Kohler RDT, HDT, KSS-J Installation Instructions Manual
Original Issue Date: 12/04
Model: RDT, HDT, and KSS-J Automatic Transfer Switches
Market: ATS
Subject: Programmable Exerciser Kits GM47597-KA1, -KA2, KA3, -KP1, -KP2,
and -KP3; GM48913; GM48919, and GM64108
(GM38798-KA1, -KA2, KP1, KP2, discontinued*)
TT-1403 4/16c
INSTALLATION INSTRUCTIONS
Introduction
Use the Programmable Exerciser Kit with the following
transfer switch models:
D RDT
D HDT
D KSS-J with Decision-Makerr MPAC 750 Controller
Service kits are also available to replace the exercise
timer on transfer switches equipped with S340 controls.
Figure 1 shows the programmable exerciser timer. See
Figure 3 through Figure 5 for illustrations of installed
exerciser timers.
Use the programmable exerciser kit to schedule
generator set exercise runs in addition to the weekly or
biweekly exercise set through the ATS controls. The
programmable exerciser kit can also be used for peak
shaving by scheduling the system to start the generator
set and transfer the load at selected times and days.
Optional Accessory Board GM38796-KA1 or -KP1 is
required for connection and operation of the
programmable exerciser kit on Model RDT transfer
switches.
Timer Features
D 24 hour/7 day timing combined
D 8 on/off operations daily, up to 56 switching (on or off)
cycles per week
D 5 year lithium battery for backup power
D 24 hour display (military time or AM/PM)
D Manual override
D Skip a day feature
Programmable Timer Specifications
Switching SPDT
Switch rating 16 A @ 45C; 10 A @ 55C
Supply voltage 120VAC, 50/60 Hz (GM60427)
Rated power 3.5 VA
Operating
temperature range
Connections 6.3 x 0.8 tab terminals
Shortest switch time 1 minute
240VAC, 50/60 Hz (GM64028)
5-year lithium backup battery
-- 1 0 Cto55C
(--14F to 131F)
The programmable exerciser kits include
programmable timer GM64027 or GM64028, mounting
hardware, and connecting leads as required.
Read the entire installation procedure and compare the
kit parts with the parts list at the end of this publication
before beginning installation. Perform the steps in the
order shown. The installation and wiring must comply
with the National Electrical Code and applicable local
codes.
* Discontinued kits. See page 13 for instructions.
Figure 1 Programmable Exerciser GM64027 (120V)
and GM64028 (240V)
Safety Precautions
Observe thefollowing safetyprecautions whileinstalling
the kit.
DANGER
WARNING
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery.
Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on the
generator set or connected equipment, disable the generator
set as follows: (1) Move the generator set master switch to the
OFF position. (2) Disconnect thepower to the battery charger.
(3) Remove the battery cables, negative (--) lead first.
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.
(Decision-Makerr 3+ and 550 Generator Set Controllers)
Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on the
generator set or equipment connected to the set, disable the
generator set as follows: (1) Press the generator set off/reset
button to shut down the generator set. (2) Disconnect the
power to the battery charger, if equipped. (3) Remove the
battery cables, negative (--) lead first. Reconnect the negative
(--) lead last when reconnecting the battery. Follow these
precautions to prevent the starting of the generator set by the
remote start/stop switch.
(RDC, DC, RDC2, DC2, Decision-Makerr 3000, 3500 and
6000 Generator Set Controllers)
DANGER
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.
Hazardous voltage.
Will cause severe injury or death.
Only authorized personnel should
open the enclosure.
Short circuits. Hazardous voltage/current can cause
severe injury or death. Short circuits can cause bodily injury
and/or equipment damage. Do not contact electrical
connections with tools or jewelry while making adjustments or
repairs. Remove all jewelry before servicing the equipment.
NOTICE
Foreign material contamination. Cover the transfer switch
during installation to keep dirt, grit, metal drill chips, and other
debris out of the components. Cover the solenoid mechanism
during installation. After installation, use the manual operating
handle tocycle thecontactor toverify that it operates freely. Do
not use a screwdriver to force the contactor mechanism.
1 Kit Application Notes
Figure 2 lists the available programmable exerciser kits
and their applications. Kits include the programmable
exerciser timer and mounting hardware.
To replace the older style timer GM39330 on the
200 Amp service entrance rated model RDT, service kit
GM64108 is required. The service kit includes a retrofit
mounting panel that is required for timer replacement on
the 200 Amp service entrance rated Model RDT only.
Service kitsare also availablefor exerciser replacement
on transfer switches equipped with S340 controls.
Kit Number Application
GM47597-KP2 100--200 Amp Model RDT
GM47597-KP1 400 Amp Model RDT;
GM47597--KP3
GM48913 Service Kit for S340 Controls,
GM48919 Service Kit for S340 Controls,
GM64108 Service Kit for 200 Amp RDT SE *
GM38798-KA1,
-KA2, -KP1, -KP2
* SE = Service Entrance Model
200 and 400 Amp Model RDT SE *
Model KSS-J with Decision-Makerr
MPAC 750 Controller
120 VAC
240 VAC
(replaces timer GM39330)
Kits with timer GM39330.
Discontinued; see page 13.
2 TT-1403 4/16
Figure 2 Programmable Exerciser Kit Application
2 Installation Procedure
2.1 Mounting, 100--200 Amp Model RDT
Note: For factory-installed exerciser kits, proceed to
section 5.
1. Disable the generator set to prevent accidental
starting:
a. Shutdown the generator set by either moving
the generator set master switch to OFF or by
pressing the OFF/RESET button on the
generator set controller.
b. Disconnect power to the battery charger, if
equipped.
c. Disconnect the generator set engine starting
battery, negative (--) lead first.
2. Disconnect power to the transfer switch before
opening the ATS enclosure.
SeeFigure3.
1. Install timer mounting bracket GM64057 over the
controller bracket as shown in Figure 3. Use the
existing controller bracket nuts to secure the timer
mounting bracket to the bottom 2 studs.
2. Insert the timer through the opening in the bracket.
Secure the timer to the four standoffs using four
mounting screws X-49-2 provided with the kit.
3. Proceed to the Wiring Section for timer
connections.
Note: For 100 Amp models: Insert the lead ring
terminals through the slot under the bus and
under the flat washer on the load lug. See
Figure 3.
GM47597-- KP2
GM47597
1
2
3
1. Mounting bracket GM64057
2. Timer GM64028
Figure 3 Mounting, 100--200 Amp Model RDT
4
GM38798
3. Screws X-49-2 (qty. 4)
4. Load lugs. See step 3 and note, above.
TT-1403 4/16 3
2.2 Mounting, 400 Amp Model RDT,
Service Entrance Rated 200 Amp or
400 Amp Model RDT
SeeFigure4.
1. Replace the existing mounting bracketwith bracket
GM64055 provided with the kit. See Figure 4.
2. Insert the timer through the opening in the bracket.
Secure the timer to the four standoffs using four
mounting screws X-49-2 provided with the kit.
3. Proceed to the Wiring Section for timer
connections.
1
2.3 Mounting, Models KSS-J with
Decision-Makerr MPAC 750 Controller
1. Align the mounting holes on the timer bracket
GM89060 with the two mounting studs on the
inside of the transfer switch box. See Figure 5.
1. Secure the timer kit to the studs with the two
X-6210-2 nuts provided with the kit. See Figure 5.
2. Proceed to the Wiring Section 3.2 for timer
connections.
2
GM47597
1. Bracket GM64055
2. Timer GM64028 with screws X-49-2 (qty. 4)
Figure 4 Mounting, 400 Amp Model RDT or 200
Amp and 400 Amp Service Entrance Rated
Model RDT
1
2
1. Bracket GM89060
2. Nut X-6210-2 (qty. 2)
3. Mounting Stud
Figure 5 Mounting, Models KSS-J with
Decision-Makerr MPAC 750
3
GM46745
4 TT-1403 4/16
2.4 Service Kit GM64108, Retrofit Timer
Replacement Kit for the Service
Entrance Rated 200 Amp Model RDT
See Figure 6 and Figure 7. Use Service Kit GM64108 to
replace an old style timer GM39330 with timer
GM64028. The service kit includes retrofit mounting
panel GM64074.
from metal drill chips. Drill four 1/4 inch diameter
holes through the existing mounting bracket at the
marked locations.
2. Align and insert the mounting studs on the retrofit
mounting bracket through the newly drilled holes
on the existing mounting bracket. Thread nuts
X-6210-1 onto the mounting studs to secure. See
Figure 6 and Figure 7.
Tools Required:
D Electric drill with 1/4 in. chuck (minimum)
D 1/4 inch dia. drill bit
NOTICE
Foreign material contamination. Cover the transfer switch
during installation to keep dirt, grit, metal drill chips, and other
debris out of the components. Cover the solenoid mechanism
during installation. After installation, use the manual operating
handle tocycle thecontactor toverify that it operates freely. Do
not use a screwdriver to force the contactor mechanism.
2
1
3. Secure the timer tothe four standoffsusing the four
mounting screws X-49-2 provided with the kit.
4. Proceed to the Wiring Section for timer
connections.
1
1
2
3
2
Figure 7 Retrofit Mounting Panel GM64074
GM47597
1. Timer GM64028 with screws X-49-2 (qty. 4)
2. Mounting bracket GM64074 with nuts X-6210-1 (qty. 4)
Figure 6 Retrofit Timer Replacement Service Kit
GM64108 for Service Entrance-Rated 200
Amp Model RDT
1. Using the dimensions in Figure 7 or retrofit panel
GM64074 as a guide, mark four holes on the
existing mounting bracket at the locations of the
four studs on the retrofit panel. Cover the
components inside the enclosure to protect them
TT-1403 4/16 5
3 Wiring
3.1 RDT Models
DANGER
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.
Short circuits. Hazardous voltage/current can cause
severe injury or death. Short circuits can cause bodily injury
and/or equipment damage. Do not contact electrical
connections with tools or jewelry while making adjustments or
repairs. Remove all jewelry before servicing the equipment.
Wiring must comply with the National Electrical Code
and applicable local codes.
Note: Check that the supply voltage matches the
voltage marked on the unit. Wiring to incorrect
voltage will void the warranty.
1
1. Verify that power has been disconnected as
described in Section 2, Installation Procedure.
2. Use the leads supplied with the kit to connect the
timer according to the wiring diagrams. See
Figure 8.
Note: For 100 Amp models: Insert the lead ring
terminals through the slot under the bus and
under the flat washer on the load lug. See
Figure 3.
2
1. Accessory Board
2. DIP - Switches
3. Timer
4. Contactor (200Amp Shown)
Figure 8 Wiring Diagram for RDT Models
3
4
GM64071
6 TT-1403 4/16
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