Kohlerr Model Designation Key This chart explains the Kohlerr transfer switch model designation system.
Service Assistance For professional advice on generator set power requirements and conscientious service, please contact your nearest Kohler distributor or dealer. D Consult the Yellow Pages under the heading Generators—Electric. D Visit the Kohler Power Systems website at KOHLERPower.com. D Look at the labels and stickers on your Kohler product or review the appropriate literature or documents included with the product. D Call toll free in the US and Canada 1-800-544-2444.
Notes 10 Service Assistance TP-6345 9/13
Section 1 Description 1.1 Transfer Switch Description 1.2 Load Centers An automatic transfer switch (ATS) transfers electrical loads from a normal source of electrical power to an emergency source when the normal source voltage or frequency falls below an acceptable level. The normal source is typically utility power. The emergency source is usually a generator set. Model RDT 100 and 200 amp transfer switches are available with or without built-in load centers.
Notes 12 Section 1 Description TP-6345 9/13
Section 2 Installation 2.1 Introduction 2.2.4 Kohler transfer switches are shipped factory-wired, factory-tested, and ready for installation. Have the equipment installed only by trained and qualified personnel, and verify that the installation complies with applicable codes and standards. Protect the switch against damage before and during installation. Allow the equipment to warm to room temperature for at least 24 hours before unpacking to prevent condensation on the electrical apparatus.
2.3 Installation NOTICE Foreign material contamination. Cover the transfer switch during installation to keep dirt, grit, metal drill chips, and other debris out of the components. Cover the solenoid mechanism during installation. After installation, use the manual operating handle to cycle the contactor to verify that it operates freely. Do not use a screwdriver to force the contactor mechanism. NOTICE Hardware damage. The transfer switch may use both American Standard and metric hardware.
Manual Operation, 400 Amp Switches 2.4 Manual Operation Check Note: Never manually operate the transfer switch when the power is connected. Disconnect both power sources before manually operating the switch. DANGER 1. Check the contactor position, indicated by the A and B position indicators. See Figure 2-5. One position indicator will display ON to indicate the source position. A is utility power and B is the generator set. Hazardous voltage. Will cause severe injury or death.
2.5 Electrical Wiring The connection drawings in Figure 2-8 and Figure 2-9 show examples of essential load and whole-house configurations. Figure 2-10 and Figure 2-11 show service entrance model connections. All wiring must comply with applicable national, state, and local electrical codes. Use separate conduit for AC power wiring and low-voltage DC, control, and communication system wiring. DANGER Hazardous voltage. Will cause severe injury or death.
Conduit. Use the knock-outs provided in the enclosure for cables. Use separate conduit for AC power wiring and low-voltage DC, control, and communication system wiring. Watertight conduit hubs may be required for outdoor use. For the SE model conduit hub, thread sealant must be applied to screw threads if screws are removed or replaced. Select the proper cable clamp or use other approved methods for securing the cable or conduit to the enclosure. Connect the source and load cables.
Main Distribution Panel (Normal Source) Detail A, Engine Start Leads to ATS Main Logic Board Common Fault, 5, 6 (optional) Load Control, 1, 2 (optional) Engine Start, 3, 4 2-Pole Feeder Breaker NL1 GRD * NL2 N* Generator Set (Emergency Source) See Detail A. N* EL2 EL1 GRD * L0 * 3 4 * Connect according to NEC and local codes.
Detail A, Engine Start Leads to ATS Main Logic Board Service Disconnect (Normal Source) NL1 GRD * NL2 Common Fault, 5, 6 (optional) N* Load Control or Normal Failure, 1, 2 (optional) Transfer Switch Engine Start, 3, 4 Engine start connections 3 and 4. See Detail A. Also see Figure 2-13 and wiring decal. Generator Set (Emergency Source) EL1 EL2 GRD GRD * L0 Engine Start N* 3 4 Ground LL1 LL2 N* * Connect according to NEC and local codes.
Detail A, Engine Start Leads to ATS Main Logic Board Utility Power (Normal Source) GRD * N * NL1 NL2 Common Fault, 5, 6 (optional) Service Entrance Model Transfer Switch Load Control, 1, 2 (optional) Engine Start, 3, 4 Generator Set (Emergency Source) L0 Engine Start See Detail A N* 3 4 See Detail B GRD GRD * EL1 See Note EL2 LL1 LL2 GRD * N* Detail B, Terminal Block TB1 Main Distribution Panel (Load) * Connect according to NEC and local codes.
Engine Start Connection to ATS Main Logic Board Common Fault, 5, 6 (optional) Load Control, 1, 2 (optional) Engine Start, 3, 4 Service Entrance Model Transfer Switch Utility Power (Normal Source) NL1 NL2 GRD * Terminal Block TB1 detail To Ground. * See Ground Detail Emergency Source (Generator set) EL2 EL1 N* L0 GRD * Neutral Bonding Jumper LL1 LL2 GRD * N* Ground Neutral Ground Detail * Connect according to NEC and local codes.
2.6 Controller Connections P5 3 C2 R6 C3 R7 C4 R8 C5 R9 C6 R10 C7 R11 C8 R12 C9 Y1 1 Engine Start Connections GND +3.
2.6.2 Optional Controller Connections The green 6-pin connector P2 on the controller’s main logic board provides connection points for optional common fault and load control or normal failure circuits. See Figure 2-12 for the connector location and Figure 2-13 for connection details. See Figure 2-15 for contact ratings, connection, and wire size information. Load Control Contact. Normally open (NO) contact provided on most models; see the wiring decal on the unit.
2.7 Accessory Connections Factory-installed accessories may require power, input, and output connections. Refer to the following sections and Section 4 for instructions to connect optional accessories. Check settings on optional accessories as described in the following sections. 2.7.
2.7.4 SE Model Battery Charger Circuit Breaker Connection The SE model transfer switch has a 15-amp single-pole circuit breaker for the generator set battery charger. The circuit breaker (CB1) is factory-wired to the accessory connection terminal block TB1. Connect the battery charger power connection to the accessory connection terminal block. For connections, see Figure 2-19 or the wiring diagrams in Section 7, Diagrams and Drawings. See Figure 2-20 for the terminal block location. 2.7.
Refer to Section 3.5 for a description of the transfer switch sequence of operation. Note: The retransfer time delay does not operate during the test sequence. Note: If the generator set fails during a test, the ATS will immediately attempt to transfer to the normal (utility) source. 8. After the engine cooldown time delay, the generator set shuts down. Note: Install the front panel(s) or close and lock the enclosure door before starting the test procedure.
Unloaded exercise. The generator set runs, but the electrical load is not transferred. Press and hold the Exercise button for approximately 3 seconds until the GEN Available LED flashes to start an unloaded exercise and set the time and date of the next exercise run. The GEN available LED continues to flash throughout the exercise run to indicate an unloaded exercise. The generator set stops automatically after 20 minutes. Loaded Exercise.
Notes 28 Section 2 Installation TP-6345 9/13
Section 3 Operation 3.1 Introduction 3.2 Controls Red and green LEDs on the transfer switch controls indicate which sources are available, show which source is connected to the load, and flash to indicate fault conditions. Pushbuttons allow you to start and stop the generator set and set the exercise timer. See Figure 3-1. The controller’s user interface panel is accessible through an opening in the transfer switch cover (the inner panel on NEMA type 3R enclosures).
3.3 Faults The LEDs on the controller’s user interface flash as shown in Figure 3-2 to indicate various fault conditions. Contact an authorized distributor/dealer for service if the fault persists. 3.3.1 Failure to Acquire Emergency Source Warning The Failure to Acquire Emergency Source fault occurs if the transfer switch does not sense voltage from the generator set within 78 seconds after signaling the generator set to start.
3.5.2 Transfer Sequence Figure 3-4 illustrates the transfer sequence when the normal source fails and Figure 3-5 illustrates the sequence when it returns. Time delays before load transfer prevent nuisance transfers during brief power interruptions. See Figure 3-6. Events such as the failure of the generator set to start can change the sequence of operation.
Notes 32 Section 3 Operation TP-6345 9/13
Section 4 Accessories 4.1 Accessory Board The optional accessory board is mounted above the controller’s main logic board. The accessory board kit is available factory-installed or as a loose kit. See Figure 2-17 and Figure 4-1 for the accessory board location. The accessory components: board contains the Main Logic Board following D Audible alarm on system faults. D Rotary switches for time delay adjustments. D DIP switches for exercise, remote test switch operation, and load control functions.
1 Remote Test Input. Connect a remote switch to this input for remote starting and stopping of a loaded test. DIP switch 3 affects the operation of this switch. See Section 4.1.5, Accessory Board DIP Switches, and Section 4.2, External Alarm Module. 7 2 Generator Set Suppling Load Output. This output provides a closed contact to indicate that the generator set is supplying the load when the transfer switch is in the Emergency position and the GEN source is available.
4.1.5 Maintained/Momentary Test. Switch 3. DIP Switches DIP switches on the optional accessory board control the exercise, remote test, and load control functions. The DIP switch location is shown in Figure 4-2. The DIP switch functions are summarized in Figure 4-5. Check the DIP switch settings and adjust if necessary for the application. D With DIP switch 3 in the ON (maintained) position, 1 Week/2 Week Exercise. Switch 1.
4.2 External Alarm Module (EAM) 4.2.1 The optional External Alarm Module (EAM) is illustrated in Figure 4-6. The EAM: Locate the EAM indoors in a convenient location up to 152 m (500 ft.) from the transfer switch. The EAM is designed for indoor installation only. Mount the EAM in a standard 21 cu. in. utility box with standard GFCI cover (not provided with kit). D Allows remote starting and stopping of the generator set and load transfer.
4.2.4 EAM Indicators Figure 4-7 summarizes the operation of LEDs and the audible alarm. LEDs Alarm Condition GEN Steady One chirp/10 minutes Emergency power system supplying load after a remote start signal from the EAM Test button. GEN Steady None Emergency power system supplying load due to automatic start after utility power loss or exercise run. GEN Flashing Fast (every second) None Supply load in silent mode.
4.4 Model SE Accessories The service entrance (SE) model transfer switch offers all the standard accessories discussed in previous sections plus the additional accessories discussed here. See dimension drawings ADV-8444 or ADV-8445 in Section 7 for model SE accessory locations. 4.4.1 Green LED Red LED ON OFF AC power is present and protection is provided. ON AC power is present but the SPD module needs replacement. The remote indication changes state. See Section 6.
Circuit Breaker Trip/Reset The trip indication window appears red when the breaker is tripped. Identify and correct the cause of the overcurrent trip before resetting the breaker. To reset the circuit breaker, move the breaker handle to the O/OFF position and then back to I/ON. 4.4.3 Enclosure Space Heater (Model SE) The space heater is equipped with an adjustable temperature and humidity control. See Figure 4-13.
Notes 40 Section 4 Accessories TP-6345 9/13
Section 5 Service Disconnect, SE Model Note: This section applies only to service entrance model transfer switches. DANGER Hazardous voltage. Will cause severe injury or death. 5.2 Source Circuit Breaker Reset If the utility source circuit breaker trips due to an overcurrent condition, the transfer switch will issue an engine start signal and then transfer to the emergency source when it is available. When the circuit breaker trips, the handle moves to an intermediate position.
Notes 42 Section 5 Service Disconnect, SE Model TP-6345 9/13
Section 6 Scheduled Maintenance 6.1 Introduction Regular preventive maintenance ensures safe and reliable operation and extends the life of the transfer switch. Preventive maintenance includes periodic testing, cleaning, inspection, and replacement of worn or missing components. Section 6.4 contains a service schedule for recommended maintenance tasks. A local authorized distributor/dealer can provide complete preventive maintenance and service to keep the transfer switch in top condition.
Servicing the transfer switch. Hazardous voltage can cause severe injury or death. Deenergize all power sources before servicing. Turn off the main circuit breakers of all transfer switch power sources and disable all generator sets as follows: (1) Move all generator set master controller switches to the OFF position. (2) Disconnect power to all battery chargers. (3) Disconnect all battery cables, negative (--) leads first.
Internal Inspection. Disconnect all power sources, open the transfer switch enclosure door, and inspect internal components monthly or when any condition noticed during an external inspection may have affected internal components. Contact an authorized distributor/dealer to inspect and service the transfer switch if any of the following conditions are found inside the transfer switch. D Accumulations of dirt, dust, moisture, or other contaminants. D Signs of corrosion.
6.4 Service Schedule Follow the service schedule below for the recommended service intervals. Have all service performed by an authorized distributor/dealer except for activities designated by an X, which may be performed by the switch operator. See Section Visually Inspect Check Check for signs of overheating or loose connections: discoloration of metal, melted plastic, or a burning odor 6.3.
c. Disconnect the generator set engine starting battery, negative (--) lead first. 6.5 Surge Protective Device (SPD) Replacement The green indicator light goes out if the SPD capability is exceeded or if there is an internal safety component failure in the SPD module. See Figure 4-10. Replace the module if the green indicator is off and the red indicator is on. Follow the replacement procedure in this section and see Figure 6-1. DANGER Hazardous voltage. Will cause severe injury or death. 3.
7. Install the new module and tighten the mounting screws to 3 Nm (26 in. lb.). 1 8. Connect the SPD leads. See the service entrance transfer switch wiring diagram in Section 7. Also see Figure 6-3. 9. Replace the enclosure’s inner panel. 10. Close the Normal and Emergency service disconnect circuit breakers. 11. Reconnect the generator set engine starting battery, negative (--) lead last. 12. Reconnect power to the battery charger. 13. Close the battery charger circuit breaker. 2 14.
Section 7 Diagrams and Drawings Drawings are arranged in alphanumeric order on the following pages. Diagram or Drawing Drawing Number Enclosure Dimensions Drawings 100 Amp NEMA 1 without Load Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Amp NEMA 1 with Load Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Amp NEMA 3R without Load Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Amp NEMA 3R with Load Center . . . . . . . . . .
Figure 7-1 50 Dimension Drawing, 100 Amp NEMA Type 1 Enclosure with Load Center, ADV-8435 Section 7 Diagrams and Drawings TP-6345 9/13
- Figure 7-2 TP-6345 9/13 Dimension Drawing, 200 Amp NEMA Type 1 Enclosure with Load Center, ADV-8436 Section 7 Diagrams and Drawings 51
Figure 7-3 52 Enclosure Dimensions 100 Amp NEMA 1 without Load Center, ADV-8437 Section 7 Diagrams and Drawings TP-6345 9/13
Figure 7-4 TP-6345 9/13 Dimension Drawing, 200 Amp NEMA Type 1 Enclosure without Load Center, ADV-8438 Section 7 Diagrams and Drawings 53
Figure 7-5 54 Dimension Drawing, 400 Amp NEMA Type 1 and 3R Enclosure, ADV-8439, Sheet 1 of 2 Section 7 Diagrams and Drawings TP-6345 9/13
Figure 7-6 TP-6345 9/13 Dimension Drawing, 400 Amp NEMA Type 1 and 3R Enclosure, ADV-8439, Sheet 2 of 2 Section 7 Diagrams and Drawings 55
Figure 7-7 56 Dimension Drawing, 100 Amp NEMA Type 3R Enclosure without Load Center, ADV-8440 Section 7 Diagrams and Drawings TP-6345 9/13
Figure 7-8 TP-6345 9/13 Dimension Drawing, 200 Amp NEMA Type 3R Enclosure without Load Center, ADV-8441 Section 7 Diagrams and Drawings 57
Figure 7-9 58 Dimension Drawing, 100 Amp NEMA Type 3R Enclosure with Load Center, ADV-8442 Section 7 Diagrams and Drawings TP-6345 9/13
Figure 7-10 Dimension Drawing, 200 Amp NEMA Type 3R Enclosure with Load Center, ADV-8443 TP-6345 9/13 Section 7 Diagrams and Drawings 59
Figure 7-11 Dimension Drawing, 200 Amp Service Entrance Model, ADV-8444, Sheet 1 of 2 60 Section 7 Diagrams and Drawings TP-6345 9/13
Figure 7-12 Dimension Drawing, 200 Amp Service Entrance Model, ADV-8444, Sheet 2 of 2 TP-6345 9/13 Section 7 Diagrams and Drawings 61
Figure 7-13 Dimension Drawing, 400 Amp Service Entrance Model, ADV-8445, Sheet 1 of 2 62 Section 7 Diagrams and Drawings TP-6345 9/13
Figure 7-14 Dimension Drawing, 400 Amp Service Entrance Model, ADV-8445, Sheet 2 of 2 TP-6345 9/13 Section 7 Diagrams and Drawings 63
Figure 7-15 Dimension Drawing, 200 Amp Service Entrance Model with Load Center, ADV-8540, Sheet 1 of 3 64 Section 7 Diagrams and Drawings TP-6345 9/13
Figure 7-16 Dimension Drawing, 200 Amp Service Entrance Model with Load Center, ADV-8540, Sheet 2 of 3 TP-6345 9/13 Section 7 Diagrams and Drawings 65
Figure 7-17 Dimension Drawing, 200 Amp Service Entrance Model with Load Center, ADV-8540, Sheet 3 of 3 66 Section 7 Diagrams and Drawings TP-6345 9/13
Figure 7-18 Wiring Diagram, 100/200 amp without Load Center, GM34465 TP-6345 9/13 Section 7 Diagrams and Drawings 67
Figure 7-19 Schematic Diagram, 100/200 Amp without Load Center, GM34466 68 Section 7 Diagrams and Drawings TP-6345 9/13
Figure 7-20 Schematic Diagram, 100/200 Amp with Load Center, GM37649 TP-6345 9/13 Section 7 Diagrams and Drawings 69
Figure 7-21 Wiring Diagram, 100/200 Amp with Load Center, GM37650 70 Section 7 Diagrams and Drawings TP-6345 9/13
Figure 7-22 Schematic Diagram, 400 Amp, GM37651 TP-6345 9/13 Section 7 Diagrams and Drawings 71
Figure 7-23 Wiring Diagram, 400 Amp, GM37652 72 Section 7 Diagrams and Drawings TP-6345 9/13
Figure 7-24 Schematic Diagram, 200 Amp Service Entrance Switch Accessories, GM52482 TP-6345 9/13 Section 7 Diagrams and Drawings 73
Figure 7-25 Wiring Diagram for Programmable Exerciser GM64027 and GM64028, Drawing GM64071 74 Section 7 Diagrams and Drawings TP-6345 9/13
Figure 7-26 Schematic Diagram, 400 Amp Service Entrance Switch Accessories, GM65397 TP-6345 9/13 Section 7 Diagrams and Drawings 75
Figure 7-27 Wiring Diagram, 200 Amp Service Entrance Switch with Load Center, GM83844, Sheet 1 of 2 76 Section 7 Diagrams and Drawings TP-6345 9/13
Figure 7-28 Wiring Diagram, 200 Amp Service Entrance Switch with Load Center, GM83844, Sheet 2 of 2 TP-6345 9/13 Section 7 Diagrams and Drawings 77
Figure 7-29 Schematic Diagram, 200 Amp Service Entrance Switch with Load Center, GM83845 78 Section 7 Diagrams and Drawings TP-6345 9/13
Figure 7-30 Wiring Diagram, 400 Amp Service Entrance Switch, GM84854, Sheet 1 of 2 TP-6345 9/13 Section 7 Diagrams and Drawings 79
Figure 7-31 Wiring Diagram, 400 Amp Service Entrance Switch Accessories, GM84854, Sheet 2 of 2 80 Section 7 Diagrams and Drawings TP-6345 9/13
Figure 7-32 Schematic Diagram, 400 Amp Service Entrance Switch, GM84855 TP-6345 9/13 Section 7 Diagrams and Drawings 81
Figure 7-33 Schematic Diagram, 200 Amp Service Entrance Switch, GM84856 Section 7 Diagrams and Drawings 82 TP-6345 9/13
Figure 7-34 Wiring Diagram, 200 Amp Service Entrance Switch, GM84857, Sheet 1 of 2 TP-6345 9/13 Section 7 Diagrams and Drawings 83
Figure 7-35 Wiring Diagram, 200 Amp Service Entrance Switch, GM84857, Sheet 2 of 2 Section 7 Diagrams and Drawings 84 TP-6345 9/13
Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ABDC AC A/D ADC adj. ADV Ah AHWT AISI ALOP alt. Al ANSI AO APDC API approx. AQMD AR AS ASE ASME assy. ASTM ATDC ATS auto. aux. avg. AVR AWG AWM bat. BBDC BC BCA BCI BDC BHP blk. blk. htr. BMEP bps br. BTDC Btu Btu/min. C cal. CAN CARB CB cc CCA ccw. CEC cert.
k K kA KB KBus kg kg/cm2 kilo (1000) kelvin kiloampere kilobyte (210 bytes) Kohler communication protocol kilogram kilograms per square centimeter kgm kilogram-meter kg/m3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm, kΩ kilo-ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt-hour kWm kilowatt mechanical kWth kilowatt-thermal L liter LAN local area network L x W x H length by width by height lb.
KOHLER CO. Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KOHLERPower.com TP-6345 9/13j E 2004, 2005, 2007, 2008, 2011, 2012, 2013 by Kohler Co. All rights reserved.
