Operation and Installation Automatic Transfer Switch Model: RXT 100--400 Amp Automatic Transfer Switches For use with Kohlerr generator sets equipped with RDC2 or DC2 generator/transfer switch controllers TP-6807 1/16d
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. 2 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents, continued 4 Section 3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 Model RXT Transfer Switch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 Source Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 ATS Control Sequence of Operation . . . . . . . . . . . . . . . . . .
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.
Making line or auxiliary connections. Hazardous voltage can cause severe injury or death. To prevent electrical shock deenergize the normal power source before making any line or auxiliary connections. Servicing the transfer switch. Hazardous voltage can cause severe injury or death. Deenergize all power sources before servicing.
Introduction This manual provides operation and installation instructions for Kohlerr Model RXT automatic transfer switches. See Figure 2 for typical Model RXT transfer switches. Model RXT transfer switches operate only with Kohlerr generator sets equipped with the RDC2 or DC2 generator/transfer switch controller. See Figure 1 or Figure 3 for controller identification. The transfer switch is equipped with either a standard interface board or a combined interface/load management board.
List of Related Literature Nameplate Figure 4 identifies related literature available for the automatic transfer switches and accessories covered in this manual. Only trained and qualified personnel should install or service the transfer switch and accessories. A nameplate attached to the inside of the enclosure cover or on the upper right side wall includes a model designation, a serial number, ratings, and other information about the transfer switch. See Figure 5.
Model Designation Figure 6 explains the model designation. Model Controls Voltage Poles Enclosure Current Rating Connections Record the transfer switch model designation in the boxes. The transfer switch model designation defines ratings and characteristics as explained below.
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 decals 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.
Section 1 Description 1.1 Transfer Switch Description Service Entrance Model (UL) 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.
Loads. The transfer switch can be connected to supply all of the electrical loads in the home, or only the essential loads such as the furnace, refrigerator, well pump, and selected light circuits. Identify the essential circuits that must be supplied during a power outage. Verify that the generator set and transfer switch are adequately rated to supply all of the selected loads. Circuit breakers.
Circuit Board Relays Rating Pilot Relays and HVAC Relays (qty. 2) 125VAC, 10 A (general purpose) 120VAC, 125VA (pilot duty) Figure 1-3 Combined Interface Board Relay Specifications Figure 1-5 shows a simple diagram of a power system with load management. For detailed installation and connection instructions, refer to Section 2.7 and the instructions provided with the power relay modules.
1.5 Optional Status Indicator Panels 1.5.2 Two status indicator panels are available. One is for RXTs with the standard interface board, and the other is for the RXT with the combined interface /load management board. The two types of indicator panels use different connectors and are not interchangeable. The standard indicator panel connects only to the standard board. The combined indicator panel connects only to the combined interface/load management board.
Section 2 Installation 2.1 Introduction Kohlerr 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. Note: Do not use compressed air to clean the switch. Cleaning with compressed air can cause debris to lodge in the components and damage the switch. 2.2.
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. The transfer switch may use both American Standard and metric hardware.
2.4 Manual Operation Check DANGER CN 4 3 C NO NC NL1 NL2 EL1 EL2 SCN Hazardous voltage. Will cause severe injury or death. SCE NC NO Disconnect all power sources before opening the enclosure. C 7 8 Check the manual operation before energizing the transfer switch. Verify that the contactor operates smoothly without binding. Do not place the transfer switch into service if the contactor does not operate smoothly.
side of the operator as shown in Figure 2-6 or Figure 2-7. 3. Move the maintenance handle (or tool) up or down as shown to manually operate the transfer switch. It should operate smoothly without any binding. If it does not, check for shipping damage or construction debris. 4. Return the transfer switch to the Normal position. 5. Remove the maintenance handle and return it to the storage location. 2.
Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present. Ensure you comply with all applicable codes and standards. Electrically ground the generator set and related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the equipment.
2.6 Interface Module Connection The interface module must be connected to a Kohlerr generator set equipped with the RDC2 or DC2 controller. Connect P10 on the interface module to the A, B, PWR, and COM connections on the generator set’s field-connection terminal block. See the generator set Installation Manual for the location of the terminal block. See Figure 2-8 for P10 connection identification. Note: Engine start connections 3 and 4 on the generator set are not used with the Model RXT transfer switch.
Maximum cable length per run, meters (ft.) Indoor or Outdoor Installation Cable Size for PWR and COM Connections Indoor 20 AWG Belden #9402 or equivalent, two-pair Number of Modules per Run 1 Module 2 Modules 3 Modules 61 (200) 31 (100) 21 (67) 61 (200) 31 (100) 21 (67) Outdoor 152 (500) 152 (500) 122 (400) — 14 AWG * 152 (500) 152 (500) 152 (500) — 12 AWG * 20 AWG Belden #1075A or equivalent, two-pair * Use 12 or 14 AWG cable for PWR and COM connections only.
2.7 Combined Interface/Load Management Board The combined interface/load management board can be used with single-phase generator sets equipped with the RDC2 or DC2 controller only. Follow the instructions in this section to install the current transformer and connect the load management relays. Then connect the interface/load management board to a Kohlerr generator set equipped with the RDC2 or DC2 controller. Up to four load relays and two HVAC relays can be connected.
2.7.4 Current Transformers (CTs) A current transformer is required for load management. A 400 amp current transformer is included with the combined interface /load management board. If the application requires cables that are too large for the inside diameter of the CT provided, or a 500 Amp CT is needed for the 60RCL, order a current transformer or obtain a current transformer that meets the specifications shown in Figure 2-14. DANGER Hazardous voltage. Will cause severe injury or death.
7. RBUS connections: Connect the controller interface connection to A, B, PWR, and COM on terminal block P10 on the interface/load management board See Figure 2-16 and Figure 2-18. The RBUS connections to the generator set controller are the same for the standard interface board and the combined board. See Section 2.6 for interface connection instructions. 1 Note: Use separate conduit for the low-voltage controller communication leads and the load connection wiring.
12. Connect HVAC loads to TB3. See Figure 2-18. Note the priorities of HVAC A and HVAC B relative to Loads A through D. See Figure 2-19 and Section 2.7.3. 6 1 5 2 4 3 GM95546 1. 2. 3. 4. TB3 HVAC relay connections TB1 connection for current transformer (CT) TB2 120 VAC input connection TB2 connections to customer-supplied power relays (max 4 relays) 5. P10 RDC2/DC2 controller interface RBUS connections 6.
2.8 Load Control Module (LCM) Note: Only one load management option can be used with the generator. If the LCM is connected to an RXT equipped with the combined interface/load management board, disable the load management function on the combined board as described in Section 2.8.2, below. 2.8.1 LCM with Standard Interface Board Disabling the generator set. Accidental starting can cause severe injury or death.
8. Connect RBUS communication cable to the combined interface board: Connect the generator controller’s interface connection to A, B, PWR, and COM on terminal block P10 on the interface/load management board. See Figure 2-20. See Section 2.6 for detailed RBUS connection instructions. 9. Follow the instructions in TT-1574, provided with the LCM, to connect the load control module. 1 DO NOT CONNECT 2 a.
2.9 Optional Load Control Connection 2.10 Accessory Module Connections Connector P11 on the standard interface module provides a connection point for optional load control circuits. The load control contact provides a delayed contact closure to allow startup of selected loads 5 minutes after transfer to the emergency power source (generator set). Use this contact to delay startup of equipment with large motor-starting loads such as air conditioners.
Section 3 Operation 3.1 Model RXT Transfer Switch Operation The Model RXT transfer switch must be connected to a generator set equipped with the RDC2 or DC2 controller. The RDC2/DC2 generator set/transfer switch controller manages automatic transfer switch (ATS) functions when connected to a Kohlerr Model RXT transfer switch through the ATS interface board.
For more information about the load add and load shed timing, see Section 3.5, Load Management Theory of Operation. 1 3.4.1 2 Power Loads 3 Up to four customer-supplied power relays can be connected for management of non-essential secondary loads. If two-pole relays are used, two (2) 120 VAC loads (shed simultaneously) or a single 240 VAC load can be wired to each relay. See Section 2.7.1 for more power relay information. 3.4.
LED State/Color Utility Available On Utility power is available Off Utility power is not available Utility Connected On Utility power is connected (ATS in normal position) Off Utility power is not connected On Generator set is running and producing power Off Generator set power is not available On Generator is connected to the load (ATS in Emergency position) Off Generator Available Generator Connected Loads A through D HVAC Loads A, B Indicates Generator not connected Red Load dis
System Configuration in SiteTecht. See Figure 3-6 and TP-6701, SiteTech Software Operation Manual. The load management function will operate if the rating setting is not changed, but loads will be shed at a kW level based on the factory default rating, rather than the rating of the reconfigured generator set. 3.5.3 Overload Shed Loads are shed on a time scale which is based on the total generator overload. The loads will shed slowly when the generator is not heavily overloaded.
Figure 3-8 shows the under frequency shed timing for a 60 Hz generator set. If the underfrequency condition persists, the load shed timing can be affected by load shed acceleration. See Section 3.5.5. Frequency (Hz) Frequency Droop (Hz) Time (seconds) >59 Hz <1 Hz Never Shed 58.5 1.5 5.4 57 3 4.3 56 4 3.4 54 6 1.8 <52.5 Hz >7.5 Hz 0.3 Figure 3-8 Under Frequency Shed Timing for a 60Hz Generator 3.5.
3.6 Time Delays 3.7 Load Control Time Delay Time delays are factory-set to the values shown in Figure 3-10. An authorized distributor/dealer can adjust time delays using a personal computer and Kohlerr SiteTecht software. The standard interface board includes a load control time delay. The load control time delay allows delayed starting of large motor loads (such as air conditioners), preventing simultaneous starting of large motors after transfer to the generator set.
Section 4 Service Disconnect, SE Model Note: This section applies only to service entrance model transfer switches, which are identified with the letters SE at the end of the model designation. DANGER Hazardous voltage. Will cause severe injury or death. This equipment must be installed and serviced by qualified electrical personnel. WARNING 4.1 Service Disconnect Procedure Use the following procedure to disconnect the utility source on service entrance model transfer switches.
4.2 Source Circuit Breaker Reset The utility source circuit breaker can trip due to an overcurrent condition. Identify and correct the cause of the overcurrent condition before resetting the circuit breaker. Contact a local distributor/dealer for service if necessary. When the circuit breaker trips, the handle moves to an intermediate position. To reset a tripped circuit breaker, move the handle to the extreme OFF position and then to the ON position. 1 GM80015 2 1. Normal/utility circuit breaker 2.
Section 5 Scheduled Maintenance 5.1 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 5.4 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.
Short circuits. Hazardous voltage/current can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment. NOTICE Electrostatic discharge damage. Electrostatic discharge (ESD) damages electronic circuit boards.
maintenance that ensures the safe and reliable operation of the transfer switch. See Section 5.4, Service Schedule, for the recommended maintenance items and service intervals. Have an authorized distributor/dealer repair or replace damaged or worn internal components with manufacturer-recommended replacement parts. 5.4 Service Schedule Follow the service schedule in Figure 5-1 for the recommended service intervals.
Notes 40 Section 5 Scheduled Maintenance TP-6807 1/16
Section 6 Diagrams and Drawings Diagram or Drawing Drawing Number Page Standard Models Enclosure Dimension Drawings 100--200 Amp Single-Phase Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100--200 Amp Three-Phase, 3- and 4-Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-1 Enclosure Dimensions, 100 Amp NEMA 1 with 16-Space Load Center, ADV-8487 42 Section 5 Diagrams and Drawings TP-6807 1/16
Figure 6-2 Enclosure Dimensions, 100 Amp, CSA Certified Service Entrance, ADV-8665, Sheet 1 of 2 TP-6807 1/16 Section 5 Diagrams and Drawings 43
Figure 6-3 Enclosure Dimensions, 100 Amp, CSA Certified Service Entrance, ADV-8665, Sheet 2 of 2 44 Section 5 Diagrams and Drawings TP-6807 1/16
Figure 6-4 Enclosure Dimensions, 150--200 Amp CSA Certified Service Entrance, ADV-8666, Sheet 1 of 2 TP-6807 1/16 Section 5 Diagrams and Drawings 45
Figure 6-5 Enclosure Dimensions, 150--200 Amp CSA Certified Service Entrance, ADV-8666, Sheet 2 of 2 46 Section 5 Diagrams and Drawings TP-6807 1/16
Figure 6-6 Enclosure Dimensions, 100--200 Amp Single-Phase, Service Entrance, ADV-8687, Sheet 1 of 3 TP-6807 1/16 Section 5 Diagrams and Drawings 47
Figure 6-7 Enclosure Dimensions, 100--200 Amp Single-Phase, Service Entrance, ADV-8687, Sheet 2 of 3 48 Section 5 Diagrams and Drawings TP-6807 1/16
Figure 6-8 Enclosure Dimensions, 100--200 Amp Single-Phase, Service Entrance, ADV-8687, Sheet 3 of 3 TP-6807 1/16 Section 5 Diagrams and Drawings 49
Figure 6-9 Enclosure Dimensions, 100--200 Amp Single-Phase, ADV-8688, Sheet 1 of 2 50 Section 5 Diagrams and Drawings TP-6807 1/16
Figure 6-10 Enclosure Dimensions, 100--200 Amp Single-Phase, ADV-8688, Sheet 2 of 2 TP-6807 1/16 Section 5 Diagrams and Drawings 51
Figure 6-11 Enclosure Dimensions, 100--200 Amp Three-Phase, 3- and 4-Pole, ADV-8689 52 Section 5 Diagrams and Drawings TP-6807 1/16
Figure 6-12 Enclosure Dimensions, 100 Amp Single-Phase with Load Center, ADV-8690 TP-6807 1/16 Section 5 Diagrams and Drawings 53
Figure 6-13 Enclosure Dimensions, 400 Amp Single-Phase, ADV-8691 54 Section 5 Diagrams and Drawings TP-6807 1/16
Figure 6-14 Enclosure Dimensions, 400 Amp Three-Phase, 3-Pole/208--240 Volts, ADV-8692 TP-6807 1/16 Section 5 Diagrams and Drawings 55
Figure 6-15 Enclosure Dimensions, 400 Amp Three-Phase, 3-Pole/480 Volt and 4-Pole, ADV-8693 56 Section 5 Diagrams and Drawings TP-6807 1/16
Figure 6-16 Enclosure Dimensions, 300--400 Amp Single-Phase, Service Entrance, ADV-8694, Sheet 1 of 2 TP-6807 1/16 Section 5 Diagrams and Drawings 57
Figure 6-17 Enclosure Dimensions, 300--400 Amp Single-Phase, Service Entrance, ADV-8694, Sheet 2 of 2 58 Section 5 Diagrams and Drawings TP-6807 1/16
Figure 6-18 Enclosure Dimensions, 100 Amp NEMA 1 with 12-Space Load Center, ADV-8736 TP-6807 1/16 Section 5 Diagrams and Drawings 59
Figure 6-19 Wiring Diagram, 100--400 Amp Single-Phase, GM80663 60 Section 5 Diagrams and Drawings TP-6807 1/16
Figure 6-20 Schematic Diagram, 100--400 Amp Single-Phase, GM80664 TP-6807 1/16 Section 5 Diagrams and Drawings 61
Figure 6-21 Wiring Diagram, 100--400 Amp Service Entrance, GM80665 62 Section 5 Diagrams and Drawings TP-6807 1/16
Figure 6-22 Schematic Diagram, 100--400 Amp Service Entrance, GM80666 TP-6807 1/16 Section 5 Diagrams and Drawings 63
Figure 6-23 Wiring Diagram, 100--200 Amp Three-Phase, 3- and 4-Pole, GM80667 64 Section 5 Diagrams and Drawings TP-6807 1/16
Figure 6-24 Schematic Diagram, 100--200 Amp Three-Phase, 3- and 4-Pole, GM80668 TP-6807 1/16 Section 5 Diagrams and Drawings 65
Figure 6-25 Wiring Diagram, 400 Amp Three-Phase, 3-Pole/208--240 Volts, GM80669 66 Section 5 Diagrams and Drawings TP-6807 1/16
Figure 6-26 Schematic Diagram, 400 Amp Three-Phase, 3-Pole/208--240 Volts, GM80670 TP-6807 1/16 Section 5 Diagrams and Drawings 67
Figure 6-27 Wiring Diagram, 400 Amp Three-Phase, 3-Pole/480 Volts and 4-Pole, GM80671 68 Section 5 Diagrams and Drawings TP-6807 1/16
Figure 6-28 Schematic Diagram, 400 Amp Three-Phase, 3-Pole/480 Volts and 4-Pole, GM80672 TP-6807 1/16 Section 5 Diagrams and Drawings 69
Figure 6-29 Wiring Diagram, 100 Amp Single-Phase with Load Center, GM80675 70 Section 5 Diagrams and Drawings TP-6807 1/16
Figure 6-30 Schematic Diagram, 100 Amp Single-Phase with Load Center, GM80676 TP-6807 1/16 Section 5 Diagrams and Drawings 71
Figure 6-31 Wiring Diagram, 100--400 Amp Single-Phase with Combined Interface Board, GM95546 72 Section 5 Diagrams and Drawings TP-6807 1/16
Figure 6-32 Schematic Diagram, 100--400 Amp Single-Phase with Combined Interface Board, GM95547 TP-6807 1/16 Section 5 Diagrams and Drawings 73
Figure 6-33 Wiring Diagram, 100--400 Amp Service Entrance with Combined Interface Board, GM95548 74 Section 5 Diagrams and Drawings TP-6807 1/16
Figure 6-34 Schematic Diagram, 100--400 Amp Service Entrance with Combined Interface Board, GM95549 TP-6807 1/16 Section 5 Diagrams and Drawings 75
Notes 76 Section 5 Diagrams and Drawings TP-6807 1/16
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 kilograms per cubic meter kg/m3 kHz kilohertz kJ kilojoule km kilometer kOhm, k 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-6807 1/16d E 2011, 2014, 2015, 2016 by Kohler Co. All rights reserved.
