Operation and

Installation
Automatic Transfer Switch

Model:

RXT
100--400 Amp Automatic Transfer Switches

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

TP-6807 12/11
Product Identification Information

Product identification numbers determine service parts. 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 12/11
Table of Contents

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

Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Model Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Section 1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Transfer Switch Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Service Entrance Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 Load Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4 Controller Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5 Optional LED Indicator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Section 2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Receipt of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2.2 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2.3 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2.4 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4 Manual Operation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4.1 Manual Operation Procedure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4.2 Manual Operation Procedure 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.5 Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5.1 Load Center Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5.2 AC Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.5.3 Neutral Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.5.4 Neutral Bonding Jumper, Service Entrance Models . . . . . . . . . . . . . . . . 18
2.5.5 Engine Start Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.5.6 Interface Module Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5.7 Optional Load Control Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.5.8 Accessory Module Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.6 Test and Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.7 Warranty Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Section 3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.1 Model RXT Transfer Switch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2 Source Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.3 ATS Control Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.4 Time Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.5 Load Control Time Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Section 4 Service Disconnect, SE Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.1 Service Disconnect Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2 Source Circuit Breaker Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Section 5 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.2 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.2.1 Weekly Generator Set Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.2.2 Monthly Automatic Control System Test . . . . . . . . . . . . . . . . . . . . . . . . . . 26

TP-6807 12/11 Table of Contents 3

Table of Contents, continued

5.3 Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5.3.1 General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.3.2 Other Inspections and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.4 Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Section 6 Diagrams and Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

4 Table of Contents TP-6807 12/11

Safety Precautions and Instructions

IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting

Electromechanical equipment, 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
working on the generator set or serviced by qualified electrical
substantial property damage.
connected equipment, disable the personnel.
generator set as follows: (1) Move the
generator set master switch to the OFF
WARNING Grounding electrical equipment.
position. (2) Disconnect the power to
the battery charger. (3) Remove the Hazardous voltage can cause
Warning indicates the presence of a battery cables, negative (--) lead first. severe injury or death. Electrocution
hazard that can cause severe Reconnect the negative (--) lead last is possible whenever electricity is
personal injury, death, or when reconnecting the battery. Follow present. Ensure you comply with all
substantial property damage. these precautions to prevent starting of applicable codes and standards.
the generator set by an automatic Electrically ground the generator set,
transfer switch, remote start/stop transfer switch, and related equipment
CAUTION switch, or engine start command from a and electrical circuits. Turn off the main
remote computer. circuit breakers of all power sources
Caution indicates the presence of a before servicing the equipment. Never
hazard that will or can cause minor contact electrical leads or appliances
personal injury or property damage. Hazardous Voltage/ when standing in water or on wet
ground because these conditions
NOTICE Moving Parts increase the risk of electrocution.
Notice communicates installation, Short circuits. Hazardous
operation, or maintenance information DANGER 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 making adjustments or repairs.
or service technician to potential Hazardous voltage. Remove all jewelry before servicing the
hazards and explain how to act safely. Will cause severe injury or death. equipment.
The decals are shown throughout this
publication to improve operator Disconnect all power sources before Making line or auxiliary
recognition. Replace missing or opening the enclosure. connections. Hazardous voltage
damaged decals. can cause severe injury or death. To
prevent electrical shock deenergize the
normal power source before making
any line or auxiliary connections.

TP-6807 12/11 Safety Precautions and Instructions 5

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

6 Safety Precautions and Instructions TP-6807 12/11

Introduction

This manual provides operation and installation

instructions for Kohlerr Model RXT automatic transfer
switches. See Figure 1 for typical Model RXT transfer
switches.

Model RXT transfer switches operate only with Kohlerr

Model generator sets equipped with the RDC2 or DC2
generator/transfer switch controller. See Figure 2 for
controller identification. The following Kohlerr model
generator sets can be used with the Model RXT transfer
switch:

D 14RESA

D 14RESAL

D 20RESA

D 20RESAL

D 48RCL

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
Figure 1 Typical Model RXT Transfer Switches
Safety Precautions and Instructions section at the
(shown with optional status indicators)
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/
dealer to keep equipment in top condition.

RDC2 DC2
GM77569

Figure 2 RDC2 and DC2 Generator/Transfer Switch

Controllers (provided with and mounted on
the generator set)

TP-6807 12/11 Introduction 7

Nameplate TRANSFER SWITCH
FOR EMERGENCY SYSTEMS
TYPE ENCLOSURE
A nameplate attached to the inside of the enclosure 1 MFG. DATE
3
MATERIAL ACCESSORIES:
cover or on the upper right side wall includes a model 2 MODEL
SERIAL NO.
designation, a serial number, ratings, and other AMPS VOLTS
WIRES PHASE
information about the transfer switch. See Figure 3. POLES HERTZ

BAR CODE
Check the transfer switch model number from the
transfer switch nameplate and verify that it matches the
model shown on the front cover of this manual before
proceeding with installation.

Copy the model designation, serial number, and LISTED TRANSFER SWITCH
accessory information from the nameplate to the spaces R FOR EMERGENCY SYSTEMS

provided in the Product Identification Information 1. Model designation

GM21291-E

section located inside the front cover of this manual for 2. Serial number
use when requesting service or parts. 3. Factory-installed accessory numbers

Figure 3 Typical Transfer Switch Nameplate

Model Designation
Figure 4 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 an
characteristics as explained below.

Sample Model Designation: RXT-JFNC-0200A

Model
RXT: Kohler Automatic Transfer Switch Enclosure
Controls C: NEMA 3R
J: Interface for RDC2/DC2 Controller Current Rating: Numbers indicate the current rating
Voltage/Frequency of the switch in amperes:
C: 208 Volts/60 Hz (3-phase only) 0100
F: 240 Volts/60 Hz 0200
M: 480 Volts/60 Hz (3-phase only) 0400
Number of Poles/Wires Connections
N: 2-pole, 3-wire, solid neutral (120/240 V only) A: No load center
T: 3-pole, 4-wire, solid neutral B: With load center (100 amp single-phase only)
V: 4-pole, 4-wire, switched neutral ASE: Service entrance rated

Figure 4 Model Designation

8 Introduction TP-6807 12/11

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 stickers 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 Fax: (813) 3440-2727
3 rue de Brennus
93200 Saint Denis Latin America
France Latin America Regional Office
Phone: (33) 1 49 178300 Lakeland, Florida, USA
Fax: (33) 1 49 178301 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

TP-6807 12/11 Service Assistance 9

Notes

10 Service Assistance TP-6807 12/11

Section 1 Description

1.1 Transfer Switch Description

Service Entrance Model
An automatic transfer switch (ATS) transfers electrical
loads from a normal source of electrical power to an
emergency source when the normal source voltage or
frequency falls below an acceptable level. The normal
source is typically utility power. The emergency source
is usually a generator set.

Model RXT transfer switches must be connected to a

generator set equipped with the Kohlerr RDC2 or DC2
generator/transfer switch controller. Applicable
generator set models are listed in the Introduction.

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.

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 12/11 Section 1 Description 11

Loads. The transfer switch can be connected to supply 1.5 Optional LED Indicator Panel
all of the electrical loads in the home, or only the
essential loads such as the furnace, refrigerator, well A user interface panel that contains status-indicating
pump, and selected light circuits. Identify the essential LEDs is available. See Figure 1-3. Source available
circuits that must be supplied during a power outage. LEDs light to indicate that the utility and/or generator
Verify that the generator set and transfer switch are sources are available. The utility or generator source
adequately rated to supply all of the selected loads. supplying load LED lights to show which source is
connected to the building load (i.e. contactor position,
Circuit breakers. Because the size and number of normal or emergency).
circuit breakers required will vary with each application,
circuit breakers are not provided with the transfer switch If the status indicator is purchased as a loose kit (not
load center. factory-installed), refer to the installation instructions
provided with the kit, TT-1585.
Determine the circuits that will be connected to the
transfer switch (essential loads). Identify the breakers
for those circuits in the main distribution panel.

The ATS load center requires Square D type QO

breakers. If the main distribution panel uses the same
1
type of breakers, the breakers can be moved from the
main panel to the load center. Otherwise, obtain new
Square D type QO circuit breakers. For each circuit, the
rating of the load center circuit breaker must match the 2
rating of the existing breaker in the main panel.

Up to 8 tandem breakers can be used. Use Square D

type QOT tandem breakers.

Verify that the total rating for all of the breakers used in
the load center does not exceed the rating of the transfer 3
switch.

1.4 Controller Interface Board 4

GM78649
1. Utility power available
All ATS control functions are performed by the 2. Utility source supplying load
RDC2/DC2 controller mounted on the generator set and 3. Generator source supplying load
communicated through the interface board. The 4. Generator power available
controller interface board sends voltage sensing data to Figure 1-3 LED Indicators
the RDC2/DC2 controller and receives transfer and load
control signals from the RDC2/DC2 controller.

12 Section 1 Description TP-6807 12/11

Section 2 Installation

2.1 Introduction accumulated in the transfer switch or any of its

components.
Kohlerr transfer switches are shipped factory-wired,
factory-tested, and ready for installation. Have the Note: Do not use compressed air to clean the switch.
equipment installed only by trained and qualified Cleaning with compressed air can cause debris
personnel, and verify that the installation complies with to lodge in the components and damage the
applicable codes and standards. Protect the switch switch.
against damage before and during installation.
2.2.4 Lifting
2.2 Receipt of Unit
WARNING
2.2.1 Inspection
At the time of delivery, inspect the packaging and the
transfer switch for signs of shipping damage. Unpack
the transfer switch as soon as possible and inspect the
exterior and interior for shipping damage. If damage Unbalanced weight.
and/or rough handling is evident, immediately file a Improper lifting can cause severe
damage claim with the transportation company. injury or death and equipment
damage.

2.2.2 Storage Use adequate lifting capacity.

Never leave the transfer switch
Store the transfer switch in its protective packing until standing upright unless it is securely
final installation. Protect the transfer switch at all times bolted in place or stabilized.
from moisture, construction grit, and metal chips. Avoid
storage in cold or damp areas where moisture could See Figure 2-2 or the dimensional drawing for the
condense on the unit. See Figure 2-1 for acceptable weight of the transfer switch. Use a spreader bar to lift
storage temperatures. the transfer switch. Attach the bar only to the
enclosure’s mounting holes or lifting brackets; do not lift
Item Specification the unit any other way. Close and latch the enclosure
door before moving the unit.
Storage
--40°C to 85°C (--40°F to 185°F)
Temperature
Amps Description Weight, kg (lb.) [
Operating
--20°C to 70°C (--4°F to 158°F) Single phase 7 (14)
Temperature
With load center 8.2 (18)
Humidity 5% to 95% noncondensing 100
Three phase 14 (30)
Altitude 0 to 3050 m (10000 ft.) without derating
Service Entrance 10 (22)
Figure 2-1 Environmental Specifications Single phase 7 (15)
200 Three phase 14 (30)
2.2.3 Unpacking Service Entrance 12 (26)
Single phase 36 (80)
Allow the equipment to warm to room temperature for at
least 24 hours before unpacking to prevent 3-Pole/208--240 Volts 41 (90)
condensation on the electrical apparatus. Use care 400 3-Pole/480 Volts 59 (130)
when unpacking to avoid damaging transfer switch 4-Pole 59 (130)
components. Use a vacuum cleaner or a dry cloth to
Service Entrance 46 (100)
remove dirt and packing material that may have
Figure 2-2 Approximate Weights

TP-6807 12/11 Section 2 Installation 13

2.3 Installation Pull the bottom of the panel out and down until the top
clears the enclosure. Remove the inner panel to access
NOTICE the transfer switch components.
Foreign material contamination. Cover the transfer switch
during installation to keep dirt, grit, metal drill chips, and other NEMA 3R enclosures have locking tabs at the bottom of
debris out of the components. Cover the solenoid mechanism the enclosure and the door. While the enclosure is open,
during installation. After installation, use the manual operating turn the locking tab out so that the door can be locked
handle to cycle the contactor to verify that it operates freely. with a padlock after installation is complete.
Do not use a screwdriver to force the contactor mechanism.
Wall mounting. Mount the transfer switch to a wall or
NOTICE other rigid vertical supporting structure. Refer to the
Hardware damage. The transfer switch may use both dimension drawings in Section 6 for hole locations. Use
American Standard and metric hardware. Use the correct size shims to plumb the enclosure.
tools to prevent rounding of the bolt heads and nuts.
Cover or remove the transfer switch’s internal
Check the system voltage and frequency. Compare components to protect them from drill chips or debris
the voltage and frequency shown on the transfer switch during installation. Use a vacuum cleaner to remove
nameplate to the source voltage and frequency. Do not debris from the enclosure.
install the transfer switch if the voltage and frequency
are different from the normal (utility) source voltage and Note: Do not use compressed air to clean the switch.
frequency or the emergency source voltage and Cleaning with compressed air can cause debris
frequency shown on the generator set nameplate. to lodge in the components and cause damage.
Tighten the mounting screws to 2.9 Nm (26 in. lb.) when
Plan the installation. Use the dimensions given on the
reinstalling the components.
enclosure dimension (ADV) drawings in Section 6.
Select a mounting site that complies with local electrical Clearance holes through the back of each enclosure are
code restrictions for the enclosure type. Mount the provided for mounting. The mounting holes on NEMA
transfer switch as close to the load and power sources 3R enclosures have gaskets to seal out moisture. Use
as possible. Allow adequate space to open the washers with the mounting screws to protect the
enclosure and service the switch. gaskets.

NEMA 3R enclosures. To remove the enclosure’s front

panel, support the panel while removing the screws.

14 Section 2 Installation TP-6807 12/11

2.4 Manual Operation Check
CN

DANGER 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.

8 7
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 and 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
400 amps, 1-phase 2.4.1 Figure 2-5
400 amps, 3-phase, 3-pole,
2.4.1 Figure 2-5
208--240 Volts
400 amps, 3-phase,
2.4.2 Figure 2-7
3-pole/480 Volt and 4-pole

Figure 2-3 Manual Operation Procedure Guide GM80139

1. Shaft (attach handle or wrench here)

2.4.1 Manual Operation Procedure 1
Figure 2-5 Manual Operation, 400 Amp Single-
Note: Never manually operate the transfer switch when
the power is connected. Disconnect both power Phase and 208--240 Volt Switches
sources before manually operating the switch.
2.4.2 Manual Operation Procedure 2
1. 100-200 amp switches: These switches have an
attached handle as shown in Figure 2-4. Note: Never use the maintenance handle to transfer the
400 amp switches: Slide the detachable handle or load with the power connected. Disconnect both
a wrench over the shaft. See Figure 2-5. power sources before manually operating the
switch.
2. Move the handle up to place the transfer switch in
the Normal Source position or down to place the 1. If the transfer switch is equipped with a
contactor in the Emergency Source position. See maintenance handle, remove the handle from its
Figure 2-4 or Figure 2-5. storage location inside the enclosure. See
Figure 2-7.
3. 400 amp switches: Remove the detachable handle
or wrench.

TP-6807 12/11 Section 2 Installation 15

2. Insert the maintenance handle or a tool (such as a 2.5 Electrical Wiring
screwdriver) into the hole in the shaft on the left
side of the operator as shown in Figure 2-6 or Refer to the connection diagrams on the transfer switch
Figure 2-7. enclosure door and the wiring diagrams in Section 6
during installation.
3. Move the maintenance handle (or tool) up or down
as shown to manually operate the transfer switch. It All wiring must comply with applicable national, state,
should operate smoothly without any binding. If it and local electrical codes. Use separate conduit for AC
does not, check for shipping damage or power wiring and low-voltage DC, control, and
construction debris. communication system wiring.

4. Return the transfer switch to the Normal position. DANGER

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

Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.

1 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.
Grounding electrical equipment. Hazardous voltage can
cause severe injury or death. Electrocution is possible
whenever electricity is present. Ensure you comply with all
applicable codes and standards. Electrically ground the
generator set and related equipment and electrical circuits.
GM78867
Turn off the main circuit breakers of all power sources before
servicing the equipment. Never contact electrical leads or
1. Insert handle or tool here for manual operation appliances when standing in water or on wet ground because
these conditions increase the risk of electrocution.
Figure 2-6 Manual Operation, 100--200 Amp
3-Phase Switches
2.5.1 Load Center Circuit Breakers
The 100 amp Model RXT transfer switch is available
with a built-in load center with room for up to 16
single-pole circuit breakers. Up to 8 tandem breakers
1 can be used for a maximum of 24 circuits.
2 The load center uses Square D type QO or QOT tandem
breakers. In an essential load application, the breakers
can be moved from the main panel to the load center if
the main distribution panel uses the same type of
breakers. Otherwise, obtain and install new Square D
type QO circuit breakers. The rating of the load center
circuit breaker must match the rating of the existing
breaker in the main panel for each circuit. 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.
tp6225
1. Handle storage location Verify that the total rating for all breakers used in the load
2. Insert handle here for manual operation
center does not exceed the rating of the transfer switch.
Figure 2-7 Manual Operation, 400 Amp 3-Phase
Switches

16 Section 2 Installation TP-6807 12/11

2.5.2 AC Power Connections Single phase. For single-phase models, connect to A
and C.
Determine the cable size. Refer to Figure 2-8 or the
ADV drawings in Section 6 to determine the cable size Three phase. For three-phase models, be sure to
required for the transfer switch. Make sure the lugs follow the phase markings (A, B, C, and N).
provided are suitable for use with the cables being
Note: Connect the source and load phases as indicated
installed.
by the markings and drawings to prevent short
Conduit. Use separate conduit for AC power wiring circuits and to prevent phase-sensitive devices
and low-voltage DC, control, and communication from malfunctioning or operating in reverse.
system wiring. Watertight conduit hubs may be required Service entrance models. Connect the utility source to
for outdoor use. the lugs on the normal source disconnect circuit
breakers as shown in the service entrance switch wiring
Select the proper cable clamp or use other approved
diagram in Section 6.
methods for securing the cable or conduit to the
enclosure. Verify that all connections are consistent with drawings
before tightening the lugs. Tighten all cable lug
Source and load connections. Clean cables with a connections to the torque values shown on the label on
wire brush to remove surface oxides before connecting the switch. Carefully wipe off any excess joint
them to the terminals. Apply joint compound to the compound after tightening the terminal lugs.
connections of any aluminum conductors.
On models with built-in load centers, the load lugs are
Refer to the connection diagrams on the transfer switch factory-wired to the load center. Connect the load leads
enclosure door and the wiring diagrams in Section 6. to the circuits in the load center and tighten the
The connection points on the transfer switch contactor connections. Check the labels on the breakers for the
are labelled Normal, Emergency, and Load. Connect tightening torques.
the utility power to Normal. Connect the generator set to
Emergency.

TP-6807 12/11 Section 2 Installation 17

2.5.3 Neutral Connection 2.5.5 Engine Start Function
Connect the neutral from the main panel to the neutral The engine start function is controlled by the RDC2/DC2
lug in the ATS enclosure. controller on the generator set. There are no engine
start terminals on the Model RXT ATS.
Ground the system according to NEC and local codes.

2.5.4 Neutral Bonding Jumper, Service

Entrance Models
The transfer switch is shipped with the
neutral-to-ground jumper installed. For non-service
entrance applications, disconnect the neutral-to-ground
bonding jumper. See the transfer switch dimension
drawing.

Cable Sizes
AL/CU UL-Listed Solderless Screw-Type Terminals for External Power Connections
Switch Range of Wire Sizes, Cu/Al
Size,
Amps Switch Phases Normal and Emergency Load Neutral Ground
Standard 1 (1) #14 -- 1/0 AWG (1) #14 – 1/0 AWG (3) #12 – 1/0 AWG (9) #4 – 14 AWG
With load per customer-supplied
1 (1) #14 – 1/0 AWG (1) #2 – 2/0 AWG (9) #4 – 14 AWG
center circuit breaker

100 Normal: (1) #12 – 2/0

Service AWG
1 (1) #6 – 250 MCM (3) #6 – 250 MCM (3) #14 – 1/0 AWG
Entrance Emerg: (1) #6 – 250
MCM
3-Phase 3 (1) #8 – 3/0 AWG (1) #8 – 3/0 AWG (3) #6 AWG – 3/0 AWG (3) #6 – 3/0 AWG
Standard 1 (1) #6 AWG – 250 MCM (1) #6 AWG – 250 MCM (3) #6 AWG – 250 MCM (9) #4 – 14 AWG
Normal: (1) #4 – 300
Service MCM
1 (1) #6 AWG – 250 MCM (3) #6 AWG – 250 MCM (3) #14 – 1/0 AWG
200 Entrance Emerg: (1) #6 -- 250
MCM
(3) #4 AWG – 600 MCM
3-Phase 3 (1) #6 AWG – 250 MCM (1) #6 AWG – 250 MCM (3) #6 – 3/0 AWG
(6) 1/0 – 250 MCM
(1) #4 – 600 MCM
Standard 1 (2) #6 – 250 MCM (2) #6 – 250 MCM
(2) 1/0 – 250 MCM
Normal: (2) 3/0 – 250
Service MCM (3) #4 – 600 MCM
1 (2) #6 – 250 MCM
Entrance Emerg: (2) #6 -- 250 (6) 1/0 – 250 MCM
400 MCM (3) #14 – 1/0 AWG

3-pole (1) #4 – 600 MCM

3 (2) #6 – 250 MCM (2) #6 – 250 MCM
208-240 V (2) 1/0 – 250 MCM
3 or 4 pole (1) #4 – 600 MCM (1) #4 – 600 MCM (1) #4 – 600 MCM
3
480 V (2) #6 – 250 MCM (2) #6 – 250 MCM (2) 1/0 – 250 MCM

Figure 2-8 Cable Sizes

18 Section 2 Installation TP-6807 12/11

2.5.6 Interface Module Connection See Figure 2-9 and Figure 2-10. Use 20 AWG Belden
#9402, 8723, or equivalent shielded, twisted-pair cable
The interface module must be connected to a Kohlerr to connect P10-1 through P10-4 on the controller
generator set equipped with the RDC2 or DC2 interface module to the generator set terminal block
controller. The generator set is typically equipped with a connections A, B, PWR, and COM. The maximum cable
field-connection terminal block. See the generator set length is 61 meters (200 ft.).
Installation Manual for the location of the terminal block.
Alternatively, 12--14 AWG wire can be used for the PWR
Note: This document gives connection information for and COM connections only. If 12--14 AWG wire is used
one Model RXT transfer switch connected to a for the PWR and COM connections, the maximum cable
generator set equipped with an RDC2 or DC2 length is 152 m (500 ft.) if one Model RXT transfer
controller. If additional accessory modules such switch and no accessory modules are connected to the
as a programmable interface module (PIM) or a generator set.
load control module (LCM) are connected, refer
to the generator set installation manual for cable Note: Connections 3 and 4 on the generator set are not
requirements and connection instructions. used with the Model RXT transfer switch.

Terminal Block Connection Designation Description Wire Size

P10-1 A Communication Line 20 AWG shielded twisted-pair,
P10-2 B Communication Line Belden 9402, 8723, or equivalent
P10
P10-3 PWR 12 VDC 20 AWG shielded twisted-pair Belden 9402
P10-4 COM 12 VDC or 12--14 AWG wire

Figure 2-9 Controller Interface Connections

Connect one end of each cable shield to

GROUND at the generator set.
GND

Generator Set
A A

B
B
PWR Interface Board on the Model
PWR RXT Transfer Switch
COM COM

4
A RXT
3
B
TB1 1
PWR

COM

Generator Set Terminal Block TB1. Leave one end of each cable shield disconnected.
See the generator set manuals for location.
Check the decal on the generator set for terminal If accessory modules are connected in series, connect
block connections. the cable shields as shown below and refer to the
generator set installation manual.

RXT

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

Figure 2-10 Interface Module Connection to Generator Set Field-Connection Terminal Block

TP-6807 12/11 Section 2 Installation 19

2.5.7 Optional Load Control Connection 2.5.8 Accessory Module Connections
Connector P11 on the interface module provides a For connection of the optional load control module
connection point for optional load control circuits. The (LCM) or programmable interface module (PIM), refer to
load control contact provides a delayed contact closure the instructions provided with the modules and to the
to allow startup of selected loads 5 minutes after transfer generator set installation manual.
to the emergency power source (generator set). Use
this contact to delay startup of equipment with large
motor-starting loads such as air conditioners. 2.6 Test and Exercise
Refer to the generator set Operation Manual for
See Figure 2-11 for the location of load control
instructions to test the power system operation and to
connector P11. See Figure 2-12 for contact ratings,
set the RDC2 or DC2 controller for weekly exercise runs
connection, and wire size information.
to keep the power system in good operating condition.
Note: An optional load control module is available for
generator sets equipped with the RDC2 or DC2 2.7 Warranty Registration
controller. The load control module allows
management of up to six separate loads (two Startup Notification Form. The Startup Notification
HVAC thermostat connections and four other Form covers all equipment in the standby system.
non-essential loads). See TT-1574, Load Control Complete the Startup Notification Form and register the
Module Instructions. equipment in the Kohler online warranty system within
60 days of the initial startup date. Standby systems not
registered within 60 days of startup are automatically
registered using the manufacturer’s ship date as the
startup date.

GM80663
2 1

1. ATS/generator set interface connection P10

2. Load control connection P11
3. Factory connections

Figure 2-11 Interface Module Connections

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 2-12 Load Control Contact P11 Connections

20 Section 2 Installation TP-6807 12/11

Section 3 Operation

3.1 Model RXT Transfer Switch 3.3 ATS Control Sequence of

Operation Operation
The Model RXT transfer switch must be connected to a See Figure 3-2 for time delay settings.
generator set equipped with the RDC2 or DC2
controller. The RDC2/DC2 generator set/transfer Preferred Source Fails:
switch controller manages automatic transfer switch
(ATS) functions when connected to a Kohlerr Model 1. The load control contact opens.
RXT transfer switch through the ATS interface board.
The controller receives voltage sensing data from the 2. The engine start time delay times out.
Model RXT ATS and operates the generator set and
transfer switch to provide standby power when utility 3. The generator set is signaled to start.
power is lost. 4. The generator starts and the emergency source
See the generator set operation manual for: becomes available.

D ATS status screens and configuration menus.

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

6. The transfer switch transfers to the emergency

D Information about loaded exercise.
source.

7. The load control contact time delay times out.

3.2 Source Availability
The Model RXT transfer switch supplies voltage 8. The load control contact closes.
sensing data to the RDC2 or DC2 controller through the
ATS interface board. If the source voltage falls below Normal Source Returns:
the undervoltage dropout setting, the source is
1. The emergency-to-normal time delay times out.
considered to have failed. See Figure 3-1.
2. The contactor transfers to the normal source.
Voltage Sensing Parameter Setting
Accuracy ±5% 3. The engine cooldown time delay times out.
Undervoltage Dropout 90% of Pickup
4. The generator is signaled to stop.
Undervoltage Pickup 90% of Nominal

Figure 3-1 Voltage Sensing Parameters

TP-6807 12/11 Section 3 Operation 21

3.4 Time Delays 3.5 Load Control Time Delay
Time delays are factory-set to the values shown in The load control time delay allows delayed starting of
Figure 3-2. An authorized distributor/dealer can adjust large motor loads (such as air conditioners), preventing
time delays using a personal computer and Kohlerr simultaneous starting of large motors after transfer to
SiteTecht software. the generator set. The load control time delay is fixed at
5 minutes. It is not adjustable.
Time delays described in this section operate only when
the RDC2 or DC2 generator set controller is connected The load must be connected to the load control output
to a Kohlerr Model RXT transfer switch. on the interface board of the Model RXT transfer switch.
See the transfer switch operation and installation
The engine start and load transfer time delays prevent manual for connection instructions.
engine start and load transfer caused by brief variations
in the utility power source. Note: A separate load control module (LCM) that
provides four power relays and two HVAC relays
is available for generator sets equipped with the
RDC2 or DC2 controller. See LCM Specification
Sheet G6-120 for more information.

Time Delay Setting Description

Engine Start 3 seconds Time delay after utility source is lost until the engine start cycle begins.
Guards against starting the generator set because of a brief change 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.
Prevents simultaneous starting of large motors after transfer to the
emergency source. Recommended for delayed starting of air
conditioners.
Figure 3-2 Time Delays

22 Section 3 Operation TP-6807 12/11

Section 4 Service Disconnect, SE Model

Note: This section applies only to service entrance 4.2 Source Circuit Breaker Reset
model transfer switches, which are identified with
the letters ASE at the end of the model The utility source circuit breaker can trip due to an
designation. overcurrent condition. Identify and correct the cause of
the overcurrent condition before resetting the circuit
DANGER 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
Hazardous voltage. to the ON position.
Will cause severe injury or death.
This equipment must be installed and
serviced by qualified electrical
personnel.

1
4.1 Service Disconnect Procedure
Use the following procedure to disconnect the utility
source on service entrance model transfer switches.

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:

a. Press the OFF button on the generator set

controller.

b. Disconnect power to the generator set battery

charger.

c. Disconnect the generator set engine starting

battery, negative (--) lead first.

2. On the transfer switch, remove the outer enclosure GM80015

door only.
2
3. Move the utility source circuit breaker to the OFF
position. 1. Normal/utility circuit breaker
2. Padlock hasp
Note: Power is still present on the input side of the
utility source circuit breaker. Do not remove Figure 4-1 Service Entrance Model, Door Removed
the protective barrier around the utility
source connection lugs.

4. To lock out the transfer switch, replace the outer

door and attach a padlock to the hasp.

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

Notes

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

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.
Disconnect all power sources before
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.

Will cause severe injury or death.
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.

WARNING WARNING

Hazardous voltage. Moving parts.

Accidental starting. Can cause severe injury or death.
Can cause severe injury or death.
Operate the generator set only when
Disconnect the battery cables before all guards and electrical enclosures
working on the generator set. are in place.
Remove the negative (--) lead first
when disconnecting the battery. Grounding the transfer switch. Hazardous voltage can
Reconnect the negative (--) lead last cause severe injury or death. Electrocution is possible
when reconnecting the battery. whenever electricity is present. Open main circuit breakers of
all power sources before servicing equipment. Configure the
Disabling the generator set. Accidental starting can installation to electrically ground the transfer switch and
cause severe injury or death. Before working on the related equipment and electrical circuits to comply with
generator set or connected equipment, disable the generator applicable codes and standards. Never contact electrical
set as follows: (1) Move the generator set master switch to the leads or appliances when standing in water or on wet ground,
OFF position. (2) Disconnect the power to the battery charger. as the chance of electrocution increases under such
(3) Remove the battery cables, negative (--) lead first. conditions.
Reconnect the negative (--) lead last when reconnecting the
battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote
start/stop switch, or engine start command from a remote
computer.

TP-6807 12/11 Section 5 Scheduled Maintenance 25

Servicing the transfer switch. Hazardous voltage can D Watch and listen for signs of excessive noise or
cause severe injury or death. Deenergize all power sources vibration during operation.
before servicing. Turn off the main circuit breakers of all
transfer switch power sources and disable all generator sets D After the switch transfers the load to the standby
as follows: (1) Move all generator set master controller source, end the test and verify that the expected
switches to the OFF position. (2) Disconnect power to all
battery chargers. (3) Disconnect all battery cables, negative
sequence of operations occurs as the transfer switch
(--) leads first. Reconnect negative (--) leads last when retransfers to the preferred source.
reconnecting the battery cables after servicing. Follow these
precautions to prevent the starting of generator sets by an 5.3 Inspection and Service
automatic transfer switch, remote start/stop switch, or engine
start command from a remote computer. Before servicing any Contact an authorized distributor/dealer to inspect and
components inside the enclosure: (1) Remove all jewelry. (2)
Stand on a dry, approved electrically insulated mat. (3) Test
service the transfer switch annually and also when any
circuits with a voltmeter to verify that they are deenergized. wear, damage, deterioration, or malfunction of the
transfer switch or its components is evident or
Short circuits. Hazardous voltage/current can cause suspected.
severe injury or death. Short circuits can cause bodily injury
and/or equipment damage. Do not contact electrical
connections with tools or jewelry while making adjustments or 5.3.1 General Inspection
repairs. Remove all jewelry before servicing the equipment. External Inspection. Keep the transfer switch clean
NOTICE and in good condition by performing a weekly general
external inspection of the transfer switch. Check for any
Hardware damage. The transfer switch may use both
American Standard and metric hardware. Use the correct size
condition of vibration, leakage, excessive temperature,
tools to prevent rounding of the bolt heads and nuts. contamination, or deterioration. Remove accumulations
of dirt, dust, and other contaminants from the transfer
NOTICE switch’s external components or enclosure with a
Electrostatic discharge damage. Electrostatic discharge vacuum cleaner or by wiping with a dry cloth or brush.
(ESD) damages electronic circuit boards. Prevent
electrostatic discharge damage by wearing an approved Note: Do not use compressed air to clean the transfer
grounding wrist strap when handling electronic circuit boards switch because it can cause debris to lodge in the
or integrated circuits. An approved grounding wrist strap components and damage the switch.
provides a high resistance (about 1 megohm), not a direct
short, to ground. Tighten loose external hardware. Replace worn, missing,
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
hardware uses a numeric system. Check the markings information and ordering.
on the bolt heads and nuts for identification.
Internal Inspection. Disconnect all power sources,
open the transfer switch enclosure door, and inspect
5.2 Testing internal components monthly or when any condition
noticed during an external inspection may have affected
5.2.1 Weekly Generator Set Exercise internal components.
Use the exerciser or a manual test to start and run the Contact an authorized distributor/dealer to inspect and
generator set under load once a week to maximize the service the transfer switch if any of the following
reliability of the emergency power system. conditions are found inside the transfer switch.

5.2.2 Monthly Automatic Control D Accumulations of dirt, dust, moisture, or other

System Test contaminants.

Test the transfer switch’s automatic control system D Signs of corrosion.

monthly. Refer to the RDC2/DC2 controller operation
manual for the test procedure. D Worn, missing, or broken components.

D Verify that the expected sequence of operations D Loose hardware.

occurs as the switch transfers the load to the
emergency source when a preferred source failure D Wire or cable insulation deterioration, cuts, or
occurs or is simulated. abrasion.

26 Section 5 Scheduled Maintenance TP-6807 12/11

D Signs of overheating or loose connections: operation of the transfer switch. See Section 5.4,
discoloration of metal, melted plastic, or a burning Service Schedule, for the recommended maintenance
odor. items and service intervals.

D Other evidence of wear, damage, deterioration, or Have an authorized distributor/dealer repair or replace
malfunction of the transfer switch or its components. damaged or worn internal components with
manufacturer-recommended replacement parts.
If the application does not allow a power interruption for
the time required for the internal inspection, have an
authorized distributor/dealer perform the internal
5.4 Service Schedule
inspection. Follow the service schedule in Figure 5-1 for the
recommended service intervals. Have all service
5.3.2 Other Inspections and Service performed by an authorized distributor/dealer except for
Have an authorized distributor/dealer perform activities designated by an X, which may be performed
scheduled maintenance, service, and other by the switch operator.
maintenance that ensures the safe and reliable

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 12/11 Section 5 Scheduled Maintenance 27

Notes

28 Section 5 Scheduled Maintenance TP-6807 12/11

Section 6 Diagrams and Drawings

Diagram or Drawing Drawing Number Page

Single-Phase
Enclosure Dimension Drawings
100--200 Amp Single-Phase
Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADV-8190 1 of 2 30
Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADV-8190 2 of 2 31
100 Amp Single-Phase with Load Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADV-8197 41
400 Amp Single-Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADV-8193 36

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

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

Service Entrance
Enclosure Dimension Drawings
100--200 Amp Single-Phase Service Entrance
Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADV-8192 1 of 3 33
Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADV-8192 2 of 3 34
Sheet 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADV-8192 3 of 3 35
400 Amp Single-Phase Service Entrance Switch
Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADV-8196 1 of 2 39
Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADV-8196 2 of 2 40

Wiring Diagrams
100--400 Amp Service Entrance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GM80665 44

Schematic Diagrams
100--400 Amp Service Entrance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GM80666 45

Three-Phase
Enclosure Dimension Drawings
100--200 Amp Standard, Three-Phase, 3- and 4-Pole . . . . . . . . . . . . . . . . . . . ADV-8191 32
400 Amp Standard, Three-Phase, 3-pole 208--240 V . . . . . . . . . . . . . . . . . . . . ADV-8194 37
400 Amp Standard, Three-Phase, 4-pole and 3-Pole/480 V . . . . . . . . . . . . . . ADV-8195 38

Wiring Diagrams
100--200 Amp Standard, Three-Phase, 3- and 4-Pole . . . . . . . . . . . . . . . . . . . GM80667 46
400 Amp Standard, Three-Phase, 3-pole 208--240 V . . . . . . . . . . . . . . . . . . . . GM80669 48
400 Amp Standard, Three-Phase, 4-pole and 3-Pole/480 V . . . . . . . . . . . . . . GM80671 50

Schematic Diagrams
100--200 Amp Standard, Three-Phase, 3- and 4-Pole . . . . . . . . . . . . . . . . . . . GM80668 47
400 Amp Standard, Three-Phase, 3-pole 208--240 V . . . . . . . . . . . . . . . . . . . . GM80670 49
400 Amp Standard, Three-Phase, 4-pole and 3-Pole/480 V . . . . . . . . . . . . . . GM80672 51

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

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

30 Section 5 Diagrams and Drawings TP-6807 12/11

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

TP-6807 12/11 Section 5 Diagrams and Drawings 31

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

32 Section 5 Diagrams and Drawings TP-6807 12/11

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

TP-6807 12/11 Section 5 Diagrams and Drawings 33

Figure 6-5 Enclosure Dimensions, 100--200 Amp Single-Phase, Service Entrance, ADV-8192, Sheet 2 of 3

34 Section 5 Diagrams and Drawings TP-6807 12/11

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

TP-6807 12/11 Section 5 Diagrams and Drawings 35

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

36 Section 5 Diagrams and Drawings TP-6807 12/11

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

TP-6807 12/11 Section 5 Diagrams and Drawings 37

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

38 Section 5 Diagrams and Drawings TP-6807 12/11

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

TP-6807 12/11 Section 5 Diagrams and Drawings 39

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

40 Section 5 Diagrams and Drawings TP-6807 12/11

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

TP-6807 12/11 Section 5 Diagrams and Drawings 41

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

42 Section 5 Diagrams and Drawings TP-6807 12/11

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

TP-6807 12/11 Section 5 Diagrams and Drawings 43

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

44 Section 5 Diagrams and Drawings TP-6807 12/11

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

TP-6807 12/11 Section 5 Diagrams and Drawings 45

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

46 Section 5 Diagrams and Drawings TP-6807 12/11

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

TP-6807 12/11 Section 5 Diagrams and Drawings 47

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

48 Section 5 Diagrams and Drawings TP-6807 12/11

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

TP-6807 12/11 Section 5 Diagrams and Drawings 49

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

50 Section 5 Diagrams and Drawings TP-6807 12/11

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

TP-6807 12/11 Section 5 Diagrams and Drawings 51

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

52 Section 5 Diagrams and Drawings TP-6807 12/11

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

TP-6807 12/11 Section 5 Diagrams and Drawings 53

Notes

54 Section 5 Diagrams and Drawings TP-6807 12/11

Appendix A Abbreviations
The following list contains abbreviations that may appear in this publication.
A, amp 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 12/11 Appendix 55

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 μF 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, kΩ 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, mΩmilliohm rad. radiator, radius VFD vacuum fluorescent display
MOhm, MΩmegohm 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

56 Appendix TP-6807 12/11

Notes

TP-6807 12/11 57
Notes

58 TP-6807 12/11
KOHLER CO. Kohler, Wisconsin 53044
Phone 920-457-4441, Fax 920-459-1646
For the nearest sales/service outlet in the
US and Canada, phone 1-800-544-2444
KohlerPower.com
Kohler Power Systems
Asia Pacific Headquarters
TP-6807 12/11 7 Jurong Pier Road
Singapore 619159
E 2011 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455