Operation and Installation Automatic Transfer Switch Model: RXT 100--400 Amp Automatic Transfer Switches For use with Kohlerr Model RESA, RESAL, or RCL generator sets equipped with RDC2 or DC2 generator/transfer switch controllers TP-6807 12/11
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nameplate . .
Table of Contents, continued 5.3 5.4 Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.1 General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.2 Other Inspections and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 Kohlerr Model RXT automatic transfer switches. See Figure 1 for typical Model RXT transfer switches. Model RXT transfer switches operate only with Kohlerr Model generator sets equipped with the RDC2 or DC2 generator/transfer switch controller. See Figure 2 for controller identification.
Nameplate TRANSFER SWITCH FOR EMERGENCY SYSTEMS TYPE ENCLOSURE MFG. DATE 1 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 3. 2 MATERIAL MODEL SERIAL NO.
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-6807 12/11
Section 1 Description 1.1 Transfer Switch Description Service Entrance Model 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.
Section 2 Installation 2.1 Introduction accumulated in the transfer switch or any of its components. 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.
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.
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. 1 1.
2. Insert the maintenance handle or a tool (such as a screwdriver) into the hole in the shaft on the left 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. 2.
2.5.2 AC Power Connections Determine the cable size. Refer to Figure 2-8 or the ADV drawings in Section 6 to determine the cable size required for the transfer switch. Make sure the lugs provided are suitable for use with the cables being installed. Conduit. 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.
2.5.3 Neutral Connection 2.5.5 Connect the neutral from the main panel to the neutral lug in the ATS enclosure. Ground the system according to NEC and local codes. 2.5.4 Engine Start Function The engine start function is controlled by the RDC2/DC2 controller on the generator set. There are no engine start terminals on the Model RXT ATS. Neutral Bonding Jumper, Service Entrance Models The transfer switch is shipped with the neutral-to-ground jumper installed.
2.5.6 Interface Module Connection The interface module must be connected to a Kohlerr generator set equipped with the RDC2 or DC2 controller. The generator set is typically equipped with a field-connection terminal block. See the generator set Installation Manual for the location of the terminal block. Note: This document gives connection information for one Model RXT transfer switch connected to a generator set equipped with an RDC2 or DC2 controller.
2.5.7 Optional Load Control Connection Connector P11 on the 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. See Figure 2-11 for the location of load control connector P11.
Section 3 Operation 3.1 Model RXT Transfer Switch Operation 3.3 ATS Control Sequence of 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.
3.4 Time Delays 3.5 Load Control Time Delay Time delays are factory-set to the values shown in Figure 3-2. An authorized distributor/dealer can adjust time delays using a personal computer and Kohlerr SiteTecht software. 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. The load control time delay is fixed at 5 minutes. It is not adjustable.
Section 4 Service Disconnect, SE Model Note: This section applies only to service entrance model transfer switches, which are identified with the letters ASE at the end of the model designation. DANGER Hazardous voltage. Will cause severe injury or death. 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.
Notes 24 Section 4 Service Disconnect, SE Model TP-6807 12/11
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.
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.
D Signs of overheating or loose connections: discoloration of metal, melted plastic, or a burning odor. operation of the transfer switch. See Section 5.4, Service Schedule, for the recommended maintenance items and service intervals. D Other evidence of wear, damage, deterioration, or Have an authorized distributor/dealer repair or replace damaged or worn internal components with manufacturer-recommended replacement parts. malfunction of the transfer switch or its components.
Notes 28 Section 5 Scheduled Maintenance TP-6807 12/11
Section 6 Diagrams and Drawings Diagram or Drawing Drawing Number Page Single-Phase Enclosure Dimension Drawings 100--200 Amp Single-Phase Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Amp Single-Phase with Load Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400 Amp Single-Phase . . . . . .
Figure 6-1 30 Enclosure Dimensions, 100--200 Amp Single-Phase, ADV-8190, Sheet 1 of 2 Section 5 Diagrams and Drawings TP-6807 12/11
Figure 6-2 Enclosure Dimensions, 100--200 Amp Single-Phase, ADV-8190, Sheet 2 of 2 TP-6807 12/11 Section 5 Diagrams and Drawings 31
Figure 6-3 32 Enclosure Dimensions, 100--200 Amp Three-Phase, 3- and 4-Pole, ADV-8191 Section 5 Diagrams and Drawings TP-6807 12/11
Figure 6-4 Enclosure Dimensions, 100--200 Amp Single-Phase, Service Entrance, ADV-8192, Sheet 1 of 3 TP-6807 12/11 Section 5 Diagrams and Drawings 33
Figure 6-5 34 Enclosure Dimensions, 100--200 Amp Single-Phase, Service Entrance, ADV-8192, Sheet 2 of 3 Section 5 Diagrams and Drawings TP-6807 12/11
Figure 6-6 Enclosure Dimensions, 100--200 Amp Single-Phase, Service Entrance, ADV-8192, Sheet 3 of 3 TP-6807 12/11 Section 5 Diagrams and Drawings 35
Figure 6-7 36 Enclosure Dimensions, 400 Amp Single-Phase, ADV-8193 Section 5 Diagrams and Drawings TP-6807 12/11
Figure 6-8 Enclosure Dimensions, 400 Amp Three-Phase, 3-Pole/208--240 Volts, ADV-8194 TP-6807 12/11 Section 5 Diagrams and Drawings 37
Figure 6-9 38 Enclosure Dimensions, 400 Amp Three-Phase, 3-Pole/480 Volt and 4-Pole, ADV-8195 Section 5 Diagrams and Drawings TP-6807 12/11
Figure 6-10 Enclosure Dimensions, 400 Amp Single-Phase, Service Entrance, ADV-8196, Sheet 1 of 2 TP-6807 12/11 Section 5 Diagrams and Drawings 39
Figure 6-11 Enclosure Dimensions, 400 Amp Single-Phase, Service Entrance, ADV-8196, Sheet 2 of 2 40 Section 5 Diagrams and Drawings TP-6807 12/11
Figure 6-12 Enclosure Dimensions, 100 Amp Single-Phase with Load Center, ADV-8197 TP-6807 12/11 Section 5 Diagrams and Drawings 41
Figure 6-13 Wiring Diagram, 100--400 Amp Single-Phase, GM80663 42 Section 5 Diagrams and Drawings TP-6807 12/11
Figure 6-14 Schematic Diagram, 100--400 Amp Single-Phase, GM80664 TP-6807 12/11 Section 5 Diagrams and Drawings 43
Figure 6-15 Wiring Diagram, 100--400 Amp Service Entrance, GM80665 44 Section 5 Diagrams and Drawings TP-6807 12/11
Figure 6-16 Schematic Diagram, 100--400 Amp Service Entrance, GM80666 TP-6807 12/11 Section 5 Diagrams and Drawings 45
Figure 6-17 Wiring Diagram, 100--200 Amp Three-Phase, 3- and 4-Pole, GM80667 46 Section 5 Diagrams and Drawings TP-6807 12/11
Figure 6-18 Schematic Diagram, 100--200 Amp Three-Phase, 3- and 4-Pole, GM80668 TP-6807 12/11 Section 5 Diagrams and Drawings 47
Figure 6-19 Wiring Diagram, 400 Amp Three-Phase, 3-Pole/208--240 Volts, GM80669 48 Section 5 Diagrams and Drawings TP-6807 12/11
Figure 6-20 Schematic Diagram, 400 Amp Three-Phase, 3-Pole/208--240 Volts, GM80670 TP-6807 12/11 Section 5 Diagrams and Drawings 49
Figure 6-21 Wiring Diagram, 400 Amp Three-Phase, 3-Pole/480 Volts and 4-Pole, GM80671 50 Section 5 Diagrams and Drawings TP-6807 12/11
Figure 6-22 Schematic Diagram, 400 Amp Three-Phase, 3-Pole/480 Volts and 4-Pole, GM80672 TP-6807 12/11 Section 5 Diagrams and Drawings 51
Figure 6-23 Wiring Diagram, 100 Amp Single-Phase with Load Center, GM80675 52 Section 5 Diagrams and Drawings TP-6807 12/11
Figure 6-24 Schematic Diagram, 100 Amp Single-Phase with Load Center, GM80676 TP-6807 12/11 Section 5 Diagrams and Drawings 53
Notes 54 Section 5 Diagrams and Drawings TP-6807 12/11
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.
Notes TP-6807 12/11 57
Notes 58 TP-6807 12/11
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 12/11 E 2011 by Kohler Co. All rights reserved.
