Kohler

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. Transfer Switch Identification Numbers
Record the product identification numbers in the spaces
below immediately after unpacking the products so that Record the product identification numbers from the
the numbers are readily available for future reference. transfer switch nameplate.
Record field-installed kit numbers after installing the Model Designation
kits.
Serial Number
2 TP-6807 1/16
Table of Contents
Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
List of Related Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Model Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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
1.4.1 Standard Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.4.2 Combined Interface/Load Management Board . . . . . . . . . . . . . . . . . . . . . 12
1.5 Optional Status Indicator Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5.1 Standard Status Indicator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5.2 Status Indicator Panel for Combined Interface/ Load Management Board . .
14
Section 2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2 Receipt of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2.2 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2.3 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2.4 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.4 Manual Operation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4.1 Manual Operation Procedure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4.2 Manual Operation Procedure 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.5 Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.5.1 Load Center Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5.2 AC Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5.3 Neutral Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5.4 Neutral Bonding Jumper, Service Entrance Models . . . . . . . . . . . . . . . . . 19
2.5.5 Engine Start Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.6 Interface Module Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.7 Combined Interface/Load Management Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.7.1 Relay Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.7.2 HVAC Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.7.3 Load Add/Shed Priority . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.7.4 Current Transformers (CTs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.7.5 Connection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.8 Load Control Module (LCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.8.1 LCM with Standard Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.8.2 LCM with Combined Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.9 Optional Load Control Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.10 Accessory Module Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.11 Test and Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.12 Warranty Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
TP-6807 1/16 Table of Contents 3

Table of Contents, continued
Section 3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.1 Model RXT Transfer Switch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.2 Source Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.3 ATS Control Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.4 Load Management Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.4.1 Power Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.4.2 HVAC Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.4.3 Load Add/Shed Priority . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.4.4 Status Indicator and Test Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.5 Load Management Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.5.1 Load Add . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.5.2 Load Shed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.5.3 Overload Shed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.5.4 Under Frequency Shed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.5.5 Load Shed Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.5.6 Changing Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.6 Time Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.7 Load Control Time Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Section 4 Service Disconnect, SE Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.1 Service Disconnect Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.2 Source Circuit Breaker Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Section 5 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.2 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.2.1 Weekly Generator Set Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.2.2 Monthly Automatic Control System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.3 Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.3.1 General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.3.2 Other Inspections and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.4 Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Section 6 Diagrams and Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4 Table of Contents TP-6807 1/16

Safety Precautions and Instructions
IMPORTANT SAFETY INSTRUCTIONS.

Electromechanical equipment,
Accidental Starting DANGER
including generator sets, transfer
switches, switchgear, and accessories, WARNING
can cause bodily harm and pose
life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be Hazardous voltage.
aware of potential dangers and act Will cause severe injury or death.
safely. Read and follow all safety Only authorized personnel should
precautions and instructions. SAVE Accidental starting.
Can cause severe injury or death. open the enclosure.
THESE INSTRUCTIONS.
Disconnect the battery cables before
This manual has several types of safety working on the generator set.
precautions and instructions: Danger, DANGER
Remove the negative (--) lead first
Warning, Caution, and Notice. when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery.
DANGER
Disabling the generator set. Hazardous voltage.
Danger indicates the presence of a Will cause severe injury or death.
Accidental starting can cause
hazard that will cause severe
severe injury or death. Before This equipment must be installed and
personal injury, death, or substantial
working on the generator set or serviced by qualified electrical
property damage.
equipment connected to the set, personnel.
disable the generator set as follows:
(1) Press the generator set off/reset
WARNING button to shut down the generator set. Grounding electrical equipment.
(2) Disconnect the power to the battery Hazardous voltage can cause
Warning indicates the presence of a charger, if equipped. (3) Remove the severe injury or death. Electrocution
hazard that can cause severe battery cables, negative (--) lead first. is possible whenever electricity is
personal injury, death, or substantial Reconnect the negative (--) lead last present. Ensure you comply with all
property damage. when reconnecting the battery. Follow applicable codes and standards.
these precautions to prevent the Electrically ground the generator set,
starting of the generator set by the transfer switch, and related equipment
CAUTION remote start/stop switch. and electrical circuits. Turn off the main
circuit breakers of all power sources
Caution indicates the presence of a before servicing the equipment. Never
hazard that will or can cause minor Hazardous Voltage/ contact electrical leads or appliances
when standing in water or on wet
personal injury or property damage.
Moving Parts ground because these conditions
NOTICE increase the risk of electrocution.
Notice communicates installation, DANGER Short circuits. Hazardous
operation, or maintenance information voltage/current can cause severe
that is safety related but not hazard injury or death. Short circuits can
related. cause bodily injury and/or equipment
damage. Do not contact electrical
Safety decals affixed to the equipment connections with tools or jewelry while
in prominent places alert the operator Hazardous voltage. making adjustments or repairs.
or service technician to potential Will cause severe injury or death. Remove all jewelry before servicing the
hazards and explain how to act safely. equipment.
The decals are shown throughout this Disconnect all power sources before
publication to improve operator opening the enclosure.
recognition. Replace missing or
damaged decals.
TP-6807 1/16 Safety Precautions and Instructions 5

Making line or
connections. Hazardous voltage
auxiliary Heavy Equipment Notice
can cause severe injury or death. To NOTICE
prevent electrical shock deenergize the WARNING
Foreign material contamination.
normal power source before making
Cover the transfer switch during
any line or auxiliary connections.
installation to keep dirt, grit, metal drill
Servicing the transfer switch. chips, and other debris out of the
Hazardous voltage can cause components. Cover the solenoid
severe injury or death. Deenergize all mechanism during installation. After
power sources before servicing. Turn installation, use the manual operating
Unbalanced weight. handle to cycle the contactor to verify
off the main circuit breakers of all
transfer switch power sources and Improper lifting can cause severe that it operates freely. Do not use a
disable all generator sets as follows: injury or death and equipment screwdriver to force the contactor
(1) Press the generator set off/reset damage. mechanism.
button to shut down the generator set. Use adequate lifting capacity.
(2) Disconnect power to all battery Never leave the transfer switch
NOTICE
chargers. (3) Disconnect all battery standing upright unless it is securely Electrostatic discharge damage.
cables, negative (--) leads first. bolted in place or stabilized. Electrostatic discharge (ESD)
Reconnect negative (--) leads last when damages electronic circuit boards.
reconnecting the battery cables after Prevent electrostatic discharge
servicing. Follow these precautions to damage by wearing an approved
prevent the starting of generator sets grounding wrist strap when handling
by an automatic transfer switch, remote electronic circuit boards or integrated
start/stop switch, or engine start circuits. An approved grounding wrist
command from a remote computer. strap provides a high resistance (about
Before servicing any components 1 megohm), not a direct short, to
inside the enclosure: (1) Remove all ground.
jewelry. (2) Stand on a dry, approved
electrically insulated mat. (3) Test
circuits with a voltmeter to verify that
they are deenergized.
6 Safety Precautions and Instructions TP-6807 1/16

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. The
interface board communicates with the RDC2 or DC2
controller on the generator set.
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.
Read this manual and carefully follow all procedures

and safety precautions to ensure proper equipment
operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section at the
beginning of this manual. Keep this manual with the
equipment for future reference.
The equipment service requirements are very important

to safe and efficient operation. Inspect parts often and
perform required service at the prescribed intervals.
Obtain service from an authorized service distributor/ Figure 2 Typical Model RXT Transfer Switches
dealer to keep equipment in top condition. (shown with optional status indicators)
RDC2 DC2 RDC2 DC2

GM89864
GM77569
Figure 1 Original (green-board) RDC2 and DC2 Figure 3 Revised (red-board) RDC2 and DC2
Generator/ Transfer Switch Controllers Generator/ Transfer Switch Controllers
(mounted on the generator set) (mounted on the generator set)
TP-6807 1/16 Introduction 7

List of Related Literature Nameplate
Figure 4 identifies related literature available for the A nameplate attached to the inside of the enclosure
automatic transfer switches and accessories covered in cover or on the upper right side wall includes a model
this manual. Only trained and qualified personnel designation, a serial number, ratings, and other
should install or service the transfer switch and information about the transfer switch. See Figure 5.
accessories.
Check the transfer switch model number from the
transfer switch nameplate and verify that it matches the
Literature Type Part Number
model shown on the front cover of this manual before
Specification Sheet, Model RXT G11-140 proceeding with installation.
Service and Parts Manual, Model RXT TP-6808
Copy the model designation, serial number, and
Operation Manual,
accessory information from the nameplate to the spaces
SiteTecht Software TP-6701
provided in the Product Identification Information
Installation Instructions, section located inside the front cover of this manual for
Status Indicator TT--1585 use when requesting service or parts.
Installation Instructions,
Load Shed Kit TT-1609
TRANSFER SWITCH
Installation Instructions, FOR EMERGENCY SYSTEMS
1
TYPE ENCLOSURE
3
Power Relay Module TT-1646 MATERIAL
MFG. DATE
ACCESSORIES:
Figure 4 Related Literature 2 MODEL

SERIAL NO.
AMPS VOLTS
WIRES PHASE
POLES HERTZ
BAR CODE
LISTED TRANSFER SWITCH

R FOR EMERGENCY SYSTEMS
GM21291-E
1. Model designation
2. Serial number
3. Factory-installed accessory numbers
Figure 5 Typical Transfer Switch Nameplate
8 Introduction TP-6807 1/16

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.
Sample Model Designation: RXT-JFNC-0200A

Model
RXT: Kohler Automatic Transfer Switch Enclosure
Controls C: NEMA 3R
J: Interface board (standard or combined) for RDC2/DC2 Current Rating: Numbers indicate the current rating
Controller of the switch in amperes:
Voltage/Frequency 0100 0200 0400
C: 208 Volts/60 Hz (3-phase only) 0150 0300
F: 240 Volts/60 Hz
M: 480 Volts/60 Hz (3-phase only) Connections
A: No load center
Number of Poles/Wires B: With load center (100 amp single-phase only)
N: 2-pole, 3-wire, solid neutral (120/240 V only) ASE: Service entrance rated
T: 3-pole, 4-wire, solid neutral CSE: Service entrance rated with CSA certification
V: 4-pole, 4-wire, switched neutral (100/150/200 amp models only)
Note: GM85273-SA_ is a 100 amp single-phase model with a 12-circuit load center and NEMA 1 enclosure.
Figure 6 Model Designation
TP-6807 1/16 Introduction 9

Service Assistance
For professional advice on generator set power China

requirements and conscientious service, please contact North China Regional Office, Beijing
your nearest Kohler distributor or dealer. Phone: (86) 10 6518 7950
(86) 10 6518 7951
D Consult the Yellow Pages under the heading (86) 10 6518 7952
Generators—Electric. Fax: (86) 10 6518 7955
D Visit
the Kohler Power Systems website at East China Regional Office, Shanghai
KOHLERPower.com. Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
D Look at the labels and decals on your Kohler product India, Bangladesh, Sri Lanka
or review the appropriate literature or documents India Regional Office
included with the product. Bangalore, India
Phone: (91) 80 3366208
D Call toll free in the US and Canada 1-800-544-2444.
(91) 80 3366231
D Outside the US and Canada, call the nearest regional Fax: (91) 80 3315972
office. Japan, Korea
North Asia Regional Office
Headquarters Europe, Middle East, Africa Tokyo, Japan
(EMEA) Phone: (813) 3440-4515
Kohler Power Systems Netherlands B.V. Fax: (813) 3440-2727
Kristallaan 1
4761 ZC Zevenbergen Latin America
The Netherlands Latin America Regional Office
Phone: (31) 168 331630 Lakeland, Florida, USA
Fax: (31) 168 331631 Phone: (863) 619-7568
Fax: (863) 701-7131
Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: (65) 6264-6422
Fax: (65) 6264-6455
10 Service Assistance TP-6807 1/16

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.
Model RXT transfer switches must be connected to a

generator set equipped with the Kohlerr RDC2 or DC2
generator/transfer switch controller.
Voltage sensing data from the ATS is continuously

transmitted to the RDC2/DC2 controller mounted on the
generator set. When the normal source fails, the
RDC2/DC2 controller signals the emergency source
generator set to start. When the emergency source
reaches acceptable levels and stabilizes, the ATS
transfers the electrical load to the emergency source.
The RDC2/DC2 controller signals the ATS to transfer

the load back when the normal source returns and
stabilizes. See Section 3 for detailed operation
dscriptions.
Figure 1-1 shows a typical installation block diagram.
Emergency Load Center Model Standard Model

(Generator)
Power
Generator
Figure 1-2 Selected Transfer Switches
(covers removed)
Normal Electrical
(Utility) Controls
Power
1.2 Service Entrance Models
Service entrance models use a circuit breaker to provide
Power
the service disconnect for the utility source. A service
Interface
Switching Board entrance model is shown in Figure 1-2.
Device
Automatic Transfer Switch 1.3 Load Centers

Model RXT 100 amp transfer switches are available with
a built-in load center. A model with a built-in load center
is shown in Figure 1-2. Models without load centers
To Load
TP-6751
require the installation of a separate load panel.
Figure 1-1 Typical ATS Block Diagram
TP-6807 1/16 Section 1 Description 11

Loads. The transfer switch can be connected to supply 1.4.2 Combined Interface/Load
all of the electrical loads in the home, or only the Management Board
essential loads such as the furnace, refrigerator, well
pump, and selected light circuits. Identify the essential The combined interface/load management board
circuits that must be supplied during a power outage. perfoms all of the functions of the standard interface
Verify that the generator set and transfer switch are board and also provides load add and shed based on
adequately rated to supply all of the selected loads. generator capacity. The combined interface/load
management board can be used with single-phase
Circuit breakers. Because the size and number of generator sets equipped with the RDC2 or DC2
circuit breakers required will vary with each application, controller only.
circuit breakers are not provided with the transfer switch
load center. Note: Do not install a load shed kit or a load control
module (LCM) on a system that includes the
Determine the circuits that will be connected to the combined interface/load management board.
transfer switch (essential loads). Identify the breakers
for those circuits in the main distribution panel. Many appliances do not run continuously. Air
conditioners and furnaces, refrigerators, sump pumps,
The ATS load center requires Square D type QO and other appliances cycle on and off as needed. With
breakers. If the main distribution panel uses the same load management, less critical appliances can be
type of breakers, the breakers can be moved from the powered by the generator set when the more important
main panel to the load center. Otherwise, obtain new appliances are not running, allowing the use of a smaller
Square D type QO circuit breakers. For each circuit, the
generator set than would be needed to run all of the
rating of the load center circuit breaker must match the
building’s electrical equipment at the same time.
rating of the existing breaker in the main panel.
The combined interface/load management board
Up to 8 tandem breakers can be used in the 16-space
provides an automatic load management system to
load center. Use Square D type QOT tandem breakers.
comply with Section 702.5 of NEC 2008. The installer is
The 12-space load center uses only single breakers. responsible for ensuring that the power system
installation complies with all applicable state and local
Verify that the total rating for all of the breakers used in codes.
the load center does not exceed the rating of the transfer
switch. The combined interface/load management board
automatically manages up to six residential loads.
1.4 Controller Interface Board D Two relays are included to control two independent
heating, ventilation, and air conditioning (HVAC)
The Model RXT transfer switch is available with either loads.
the standard interface board or the combined
interface/load management board. Both interface D Four (4) pilot relays are provided on the combined
boards connect to the RDC2 or DC2 controller on the interface board for connection of customer-supplied
generator set. load-switching contactors/relays. See Figure 1-3 for
the specifications of the circuit board relays.
1.4.1 Standard Interface Board Up to four (4) Kohlerr 50 amp power relay modules
All ATS control functions are performed by the (GM92001-KP1-QS) or customer-supplied normally
RDC2/DC2 controller mounted on the generator set and closed power relays can be connected through normally
communicated through the interface board. The open relay contacts on the circuit board. See Figure 1-4
controller interface board sends voltage sensing data to for specifications for customer-supplied relays.
the RDC2/DC2 controller and receives transfer and load Customer-supplied relays must be either normally
control signals from the RDC2/DC2 controller. closed or double-pole double-throw (DPDT) and
maximum 50 amps. Note that the load must be
connected to the normally closed contacts of the relay.
Kohlerr Power Relay Modules are recommended.
Note: Connect only non-essential loads to the load

shed kit.
12 Section 1 Description TP-6807 1/16

Circuit Board Relays Rating Figure 1-5 shows a simple diagram of a power system
Pilot Relays and HVAC 125VAC, 10 A (general purpose) with load management. For detailed installation and
Relays (qty. 2) 120VAC, 125VA (pilot duty) connection instructions, refer to Section 2.7 and the
Figure 1-3 Combined Interface Board Relay instructions provided with the power relay modules.
Specifications
Power Relay Specifications

Relay Rating 50 A @ 240 VAC
Relay Type DPST -- NC or DPDT
Coil Voltage 120 VAC
Figure 1-4 Customer-Supplied Power Relay

Specifications
Non-critical
Power relay load, can add
HVAC load, module #1
can add or or shed
Utility power shed
Non-critical
Combined module #2 or shed
Kohler Model RXT Interface/
transfer switch Load
Management
Board Non-critical
Kohler single-phase module #3 or shed
generator set
equipped with RDC2 HVAC load,
or DC2 controller can add or
Critical loads, shed Non-critical
always module #4
powered or shed
Connect up to 4 power relay modules.

G6--143
Figure 1-5 Power System with Load Management
TP-6807 1/16 Section 1 Description 13

1.5 Optional Status Indicator 1.5.2 Status Indicator Panel for
Panels Combined Interface/Load
Management Board
Two status indicator panels are available. One is for
RXTs with the standard interface board, and the other is The LED Indicator panel includes the source available
for the RXT with the combined interface /load and source connection LEDs that are included on the
management board. standard indicator panel. The combined panel also
incudes load status LEDs and a Test button that cycles
The two types of indicator panels use different the load management relays. See Figure 1-7. See
connectors and are not interchangeable. The standard Section 3.4 for load management operation and test
indicator panel connects only to the standard board. information.
The combined indicator panel connects only to the
combined interface/load management board.
If the status indicator is purchased as a loose kit (not 1

factory-installed), refer to the installation instructions
provided with the kit, TT-1585.
2
3
1.5.1 Standard Status Indicator Panel
A user interface panel that contains status-indicating
LEDs is available. See Figure 1-6. Source available 4
LEDs light to indicate that the utility and/or generator
sources are available. The utility or generator source
supplying load LED lights to show which source is
connected to the building load (i.e. contactor position,
normal or emergency).
5
2 6
GM90763
1. Utility power available
4 2. Utility source supplying load
GM78649 3. Generator source supplying load
1. Utility power available 4. Generator power available
2. Utility source supplying load 5. Load add/shed relay status indicators
3. Generator source supplying load 6. Load shed test button (cycles relays)
4. Generator power available
Figure 1-6 Optional Status Indicator Panel Figure 1-7 Optional Status Indicator Panel for
Combined Board
14 Section 1 Description TP-6807 1/16

Section 2 Installation
2.1 Introduction Note: Do not use compressed air to clean the switch.
Cleaning with compressed air can cause debris
Kohlerr transfer switches are shipped factory-wired, to lodge in the components and damage the
factory-tested, and ready for installation. Have the switch.
equipment installed only by trained and qualified
personnel, and verify that the installation complies with
applicable codes and standards. Protect the switch
2.2.4 Lifting
against damage before and during installation.
WARNING
2.2 Receipt of Unit
2.2.1 Inspection
At the time of delivery, inspect the packaging and the Unbalanced weight.
transfer switch for signs of shipping damage. Unpack Improper lifting can cause severe
the transfer switch as soon as possible and inspect the injury or death and equipment
exterior and interior for shipping damage. If damage damage.
and/or rough handling is evident, immediately file a
Use adequate lifting capacity.
damage claim with the transportation company. Never leave the transfer switch
standing upright unless it is securely
bolted in place or stabilized.
2.2.2 Storage
Store the transfer switch in its protective packing until See Figure 2-2 or the dimensional drawing for the
final installation. Protect the transfer switch at all times weight of the transfer switch. Use a spreader bar to lift
from moisture, construction grit, and metal chips. Avoid the transfer switch. Attach the bar only to the
storage in cold or damp areas where moisture could enclosure’s mounting holes or lifting brackets; do not lift
condense on the unit. See Figure 2-1 for acceptable the unit any other way. Close and latch the enclosure
storage temperatures. door before moving the unit.
Item Specification Weight ]
Storage Amps Description kg (lb.)

--40C to 85C (--40F to 185F) Single phase 7 (15)
Temperature
With 12- or 16-space load center
Operating 12 (26)
--20C to 70C (--4F to 158F) (NEMA 1)
Temperature
100 With 16-space load center 8 (18)
Humidity 5% to 95% noncondensing Three phase 14 (30)
Altitude 0 to 3050 m (10000 ft.) without derating Service entrance (ASE) 12 (26)
Service entrance (CSE) 16 (34)
Figure 2-1 Environmental Specifications
Service entrance (ASE) 12 (26)
150--200
Service entrance (CSE) 16 (34)
2.2.3 Unpacking Single phase 7 (15)
200
Three phase 14 (30)
Allow the equipment to warm to room temperature for at
300 Service entrance 46 (101)
least 24 hours before unpacking to prevent
Single phase 55 (120)
condensation on the electrical apparatus. Use care
3-Pole/208--240 volts 41 (90)
when unpacking to avoid damaging transfer switch
components. Use a vacuum cleaner or a dry cloth to 400 3-Pole/480 volts 59 (130)
remove dirt and packing material that may have 4-Pole 59 (130)
accumulated in the transfer switch or any of its Service entrance 46 (101)
components. ] Transfer switch weights are approximate and do not include
packaging.
Note: Enclosures are type NEMA 3R except as noted.
Figure 2-2 Weights (approximate)
TP-6807 1/16 Section 2 Installation 15

2.3 Installation NEMA 3R enclosures. To remove the enclosure’s front
panel, support the panel while removing the screws.
NOTICE Pull the bottom of the panel out and down until the top
Foreign material contamination. Cover the transfer switch clears the enclosure. Remove the inner panel to access
during installation to keep dirt, grit, metal drill chips, and other the transfer switch components.
debris out of the components. Cover the solenoid mechanism
during installation. After installation, use the manual operating NEMA 3R enclosures have locking tabs at the bottom of
handle to cycle the contactor to verify that it operates freely. the enclosure and the door. Use a padlock to lock the
Do not use a screwdriver to force the contactor mechanism. door after installation is complete.
The transfer switch may use both American Standard and
metric hardware. Use the correct size tools to prevent Wall mounting. Mount the transfer switch to a wall or
rounding of the bolt heads and nuts. other rigid vertical supporting structure. Refer to the
dimension drawings in Section 6 for hole locations. Use
Check the system voltage and frequency. Compare shims to plumb the enclosure.
the voltage and frequency shown on the transfer switch
nameplate to the source voltage and frequency. Do not Cover the transfer switch’s internal components to
install the transfer switch if the voltage and frequency protect them from drill chips or debris during installation.
are different from the normal (utility) source voltage and Use a vacuum cleaner to remove debris from the
frequency or the emergency source voltage and enclosure.
frequency shown on the generator set nameplate.
Note: Do not use compressed air to clean the switch.
Plan the installation. Use the dimensions given on the Cleaning with compressed air can cause debris
enclosure dimension (ADV) drawings in Section 6. to lodge in the components and cause damage.
Select a mounting site that complies with local electrical
code restrictions for the enclosure type. Mount the Clearance holes through the back of each enclosure are
transfer switch as close to the load and power sources provided for mounting. The mounting holes on NEMA
as possible. Allow adequate space to open the 3R enclosures have gaskets to seal out moisture. Use
enclosure and service the switch. washers with the mounting screws to protect the
gaskets.
16 Section 2 Installation TP-6807 1/16

2.4 Manual Operation Check
DANGER
CN
4 3
NO
NL1 NL2
NC
SCN
Hazardous voltage. SCE
Will cause severe injury or death. NC EL1 EL2

NO
Disconnect all power sources before C
opening the enclosure. 7

8
CE
Check the manual operation before energizing the

transfer switch. Verify that the contactor operates 1
smoothly without binding. Do not place the transfer
switch into service if the contactor does not operate 1. Handle (not detachable)
smoothly. Figure 2-4 Manual Operation, 100 -- 200 Amp
Single-Phase Switches
After checking the manual operation, place the
contactor in the Normal (utility) position.
See Figure 2-3 to identify the manual operation 1

procedure 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
400 amps, 1-phase
2.4.1 Figure 2-5
400 amps, 3-phase, 3-pole,
208--240 Volts
400 amps, 3-phase,
2.4.2 Figure 2-7
3-pole/480 Volt and 4-pole
GM80139
Figure 2-3 Manual Operation Procedure Guide 1. Shaft (attach handle or wrench here)
2.4.1 Manual Operation Procedure 1 Figure 2-5 Manual Operation, 300--400 Amp Single-
Phase and 208--240 Volt Switches
Note: Never manually operate the transfer switch when
the power is connected. Disconnect both power
sources before manually operating the switch. 2.4.2 Manual Operation Procedure 2
1. 100-200 amp switches: These switches have an Note: Never use the maintenance handle to transfer the
attached handle as shown in Figure 2-4. load with the power connected. Disconnect both
400 amp switches: Slide the detachable handle or power sources before manually operating the
a wrench over the shaft. See Figure 2-5. switch.
2. Move the handle up to place the transfer switch in 1. If the transfer switch is equipped with a
the Normal Source position or down to place the maintenance handle, remove the handle from its
contactor in the Emergency Source position. See storage location inside the enclosure. See
Figure 2-4 or Figure 2-5. Figure 2-7.
3. 400 amp switches: Remove the detachable handle 2. Insert the maintenance handle or a tool (such as a
or wrench. screwdriver) into the hole in the shaft on the left

side of the operator as shown in Figure 2-6 or 2.5 Electrical Wiring
Figure 2-7.
Refer to the connection diagrams on the transfer switch
3. Move the maintenance handle (or tool) up or down enclosure door and the wiring diagrams in Section 6
as shown to manually operate the transfer switch. It during installation.
should operate smoothly without any binding. If it
does not, check for shipping damage or All wiring must comply with applicable national, state,
construction debris. and local electrical codes. Use separate conduit for AC
power wiring and low-voltage DC, control, and
4. Return the transfer switch to the Normal position. communication system wiring.
5. Remove the maintenance handle and return it to the
storage location. WARNING
Accidental starting.
Can cause severe injury or death.
1 Disconnect the battery cables before
working on the generator set.
when disconnecting the battery.
Disabling the generator set. Accidental starting can

cause severe injury or death. Before working on the
GM78867 generator set or equipment connected to the set, disable the
generator set as follows: (1) Press the generator set off/reset
1. Insert handle or tool here for manual operation
button to shut down the generator set. (2) Disconnect the
power to the battery charger, if equipped. (3) Remove the
Figure 2-6 Manual Operation, 100--200 Amp battery cables, negative (--) lead first. Reconnect the negative
3-Phase Switches (--) lead last when reconnecting the battery. Follow these
precautions to prevent the starting of the generator set by the
remote start/stop switch.
DANGER
1
2
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.
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.
tp6225
1. Handle storage location
2. Insert handle here for manual operation
Figure 2-7 Manual Operation, 400 Amp 3-Phase

Switches

Grounding electrical equipment. Hazardous voltage can Refer to the connection diagrams on the transfer switch
cause severe injury or death. Electrocution is possible enclosure door and the wiring diagrams in Section 6.
whenever electricity is present. Ensure you comply with all The connection points on the transfer switch contactor
applicable codes and standards. Electrically ground the
are labelled Normal, Emergency, and Load. Connect
generator set and related equipment and electrical circuits.
Turn off the main circuit breakers of all power sources before the utility power to Normal. Connect the generator set to
servicing the equipment. Never contact electrical leads or Emergency.
appliances when standing in water or on wet ground because
these conditions increase the risk of electrocution. Single phase. For single-phase models, connect to A
and C.
2.5.1 Load Center Circuit Breakers Three phase. For three-phase models, be sure to
follow the phase markings (A, B, C, and N).
The 100 amp Model RXT transfer switch is available
with a built-in load center with room for up to 16 Note: Connect the source and load phases as indicated
single-pole circuit breakers. Up to 8 tandem breakers by the markings and drawings to prevent short
can be used for a maximum of 24 circuits. circuits and to prevent phase-sensitive devices
from malfunctioning or operating in reverse.
A 100 amp model with a 12-space load center is also
available. The 12-space load center uses only single Service entrance models. Connect the utility source to
breakers. Do not install tandem breakers on the the lugs on the normal source disconnect circuit
12-space load center. breakers as shown in the service entrance switch wiring
diagram in Section 6.
The load centers use Square D type QO or QOT tandem
breakers. In an essential load application, the breakers Verify that all connections are consistent with drawings
can be moved from the main panel to the load center if before tightening the lugs. Tighten all cable lug
the main distribution panel uses the same type of connections to the torque values shown on the label on
breakers. Otherwise, obtain and install new Square D the switch. Carefully wipe off any excess joint
type QO circuit breakers. The rating of the load center compound after tightening the terminal lugs.
circuit breaker must match the rating of the existing
breaker in the main panel for each circuit. On models with built-in load centers, the load lugs are
factory-wired to the load center. Connect the load leads
Verify that the total rating for all breakers used in the load to the circuits in the load center and tighten the
center does not exceed the rating of the transfer switch. connections. Check the labels on the breakers for the
tightening torques.
If circuit breakers are removed from the load panel,
install cover plates over the vacant positions. Cover
plates can be obtained from a local Square D supplier. 2.5.3 Neutral Connection
2.5.2 AC Power Connections Connect the neutral from the main panel to the neutral
lug in the ATS enclosure.
Determine the cable size. Refer to the ADV drawings
in Section 6 or the transfer switch specification sheet to Ground the system according to NEC and local codes.
determine the cable size required for the transfer switch.
Make sure the lugs provided are suitable for use with the
2.5.4 Neutral Bonding Jumper, Service
cables being installed.
Entrance Models
Conduit. Use separate conduit for AC power wiring
The transfer switch is shipped with the
and low-voltage DC, control, and communication
neutral-to-ground jumper installed. For non-service
system wiring. Watertight conduit hubs may be required
entrance applications, disconnect the neutral-to-ground
for outdoor use.
bonding jumper. See the transfer switch dimension
Select the proper cable clamp or use other approved drawing.
methods for securing the cable or conduit to the
enclosure. 2.5.5 Engine Start Function
Source and load connections. Clean cables with a The engine start function is controlled by the RDC2/DC2
wire brush to remove surface oxides before connecting controller on the generator set. There are no engine
them to the terminals. Apply joint compound to the start terminals on the Model RXT ATS.
connections of any aluminum conductors.

2.6 Interface Module Connection Making line or auxiliary connections. Hazardous voltage
can cause severe injury or death. To prevent electrical
The interface module must be connected to a Kohlerr shock deenergize the normal power source before making any
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 RBUS Connections A and B
set’s field-connection terminal block. See the generator See Figure 2-9 and Figure 2-10.
set Installation Manual for the location of the terminal
block. See Figure 2-8 for P10 connection identification. For the RBUS communication connections A and B to
the Model RXT transfer switch, optional PIM and/or
Note: Engine start connections 3 and 4 on the optional LCM or load shed kit, use 20 AWG shielded,
generator set are not used with the Model RXT twisted-pair communication cable. Belden #9402
transfer switch. (two-pair) or Belden #8762 (single-pair) or equivalent
cable is recommended.
This document gives connection information for one
Model RXT transfer switch connected to a generator set For outdoor installations, including those with buried
equipped with an RDC2 or DC2 controller. If additional cables and/or conduit, use outdoor-rated Belden
accessory modules such as a programmable interface #1075A or equivalent 20 AWG shielded, twisted-pair
module (PIM) or a load control module (LCM) are communication cable.
connected, refer to the generator set installation manual
for connection instructions.
PWR and COM Connections
WARNING For the PWR and COM connections, the cable size and
maximum cable length depends on the number of
modules connected. See Figure 2-9.
D For short cable runs shown in the first two rows of

Figure 2-9, use one pair in the two-pair
Accidental starting. communication cable for the A and B connections,
Can cause severe injury or death. and use the second pair for the PWR and COM
connections.
working on the generator set.
D For the longer cable runs shown in the last two rows of
when disconnecting the battery. Figure 2-9, use 12 or 14 AWG cable for PWR and
Reconnect the negative (--) lead last COM, and use the 20 AWG communication cable
when reconnecting the battery. specified above for the A and B connections only. In
this case, single-pair communication cable such as
Belden #8762 can be used for the A and B
cause severe injury or death. Before working on the connections.
generator set or equipment connected to the set, disable the
generator set as follows: (1) Press the generator set off/reset The maximum cable length depends on the number of
button to shut down the generator set. (2) Disconnect the optional modules connected. See Figure 2-9 for the
power to the battery charger, if equipped. (3) Remove the maximum cable lengths with 1, 2, or 3 modules per cable
battery cables, negative (--) lead first. Reconnect the negative run.
(--) lead last when reconnecting the battery. Follow these
remote start/stop switch. Connection Designation Description
P10-1 A Communication Line
DANGER P10-2 B Communication Line
P10-3 PWR 12 VDC
P10-4 COM 12 VDC
Figure 2-8 Controller Interface Connections
Hazardous voltage.
opening the enclosure.

Maximum cable length per run, meters (ft.)
Indoor or
Number of Modules per Run
Outdoor
1 Module 2 Modules 3 Modules Installation Cable Size for PWR and COM Connections
61 (200) 31 (100) 21 (67) Indoor 20 AWG Belden #9402 or equivalent, two-pair
61 (200) 31 (100) 21 (67) Outdoor 20 AWG Belden #1075A or equivalent, two-pair
152 (500) 152 (500) 122 (400) — 14 AWG *
152 (500) 152 (500) 152 (500) — 12 AWG *
* Use 12 or 14 AWG cable for PWR and COM connections only. For RBUS connections A and B, use shielded, twisted pair communication
cable specified in Section 2.6.
Figure 2-9 Cable Specifications for PWR and COM Connections
Connect one end of each

cable shield to GROUND at
the generator set.
GND Interface Board on the Model
RXT Transfer Switch
Generator Set
A A A RXT
B B B
PWR PWR PWR
COM COM COM
4
3 Leave one end of each cable shield disconnected.
1
If accessory modules are connected in series, connect
the cable shields as shown below and refer to the
generator set installation manual.
Generator Set Terminal Block. RXT

See the generator set manuals for location.
Check the decal on the generator set for terminal
block connections.
Note: Generator set terminal block connections 3 and 4 are

NOT USED with the Model RXT ATS.
1. Communication cable Belden #9402 or equivalent 20 AWG shielded, twisted-pair cable.

See Figure 2-9 for cable specifications.
Figure 2-10 Interface Module Connection to Generator Set Field-Connection Terminal Block

2.7 Combined Interface/Load Before starting the installation, confirm that the
generator set is equipped with an RDC2 or DC2
Management Board controller. RDC2/DC2 controller firmware version 5.04
The combined interface/load management board can or higher is required. Check the version number on the
be used with single-phase generator sets equipped with controller and update the firmware, if necessary.
the RDC2 or DC2 controller only. Follow the instructions
in this section to install the current transformer and An adequate electrical supply is required for operation
connect the load management relays. Then connect the of the customer-supplied relays connected to the load
interface/load management board to a Kohlerr shed kit. 120 VAC relays require a customer-supplied
generator set equipped with the RDC2 or DC2 voltage source. Check the electrical requirements of the
controller. customer-provided equipment prior to installation to
determine the wire size and circuit protection required.
Up to four load relays and two HVAC relays can be Verify that customer-provided equipment complies with
connected. The load management operation will cycle applicable local and national electrical codes.
through all six connections regardless of the number of
loads connected. The load management timing is
affected by the generator’s capacity as described in
Section 3.5.
Note: Only one load management option can be used

with the generator. If a load control module (LCM)
is connected, disable the load management
function on the combined interface/load
management board as described in Section 2.8
and connect the LCM according to instruction
sheet TT-1574, provided with the LCM.
2.7.1 Relay Modules

Figure 2-13 Kohler Power Relay Module
Up to four power relay modules (GM92001-KP1-QS)
can be connected for management of non-essential
secondary loads. Two (2) 120 VAC loads (shed 2.7.2 HVAC Loads
simultaneously) or a single 240 VAC load can be wired
to each relay. Customer-supplied relays must be either There are two (2) relays available to control two (2)
normally closed or double-pole double-trhow (DPDT) independent heating, ventilation, and air conditioning
and maximum 50 amps. Note that the load must be (HVAC) loads. The operation of the HVAC relays
connected to the normally closed contacts of the relay. includes a five-minute start delay and different timing for
Kohlerr Power Relay Modules are recommended. load add compared to the power relays. See
Section 3.5.1 for more details about the HVAC relay
Circuit Board operation.
Relays Rating
Pilot Relays and
HVAC Relays
125VAC, 10 A (general purpose) 2.7.3 Load Add/Shed Priority
120VAC, 125VA (pilot duty)
(qty. 2)
Loads are prioritized from priority 1 to priority 6. See
Figure 2-11 Combined Interface Board Relay Figure 2-19 on page 25. Priority 1 is considered the
Specifications most critical; it will add first and shed last. Priority 6 is
considered the least critical; it will add last and shed first.
Power Relay Specifications
Relay Rating 50 A @ 240 VAC
Relay Type DPST -- NC or DPDT
Coil Voltage 120 VAC
Figure 2-12 Customer-Supplied Power Relay

Specifications
Kohlerr power relay modules include one power relay

mounted inside a NEMA type 3R enclosure. Connect up
to four (4) power relay modules to the load shed kit. See
Figure 2-13 for an illustration of a power relay module.
2.7.4 Current Transformers (CTs) DANGER
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 Hazardous voltage.
needed for the 60RCL, order a current transformer or Will cause severe injury or death.
obtain a current transformer that meets the Disconnect all power sources before
specifications shown in Figure 2-14. opening the enclosure.
Larger
Standard Diameter CT* 500 Amp CT[
CT (sold (sold can cause severe injury or death. To prevent electrical
(included) separately) separately) shock deenergize the normal power source before making any
Kit Number GM83929 GM17250-KP1-QS GM17250-KP2-QS
CT Service Part 1. Press the OFF button on the generator set
GM83929 GM17250 GM60264
Number
Primary Rating 400 Amps 400 Amps 500 Amps
controller.
Secondary 2. Disconnect the utility power to the generator set.
3 VAC 3 VAC 3 VAC
Rating
Burden
16 Ohms 16 Ohms 16 Ohms 3. Disconnect the generator set engine starting
Resistor
battery(ies), negative (--) lead first.
Burden
Resistor Internal Internal Internal
Location 4. Disconnect power to the transfer switch.
Outer Diameter 63.5 mm 111.8 mm 171.5 mm
(O.D.) (2.50 in.) (4.40 in.) (6.75 in.) 5. Remove the ATS enclosure cover.
Inner Diameter 28.7 mm 57.2 mm 108.0 mm 6. Install the current transformer (CT) on the
(I.D.) (1.13 in.)* (2.25 in.) (4.25 in.)
* Order GM17250--KP1--QS for applications that use larger cables.
emergency source lines. Installation inside the
[ Order GM17250--KP2--QS for 60RCL only. transfer switch enclosure is recommended.
Figure 2-14 Current Transformer (CT) Specifications Note: Be sure to route the leads through the
current transformer from opposite sides as
shown in Figure 2-15. The leads must cross
2.7.5 Connection Procedure in opposite directions as they pass through
the transformer.
WARNING
Note: See Section 2.7.4 for CT specifications.
EMERGENCY LUGS ON ATS
Emergency source
working on the generator set. leads must cross
Remove the negative (--) lead first through CT in opposite
when disconnecting the battery. directions as shown.
Disabling the generator set. Accidental starting can To TB1 on Load

Shed Circuit Board
button to shut down the generator set. (2) Disconnect the CT
power to the battery charger, if equipped. (3) Remove the side view
battery cables, negative (--) lead first. Reconnect the negative
FROM GENERATOR GM88804
Figure 2-15 Current Transformer (CT) Wiring
7. RBUS connections: Connect the controller
1
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.
Note: Use separate conduit for the low-voltage

controller communication leads and the load
connection wiring.
Note: Refer to the wiring diagrams in Section 6.
8. Connect the CT leads to connector TB1 on the

interface/load management circuit board. Extend
the leads, if necessary, using customer-supplied SIDE VIEW
wiring. See Figure 2-18 and/or the wiring diagram
ADV--8691
in Section 6 for the connector location.
1. Combined interface / load management board inside the
9. Note the load priorities shown in Figure 2-19. enclosure
Priority 1 is considered the most critical and will add
Figure 2-16 Typical Interface Board Location
first and shed last. Priority 6 is considered the least
critical and will add last and shed first.
Connect the customer-provided load relays to

terminal block TB2 for Loads A, B, C, and D. See
Figure 2-17 for the connections. See Section 2.7.1
for the recommended relay specifications.
Note: The combination of four load relay outputs

cannot exceed 10 amps total current draw.
10. Connect 120 VAC power to TB2 connections AC1

and N. See Figure 2-17. Connect 120 VAC line
voltage to terminal AC1. Connect the neutral to N.
The power to this circuit must be backed up by the
generator set and not be part of a sheddable circuit.
11. Verify that the jumper is installed across P11--2 and GM95547
P11--3 on the combined interface board. See

Figure 2-18. Figure 2-17 Power Relay Circuit on the Combined
Interface/Load Management Board

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 The air conditioner control scheme requires

splicing into the existing building low voltage wiring
1 from the thermostat to the air conditioner/furnace.
In a typical four wire scheme, connect the cooling
wire (Y) in series to the respective terminal block on
the load shed kit.
13. Record the names of the loads connected to each

5 relay in Figure 2-19. For example, Load A may be
2 a sump pump, and HVAC A may be the air
conditioner.
Note: If the OnCuer Plus Generator Management

System is used, the load descriptions can be
changed remotely. For instructions, see
TP-6928, OnCue Plus Operation Manual.
To avoid confusion, make sure that the load
description matches the equipment
connected to the corresponding relay.
4 3 GM95546
1. TB3 HVAC relay connections 14. Install the ATS enclosure cover.
2. TB1 connection for current transformer (CT)
3. TB2 120 VAC input connection 15. Check that the generator set is OFF.
4. TB2 connections to customer-supplied power relays
(max 4 relays) 16. Reconnect the utility power to the transfer switch.
5. P10 RDC2/DC2 controller interface RBUS connections
6. P11 jumper (factory-installed across 2 and 3 for load
management) 17. Reconnect the generator set engine starting
battery, negative (--) lead last.
Figure 2-18 Combined Interface/Load Management
Board Customer Connections 18. Reconnect utility power to the generator set.
Priority Relay Record the Load Description
1 Load A
2 HVAC A
3 Load B
4 Load C
5 HVAC B
6 Load D
Note: Priority 1 (Load A) adds first and sheds last.

Figure 2-19 Load Priority and Descriptions

2.8 Load Control Module (LCM) Disabling the generator set. Accidental starting can
Note: Only one load management option can be used generator set or equipment connected to the set, disable the
with the generator. If the LCM is connected to an
RXT equipped with the combined interface/load power to the battery charger, if equipped. (3) Remove the
management board, disable the load battery cables, negative (--) lead first. Reconnect the negative
management function on the combined board as (--) lead last when reconnecting the battery. Follow these
described in Section 2.8.2, below. precautions to prevent the starting of the generator set by the
2.8.1 LCM with Standard Interface

DANGER
Board
If the Load Control Module (LCM) is used with an RXT
transfer switch equipped with the standard interface
board, follow the instructions in TT-1574, provided with
the LCM, to connect the load control module and the Hazardous voltage.
current transformer. Will cause severe injury or death.
2.8.2 LCM with Combined Interface opening the enclosure.
Board
If the LCM is used with an RXT that is equipped with the can cause severe injury or death. To prevent electrical
combined interface/load management board, disable shock deenergize the normal power source before making any
the load management function on the interface board as line or auxiliary connections.
described in the procedure below. Connect the LCM as
described in TT-1574. Be sure to connect the current Procedure to connect an LCM if the combined
transformer to the LCM (not to the combined board is used on the RXT
interface/load management board on the RXT).
1. Press the OFF button on the generator set
Note: The load status LEDs on the status indicator for controller.
the combined interface/load management board 2. Disconnect the utility power to the generator set.
will not show the load control status of the LCM.
3. Disconnect the generator set engine starting
battery(ies), negative (--) lead first.
WARNING
4. Disconnect power to the transfer switch.
5. Remove the ATS enclosure cover.
6. Find the combined interface/load management

board, which is typically mounted on the upper left
Can cause severe injury or death. side of the enclosure. See Figure 2-16, if
necessary.
working on the generator set. 7. See Figure 2-20. Move the P11 jumper from
Remove the negative (--) lead first terminals 2 and 3 to terminals 1 and 2 to disable the
when disconnecting the battery.
load management function on the combined board.

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
1
management board. See Figure 2-20. See
Section 2.6 for detailed RBUS connection
instructions.
DO NOT
9. Follow the instructions in TT-1574, provided with CONNECT
the LCM, to connect the load control module. 2
a. Connect the LCM RBUS connections to either

the combined interface board or to the
generator’s RDC2 or DC2 controller.
b. Connect the current transformer (CT) to the

LCM. Do not connect the CT to the combined
interface board in the RXT enclosure.
c. Connect power relays, HVAC connections, and

120 VAC power to the LCM as described in
TT-1574.
GM90773
10. Install the ATS enclosure cover.
TB2: DO NOT CONNECT
11. Check that the generator set is OFF.
1. P11: Install jumper across pins 1 and 2 to disable load
12. Reconnect the utility power to the transfer switch. management
2. Connect RBUS communication cable to P10 on the
13. Reconnect the generator set engine starting combined board.
battery, negative (--) lead last. Note: DO NOT connect power relays, HVAC relays, or
current transformer to the combined board.
14. Reconnect utility power to the generator set. Connect to the LCM as described in the LCM
instruction sheet.
Figure 2-20 Combined Interface/ Load Management

Board Connections with LCM

2.9 Optional Load Control 2.10 Accessory Module
Connection Connections
Connector P11 on the standard interface module For connection of the optional programmable interface
provides a connection point for optional load control module (PIM), refer to the instructions provided with the
circuits. The load control contact provides a delayed module and to the generator set installation manual.
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 2.11 Test and Exercise
equipment with large motor-starting loads such as air
conditioners. Refer to the generator set Operation Manual for
instructions to test the power system operation and to
See Figure 2-21 for the location of load control set the RDC2 or DC2 controller for weekly exercise runs
connector P11. See Figure 2-22 for contact ratings, to keep the power system in good operating condition.
connection, and wire size information.
2.12 Warranty Registration
Note: For load add and load shed operation based on
generator capacity, use the load shed kit or the Startup Notification Form. The Startup Notification
combined interface/load management board. Form covers all equipment in the standby system.
See Sections 1.4.2, 2.7, and 3.4 for more Complete the Startup Notification Form and register the
information about load management. equipment in the Kohler online warranty system within
60 days of the initial startup date.
GM80663
1
1. Load control connection P11
Figure 2-21 Load Control Connection, Standard

Interface Board
Terminal Block Connection Designation Description Contact Rating Wire Size

P11-1 LC1 10 A @ 250 VAC
P11 Load Control Output #12--18 AWG
P11-2 LC2 1 A @ 30 VDC
Figure 2-22 Load Control Contact P11 Connections

Section 3 Operation
3.1 Model RXT Transfer Switch 6. The transfer switch transfers to the emergency
source.
Operation
7. The load control contact time delay times out.
The Model RXT transfer switch must be connected to a
generator set equipped with the RDC2 or DC2 8. The load control contact closes.
controller. The RDC2/DC2 generator set/transfer
switch controller manages automatic transfer switch
Normal Source Returns:
(ATS) functions when connected to a Kohlerr Model
RXT transfer switch through the ATS interface board. 1. The emergency-to-normal time delay times out.
The controller receives voltage sensing data from the
Model RXT ATS and operates the generator set and 2. The contactor transfers to the normal source.
transfer switch to provide standby power when utility
power is lost. 3. The engine cooldown time delay times out.
See the generator set operation manual for: 4. The generator is signaled to stop.
D ATS status screens and configuration menus.

3.4 Load Management Operation
D Information about loaded exercise.
The combined interface/load management board
provides load add and shed based on generator
3.2 Source Availability capacity as described in this section.
The Model RXT transfer switch supplies voltage Many appliances do not run continuously. Air
sensing data to the RDC2 or DC2 controller through the conditioners and furnaces, refrigerators, sump pumps,
ATS interface board. If the source voltage falls below and other appliances cycle on and off as needed. With
the undervoltage dropout setting, the source is load management, less critical appliances can be
considered to have failed. See Figure 3-1. powered by the generator set when the more important
appliances are not running, allowing the use of a smaller
Voltage Sensing Parameter Setting generator set than would be needed to run all of the
Accuracy ±5% building’s electrical equipment at the same time.
Undervoltage Dropout 90% of Pickup
Undervoltage Pickup 90% of Nominal
The RDC2/DC2 generator controller receives input from
current transformer (provided with the combined
Figure 3-1 Voltage Sensing Parameters interface/load management board for installation in the
ATS) and determines whether to add or shed loads. The
combined interface/load management board receives
3.3 ATS Control Sequence of commands from the generator controller and energizes
Operation or de-energizes the appropriate load relays.
See Figure 3-10 for time delay settings. The load management function is activated by the ATS
transferring from the utility (normal) source to the
Preferred Source Fails: generator. When activated, the load management
board sheds all connected loads. After transfer to the
1. The load control contact opens.
generator set, loads are added according to their
2. The engine start time delay times out. priority.
3. The generator set is signaled to start. If the ATS fails to transfer from the utility source to the
generator, the load management board will re-add all
4. The generator starts and the emergency source loads. When the ATS transfers to utility, the load
becomes available. management board adds all loads that have been
previously shed.
5. The normal-to-emergency time delay times out.
TP-6807 1/16 Section 3 Operation 29

For more information about the load add and load shed
timing, see Section 3.5, Load Management Theory of
Operation. 1
3.4.1 Power Loads 2
Up to four customer-supplied power relays can be 3

connected for management of non-essential secondary
loads. If two-pole relays are used, two (2) 120 VAC
4
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.
3.4.2 HVAC Loads

5
There are two (2) relays available to control two (2)
independent heating, ventilation, and air conditioning
(HVAC) loads.
A 5-minute time delay prevents HVAC loads from adding

too quickly. Air conditioning compressors may be
damaged if they start too soon after being stopped due
to the necessity of starting the compressor against a
large residual pressure. Five minutes is a typically 6
accepted time required for an AC compressor to bleed
off to a pressure level that the motor can successfully
start against.
3.4.3 Load Add/Shed Priority

Loads are prioritized from priority 1 to priority 6. See
Figure 2-19 on page 25. Priority 1 is considered the GM90763
most critical; it will add first and shed last. Priority 6 is 1. Utility power available
2. Utility source supplying load
considered the least critical; it will add last and shed first. 3. Generator source supplying load
4. Generator power available
5. Load add/shed relay status indicators (see Figure 3-3)
3.4.4 Status Indicator and Test Button 6. Load shed test button (cycles relays)
The optional status indicator panel for the combined Figure 3-2 Optional Status Indicator Panel for
interface/load management board includes the source Combined Board
available and source connection LEDs and load status
LEDs. The panel also includes a Test button that cycles
the load management relays. See Figure 3-2.
30 Section 3 Operation TP-6807 1/16

LED State/Color Indicates loads are added more slowly to give the generator time
On Utility power is available
to recover and to allow ample time to ensure that any
Utility
Available switching loads will come on before adding more load
Off Utility power is not available
than the generator can handle.
Utility power is connected (ATS
Utility On
in normal position)
Connected The load add time ranges from 15 to 120 seconds
Off Utility power is not connected
depending on the loading of the generator set.
Generator set is running and
On
producing power
Figure 3-4 shows an example of the load add timing for a
Generator
Available
20 kW generator set with the maximum capacity set to
Generator set power is not
Off
available the default setting of 70%. Figure 3-5 shows the HVAC
Generator is connected to the
load add timing for a 20 kW generator set.
Generator On load (ATS in Emergency
position) Available Load (kW) for
Connected Capacity a 20 kW Time
Off Generator not connected (%) Load (%) Generator (Seconds)
Red Load disconnected (shed) 70% 0% 0 15
Loads A Green Load connected (added) 50% 20% 4 23
through D
Flashing red Disconnected (test) 37% 33% 6.6 34
Red Load disconnected (shed) 30% 40% 8 40
HVAC Loads Green Load connected (added) 20% 50% 10 48
A, B
Flashing red Disconnected (test) 5% 65% 13 60
<5% >65% >13 kW Never Add
Figure 3-3 LED Operation
Figure 3-4 Example: Power Relay Load Add Timing
LEDs provide visual indication of the status of each load. for a 20 kW Generator
See Figure 3-2 and Figure 3-3. Available Load (kW) for
Capacity a 20 kW Time *
Use the TEST button to exercise the load shed relays in (%) Load (%) Generator (Seconds)
sequence according to the assigned priorities. Run the 70% 0% 0 30
generator set in RUN mode, not AUTO, during this test. 50% 20% 4 66
The generator set must be running, but the ATS must 37% 33% 6.6 91
NOT transfer to the generator set for this test. 30% 40% 8 102
20% 50% 10 120
Test Procedure <20% >50% >10 kW Never Add
* After the 5-minute HVAC delay
1. Press RUN on the RDC2 or DC2 generator set
controller to start the generator set. Figure 3-5 Example: HVAC Load Add Timing for a
20 kW Generator
2. Press the TEST button on the indicator panel to
exercise the first relay. Capacity
3. Press TEST again for the next relay, and repeat to The Generator Maximum Percent Capacity setting
cycle through all of the relays in order. dictates the maximum level that the load management
board will automatically place on the generator. This
The test mode ends automatically after 15 minutes. To
setting is adjustable using a laptop computer connected
end the test manually, hold the TEST button for
to the RDC2 or DC2 controller and Kohlerr SiteTecht
5 seconds or press OFF or AUTO on the RDC2 or DC2
software. See Section 3.5.6.
generator set controller.
The maximum load is calculated by multiplying the
3.5 Load Management Theory of Generator Maximum Percent Capacity by the Genset
Power Rating, which is a setting in the RDC2/DC2
Operation controller. The Genset Power Rating, in kW, is
factory-set to the natural gas rating. If the 14RESA or
3.5.1 Load Add 20RESA has been converted to LP fuel, use SiteTech to
verify that the fuel type has been changed on the
The load management board adds and sheds loads controller and the Genset Power Rating is correct. Refer
based on the available capacity of the generator set. to the generator set specification sheet for the new
When the generator has ample available capacity, loads rating, and change the fuel type under the Genset
are added quickly. When the available capacity is low,

System Configuration in SiteTecht. See Figure 3-6 3.5.3 Overload Shed
and TP-6701, SiteTech Software Operation Manual.
Loads are shed on a time scale which is based on the
The load management function will operate if the rating total generator overload. The loads will shed slowly
setting is not changed, but loads will be shed at a kW when the generator is not heavily overloaded. Loads
level based on the factory default rating, rather than the are shed much more quickly when the overload is
rating of the reconfigured generator set. higher. The timing variation allows consistent overloads
to be removed, instantaneous excessive overloads to
be very quickly removed and normal overloads (such as
motor inrush) to remain online until the transient
overload condition is removed.
Figure 3-7 shows the overload shed timing for a 20 kW

generator set with the generator overloaded percent set
to the default setting of 85%. If the overload condition
persists, the load shed timing can be affected by load
shed acceleration. See Section 3.5.5.
The Generator Overload Percent setting is the

1 maximum load that the load management board will
accept without shedding. The setting is adjustable using
a laptop computer connected to the RDC2 or DC2
controller and Kohler SiteTech software. See Section
3.5.6. Set the Generator Overload Percent at least 10%
higher than the Generator Maximum Percent Capacity.
Generator Load (kW) for
Time
Overload Load (%) a 20 kW
(seconds)
(%) Generator
0% <85% <17 kW Never Shed
0% 85% 17 40
2
10% 95% 19 28
13% 98% 19.6 24
15% 100% 20 22
20% 105% 21 17
1. Genset Power Rating setting
2. Genset Fuel Type setting >35% >120% >24 kW 0.5
Figure 3-7 Overload Shed Timing for a 20 kW

Figure 3-6 Genset Power Rating in SiteTech Generator
3.5.2 Load Shed 3.5.4 Under Frequency Shed

Less important (larger priority number) loads are shed Loads are shed on a time scale which is based on the
when the generator is unable to support them. This generator frequency droop. The loads will shed quickly
permits more important loads to continue to receive when the frequency droop is high (output frequency is
power from the generator. The less important loads are lower), and more slowly when the generator is running
re-added after the generator loading has gone down close to rated frequency. The timing variation allows
enough to support them again. The load management large overloads to be shed very quickly, while allowing
board sheds less important loads before the power the generator to ride through normal transients (such as
quality of the generator suffers from the overload. starting an AC compressor).
Loads are shed in two ways – Overload and Under
Frequency.

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
Frequency (Hz) 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
3.5.5 Load Shed Acceleration

Load shed acceleration is used to shed loads more
quickly if an overload or underfrequency condition
persists. If an overload condition is not cleared by
shedding a load, each subsequent load will shed more tt1574
quickly. The acceleration is more pronounced for an 1
underfrequency shed.
3.5.6 Changing Settings 1. Load shed settings
The Generator Maximum Percent Capacity and Figure 3-9 SiteTech Screen
Generator Overloaded Percent settings can be
changed using a laptop computer connected to the
RDC2 or DC2 controller and Kohlerr SiteTecht
software. The load control settings are found in the
Genset System Configuration group. See Figure 3-9
and TP-6701, SiteTech Software Operation Manual.
Set the Generator Overload Percent at least 10% higher

than the Generator Maximum Percent Capacity.

3.6 Time Delays 3.7 Load Control Time Delay
Time delays are factory-set to the values shown in The standard interface board includes a load control
Figure 3-10. An authorized distributor/dealer can adjust time delay. The load control time delay allows delayed
time delays using a personal computer and Kohlerr starting of large motor loads (such as air conditioners),
SiteTecht software. preventing simultaneous starting of large motors after
transfer to the generator set. The load control time delay
Time delays shown in Figure 3-10 operate only when is fixed at 5 minutes. It is not adjustable.
the RDC2 or DC2 generator set controller is connected
to a Kohlerr Model RXT transfer switch. The load must be connected to the load control output
on the interface board of the Model RXT transfer switch.
The engine start and load transfer time delays prevent See Section 2.9 for connection instructions.
engine start and load transfer caused by brief variations
in the utility power source. Note: For load add and load shed operation based on
generator capacity, use the load shed kit or the
combined interface/load management board.
See Sections 1.4.2, 2.7, and 3.4 for more
information about load management.
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 in
the utility source.
Transfer, Normal to Emergency 3 seconds Time delay after emergency source becomes available until transfer to
emergency 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 the
emergency source.
Load Control 5 minutes Allows delayed connection of selected loads to the generator set.
(standard interface board only) Prevents simultaneous starting of large motors after transfer to the
emergency source. Recommended for delayed starting of air
conditioners.
Figure 3-10 Time Delays

Section 4 Service Disconnect, SE Model
Note: This section applies only to service entrance 4.1 Service Disconnect Procedure
model transfer switches, which are identified with
the letters SE at the end of the model designation. Use the following procedure to disconnect the utility
source on service entrance model transfer switches.
DANGER
Note: Power is still present on the input side of the utility
source circuit breaker after this procedure.
1. Prevent the emergency generator set from

starting:
Hazardous voltage.
Will cause severe injury or death. a. Press the OFF button on the generator set
controller.
This equipment must be installed and
serviced by qualified electrical
personnel. b. Disconnect power to the generator set battery
charger.
c. Disconnect the generator set engine starting

WARNING battery, negative (--) lead first.
2. On the transfer switch, remove the outer enclosure

door only.
3. Move the utility source circuit breaker to the OFF

Accidental starting. position.
Disconnect the battery cables before Note: Power is still present on the input side of the
working on the generator set. utility source circuit breaker. Do not remove
Remove the negative (--) lead first the protective barrier around the utility
when disconnecting the battery. source connection lugs.
when reconnecting the battery. 4. To lock out the transfer switch, replace the outer
door and attach a padlock to the hasp.
power to the battery charger, if equipped. (3) Remove the
battery cables, negative (--) lead first. Reconnect the negative
TP-6807 1/16 Section 4 Service Disconnect, SE Model 35

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.
GM80015
1. Normal/utility circuit breaker

2. Padlock hasp
Figure 4-1 Service Entrance Model, Door Removed
36 Section 4 Service Disconnect, SE Model TP-6807 1/16

Section 5 Scheduled Maintenance
5.1 Introduction DANGER

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 Hazardous voltage.
schedule for recommended maintenance tasks. Will cause severe injury or death.
A local authorized distributor/dealer can provide opening the enclosure.
complete preventive maintenance and service to keep
the transfer switch in top condition. Unless otherwise
specified, have maintenance or service performed by an DANGER
authorized distributor/dealer in accordance with all
applicable codes and standards. See the Service
Assistance section in this manual for how to locate a
local distributor/dealer.
Keep records of all maintenance or service. Hazardous voltage.

Replace all barriers and close and lock the enclosure Only authorized personnel should
door after maintenance or service and before reapplying open the enclosure.
power.
Grounding the transfer switch. Hazardous voltage can
WARNING cause severe injury or death. Electrocution is possible
whenever electricity is present. Open main circuit breakers of
all power sources before servicing equipment. Configure the
installation to electrically ground the transfer switch and
related equipment and electrical circuits to comply with
applicable codes and standards. Never contact electrical
leads or appliances when standing in water or on wet ground,
Accidental starting. as the chance of electrocution increases under such
Can cause severe injury or death. conditions.
Disconnect the battery cables before Servicing the transfer switch. Hazardous voltage can
working on the generator set. cause severe injury or death. Deenergize all power sources
Remove the negative (--) lead first before servicing. Turn off the main circuit breakers of all
when disconnecting the battery. transfer switch power sources and disable all generator sets
Reconnect the negative (--) lead last as follows: (1) Press the generator set off/reset button to shut
when reconnecting the battery. down the generator set. (2) Disconnect power to all battery
chargers. (3) Disconnect all battery cables, negative (--) leads
first. Reconnect negative (--) leads last when reconnecting the
Disabling the generator set. Accidental starting can battery cables after servicing. Follow these precautions to
cause severe injury or death. Before working on the prevent the starting of generator sets by an automatic transfer
generator set or equipment connected to the set, disable the switch, remote start/stop switch, or engine start command
generator set as follows: (1) Press the generator set off/reset from a remote computer. Before servicing any components
button to shut down the generator set. (2) Disconnect the inside the enclosure: (1) Remove all jewelry. (2) Stand on a
power to the battery charger, if equipped. (3) Remove the dry, approved electrically insulated mat. (3) Test circuits with a
battery cables, negative (--) lead first. Reconnect the negative voltmeter to verify that they are deenergized.
TP-6807 1/16 Section 5 Scheduled Maintenance 37

Short circuits. Hazardous voltage/current can cause 5.3.1 General Inspection
severe injury or death. Short circuits can cause bodily injury
and/or equipment damage. Do not contact electrical External Inspection. Keep the transfer switch clean
connections with tools or jewelry while making adjustments or and in good condition by performing a weekly general
repairs. Remove all jewelry before servicing the equipment. external inspection of the transfer switch. Check for any
condition of vibration, leakage, excessive temperature,
NOTICE contamination, or deterioration. Remove accumulations
Electrostatic discharge damage. Electrostatic discharge of dirt, dust, and other contaminants from the transfer
(ESD) damages electronic circuit boards. Prevent
switch’s external components or enclosure with a
electrostatic discharge damage by wearing an approved
grounding wrist strap when handling electronic circuit boards vacuum cleaner or by wiping with a dry cloth or brush.
or integrated circuits. An approved grounding wrist strap
provides a high resistance (about 1 megohm), not a direct Note: Do not use compressed air to clean the transfer
short, to ground. switch because it can cause debris to lodge in the
components and damage the switch.
The transfer switch may use both American Standard and
metric hardware. Use the correct size tools to prevent Tighten loose external hardware. Replace worn, missing,
rounding of the bolt heads and nuts.
or broken external components with manufacturer-
Screws and nuts are available in different hardness recommended replacement parts. Contact an
ratings. To indicate hardness, American Standard authorized distributor/dealer for specific part
hardware uses a series of markings and metric information and ordering.
hardware uses a numeric system. Check the markings
on the bolt heads and nuts for identification. Internal Inspection. Disconnect all power sources,
open the transfer switch enclosure door, and inspect
internal components monthly or when any condition
5.2 Testing noticed during an external inspection may have affected
internal components.
5.2.1 Weekly Generator Set Exercise
Contact an authorized distributor/dealer to inspect and
Use the exerciser or a manual test to start and run the
service the transfer switch if any of the following
generator set under load once a week to maximize the
conditions are found inside the transfer switch.
reliability of the emergency power system.
D Accumulations of dirt, dust, moisture, or other
5.2.2 Monthly Automatic Control contaminants.
System Test
D Signs of corrosion.
Test the transfer switch’s automatic control system
monthly. Refer to the RDC2/DC2 controller operation D Worn, missing, or broken components.
manual for the test procedure.
D Loose hardware.
D Verify that the expected sequence of operations
occurs as the switch transfers the load to the D Wire or cable insulation deterioration, cuts, or
emergency source when a preferred source failure abrasion.
occurs or is simulated.
D Signs of overheating or loose connections:
D Watch and listen for signs of excessive noise or discoloration of metal, melted plastic, or a burning
vibration during operation. odor.
D After the switch transfers the load to the standby D Other evidence of wear, damage, deterioration, or
source, end the test and verify that the expected malfunction of the transfer switch or its components.
sequence of operations occurs as the transfer switch
retransfers to the preferred source. If the application does not allow a power interruption for
the time required for the internal inspection, have an
5.3 Inspection and Service authorized distributor/dealer perform the internal
inspection.
Contact an authorized distributor/dealer to inspect and
service the transfer switch annually and also when any 5.3.2 Other Inspections and Service
wear, damage, deterioration, or malfunction of the Have an authorized distributor/dealer perform
transfer switch or its components is evident or scheduled maintenance, service, and other
suspected.
38 Section 5 Scheduled Maintenance TP-6807 1/16

maintenance that ensures the safe and reliable 5.4 Service Schedule
operation of the transfer switch. See Section 5.4,
Service Schedule, for the recommended maintenance Follow the service schedule in Figure 5-1 for the
items and service intervals. recommended service intervals. Have all service
performed by an authorized distributor/dealer except for
Have an authorized distributor/dealer repair or replace activities designated by an X, which may be performed
damaged or worn internal components with by the switch operator.
manufacturer-recommended replacement parts.
Adjust,
See Visually Repair,
System Component or Procedure Section Inspect Check Replace Clean Test Frequency
Electrical System
Check for signs of overheating or loose connections:
5.3.1 X X Y
discoloration of metal, melted plastic, or a burning odor
Check the contactor’s external operating mechanism D (clean
5.3.1 X Y
for cleanliness; clean and relubricate if dirty * and lube)
Inspect wiring insulation for deterioration, cuts, or
abrasion. Repair or replace deteriorated or damaged 5.3.1 X D D Y
wiring
Tighten control and power wiring connections to
2.5 D D Y
specifications
Check the transfer switch’s main power switching
contacts’ condition; clean or replace the main contacts S/M D D D Y
or replace the contactor assembly as necessary
General Equipment Condition
Inspect the outside of the transfer switch for any signs
of excessive vibration, leakage, high temperature, 5.3 X X M
contamination, or deterioration *
Check that all external hardware is in place, tightened,
5.3 X X X M
and not badly worn
Inspect the inside of transfer switch for any signs of
excessive vibration, leakage, high temperature, 5.3 D D D Y
contamination, or deterioration *
Check that all internal hardware is in place, tightened,
5.3 X D D Y
and not badly worn
* 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 components
depending 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 or
by 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 components
and 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. Q=Quarterly
D=Authorized distributor/dealer must perform these tasks. S=Semiannually (every six months)
W=Weekly Y=Yearly (annually)
M=Monthly W/D=Wiring diagram
Figure 5-1 Service Schedule
TP-6807 1/16 Section 5 Scheduled Maintenance 39

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADV-8688 1 of 2 50
Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADV-8688 2 of 2 51
100--200 Amp Three-Phase, 3- and 4-Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADV-8689 52
100 Amp Single-Phase NEMA 1 with 12-Space Load Center . . . . . . . . . . . . . ADV-8736 59
100 Amp Single-Phase NEMA 1 with 16-Space Load Center . . . . . . . . . . . . . ADV-8487 42
100 Amp Single-Phase NEMA 3R with 16-Space Load Center . . . . . . . . . . . ADV-8690 53
400 Amp Single-Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADV-8691 54
400 Amp Three-Phase, 3-pole 208--240 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADV-8692 55
400 Amp Three-Phase, 4-pole and 3-Pole/480 V . . . . . . . . . . . . . . . . . . . . . . . ADV-8693 56
Wiring Diagrams
100--400 Amp Single-Phase with Standard Interface Board . . . . . . . . . . . . . . GM80663 60
100--400 Amp Single-Phase with Combined Interface Board . . . . . . . . . . . . . GM95546 72
100 Amp Single-Phase with Load Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GM80675 70
100--200 Amp Standard, Three-Phase, 3- and 4-Pole . . . . . . . . . . . . . . . . . . . GM80667 64
400 Amp Standard, Three-Phase, 3-pole 208--240 V . . . . . . . . . . . . . . . . . . . GM80669 66
400 Amp Standard, Three-Phase, 4-pole and 3-Pole/480 V . . . . . . . . . . . . . . GM80671 68
Schematic Diagrams
100--400 Amp Single-Phase with Standard Interface Board . . . . . . . . . . . . . . GM80664 61
100--400 Amp Single-Phase with Combined Interface Board . . . . . . . . . . . . . GM95547 73
100 Amp Single-Phase with Load Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GM80676 71
100--200 Amp Standard, Three-Phase, 3- and 4-Pole . . . . . . . . . . . . . . . . . . . GM80668 65
400 Amp Standard, Three-Phase, 3-pole 208--240 V . . . . . . . . . . . . . . . . . . . GM80670 67
400 Amp Standard, Three-Phase, 4-pole and 3-Pole/480 V . . . . . . . . . . . . . . GM80672 69
Service Entrance Models

Enclosure Dimension Drawings
100--200 Amp Single-Phase Service Entrance (UL)
Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADV-8687 1 of 3 47
Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADV-8687 2 of 3 48
Sheet 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADV-8687 3 of 3 49
100 Amp Single-Phase Service Entrance (CSA)
Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADV-8665 1 of 2 43
Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADV-8665 2 of 2 44
150--200 Amp Single-Phase Service Entrance (CSA)
Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADV-8666 1 of 2 45
Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADV-8666 2 of 2 46
300--400 Amp Single-Phase Service Entrance Switch (UL)
Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADV-8694 1 of 2 57
Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADV-8694 2 of 2 58
Wiring Diagrams
100--400 Amp Service Entrance with Standard Interface Board . . . . . . . . . . . GM80665 62
100--400 Amp Service Entrance with Combined Interface Board . . . . . . . . . . GM95548 74
Schematic Diagrams
100--400 Amp Service Entrance with Standard Interface Board . . . . . . . . . . GM80666 63
100--400 Amp Service Entrance with Combined Interface Board . . . . . . . . . . GM95549 75
Note: The drawings are arranged in alphanumeric order on the following pages.
TP-6807 1/16 Section 6 Diagrams and Drawings 41

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

Figure 6-3 Enclosure Dimensions, 100 Amp, CSA Certified Service Entrance, ADV-8665, Sheet 2 of 2

Figure 6-4 Enclosure Dimensions, 150--200 Amp CSA Certified Service Entrance, ADV-8666, Sheet 1 of 2

Figure 6-5 Enclosure Dimensions, 150--200 Amp CSA Certified Service Entrance, ADV-8666, Sheet 2 of 2

Figure 6-6 Enclosure Dimensions, 100--200 Amp Single-Phase, Service Entrance, ADV-8687, Sheet 1 of 3



Figure 6-9 Enclosure Dimensions, 100--200 Amp Single-Phase, ADV-8688, Sheet 1 of 2

Figure 6-10 Enclosure Dimensions, 100--200 Amp Single-Phase, ADV-8688, Sheet 2 of 2

Figure 6-11 Enclosure Dimensions, 100--200 Amp Three-Phase, 3- and 4-Pole, ADV-8689

Figure 6-12 Enclosure Dimensions, 100 Amp Single-Phase with Load Center, ADV-8690

Figure 6-13 Enclosure Dimensions, 400 Amp Single-Phase, ADV-8691

Figure 6-14 Enclosure Dimensions, 400 Amp Three-Phase, 3-Pole/208--240 Volts, ADV-8692

Figure 6-15 Enclosure Dimensions, 400 Amp Three-Phase, 3-Pole/480 Volt and 4-Pole, ADV-8693



Figure 6-18 Enclosure Dimensions, 100 Amp NEMA 1 with 12-Space Load Center, ADV-8736

Figure 6-19 Wiring Diagram, 100--400 Amp Single-Phase, GM80663

Figure 6-20 Schematic Diagram, 100--400 Amp Single-Phase, GM80664

Figure 6-21 Wiring Diagram, 100--400 Amp Service Entrance, GM80665

Figure 6-22 Schematic Diagram, 100--400 Amp Service Entrance, GM80666

Figure 6-23 Wiring Diagram, 100--200 Amp Three-Phase, 3- and 4-Pole, GM80667

Figure 6-24 Schematic Diagram, 100--200 Amp Three-Phase, 3- and 4-Pole, GM80668

Figure 6-25 Wiring Diagram, 400 Amp Three-Phase, 3-Pole/208--240 Volts, GM80669

Figure 6-26 Schematic Diagram, 400 Amp Three-Phase, 3-Pole/208--240 Volts, GM80670

Figure 6-27 Wiring Diagram, 400 Amp Three-Phase, 3-Pole/480 Volts and 4-Pole, GM80671

Figure 6-28 Schematic Diagram, 400 Amp Three-Phase, 3-Pole/480 Volts and 4-Pole, GM80672

Figure 6-29 Wiring Diagram, 100 Amp Single-Phase with Load Center, GM80675

Figure 6-30 Schematic Diagram, 100 Amp Single-Phase with Load Center, GM80676

Figure 6-31 Wiring Diagram, 100--400 Amp Single-Phase with Combined Interface Board, GM95546

Figure 6-32 Schematic Diagram, 100--400 Amp Single-Phase with Combined Interface Board, GM95547

Figure 6-33 Wiring Diagram, 100--400 Amp Service Entrance with Combined Interface Board, GM95548

Figure 6-34 Schematic Diagram, 100--400 Amp Service Entrance with Combined Interface Board, GM95549

Notes

Appendix A Abbreviations
The following list contains abbreviations that may appear in this publication.
A, amp ampere cfm cubic feet per minute est. estimated
ABDC after bottom dead center CG center of gravity E-Stop emergency stop
AC alternating current CID cubic inch displacement etc. et cetera (and so forth)
A/D analog to digital CL centerline exh. exhaust
ADC advanced digital control; cm centimeter ext. external
analog to digital converter CMOS complementary metal oxide F Fahrenheit, female
adj. adjust, adjustment substrate (semiconductor) fglass. fiberglass
ADV advertising dimensional cogen. cogeneration FHM flat head machine (screw)
drawing com communications (port) fl. oz. fluid ounce
Ah amp-hour coml commercial flex. flexible
AHWT anticipatory high water Coml/Rec Commercial/Recreational freq. frequency
temperature conn. connection FS full scale
AISI American Iron and Steel cont. continued
Institute ft. foot, feet
CPVC chlorinated polyvinyl chloride ft. lb. foot pounds (torque)
ALOP anticipatory low oil pressure
crit. critical ft./min. feet per minute
alt. alternator
CRT cathode ray tube ftp file transfer protocol
Al aluminum
CSA Canadian Standards g gram
ANSI American National Standards Association
Institute (formerly American ga. gauge (meters, wire size)
Standards Association, ASA) CT current transformer gal. gallon
AO anticipatory only Cu copper gen. generator
APDC Air Pollution Control District cUL Canadian Underwriter’s genset generator set
Laboratories
API American Petroleum Institute GFI ground fault interrupter
CUL Canadian Underwriter’s
approx. approximate, approximately Laboratories GND, ground
AQMD Air Quality Management District cu. in. cubic inch gov. governor
AR as required, as requested cw. clockwise gph gallons per hour
AS as supplied, as stated, as CWC city water-cooled gpm gallons per minute
suggested
cyl. cylinder gr. grade, gross
ASE American Society of Engineers
D/A digital to analog GRD equipment ground
ASME American Society of
Mechanical Engineers DAC digital to analog converter gr. wt. gross weight
assy. assembly dB decibel HxWxD height by width by depth
ASTM American Society for Testing dB(A) decibel (A weighted) HC hex cap
Materials DC direct current HCHT high cylinder head temperature
ATDC after top dead center DCR direct current resistance HD heavy duty
ATS automatic transfer switch deg.,  degree HET high exhaust temp., high
auto. automatic dept. department engine temp.
aux. auxiliary DFMEA Design Failure Mode and hex hexagon
avg. average Effects Analysis Hg mercury (element)
AVR automatic voltage regulator dia. diameter HH hex head
AWG American Wire Gauge DI/EO dual inlet/end outlet HHC hex head cap
AWM appliance wiring material DIN Deutsches Institut fur Normung HP horsepower
e. V. (also Deutsche Industrie hr. hour
bat. battery Normenausschuss)
BBDC before bottom dead center HS heat shrink
DIP dual inline package hsg. housing
BC battery charger, battery DPDT double-pole, double-throw
charging HVAC heating, ventilation, and air
DPST double-pole, single-throw conditioning
BCA battery charging alternator
DS disconnect switch HWT high water temperature
BCI Battery Council International
DVR digital voltage regulator Hz hertz (cycles per second)
BDC before dead center
E, emer. emergency (power source) IC integrated circuit
BHP brake horsepower
ECM electronic control module, ID inside diameter, identification
blk. black (paint color), block engine control module
(engine) IEC International Electrotechnical
EDI electronic data interchange Commission
blk. htr. block heater
EFR emergency frequency relay IEEE Institute of Electrical and
BMEP brake mean effective pressure
e.g. for example (exempli gratia) Electronics Engineers
bps bits per second
EG electronic governor IMS improved motor starting
br. brass
EGSA Electrical Generating Systems in. inch
BTDC before top dead center Association in. H2O inches of water
Btu British thermal unit EIA Electronic Industries in. Hg inches of mercury
Btu/min. British thermal units per minute Association in. lb. inch pounds
C Celsius, centigrade EI/EO end inlet/end outlet Inc. incorporated
cal. calorie EMI electromagnetic interference ind. industrial
CAN controller area network emiss. emission int. internal
CARB California Air Resources Board eng. engine int./ext. internal/external
CB circuit breaker EPA Environmental Protection I/O input/output
cc cubic centimeter Agency
IP iron pipe
CCA cold cranking amps EPS emergency power system
ISO International Organization for
ccw. counterclockwise ER emergency relay Standardization
CEC Canadian Electrical Code ES engineering special, J joule
cert. certificate, certification, certified engineered special
JIS Japanese Industry Standard
cfh cubic feet per hour ESD electrostatic discharge
TP-6807 1/16 Appendix 77

k kilo (1000) MTBO mean time between overhauls rms root mean square
K kelvin mtg. mounting rnd. round
kA kiloampere MTU Motoren-und Turbinen-Union ROM read only memory
KB kilobyte (210 bytes) MW megawatt rot. rotate, rotating
KBus Kohler communication protocol mW milliwatt rpm revolutions per minute
kg kilogram F microfarad RS right side
kg/cm2 kilograms per square N, norm. normal (power source) RTU remote terminal unit
centimeter NA not available, not applicable RTV room temperature vulcanization
kgm kilogram-meter nat. gas natural gas RW read/write
kg/m3 kilograms per cubic meter NBS National Bureau of Standards SAE Society of Automotive
kHz kilohertz NC normally closed Engineers
kJ kilojoule NEC National Electrical Code scfm standard cubic feet per minute
km kilometer NEMA National Electrical SCR silicon controlled rectifier
kOhm, k kilo-ohm Manufacturers Association s, sec. second
kPa kilopascal NFPA National Fire Protection SI Systeme international d’unites,
kph kilometers per hour Association International System of Units
kV kilovolt Nm newton meter SI/EO side in/end out
kVA kilovolt ampere NO normally open sil. silencer
kVAR kilovolt ampere reactive no., nos. number, numbers SN serial number
kW kilowatt NPS National Pipe, Straight SNMP simple network management
kWh kilowatt-hour NPSC National Pipe, Straight-coupling protocol
kWm kilowatt mechanical NPT National Standard taper pipe SPDT single-pole, double-throw
kWth kilowatt-thermal thread per general use SPST single-pole, single-throw
L liter NPTF National Pipe, Taper-Fine spec specification
LAN local area network NR not required, normal relay specs specification(s)
L x W x H length by width by height ns nanosecond sq. square
lb. pound, pounds OC overcrank sq. cm square centimeter
lbm/ft3 pounds mass per cubic feet OD outside diameter sq. in. square inch
LCB line circuit breaker OEM original equipment SS stainless steel
manufacturer std. standard
LCD liquid crystal display
OF overfrequency stl. steel
ld. shd. load shed
opt. option, optional tach. tachometer
LED light emitting diode
OS oversize, overspeed TD time delay
Lph liters per hour
OSHA Occupational Safety and Health TDC top dead center
Lpm liters per minute Administration
LOP low oil pressure TDEC time delay engine cooldown
OV overvoltage TDEN time delay emergency to
LP liquefied petroleum oz. ounce normal
LPG liquefied petroleum gas p., pp. page, pages TDES time delay engine start
LS left side PC personal computer TDNE time delay normal to
Lwa sound power level, A weighted PCB printed circuit board emergency
LWL low water level pF picofarad TDOE time delay off to emergency
LWT low water temperature PF power factor TDON time delay off to normal
m meter, milli (1/1000) ph.,  phase temp. temperature
M mega (106 when used with SI PHC Phillipsr head Crimptiter term. terminal
units), male (screw) THD total harmonic distortion
m3 cubic meter PHH Phillipsr hex head (screw) TIF telephone influence factor
m3/hr. cubic meters per hour PHM pan head machine (screw) TIR total indicator reading
m3/min. cubic meters per minute PLC programmable logic control tol. tolerance
mA milliampere PMG permanent magnet generator turbo. turbocharger
man. manual pot potentiometer, potential typ. typical (same in multiple
max. maximum ppm parts per million locations)
MB megabyte (220 bytes) PROM programmable read-only UF underfrequency
MCCB molded-case circuit breaker memory UHF ultrahigh frequency
MCM one thousand circular mils psi pounds per square inch UL Underwriter’s Laboratories, Inc.
meggar megohmmeter psig pounds per square inch gauge UNC unified coarse thread (was NC)
MHz megahertz pt. pint UNF unified fine thread (was NF)
mi. mile PTC positive temperature coefficient univ. universal
mil one one-thousandth of an inch PTO power takeoff US undersize, underspeed
min. minimum, minute PVC polyvinyl chloride UV ultraviolet, undervoltage
misc. miscellaneous qt. quart, quarts V volt
MJ megajoule qty. quantity VAC volts alternating current
mJ millijoule R replacement (emergency) VAR voltampere reactive
mm millimeter power source VDC volts direct current
mOhm, mmilliohm rad. radiator, radius VFD vacuum fluorescent display
MOhm, Mmegohm RAM random access memory VGA video graphics adapter
MOV metal oxide varistor RDO relay driver output VHF very high frequency
MPa megapascal ref. reference W watt
mpg miles per gallon rem. remote WCR withstand and closing rating
mph miles per hour Res/Coml Residential/Commercial w/ with
MS military standard RFI radio frequency interference w/o without
ms millisecond RH round head wt. weight
m/sec. meters per second RHM round head machine (screw) xfmr transformer
MTBF mean time between failure rly. relay
78 Appendix TP-6807 1/16

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
Kohler Power Systems
Asia Pacific Headquarters
TP-6807 1/16d 7 Jurong Pier Road
Singapore 619159
E 2011, 2014, 2015, 2016 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455

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Operation and

For use with Kohlerr generator sets equipped with

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

TP-6807 1/16 Table of Contents 3

4 Table of Contents TP-6807 1/16

IMPORTANT SAFETY INSTRUCTIONS.

TP-6807 1/16 Safety Precautions and Instructions 5

6 Safety Precautions and Instructions TP-6807 1/16

This manual provides operation and installation

Model RXT transfer switches operate only with Kohlerr

Information in this publication represents data available

Read this manual and carefully follow all procedures

The equipment service requirements are very important

RDC2 DC2 RDC2 DC2

TP-6807 1/16 Introduction 7

Installation Instructions, FOR EMERGENCY SYSTEMS

Figure 4 Related Literature 2 MODEL

LISTED TRANSFER SWITCH

Figure 5 Typical Transfer Switch Nameplate

8 Introduction TP-6807 1/16

Model Controls Voltage Poles Enclosure Current Rating Connections

Sample Model Designation: RXT-JFNC-0200A

Figure 6 Model Designation

TP-6807 1/16 Introduction 9

For professional advice on generator set power China

10 Service Assistance TP-6807 1/16

1.1 Transfer Switch Description

Model RXT transfer switches must be connected to a

Voltage sensing data from the ATS is continuously

The RDC2/DC2 controller signals the ATS to transfer

Figure 1-1 shows a typical installation block diagram.

Emergency Load Center Model Standard Model

Automatic Transfer Switch 1.3 Load Centers

Figure 1-1 Typical ATS Block Diagram

TP-6807 1/16 Section 1 Description 11

Note: Connect only non-essential loads to the load

12 Section 1 Description TP-6807 1/16

Power Relay Specifications

Figure 1-4 Customer-Supplied Power Relay

Connect up to 4 power relay modules.

Figure 1-5 Power System with Load Management

TP-6807 1/16 Section 1 Description 13

If the status indicator is purchased as a loose kit (not 1

14 Section 1 Description TP-6807 1/16

2.2 Receipt of Unit

Item Specification Weight ]

Storage Amps Description kg (lb.)

TP-6807 1/16 Section 2 Installation 15

16 Section 2 Installation TP-6807 1/16

Hazardous voltage. SCE

Will cause severe injury or death. NC EL1 EL2

Disconnect all power sources before C

opening the enclosure. 7

Check the manual operation before energizing the

See Figure 2-3 to identify the manual operation 1

ATS Procedure Figure

TP-6807 1/16 Section 2 Installation 17

Disabling the generator set. Accidental starting can