Kohler RXT Operation And Installation

Operation and

Installation

Automatic Transfer Switch

Model:

RXT

100--400 Amp Automatic Transfer Switches

For use with Kohlerr Model RESA, RESAL, or RCL generator sets

equipped with RDC2 or DC2 generator/transfer switch controllers

TP-6807 12/11

Product Identification Information

Product identification numbers determine service parts.
Record the product identification numbers in the spaces
below immediately after unpacking the products so that
the numbers are readily available for future reference.
Record field-installed kit numbers after installing the
kits.

Transfer Switch Identification Numbers

Record the product identification numbers from the
transfer switch nameplate.

Model Designation

Serial Number

TP-6807 12/112

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..................................................................

TP-6807 12/11Table of Contents4

Safety Precautions and Instructions

IMPORTANT SAFETY INSTRUCTIONS.

Electromechanical equipment,
including generator sets, transfer
switches, switchgear, and accessories,
can cause bodily harm and pose
life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be
aware of potential dangers and act
safely. Read and follow all safety
precautions and instructions. SAVE
THESE INSTRUCTIONS.

This manual has several types of safety
precautions and instructions: Danger,
Warning, Caution, and Notice.

DANGER

Danger indicates the presence of a
hazard that will cause severe

personal injury, death,or
substantial property damage.

WARNING

Warning indicates the presence of a
hazard that can cause severe

personal injury, death, or
substantial property damage.

CAUTION

Caution indicates the presence of a
hazard that will or can cause minor
personal injury or property damage.

NOTICE

Notice communicates installation,
operation, or maintenance information
that is safety related but not hazard
related.

Safety decals affixed to the equipment
in prominent places alert the operator
or service technician to potential
hazards and explain how to act safely.
The decals are shown throughout this
publication to improve operator
recognition. Replace missing or
damaged decals.

Accidental Starting

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 the power 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.

Hazardous Voltage/
Moving Parts

DANGER

Hazardous voltage.
Will cause severe injury or death.

Disconnect all power sources before
opening the enclosure.

DANGER

Hazardous voltage.
Will cause severe injury or death.

Only authorized personnel should
open the enclosure.

DANGER

Hazardous voltage.
Will cause severe injury or death.

This equipment must be installed and
serviced by qualified electrical
personnel.

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,
transfer switch, and related equipment
and electrical circuits. Turn off the main
circuit breakers of all power sources
before servicing the equipment. Never
contact electrical leads or appliances
when standing in water or on wet
ground because these conditions
increase the risk of electrocution.

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.

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.

TP-6807 12/11 5Safety Precautions and Instructions

Servicing the transfer switch.
Hazardous voltage can cause
severe injury or death. Deenergizeall

power sources before servicing. Turn
off the main circuit breakers of all
transfer switch power sources and
disable all generator sets as follows:
(1) Move all generator set master
controller switches to the OFF position.
(2) Disconnect power to all battery
chargers. (3) Disconnect all battery
cables, negative (--) leads first.
Reconnect negative (--) leads last when
reconnecting the battery cables after
servicing. Follow these precautions to
prevent the starting of generator sets
by an automatic transfer switch, remote
start/stop switch, or engine start
command from a remote computer.
Before servicing any components
inside the enclosure: (1) Remove all
jewelry. (2) Stand on a dry, approved
electrically insulated mat. (3) Test
circuits with a voltmeter to verify that
they are deenergized.

Heavy Equipment

WARNING

Unbalanced weight.
Improper lifting can cause severe
injury or death and equipment
damage.

Use adequate lifting capacity.
Never leave the transfer switch
standing upright unless it is securely
bolted in place or stabilized.

Notice

NOTICE

Foreign material contamination.

Cover the transfer switch during
installation to keep dirt, grit, metal drill
chips, and other debris out of the
components. Cover the solenoid
mechanism during installation. After
installation, use the manual operating
handle to cycle the contactor to verify
that it operates freely. Do not use a
screwdriver to force the contactor
mechanism.

NOTICE

Electrostatic discharge damage.

Electrostatic discharge (ESD)
damages electronic circuit boards.
Prevent electrostatic discharge
damage by wearing an approved
grounding wrist strap when handling
electronic circuit boards or integrated
circuits. An approved grounding wrist
strap provides a high resistance (about
1 megohm), not a direct short,to
ground.

TP-6807 12/116 Safety Precautions and Instructions

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.

Introduction

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/
dealer to keep equipment in top condition.

Figure 1 Typical Model RXT Transfer Switches

(shown with optional status indicators)

RDC2 DC2

GM77569

Figure 2 RDC2 and DC2 Generator/Transfer Switch

Controllers (provided with and mounted on
the generator set)

TP-6807 12/11 7Introduction

Nameplate

n

A nameplate attached to the inside of the enclosure
cover or on the upper right side wall includes a model
designation, a serial number, ratings, and other
information about the transfer switch. See Figure 3.

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.

TRANSFER SWITCH

FOR EMERGENCY SYSTEMS

VOLTS
PHASE
HERTZ

TYPE ENCLOSURE

MFG. DATE

ACCESSORIES:

1

MATERIAL
MODEL

2

SERIAL NO.

AMPS
WIRES
POLES

BAR CODE

3

Copy the model designation, serial number, and
accessory information from the nameplate to the spaces
provided in the Product Identification Information
section located inside the front cover of this manual for
use when requesting service or parts.

1. Model designation

2. Serial number

3. Factory-installed accessory numbers

LISTED

R

TRANSFER SWITCH

FOR EMERGENCY SYSTEMS

GM21291-E

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 a
characteristics as explained below.

Sample Model Designation: RXT-JFNC-0200A

Model

RXT: Kohler Automatic Transfer Switch

Controls

J: Interface for RDC2/DC2 Controller

Voltage/Frequency

C: 208 Volts/60 Hz (3-phase only)
F: 240 Volts/60 Hz
M: 480 Volts/60 Hz (3-phase only)

Number of Poles/Wires

N: 2-pole, 3-wire, solid neutral (120/240 V only)
T: 3-pole, 4-wire, solid neutral
V: 4-pole, 4-wire, switched neutral

Enclosure

C: NEMA 3R

Current Rating: Numbers indicate the current rating
of the switch in amperes:

0100
0200
0400

Connections

A: No load center
B: With load center (100 amp single-phase only)
ASE: Service entrance rated

Figure 4 Model Designation

TP-6807 12/118 Introduction

Service Assistance

For professional advice on generator set power
requirements and conscientious service, please contact
your nearest Kohler distributor or dealer.

D Consult the Yellow Pages under the heading

Generators—Electric.

D Visit the Kohler Power Systems website at

KohlerPower.com.

D Look at the labels and stickers on your Kohler product

or review the appropriate literature or documents
included with the product.

D Call toll free in the US and Canada 1-800-544-2444.

D Outside the US and Canada, call the nearest regional

office.

Headquarters Europe, Middle East, Africa
(EMEA)

Kohler Power Systems
3 rue de Brennus
93200 Saint Denis
France
Phone: [phone]
Fax: [phone]

Asia Pacific

Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: [phone]
Fax: [phone]

China

North China Regional Office, Beijing
Phone: [phone]

(86) 10 6518 7951
(86) 10 6518 7952

Fax: [phone]

East China Regional Office, Shanghai
Phone: [phone]
Fax: [phone]

India, Bangladesh, Sri Lanka

India Regional Office
Bangalore, India
Phone: [phone]

(91) 80 3366231

Fax: [phone]

Japan, Korea

North Asia Regional Office
Tokyo, Japan
Phone: [phone]
Fax: [phone]

Latin America

Latin America Regional Office
Lakeland, Florida, USA
Phone: [phone]
Fax: [phone]

TP-6807 12/11 9Service Assistance

Notes

TP-6807 12/1110 Service Assistance

Section 1 Description

1.1 Transfer Switch Description

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.

Service Entrance Model

Figure 1-1 shows a typical installation block diagram.

Emergency
(Generator)

Normal
(Utility)

Power
Switching
Device

Power

Power

Automatic T ransfer Switch

To Load

Generator

Electrical

Controls

Interface

Board

TP-6751

Figure 1-1 Typical ATS Block Diagram

Load Center Model Standard Model

Figure 1-2 Selected Transfer Switches

(covers removed)

1.2 Service Entrance Models

Service entrance models use a circuit breaker to provide
the service disconnect for the utility source. A service
entrance model is shown in Figure 1-2.

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
require the installation of a separate load panel.

TP-6807 12/11 11Section 1 Description

Loads. The transfer switch can be connected to supply
all of the electrical loads in the home, or only the
essential loads such as the furnace, refrigerator, well
pump, and selected light circuits. Identify the essential
circuits that must be supplied during a power outage.
Verify that the generator set and transfer switch are
adequately rated to supply all of the selected loads.

Circuit breakers. Because the size and number of
circuit breakers required will vary with each application,
circuit breakers are not provided with the transfer switch
load center.

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
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
rating of the existing breaker in the main panel.

1.5 Optional LED Indicator Panel

A user interface panel that contains status-indicating
LEDs is available. See Figure 1-3. Source available
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).

If the status indicator is purchased as a loose kit (not
factory-installed), refer to the installation instructions
provided with the kit, TT-1585.

1

2

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
switch.

1.4 Controller Interface Board

All ATS control functions are performed by the
RDC2/DC2 controller mounted on the generator set and
communicated through the interface board. The
controller interface board sends voltage sensing data to
the RDC2/DC2 controller and receives transfer and load
control signals from the RDC2/DC2 controller.

3

4

1. Utility power available

2. Utility source supplying load

3. Generator source supplying load

4. Generator power available

Figure 1-3 LED Indicators

GM78649

TP-6807 12/1112 Section 1 Description

Section 2 Installation

2.1 Introduction

Kohlerr transfer switches are shipped factory-wired,
factory-tested, and ready for installation. Have the
equipment installed only by trained and qualified
personnel, and verify that the installation complies with
applicable codes and standards. Protect the switch
against damage before and during installation.

2.2 Receipt of Unit

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
and/or rough handling is evident, immediately file a
damage claim with the transportation company.

2.2.2 Storage

Store the transfer switch in its protective packing until
final installation. Protect the transfer switch at all times
from moisture, construction grit, and metal chips. Avoid
storage in cold or damp areas where moisture could
condense on the unit. See Figure 2-1 for acceptable
storage temperatures.

Item Specification

Storage
Temperature

Operating
Temperature

Humidity 5% to 95% noncondensing

Altitude 0 to 3050 m (10000 ft.) without derating

Figure 2-1 Environmental Specifications

2.2.3 Unpacking

Allow the equipment to warm to room temperature for at
least 24 hours before unpacking to prevent
condensation on the electrical apparatus. Use care
when unpacking to avoid damaging transfer switch
components. Use a vacuum cleaner or a dry cloth to
remove dirt and packing material that may have

-- 4 0 °Cto85°C(--40°F to 185°F)

-- 2 0 °Cto70°C(--4°F to 158°F)

accumulated in the transfer switch or any of its
components.

Note: Do not use compressed air to clean the switch.

Cleaning with compressed air can cause debris
to lodge in the components and damage the
switch.

2.2.4 Lifting

WARNING

Unbalanced weight.
Improper lifting can cause severe
injury or death and equipment
damage.

Use adequate lifting capacity.
Never leave the transfer switch
standing upright unless it is securely
bolted in place or stabilized.

See Figure 2-2 or the dimensional drawing for the
weight of the transfer switch. Use a spreader bar to lift
the transfer switch. Attach the bar only to the
enclosure’s mounting holes or lifting brackets; do not lift
the unit any other way. Close and latch the enclosure
door before moving the unit.

Amps Description

Single phase 7 (14)

100

200

400

With load center 8.2 (18)

Three phase 14 (30)

Service Entrance 10 (22)

Single phase 7 (15)

Three phase 14 (30)

Service Entrance 12 (26)

Single phase 36 (80)

3-Pole/208--240 Volts 41 (90)

3-Pole/480 Volts 59 (130)

4-Pole 59 (130)

Service Entrance 46 (100)

Figure 2-2 Approximate Weights

Weight, kg (lb.) [

TP-6807 12/11 13Section 2 Installation

2.3 Installation

NOTICE

Foreign material contamination. Cover the transfer switch
during installation to keep dirt, grit, metal drill chips, and other
debris out of the components. Cover the solenoid mechanism
during installation. Afterinstallation, use the manual operating
handle to cycle the contactor to verify that it operates freely.
Do not use a screwdriver to force the contactor mechanism.

NOTICE

Hardware damage. The transfer switch may use both
American Standard and metric hardware. Use the correct size
tools to prevent rounding of the bolt heads and nuts.

Check the system voltage and frequency. Compare
the voltage and frequency shown on the transfer switch
nameplate to the source voltage and frequency. Do not
install the transfer switch if the voltage and frequency
are different from the normal (utility) source voltage and
frequency or the emergency source voltage and
frequency shown on the generator set nameplate.

Plan the installation. Use the dimensions given on the
enclosure dimension (ADV) drawings in Section 6.
Select a mounting site that complies with local electrical
code restrictions for the enclosure type. Mount the
transfer switch as close to the load and power sources
as possible. Allow adequate space to open the
enclosure and service the switch.

Pull the bottom of the panel out and down until the top
clears the enclosure. Remove the inner panel to access
the transfer switch components.

NEMA 3R enclosures have locking tabs at the bottom of
the enclosure and the door. Whilethe enclosure is open,
turn the locking tab out so that the door can be locked
with a padlock after installation is complete.

Wall mounting. Mount the transfer switch to a wall or
other rigid vertical supporting structure. Refer to the
dimension drawings in Section 6 for hole locations. Use
shims to plumb the enclosure.

Cover or remove the transfer switch’s internal
components to protect them from drill chips or debris
during installation. Use a vacuum cleaner to remove
debris from the enclosure.

Note: Do not use compressed air to clean the switch.

Cleaning with compressed air can cause debris
to lodge in the components and cause damage.

Tighten the mounting screws to 2.9 Nm (26 in. lb.) when
reinstalling the components.

Clearance holes through the back of each enclosure are
provided for mounting. The mounting holes on NEMA
3R enclosures have gaskets to seal out moisture. Use
washers with the mounting screws to protect the
gaskets.

NEMA 3R enclosures. To remove the enclosure’s front
panel, support the panel while removing the screws.

TP-6807 12/1114 Section 2 Installation

2.4 Manual Operation Check

DANGER

CN

3

4

C

NO

NL1

NC

SCN

NL2

Hazardous voltage.
Will cause severe injury or death.

Disconnect all power sources before
opening the enclosure.

Check the manual operation before energizing the
transfer switch. Verify that the contactor operates
smoothly without binding. Do not place the transfer
switch into service if the contactor does not operate
smoothly.

After checking the manual operation, place the
contactor in the Normal (utility) position.

See Figure 2-3 to identify the manual operation
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,
208--240 Volts

400 amps, 3-phase,
3-pole/480 Volt and 4-pole

2.4.1 Figure 2-5

2.4.2 Figure 2-7

Figure 2-3 Manual Operation Procedure Guide

2.4.1 Manual Operation Procedure 1

Note: Never manually operate the transfer switch when

the power is connected. Disconnect both power
sources before manually operating the switch.

1. 100-200 amp switches: These switches have an
attached handle as shown in Figure 2-4.
400 amp switches: Slide the detachable handle or
a wrench over the shaft. See Figure 2-5.

2. Move the handle up to place the transfer switch in
the Normal Source position or down to place the
contactor in the Emergency Source position. See
Figure 2-4 or Figure 2-5.

3. 400 amp switches: Remove the detachable handle
or wrench.

SCE

NC

NO

C

7

8

CE

EL2EL1

1

1. Handle (not detachable)

Figure 2-4 Manual Operation, 100 and 200 Amp

Single-Phase Switches

1

GM80139

1. Shaft (attach handle or wrench here)

Figure 2-5 Manual Operation, 400 Amp Single-

Phase and 208--240 Volt Switches

2.4.2 Manual Operation Procedure 2

Note: Never use the maintenance handle to transfer the

load with the power connected. Disconnect both
power sources before manually operating the
switch.

1. If the transfer switch is equipped with a
maintenance handle, remove the handle from its
storage location inside the enclosure. See
Figure 2-7.

TP-6807 12/11 15Section 2 Installation

2. Insert the maintenance handle or a tool (such as a
screwdriver) into the hole in the shaft on the left
side of the operator as shown in Figure 2-6 or
Figure 2-7.

3. Move the maintenance handle (or tool) up or down
as shown to manually operate the transfer switch. It
should operate smoothly without any binding. If it
does not, check for shipping damage or
construction debris.

2.5 Electrical Wiring

Refer to the connection diagrams on the transfer switch
enclosure door and the wiring diagrams in Section 6
during installation.

All wiring must comply with applicable national, state,
and local electrical codes. Use separate conduit for AC
power wiring and low-voltage DC, control, and
communication system wiring.

4. Return the transfer switch to the Normal position.

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

1

GM78867

1. Insert handle or tool here for manual operation

Figure 2-6 Manual Operation, 100--200 Amp

3-Phase Switches

DANGER

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.

Grounding electrical equipment. Hazardous voltage can
cause severe injury or death. Electrocution is possible

whenever electricity is present. Ensure you comply with all
applicable codes and standards. Electrically ground the
generator set and related equipment and electrical circuits.
Turn off the main circuit breakers of all power sources before
servicing the equipment. Never contact electrical leads or
appliances when standing in water or on wet ground because
these conditions increase the risk of electrocution.

2.5.1 Load Center Circuit Breakers

1

2

1. Handle storage location

2. Insert handle here for manual operation

Figure 2-7 Manual Operation, 400 Amp 3-Phase

Switches

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
can be used for a maximum of 24 circuits.

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

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

TP-6807 12/1116 Section 2 Installation

2.5.2 AC Power Connections

Determine the cable size. Refer to Figure 2-8 or the
ADV drawings in Section 6 to determine the cable size
required for the transfer switch. Make sure the lugs
provided are suitable for use with the cables being
installed.

Conduit. Use separate conduit for AC power wiring
and low-voltage DC, control, and communication
system wiring. Watertight conduit hubs may be required
for outdoor use.

Select the proper cable clamp or use other approved
methods for securing the cable or conduit to the
enclosure.

Source and load connections. Clean cables with a
wire brush to remove surface oxides before connecting
them to the terminals. Apply joint compound to the
connections of any aluminum conductors.

Refer to the connection diagrams on the transfer switch
enclosure door and the wiring diagrams in Section 6.
The connection points on the transfer switch contactor
are labelled Normal, Emergency, and Load. Connect
the utility power to Normal. Connect the generator set to
Emergency.

Single phase. For single-phase models, connect to A
and C.

Three phase. For three-phase models, be sure to
follow the phase markings (A, B, C, and N).

Note: Connect the source and load phases as indicated

by the markings and drawings to prevent short
circuits and to prevent phase-sensitive devices
from malfunctioning or operating in reverse.

Service entrance models. Connect the utility source to
the lugs on the normal source disconnect circuit
breakers as shown in the service entrance switch wiring
diagram in Section 6.

Verify that all connections are consistent with drawings
before tightening the lugs. Tighten all cable lug
connections to the torque values shown on the label on
the switch. Carefully wipe off any excess joint
compound after tightening the terminal lugs.

On models with built-in load centers, the load lugs are
factory-wired to the load center. Connect the load leads
to the circuits in the load center and tighten the
connections. Check the labels on the breakers for the
tightening torques.

TP-6807 12/11 17Section 2 Installation

2.5.3 Neutral Connection

2.5.5 Engine Start Function

Connect the neutral from the main panel to the neutral
lug in the ATS enclosure.

Ground the system according to NEC and local codes.

2.5.4 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

Size,

Amps

100

200

400

Figure 2-8 Cable Sizes

Switch Phases Normal and Emergency Load Neutral Ground

Standard 1 (1) #14 -- 1/0 AWG (1)#14–1/0AWG (3)#12–1/0AWG (9)#4–14AWG

With load

center

Service

Entrance

3-Phase 3 (1)#8–3/0AWG (1)#8–3/0AWG (3)#6AWG–3/0AWG (3)#6–3/0AWG

Standard 1 (1) #6 AWG – 250 MCM (1) #6 AWG – 250 MCM (3) #6 AWG – 250 MCM (9)#4–14AWG

Service

Entrance

3-Phase 3 (1) #6 AWG – 250 MCM (1) #6 AWG – 250 MCM

Standard 1 (2) #6 – 250 MCM (2) #6 – 250 MCM

Service

Entrance

3-pole

208-240 V

3 or 4 pole

480 V

1 (1)#14–1/0AWG

Normal: (1) #12 – 2/0

1

1

1

3 (2) #6 – 250 MCM (2) #6 – 250 MCM

3

AWG

Emerg: (1) #6 – 250

MCM

Normal: (1) #4 – 300

MCM

Emerg: (1) #6 -- 250

MCM

Normal: (2) 3/0 – 250

MCM

Emerg: (2) #6 -- 250

MCM

(1) #4 – 600 MCM
(2) #6 – 250 MCM

(1) #6 AWG – 250 MCM (3) #6 AWG – 250 MCM (3)#14–1/0AWG

The engine start function is controlled by the RDC2/DC2
controller on the generator set. There are no engine
start terminals on the Model RXT ATS.

Range of Wire Sizes, Cu/Al

per customer-supplied

circuit breaker

(1) #6 – 250 MCM (3) #6 – 250 MCM (3)#14–1/0AWG

(2) #6 – 250 MCM

(1) #4 – 600 MCM
(2) #6 – 250 MCM

(1)#2–2/0AWG (9)#4–14AWG

(3) #4 AWG – 600 MCM

(6) 1/0 – 250 MCM

(1) #4 – 600 MCM

(2) 1/0 – 250 MCM

(3) #4 – 600 MCM

(6) 1/0 – 250 MCM

(1) #4 – 600 MCM

(2) 1/0 – 250 MCM

(1) #4 – 600 MCM

(2) 1/0 – 250 MCM

(3)#6–3/0AWG

(3)#14–1/0AWG

TP-6807 12/1118 Section 2 Installation

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
generator set equipped with the RDC2 or DC2
controller. The generator set is typically equipped with a
field-connection terminal block. See the generator set

to connect P10-1 through P10-4 on the controller
interface module to the generator set terminal block
connections A, B, PWR, and COM. The maximum cable
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

one Model RXT transfer switch connected to a
generator set equipped with an RDC2 or DC2
controller. If additional accessory modules such
as a programmable interface module (PIM) or a

and COM connections only. If 12--14 AWG wire is used
for the PWR and COM connections, the maximum cable
length is 152 m (500 ft.) if one Model RXT transfer
switch and no accessory modules are connected to the
generator set.

load control module (LCM) are connected, refer
to the generator set installation manual for cable
requirements and connection instructions.

Terminal Block Connection Designation Description Wire Size

P10-1 A Communication Line

P10

P10-2 B Communication Line

P10-3 PWR 12 VDC

P10-4 COM 12 VDC

Note: Connections 3 and 4 on the generator set are not

used with the Model RXT transfer switch.

20 AWG shielded twisted-pair,

Belden 9402, 8723, or equivalent

20 AWG shielded twisted-pair Belden 9402

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

B

PWR

COM

4

3

TB1

Generator Set Terminal Block TB1.

See the generator set manuals for location.
Check the decal on the generator set for terminal
block connections.

A

B

PWR

COM

1

Note: Generator set terminal block connections 3 and 4 are

NOT USED with the Model RXT ATS.

Interface Board on the Model

RXT Transfer Switch

A

B

PWR

COM

Leave one end of each cable shield disconnected.

If accessory modules are connected in series, connect
the cable shields as shown below and refer to the
generator set installation manual.

RXT

RXT

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 19Section 2 Installation

2.5.7 Optional Load Control Connection

2.5.8 Accessory Module Connections

Connector P11 on the interface module provides a
connection point for optional load control circuits. The
load control contact provides a delayed contact closure
to allow startup of selected loads 5 minutes after transfer
to the emergency power source (generator set). Use
this contact to delay startup of equipment with large
motor-starting loads such as air conditioners.

See Figure 2-11 for the location of load control
connector P11. See Figure 2-12 for contact ratings,
connection, and wire size information.

Note: An optional load control module is available for

generator sets equipped with the RDC2 or DC2
controller. The load control module allows
management of up to six separate loads (two
HVAC thermostat connections and four other
non-essential loads). See TT-1574, Load Control
Module Instructions.

For connection of the optional load control module
(LCM) or programmable interface module (PIM), refer to
the instructions provided with the modules and to the
generator set installation manual.

2.6 Test and Exercise

Refer to the generator set Operation Manual for
instructions to test the power system operation and to
set the RDC2 or DC2 controller for weekly exercise runs
to keep the power system in good operating condition.

2.7 Warranty Registration

Startup Notification Form. The Startup Notification
Form covers all equipment in the standby system.
Complete the Startup Notification Form and register the
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.

3

2

1. ATS/generator set interface connection P10

2. Load control connection P11

3. Factory connections

1

GM80663

Figure 2-11 Interface Module Connections

Terminal Block Connection Designation Description Contact Rating Wire Size

P11

P11-1 LC1

P11-2 LC2

Load Control Output

10 A @ 250 VAC

1A@30VDC

#12--18 AWG

Figure 2-12 Load Control Contact P11 Connections

TP-6807 12/1120 Section 2 Installation

Section 3 Operation

3.1 Model RXT Transfer Switch

Operation

The Model RXT transfer switch must be connected to a
generator set equipped with the RDC2 or DC2
controller. The RDC2/DC2 generator set/transfer
switch controller manages automatic transfer switch
(ATS) functions when connected to a Kohlerr Model
RXT transfer switch through the ATS interface board.
The controller receives voltage sensing data from the
Model RXT ATS and operates the generator set and
transfer switch to provide standby power when utility
power is lost.

See the generator set operation manual for:

D ATS status screens and configuration menus.

D Information about loaded exercise.

3.2 Source Availability

The Model RXT transfer switch supplies voltage
sensing data to the RDC2 or DC2 controller through the
ATS interface board. If the source voltage falls below
the undervoltage dropout setting, the source is
considered to have failed. See Figure 3-1.

Voltage Sensing Parameter Setting

Accuracy ±5%

Undervoltage Dropout 90% of Pickup

Undervoltage Pickup 90% of Nominal

3.3 ATS Control Sequence of
Operation

See Figure 3-2 for time delay settings.

Preferred Source Fails:

1. The load control contact opens.

2. The engine start time delay times out.

3. The generator set is signaled to start.

4. The generator starts and the emergency source
becomes available.

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

6. The transfer switch transfers to the emergency
source.

7. The load control contact time delay times out.

8. The load control contact closes.

Normal Source Returns:

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

2. The contactor transfers to the normal source.

3. The engine cooldown time delay times out.

4. The generator is signaled to stop.

Figure 3-1 Voltage Sensing Parameters

TP-6807 12/11 21Section 3 Operation

3.4 Time Delays

3.5 Load Control Time Delay

Time delays are factory-set to the values shown in
Figure 3-2. An authorized distributor/dealer can adjust
time delays using a personal computer and Kohlerr
SiteTecht software.

The load control time delay allows delayed starting of
large motor loads (such as air conditioners), preventing
simultaneous starting of large motors after transfer to
the generator set. The load control time delay is fixed at
5 minutes. It is not adjustable.

Time delays described in this section operate only when
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.
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.

Transfer, Normal to Emergency 3 seconds Time delay after emergency source becomes available until transfer to

Transfer, Emergency to Normal 2 minutes Time delay after the utility source returns until transfer back to normal.

Load Control 5 minutes Allows delayed connection of selected loads to the generator set.

Guards against starting the generator set because of a brief change in
the utility source.

emergency source.

Ensures that the the utility source is stable before transferring from the
emergency source.

Prevents simultaneous starting of large motors after transfer to the
emergency source. Recommended for delayed starting of air
conditioners.

Figure 3-2 Time Delays

TP-6807 12/1122 Section 3 Operation

Section 4 Service Disconnect, SE Model

Note: This section applies only to service entrance

model transfer switches, which are identified with
the letters ASE at the end of the model
designation.

DANGER

Hazardous voltage.
Will cause severe injury or death.

This equipment must be installed and
serviced by qualified electrical
personnel.

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.

4.2 Source Circuit Breaker Reset

The utility source circuit breaker can trip due to an
overcurrent condition. Identify and correct the cause of
the overcurrent condition before resetting the circuit
breaker. Contact a local distributor/dealer for service if
necessary.

When the circuit breaker trips, the handle moves to an
intermediate position. To reset a tripped circuit breaker,
move the handle to the extreme OFF position and then
to the ON position.

1

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
door only.

3. Move the utility source circuit breaker to the OFF
position.

Note: Power is still present on the input side of the

utility source circuit breaker. Do not remove
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.

GM80015

2

1. Normal/utility circuit breaker

2. Padlock hasp

Figure 4-1 Service Entrance Model, Door Removed

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

Notes

TP-6807 12/1124 Section 4 Service Disconnect, SE Model

Section 5 Scheduled Maintenance

5.1 Introduction

Regular preventive maintenance ensures safe and
reliable operation and extends the life of the transfer
switch. Preventive maintenance includes periodic
testing, cleaning, inspection, and replacement of worn
or missing components. Section 5.4 contains a service
schedule for recommended maintenance tasks.

A local authorized distributor/dealer can provide
complete preventive maintenance and service to keep
the transfer switch in top condition. Unless otherwise
specified, have maintenance or service performed by an
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.

Replace all barriers and close and lock the enclosure
door after maintenance or service and before reapplying
power.

WARNING

DANGER

Hazardous voltage.
Will cause severe injury or death.

Disconnect all power sources before
opening the enclosure.

DANGER

Hazardous voltage.
Will cause severe injury or death.

Only authorized personnel should
open the enclosure.

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) Disconnectthe power 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.

Hazardous voltage.
Can cause severe injury or death.

Operate the generator set only when
all guards and electrical enclosures
areinplace.

Grounding the transfer switch. Hazardous voltage can
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,
as the chance of electrocution increases under such
conditions.

Moving parts.

TP-6807 12/11 25Section 5 Scheduled Maintenance

Servicing the transfer switch. Hazardous voltage can
cause severe injury or death. Deenergize all power sources

before servicing. Turn off the main circuit breakers of all
transfer switch power sources and disable all generator sets
as follows: (1) Move all generator set master controller
switches to the OFF position. (2) Disconnect power to all
battery chargers. (3) Disconnect all battery cables, negative
(--) leads first. Reconnect negative (--) leads last when
reconnecting the battery cables after servicing. Follow these
precautions to prevent the starting of generator sets by an
automatic transfer switch, remote start/stop switch, or engine
start command from a remote computer. Before servicing any
components inside the enclosure: (1) Remove all jewelry. (2)
Stand on a dry, approved electrically insulated mat. (3) Test
circuits with a voltmeter to verify that they are deenergized.

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

Hardware damage. The transfer switch may use both
American Standard and metric hardware. Use the correct size
tools to prevent rounding of the bolt heads and nuts.

NOTICE

Electrostatic discharge damage. Electrostatic discharge
(ESD) damages electronic circuit boards. Prevent
electrostatic discharge damage by wearing an approved
grounding wrist strap when handling electronic circuit boards
or integrated circuits. An approved grounding wrist strap
provides a high resistance (about 1 megohm), not a direct
short, to ground.

Screws and nuts are available in different hardness
ratings. To indicate hardness, American Standard
hardware uses a series of markings and metric
hardware uses a numeric system. Check the markings
on the bolt heads and nuts for identification.

5.2 Testing

5.2.1 Weekly Generator Set Exercise

D Watch and listen for signs of excessive noise or

vibration during operation.

D After the switch transfers the load to the standby

source, end the test and verify that the expected
sequence of operations occurs as the transfer switch
retransfers to the preferred source.

5.3 Inspection and Service

Contact an authorized distributor/dealer to inspect and
service the transfer switch annually and also when any
wear, damage, deterioration, or malfunction of the
transfer switch or its components is evident or
suspected.

5.3.1 General Inspection

External Inspection. Keep the transfer switch clean
and in good condition by performing a weekly general
external inspection of the transfer switch. Check for any
condition of vibration, leakage, excessive temperature,
contamination, or deterioration. Remove accumulations
of dirt, dust, and other contaminants from the transfer
switch’s external components or enclosure with a
vacuum cleaner or by wiping with a dry cloth or brush.

Note: Do not use compressed air to clean the transfer

switch because it can cause debris to lodge in the
components and damage the switch.

Tighten loose external hardware. Replace worn, missing,
or broken external components with manufacturer­recommended replacement parts. Contact an
authorized distributor/dealer for specific part
information and ordering.

Internal Inspection. Disconnect all power sources,
open the transfer switch enclosure door, and inspect
internal components monthly or when any condition
noticed during an external inspection may have affected
internal components.

Use the exerciser or a manual test to start and run the
generator set under load once a week to maximize the
reliability of the emergency power system.

5.2.2 Monthly Automatic Control
System Test

Test the transfer switch’s automatic control system
monthly. Refer to the RDC2/DC2 controller operation
manual for the test procedure.

D Verify that the expected sequence of operations

occurs as the switch transfers the load to the
emergency source when a preferred source failure
occurs or is simulated.

Contact an authorized distributor/dealer to inspect and
service the transfer switch if any of the following
conditions are found inside the transfer switch.

D Accumulations of dirt, dust, moisture, or other

contaminants.

D Signs of corrosion.

D Worn, missing, or broken components.

D Loose hardware.

D Wire or cable insulation deterioration, cuts, or

abrasion.

TP-6807 12/1126 Section 5 Scheduled Maintenance

D Signs of overheating or loose connections:

discoloration of metal, melted plastic, or a burning
odor.

operation of the transfer switch. See Section 5.4,
Service Schedule, for the recommended maintenance
items and service intervals.

D Other evidence of wear, damage, deterioration, or

malfunction of the transfer switch or its components.

Have an authorized distributor/dealer repair or replace
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
inspection.

5.4 Service Schedule

Follow the service schedule in Figure 5-1 for the
recommended service intervals. Have all service

5.3.2 Other Inspections and Service

Have an authorized distributor/dealer perform
scheduled maintenance, service, and other

performed by an authorized distributor/dealer except for
activities designated by an X, which may be performed
by the switch operator.

maintenance that ensures the safe and reliable

Adjust,
Repair,

Replace

Clean Test Frequency

D (clean

and lube)

Y

System Component or Procedure

See

Section

Visually

Inspect

Check

Electrical System

Check for signs of overheating or loose connections:
discoloration of metal, melted plastic, or a burning odor

Check the contactor’s external operating mechanism
for cleanliness; clean and relubricate if dirty *

Inspect wiring insulation for deterioration, cuts, or
abrasion. Repair or replace deteriorated or damaged
wiring

Tighten control and power wiring connections to
specifications

Check the transfer switch’s main power switching
contacts’ condition; clean or replace the main contacts
or replace the contactor assembly as necessary

5.3.1 X X Y

5.3.1 X

5.3.1 X D D Y

2.5 D D Y

S/M D D D Y

General Equipment Condition

Inspect the outside of the transfer switch for any signs
of excessive vibration, leakage, high temperature,
contamination, or deterioration *

Check that all external hardware is in place, tightened,
and not badly worn

Inspect the inside of transfer switch for any signs of
excessive vibration, leakage, high temperature,
contamination, or deterioration *

Check that all internal hardware is in place, tightened,
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.
D=Authorized distributor/dealer must perform these tasks.
W=Weekly
M=Monthly

5.3 X X M

5.3 X X X M

5.3 D D D Y

5.3 X D D Y

Q=Quarterly
S=Semiannually (every six months)
Y=Yearly (annually)
W/D=Wiring diagram

Figure 5-1 Service Schedule

TP-6807 12/11 27Section 5 Scheduled Maintenance

Notes

TP-6807 12/1128 Section 5 Scheduled Maintenance

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 29Section 6 Diagrams and Drawings

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

TP-6807 12/1130 Section 5 Diagrams and Drawings

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

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

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

TP-6807 12/1132 Section 5 Diagrams and Drawings

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

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

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

TP-6807 12/1134 Section 5 Diagrams and Drawings

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

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

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

TP-6807 12/1136 Section 5 Diagrams and Drawings

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

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

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

TP-6807 12/1138 Section 5 Diagrams and Drawings

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

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

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

TP-6807 12/1140 Section 5 Diagrams and Drawings

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

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

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

TP-6807 12/1142 Section 5 Diagrams and Drawings

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

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

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

TP-6807 12/1144 Section 5 Diagrams and Drawings

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

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

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

TP-6807 12/1146 Section 5 Diagrams and Drawings

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

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

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

TP-6807 12/1148 Section 5 Diagrams and Drawings

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

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

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

TP-6807 12/1150 Section 5 Diagrams and Drawings

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

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

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

TP-6807 12/1152 Section 5 Diagrams and Drawings

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

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

Notes

TP-6807 12/1154 Section 5 Diagrams and Drawings

Appendix A Abbreviations

The following list contains abbreviations that may appear in this publication.

A, amp ampere
ABDC after bottom dead center
AC alternating current
A/D analog to digital
ADC advanced digital control;

adj. adjust, adjustment
ADV advertising dimensional

Ah amp-hour
AHWT anticipatory high water

AISI American Iron and Steel

ALOP anticipatory low oil pressure
alt. alternator
Al aluminum
ANSI American National Standards

AO anticipatory only
APDC Air Pollution Control District
API American Petroleum Institute
approx. approximate, approximately
AQMD Air Quality Management District
AR as required, as requested
AS as supplied, as stated, as

ASE American Society of Engineers
ASME American Society of

assy. assembly
ASTM American Society for Testing

ATDC after top dead center
ATS automatic transfer switch
auto. automatic
aux. auxiliary
avg. average
AVR automatic voltage regulator
AWG American Wire Gauge
AWM appliance wiring material
bat. battery
BBDC before bottom dead center
BC battery charger, battery

BCA battery charging alternator
BCI Battery Council International
BDC before dead center
BHP brake horsepower
blk. black (paint color), block

blk. htr. block heater
BMEP brake mean effective pressure
bps bits per second
br. brass
BTDC before top dead center
Btu British thermal unit
Btu/min. British thermal units per minute
C Celsius, centigrade
cal. calorie
CAN controller area network
CARB California Air Resources Board
CB circuit breaker
cc cubic centimeter
CCA cold cranking amps
ccw. counterclockwise
CEC Canadian Electrical Code
cert. certificate, certification, certified
cfh cubic feet per hour

analog to digital converter

drawing

temperature

Institute

Institute (formerly American
Standards Association, ASA)

suggested

Mechanical Engineers

Materials

charging

(engine)

cfm cubic feet per minute
CG center of gravity
CID cubic inch displacement
CL centerline
cm centimeter
CMOS complementary metal oxide

cogen. cogeneration
com communications (port)
coml commercial
Coml/Rec Commercial/Recreational
conn. connection
cont. continued
CPVC chlorinated polyvinyl chloride
crit. critical
CRT cathode ray tube
CSA Canadian Standards

CT current transformer
Cu copper
cUL Canadian Underwriter’s

CUL Canadian Underwriter’s

cu. in. cubic inch
cw. clockwise
CWC city water-cooled
cyl. cylinder
D/A digital to analog
DAC digital to analog converter
dB decibel
dB(A) decibel (A weighted)
DC direct current
DCR direct current resistance
deg., ° degree
dept. department
DFMEA Design Failure Mode and

dia. diameter
DI/EO dual inlet/end outlet
DIN Deutsches Institut fur Normung

DIP dual inline package
DPDT double-pole, double-throw
DPST double-pole, single-throw
DS disconnect switch
DVR digital voltage regulator
E, emer. emergency (power source)
ECM electronic control module,

EDI electronic data interchange
EFR emergency frequency relay
e.g. for example (exempli gratia)
EG electronic governor
EGSA Electrical Generating Systems

EIA Electronic Industries

EI/EO end inlet/end outlet
EMI electromagnetic interference
emiss. emission
eng. engine
EPA Environmental Protection

EPS emergency power system
ER emergency relay
ES engineering special,

ESD electrostatic discharge

substrate (semiconductor)

Association

Laboratories

Laboratories

Effects Analysis

e. V. (also Deutsche Industrie
Normenausschuss)

engine control module

Association

Association

Agency

engineered special

est. estimated
E-Stop emergency stop
etc. et cetera (and so forth)
exh. exhaust
ext. external
F Fahrenheit, female
fglass. fiberglass
FHM flat head machine (screw)
fl. oz. fluid ounce
flex. flexible
freq. frequency
FS full scale
ft. foot, feet
ft. lb. foot pounds (torque)
ft./min. feet per minute
ftp file transfer protocol
ggram
ga. gauge (meters, wire size)
gal. gallon
gen. generator
genset generator set
GFI ground fault interrupter

GND,
gov. governor
gph gallons per hour
gpm gallons per minute
gr. grade, gross
GRD equipment ground
gr. wt. gross weight
H x W x D height by width by depth
HC hex cap
HCHT high cylinder head temperature
HD heavy duty
HET high exhaust temp., high

hex hexagon
Hg mercury (element)
HH hex head
HHC hex head cap
HP horsepower
hr. hour
HS heat shrink
hsg. housing
HVAC heating, ventilation, and air

HWT high water temperature
Hz hertz (cycles per second)
IC integrated circuit
ID inside diameter, identification
IEC International Electrotechnical

IEEE Institute of Electrical and

IMS improved motor starting
in. inch
in. H
in. Hg inches of mercury
in. lb. inch pounds
Inc. incorporated
ind. industrial
int. internal
int./ext. internal/external
I/O input/output
IP iron pipe
ISO International Organization for

J joule
JIS Japanese Industry Standard

ground

engine temp.

conditioning

Commission

Electronics Engineers

O inches of water

2

Standardization

TP-6807 12/11 Appendix 55

k kilo (1000)
K kelvin
kA kiloampere
KB kilobyte (2

10

bytes)
KBus Kohler communication protocol
kg kilogram

2

kg/cm

kgm kilogram-meter
kg/m

kilograms per square
centimeter

3

kilograms per cubic meter
kHz kilohertz
kJ kilojoule
km kilometer
kOhm, kΩ kilo-ohm
kPa kilopascal
kph kilometers per hour
kV kilovolt
kVA kilovolt ampere
kVAR kilovolt ampere reactive
kW kilowatt
kWh kilowatt-hour
kWm kilowatt mechanical
kWth kilowatt-thermal
L liter
LAN local area network
L x W x H length by width by height
lb. pound, pounds

3

lbm/ft

pounds mass per cubic feet
LCB line circuit breaker
LCD liquid crystal display
ld. shd. load shed
LED light emitting diode
Lph liters per hour
Lpm liters per minute
LOP low oil pressure
LP liquefied petroleum
LPG liquefied petroleum gas
LS left side
L

wa

LWL low water level

sound power level, A weighted

LWT low water temperature
m meter, milli (1/1000)
M mega (10

3

m

3

m

3

m

units), male

cubic meter

/hr. cubic meters per hour
/min. cubic meters per minute

6

when used with SI

mA milliampere
man. manual
max. maximum
MB megabyte (2

20

bytes)
MCCB molded-case circuit breaker
MCM one thousand circular mils
meggar megohmmeter
MHz megahertz
mi. mile
mil one one-thousandth of an inch
min. minimum, minute
misc. miscellaneous
MJ megajoule
mJ millijoule
mm millimeter
mOhm, mΩ milliohm
MOhm, MΩmegohm
MOV metal oxide varistor
MPa megapascal
mpg miles per gallon
mph miles per hour
MS military standard
ms millisecond
m/sec. meters per second
MTBF mean time between failure

MTBO mean time between overhauls
mtg. mounting
MTU Motoren-und Turbinen-Union
MW megawatt
mW milliwatt
μF microfarad
N, norm. normal (power source)
NA not available, not applicable
nat. gas natural gas
NBS National Bureau of Standards
NC normally closed
NEC National Electrical Code
NEMA National Electrical

Manufacturers Association

NFPA National Fire Protection

Association
Nm newton meter
NO normally open
no., nos. number, numbers
NPS National Pipe, Straight
NPSC National Pipe, Straight-coupling
NPT National Standard taper pipe

thread per general use
NPTF National Pipe, Taper-Fine
NR not required, normal relay
ns nanosecond
OC overcrank
OD outside diameter
OEM original equipment

manufacturer
OF overfrequency
opt. option, optional
OS oversize, overspeed
OSHA Occupational Safety and Health

Administration
OV overvoltage
oz. ounce
p., pp. page, pages
PC personal computer
PCB printed circuit board
pF picofarad
PF power factor
ph., ∅ phase
PHC Phillipsr head Crimptiter

(screw)
PHH Phillipsr hex head (screw)
PHM pan head machine (screw)
PLC programmable logic control
PMG permanent magnet generator
pot potentiometer, potential
ppm parts per million
PROM programmable read-only

memory
psi pounds per square inch
psig pounds per square inch gauge
pt. pint
PTC positive temperature coefficient
PTO power takeoff
PVC polyvinyl chloride
qt. quart, quarts
qty. quantity
R replacement (emergency)

power source
rad. radiator, radius
RAM random access memory
RDO relay driver output
ref. reference
rem. remote
Res/Coml Residential/Commercial
RFI radio frequency interference
RH round head
RHM round head machine (screw)
rly. relay

rms root mean square
rnd. round
ROM read only memory
rot. rotate, rotating
rpm revolutions per minute
RS right side
RTU remote terminal unit
RTV room temperature vulcanization
RW read/write
SAE Society of Automotive

Engineers
scfm standard cubic feet per minute
SCR silicon controlled rectifier
s, sec. second
SI Systeme international d’unites,

International System of Units
SI/EO side in/end out
sil. silencer
SN serial number
SNMP simple network management

protocol
SPDT single-pole, double-throw
SPST single-pole, single-throw
spec specification
specs specification(s)
sq. square
sq. cm square centimeter
sq. in. square inch
SS stainless steel
std. standard
stl. steel
tach. tachometer
TD time delay
TDC top dead center
TDEC time delay engine cooldown
TDEN time delay emergency to

normal
TDES time delay engine start
TDNE time delay normal to

emergency
TDOE time delay off to emergency
TDON time delay off to normal
temp. temperature
term. terminal
THD total harmonic distortion
TIF telephone influence factor
TIR total indicator reading
tol. tolerance
turbo. turbocharger
typ. typical (same in multiple

locations)
UF underfrequency
UHF ultrahigh frequency
UL Underwriter’s Laboratories, Inc.
UNC unified coarse thread (was NC)
UNF unified fine thread (was NF)
univ. universal
US undersize, underspeed
UV ultraviolet, undervoltage
V volt
VAC volts alternating current
VAR voltampere reactive
VDC volts direct current
VFD vacuum fluorescent display
VGA video graphics adapter
VHF very high frequency
W watt
WCR withstand and closing rating
w/ with
w/o without
wt. weight
xfmr transformer

TP-6807 12/1156 Appendix

Notes

TP-6807 12/11 57

Notes

TP-6807 12/1158

TP-6807 12/11

E 2011 by Kohler Co. All rights reserved.

KOHLER CO. Kohler, Wisconsin 53044
Phone [phone], Fax [phone]
For the nearest sales/service outlet in the
US and Canada, phone [phone]
KohlerPower.com

Kohler Power Systems
Asia Pacific Headquarters
7 Jurong Pier Road
Singapore 619159
Phone [phone], Fax [phone]