HomeMy WebLinkAboutOPERATION & INSTALLATIONSCANNED
Operation and
Installation
natic Transfer Switch
Model:
RXT
Automatic Transfer Switches
generator sets equipped with
dor/transfer switch controllers
09001
4 m,,% , " .
KOHLER, NATIONALLY REGISTERED
w1 TP-6807 7O�Sx,ls*-tems/16e
7
Table of Contents
Product Identification Information.!........................................................... 2
Safety Precautions and Instructionsl......................................................... 5
Introduction..................... I ..... ..... ...... ............................ .............. 7
List of Related Literature..................................................... 8
Nameplate............................................................... 8
Model Designation......................................................... 9
ServiceAssistance......................................................................... 10
Section 1 Description .......... i......................................................... 11
1.1 Transfer Switch Description ............................................. 11
1.2 Service Entrance Models ............................................... 11
1.3 Load Centers......................................................... 11
1.4 Controller lnterface Board ............................................... 12
1.4.1 Standardlnterface Board ....................................... 12
1.4.2 Combined Interface/Load Management Board ..................... 12
1.5 Optional Status Indicator Panels ......................................... 14
1.5.1 Standard Status Indicator Panel ................................. 14
1.5.2 Status Indicator Panel for Combined Interface/Load Management Board . .
14I
Section 2 Installation ................................................................... 15
2.1 Introduction�........................................................... 15
2.2 Receipt ofllnit........................................................ 15
2.2.1 Inspection.................................................... 15
2.2.2 Storage ...................................................... 15
2.2.3 Unpacking .................................................... 15
2.2.4 Lifting........................................................ 15
2.3 InstallationI ......................................................... 16
2.4 Manual Op ..
Operation Check ............................................... 17
2.4.1 Manual Operation Procedure 1.................................. 17
2.4.2 Manual Operation Procedure 2.................................. 17
2.5 Electrical Wiring ....................................................... 18
2.5.1 Load Center Circuit Breakers .................................... 19
2.5.2 AC Power Connections ......................................... 19
2.5.3 Neutral Connection ............................................ 19
2.5.4 Neutral Bonding Jumper, Service Entrance Models ................. 19
2.5.5 Engine Start Function .......................................... 19
2.6 Interface Module Connection ............................................ 20
2.7 Combined Interface/Load Management Board ............................. 22
2.7.1 Relay Modules ................................................ 22
2.7.2 HVAC Loads .................................................. 22
2.7.3 Load Add/Shed Priority ......................................... 22
2.7.4 Current Transformers (CTs)..................................... 23
2.7.5 Connection Procedure .......................................... 23
2.8 Load Control Module (LCM)............................................. 26
2.8.1 LCM with Standard Interface Board .............................. 26
2.8.2 LCM with Combined Interface Board ............................. 26
2.9 Optional Load Control Connection ....................................... 28
2.10 Accessory Module Connections ......................................... 28
2.11 Test and Exercise..; ................................................... 28
2.12 Warranty Registration.................................................. 28
TP-6807 7/16
Table of Contents 3
Table of Contents, continued
Section3 Operation........................................................................ 29
3.1 Model RXT Transfer Switch Operation ..................................... 29
3.2 Source Availability ..................................................... 29
3.3 ATS Control Sequence of Operation ...................................... 29
3.4 Load Management Operation ........................................... 29
3.4.1 Power Loads .................................................. 30
3.4.2 HVAC Loads .................................................. 30
3.4.3 Load Add/Shed Priority ......................................... 30
3.4.4 Status Indicator and Test Button ................................. 30
3.5 Load Management Theory of Operation .................................. 31
3.5.1 Load Adds ..................................................... 31
3.5.2 Load Shed .................................................... 32
3.5.3 Overload Shed ................................................ 32
3.5.4 Under Frequency Shed ......................................... 32
3.5.5 Load Shed Acceleration ........................................ 33
3.5.6 Changing Settings ............................................. 33
3.6 Time Delays.......................................................... 34
3.7 Load Control Time Delay ............................................... 34
Section 4 Service Disconnect, SE Model .................................................... 35
4.1 Service Disconnect Procedure ........................................... 35
4.2 Source Circuit Breaker Reset ............................................ 36
Section 5 Scheduled Maintenance.......................................................... 37
5.1 Introduction........................................................... 37
5.2 Testing............................................................... 38
5.2.1 Weekly Generator Set Exercise .................................. 38
5.2.2 Monthly Automatic Control System Test ........................... 38
5.3 Inspection and Service ................................................. 38
5.3.1 General Inspection ............................................. 38
5.3.2 Other Inspections and Service ................................... 38
5.4 Service Schedule...................................................... 39
Section 6 Diagrams and Drawings.......................................................... 41
Appendix A Abbreviations................................................................ 77
4 Table of Contents TP-6807 7116
2.1 Introduction
Kohler® transfer switches are shipped fa
'factory -tested, and ready for installation.
equipment installed only by trained ar
personnel, and verify that the installation c(
applicable codes and standards. Protecr
against damage before and during installa'
2.2 Receipt of Unit
2.2.1 Inspection
At the time of delivery, inspect the pac
transfer switch for signs of shipping da
the transfer switch as soon as possible
exterior and interior for shipping damE
and/or rough handling is evident, imr
damage claim with the transportation c
2.2.2 Storage
Store the transfer switch in its protective
final installation. Protect the transfer swit
from moisture, construction grit, and meta
storage in cold or damp areas where IT
condense on the unit. See Figure 2-1 fi
storage temperatures.
tory-wired,
Have the
I qualified
nplies with
the switch
ing and the
le. Unpack
inspect the
If damage
atelv file a
Section 2 Installation
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
A WARNING
01
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.
Decking until See Figure 2-2 or the dimensional drawing for the
h at all times weight of the transfer switch. Use a spreader bar to lift
chips. Avoid the transfer switch. Attach the bar only to the
)isture could enclosure's mounting holes or lifting brackets; do not lift
r acceptable the unit any other way. Close and latch the enclosure
door before moving the unit.
Item
Specification
Storage
Temperature
-40°C to 85°C (-40T to 185T)
Operating
Temperature
-20°C.to 70°C (-4°F to 1581 F)
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
accumulated in the transfer switch or any of its
components.
Amps
Description
Weight $
kg Ob.)
Single phase
7 (15)
With 12- or 16-space load center
(NEMA 1)
12 (26)
100
With 16-space load center
8 (18)
Three phase
14 (30)
Service entrance (ASE)
12 (26)
Service entrance (CSE)
16 (34)
Service entrance (ASE)
12 (26)
150-200
Service entrance (CSE)
16 (34)
Single phase
7 (15)
200
Three phase
14 (30)
300
Service entrance
46 (101)
Single phase
55 (120)
3-Pole/208-240 volts
41 (90)
400
3-Pole/480 volts
59 (130)
4-Pole
59 (130)
Service entrance
46 (101)
$ Transfer switch weights are approximate and do not include
packaging.
Note: Enclosures are type NEMA 3R except as noted.
Figure 2-2 Weights (approximate)
TP-6807 7/16 Section 2 Installation 15
2.3 Installation
NOTICE
Foreign material contamination. Cover the transfer switch
during installation to keep dirt, grit, metal drill chips, and other
debris out of the components. Cover the solenoid mechanism
during installation. After installation, use the manual operating
handle to cycle the contactor to verify that it operates freely. Do
not use a screwdriver to force the contactor mechanism.
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.
NEMA3Renclosures. To remove the enclosure's front
panel, support the panel while removing the screws.
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 atthe bottom of
the enclosure and the door. Use a padlock to lock the
door 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 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.
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.
16 Section 2 Installation TP-6807 7/16
I
2.4 Manual Operation Check
A DANGER
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources bef Ire
opening the enclosure. i
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
300 amps, 1-phase
2.4.1
Figure 2-5
400 amps, 1-phase
400 amps, 3-phase, 3-pole,
208-240 Volts
400 amps, 3-phase,
3-pole/480 Volt and 4-pole
2.4.2 I
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.
L®J LAJ
1
1. Handle (not detachable)
Figure 2-4 Manual Operation, 100 - 200 Amp
Single -Phase Switches
1 n�a 00
NB
0
O EO OEBO
OHO O�BO
GM80139
1. Shaft (attach handle or wrench here)
Figure 2-5 Manual Operation, 300-400 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.
2. Insert the maintenance handle or a tool (such as a
screwdriver) into the hole in the shaft on the left
TP-6807 7/16 Section 2 Installation 17
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.
4. Return the transfer switch to the Normal position.
5. Remove the maintenance handle and return it to the
storage location.
Figure 2-6 Manual Operation, 100-200 Amp
3-Phase Switches
0000 1
2
0
0 q0
o v v o i
tp6225
1. Handle storage location
2. Insert handle here for manual operation
Figure 2-7 Manual Operation, 400 Amp 3-Phase
Switches
18 Section 2 Installation
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.
A 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 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.
A 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.
TP-6807 7/16
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 Brealkers
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.
A 100 amp model with a 12-space load center is also
available. The 12-space load center uses only single
breakers. Do not install tandem breakers on the
12-space load center.
The load centers use Square D type QO or QOTtandem
breakers. In an essential load applicatio n� , 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 lof the existing
breaker in the main panel for each circuit.
Verify that the total rating for all breakers 'used in the load
center does not exceed the rating of thejtransfer switch.
If circuit breakers are removed from the load panel,
install cover plates over the vacant positions. Cover
plates can be obtained from a local Square D supplier.
2.5.2 AC Power Conn
Determine the cable size. Refer to the ADV drawings
in Section 6 or the transfer switch specification sheet 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: Connectthe 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.
2.5.3 Neutral Connection
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.
2.5.5 Engine Start Function
The engine startfunction is controlled bythe RDC2/DC2
controller on the generator set. There are no engine
start terminals on the Model RXT ATS.
TP-6807 7/16 Section 2 Installation 19
2.6 Interface Module Connection
The interface module must be connected to a Kohler®
generator set equipped with the RDC2 or DC2
controller. Connect P10 on the interface module to the
A, B, PWR, and COM connections on the generator
set's field -connection terminal block. See the generator
set Installation Manual for the location of the terminal
block. See Figure 2-8 for P10 connection identification.
Note: Engine start connections 3 and 4 on the
generator set are not used with the Model RXT
transfer switch.
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 load control module (LCM) are
connected, referto the generator set installation manual
for connection instructions.
A 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 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.
A 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.
RBUS Connections A and B
See Figure 2-9 and Figure 2-10.
For the RBUS communication connections A and B to
the Model RXT transfer switch, optional PIM and/or
optional LCM or load shed kit, use 20 AWG shielded,
twisted -pair communication cable. Belden #9402
(two -pair) or Belden #8762 (single -pair) or equivalent
cable is recommended.
For outdoor installations, including those with buried
cables and/or conduit, use outdoor -rated Belden
#1075A or equivalent 20 AWG shielded, twisted -pair
communication cable.
PWR and COM Connections
For the PWR and COM connections, the cable size and
maximum cable length depends on the number of
modules connected. See Figure 2-9.
• For short cable runs shown in the first two rows of
Figure 2-9, use one pair in the two -pair
communication cable for the A and B connections,
and use the second pair for the PWR and COM
connections.
• For the longer cable runs shown in the last two rows
of Figure 2-9, use 12 or 14 AWG cable for PWR and
COM, and use the 20 AWG communication cable
specified above for the A and.B connections only. In
this case, single -pair communication cable such as
Belden #8762 can be used for the A and B
connections.
The maximum cable length depends on the number of
optional modules connected. See Figure 2-9 for the
maximum cable lengths with 1, 2, or 3 modules per
cable run.
Connection
Designation
Description
Pi 0-1
A
Communication Line
P10-2
B
Communication Line
Pi 0-3
PWR
12 VDC
P10-4
COM
12 VDC
Figure 2-8 Controller Interface Connections
20 Section 2 Installation TP-6807 7/16
Maximum cable length per run, meters (ft.)
Indoor or
Outdoor
Installation
Cable Size for PWR and COM Connections
Number
of Modules per Run I
1 Module
2 Modules
3 Modules
61 (200)
31 (i oo)
21 (67)
Indoor
20 AWG Belden #9402 or equivalent, two -pair
61 (200)
31 (100)
121 (67)
Outdoor
20 AWG Belden #1075A or equivalent, two -pair
152 (500)
152 (500)
1i22 (400)
—
14 AWG
152 (500)
152 (500)
152 (500)
—
12 AWG *
* Use 12 or 14 AWG cable for PWR and COM connections only. For RBUS connections A and B, use shielded, twisted pair communication
cable specified in Section 2.6.
Figure 2-9 Cable Specifications for
Generator Set
and COM Connections
i
Connect one end of each
cable shield to GROUND at
the generator set.
A
GND
IA
IB
B
i
PWR
PWR
coM
COM
1
I4
i3
Generator Set Terminal Block.
See the generator set manuals for location.
Check the decal on the generator set for terminal
block connections.
Note: Generator set terminal block connections 3 and 4 are
NOT USED with the Model RXT ATS.
Interface Board on the Model
RXT Transfer Switch
A —
B —
PWR -
com -
>
>
RXT
m
v
%
m
v
�
co
c
8
8
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.
1. Communication cable Belden #9402 or equivalent 20 AWG shielded, twisted -pair cable.
See Figure 2-9 for cable specifications.
Figure 2-10 Interface Module Connection to Generator Set Field -Connection Terminal Block
TP-6807 7/16 Section 2 Installation 21
2.7 Combined Interface/Load
Management Board
The combined interface/load management board can
be used with single-phase generator sets equipped with
the RDC2 or DC2 controller only. Followthe instructions
in this section to install the current transformer and
connect the load management relays. Then connect
the interface/load management board to a Kohler®
generator set equipped with the RDC2 or DC2
controller.
Up to four load relays and two HVAC relays can be
connected. The load management operation will cycle
through all six connections regardless of the number of
loads connected. The load management timing is
affected by the generator's capacity as described in
Section 3.5.
Note: Only one load management option can be used
with the generator. If a load control module
(LCM) is connected, disable the 1 load
management function on the combined
interface/load management board as described
in Section 2.8 and connect the LCM according to
instruction sheet TT-1574, provided with the
LCM.
2.7.1 Relay Modules
Up to four power relay modules (GM92001-KP1-QS)
can be connected for management of non -essential
secondary loads. Two (2) 120 VAC loads (shed
simultaneously) or a single 240 VAC load can be wired
to each relay. Customer -supplied relays must be either
normally closed or double -pole double-trhow (DPDT)
and maximum 50 amps. Note that the load must be
connected to the normally closed contacts of the relay.
Kohler® Power Relay Modules are recommended.
Circuit Board
Relays Rating
Pilot Relays and 125VAC, 10 A (general purpose)
HVAC Relays 120VAC, 125VA (pilot duty)
(qty. 2)
Figure 2-11 Combined Interface Board Relay
Specifications
Power Relay Specifications
Relay Rating
50 A @ 240 VAC
Relay Type
DPST - NC or DPDT
Coil Voltage
120 VAC
Figure 2-12 Customer -Supplied Power Relay
Specifications
Kohler® power relay modules include one power relay
mounted inside a NEMA type 3R enclosure. Connect
up to four (4) power relay modules to the load shed kit.
See Figure 2-13 for an illustration of a power relay
module.
Before starting the installation, confirm that the
generator set is equipped with an RDC2 or DC2
controller. RDC2/DC2 controller firmware version 5.04
or higher is required. Check the version number on the
controller and update the firmware, if necessary.
An adequate electrical supply is required for operation
of the customer -supplied relays connected to the load
shed kit. 120 VAC relays require a customer -supplied
voltage source. Check the electrical requirements of
the customer -provided equipment prior to installation to
determine the wire size and circuit protection required.
Verify that customer -provided equipment complies with
applicable local and national electrical codes.
Figure 2-13 Kohler Power Relay Module
2.7.2 HVAC Loads
There are two (2) relays available to control two (2)
independent heating, ventilation, and air conditioning
(HVAC) loads. The operation of the HVAC relays
includes afive-minute start delay and different timing for
load add compared to the power relays. See
Section 3.5.1 for more details about the HVAC relay
operation.
2.7.3 Load Add/Shed Priority
Loads are prioritized from priority 1 to priority 6. See
Figure 2-19 on page 25. Priority 1 is considered the
most critical; it will add first and shed last. Priority 6 is
considered the least critical; itwill add last and shed first.
22 Section 2 Installation TP-6807 7/16
2.7.4 Current Transformers (CTs)
A current transformer is required for load management.
A 400 amp current transformer is included with the
combined interface/load management board. If the
application requires cables that are too large for the
inside diameter of the CT provided, or a 500 Amp CT is
needed for the 60RCL, order a current transformer or
obtain a current transformer that I meets the
specifications shown in Figure 2-14.
Larger
I
Standard
Diameter CT*
500 Amp CT#
CT
(sold
(sold
(included)
separately)
separately)
Kit Number
GM83929
GM17250-KPi-QS
GM17250-KP2-QS
CT Service Part
Number
GM83929
GM17250
GM60264
Primary Rating
400 Amps
400 Amps
i 500 Amps
Secondary
3 VAC
3 VAC
3 VAC
Rating
Burden
Resistor
16 Ohms
15 Ohms
16 Ohms
Burden
Resistor
Internal
Internal
Internal
Location
Outer Diameter
63.5 mm
111.8 mm
171.5 mm
(O.D.)
(2.50 in.)
(4.40 in.)
(6.75 In.)
Inner Diameter
28.7 mm
57.2 mm
108.0 mm
(I.D.)
(1.13 in.)*
(2.25 in.)
(4.25 in.)
* Order GM17250-KPi-QS for applications that use larger cables.
Order GM17250-KP2-QS for 60ROL only.
Figure 2-14 Current Transformer (CT) Specifications
2.7.5 Connection Procedure
A 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 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.
TP-6807 7/16
A DANGER
�)N I
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.
1. Press the OFF button on the generator set
controller.
2. Disconnect the utility power to the generator set.
3. Disconnect the generator set engine starting
battery(ies), negative (-) lead first.
4. Disconnect power to the transfer switch.
5. Remove the ATS enclosure cover.
6. Install the current transformer (CT) on the
emergency source lines. Installation inside the
transfer switch enclosure is recommended.
Note: Be sure to route the leads through the
current transformer from opposite sides as
shown in Figure 2-15. The leads must cross
in opposite directions as they pass through
the transformer.
Note: See Section 2.7.4 for CT specifications.
EMERGENCY LUGS ON ATS
FCONTACTOR
ELI EL2
I I
L
Emergency source
leads must cross
through CT in opposite
directions as shown.
X2 1113 (TB1-IIR)--------
To TB1 on Load
Shed Circuit Board
X1 11 (1131-11)�
CT
side view
FROM GENERATOR GM88804
Figure 2-15 Current Transformer (CT) Wiring
Section 2 Installation 23
It
7. RBUS connections: Connect the controller
interface connection to A, B, PWR, and COM on
terminal block P10 on the interface/load
management board See Figure 2-16 and
Figure 2-18. The RBUS connections to the
generator set controller are the same for the
standard interface board and the combined board.
See Section 2.6 for interface connection
instructions.
Note: Use separate conduit for the low -voltage
controller communication leads and the
load connection wiring.
Note: Refer to the wiring diagrams in Section 6.
8. Connect the CT leads to connector TB1 on the
interface/load management circuit board. Extend
the leads, if necessary, using customer -supplied
wiring. See Figure 2-18 and/or the wiring diagram
in Section 6 for the connector location.
9. Note the load priorities shown in Figure 2-19.
Priority 1 is considered the most critical and will
add first and shed last. Priority 6 is considered the
least critical and will add last and shed first.
Connect the customer -provided load relays to
terminal block TB2 for Loads A, B, C, and D. See
Figure 2-17forthe connections. See Section 2.7.1
for the recommended relay specifications.
Note: The combination of four load relay outputs
cannot exceed 10 amps total current draw.
10. Connect 120 VAC power to T132 connections ACi .
and N. See Figure 2-17. Connect 120 VAC line
voltage to terminal ACi . Connect the neutral to, N.
The power to this circuit must be backed up by the
generator set and not be part of a sheddable
circuit.
11. Verify that the jumper is installed across P11-2 and
P11-3 on the combined interface board. See
Figure 2-18.
1
.®e
SIDE VIEW
ti ADV-8691
1. Combined interface/load management board inside the
enclosure
Figure 2-16 Typical Interface Board Location
(LOAD A)
(LOAD B) (LOAD C) (LOAD D)
RELAY
RELAY RELAY RELAY
TB2
nInIE11001010 Ell
A N 8 N C N D N N AC1
TOTAL COMBINED LOAD 120VAC IN
RELAY OUTPUTS No
GREATER THAN 10A MAX.
EXTERNAL LOAD CONTROL
(WIRING BY OTHERS) GM95547
Figure 2-17 Power Relay Circuit on the Combined
Interface/Load Management Board
24 Section 2 Installation TP-6807 7/16
0
I
K1
P12
Pi
TB3
2
3 RXT/LNC
6 COMBO INTERCM FACE C >
BOARD
NC
C�
P10 I m
(R-BUS)
t m A- K2
2Ip B+
3 m PWR TB1
4 m C0M
n
5 UR
2
P13
8 4
n
K4 KS K6 EE
ffl
LOAD RELAY 5 1
LOAD RELAY OUIPUIS INPUT
I I I I
T92 ®®®®®®®®®® i
A N B N C N D N N ACI
� I T
4 3 GM95546
1. T133 HVAC relay connections
2. T131 connection for current transformer (CT)
3. T132 120 VAC input connection
4. T132 connections to customer -supplied power relays
(max 4 relays)
5. PI RDC2/DC2 controller interface RBUS connections
6. Pii jumper (factory -installed across 2 and 3 for load
management)
Figure 2-18 Combined Interface/Load Management
Board Customer Connections
12. Connect HVAC loads to TB3. See Figure 2-18.
Note the priorities of HVAC A and HVAC B relative
to Loads A through D. See Figure 2-19 and
Section 2.7.3.
The air conditioner control scheme requires
splicing into the existing building low voltage wiring
from the thermostat to the air conditioner/furnace.
In a typical four wire scheme, connect the cooling
wire (`) in series to the respective terminal block
on the load shed kit.
13. Record the names of the loads connected to each
relay in Figure 2-19. For example, Load A may be
a sump pump, and HVAC A may be the air
conditioner.
Note: If the OnCuee Plus Generator Management
System is used, the load descriptions can
be changed remotely. For instructions, see
TP-6928, OnCue Plus Operation Manual.
To avoid confusion, make sure that the load
description matches the equipment
connected to the corresponding relay.
14. Install the ATS enclosure cover.
15. Check that the generator set is OFF
16. Reconnect the utility power to the transfer switch.
17. Reconnect the generator set engine starting
battery, negative (-) lead last.
18. Reconnect utility power to the generator set.
Priority
Relay
Record the Load Description
1
Load A
2
HVAC A
3
Load B
4
Load C
5
HVAC B
6
Load D
Note: Priority 1 (Load A) adds
first and sheds last.
Figure 2-19 Load Priority and Descriptions
TP-6807 7/16
Section 2 Installation 25
2.8 Load Control Module (LCM)
Note: Only one load management option can be used
with the generator. If the LCM is connected to an
RXT equipped with the combined interface/load
management board, disable the load
management function on the combined board as
described in Section 2.8.2, below.
2.8.1 LCM with Standard Interface
Board
If the Load Control Module (LCM) is used with an RXT
transfer switch equipped with the standard interface
board, follow the instructions in TT-1574, provided with
the LCM, to connect the load control module and the
current transformer.
2.8.2 LCM with Combined Interface
Board
If the LCM is used with an RXT that is equipped with the
combined interface/load management board, disable
the load management function on the interface board as
described in the procedure below. Connect the LCM as
described in TT-1574. Be sure to connect the current
transformer to the LCM (not to the combined
interface/load management board on the RXT).
Note: The load status LEDs on the status indicator for
the combined interface/load management board
will not show the load control status of the LCM.
A 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 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.
A 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.
Procedure to connect an LCM if the combined
board is used on the RXT
1. Press the OFF button on the generator set
controller.
2. Disconnect the utility power to the generator set.
3. Disconnect the generator set engine starting
battery(ies), negative (-) lead first.
4. Disconnect power to the transfer switch.
5. Remove the ATS enclosure cover.
6. Find the combined interface/load management
board, which is typically mounted on the upper left
side of the enclosure. See Figure 2-16, if
necessary.
7. See Figure 2-20. Move the P11 jumper from
terminals 2 and 3 to terminals 1 and 2 to disable the
load management function on the combined
board.
26 Section 2 Installation TP-6807 7/16
8. Connect RBUS communication cable to the
combined interface board: Connect the generator
controller's interface connection to A, B, PWR, and
COM on terminal block P10 on the interface/load
management board. See Figure 2-20. See
Section 2.6 for detailed RBUS connection
instructions.
9. Follow the instructions in TT-1574, provided with
the LCM, to connect the load control module.
a. Connect the LCM RBUS connections to either
the combined interface board or to the
generator's RDC2 or DC2 controller.
b. Connect the current transformer (CT) to the
LCM. Do not connect the CT to the combined
interface board in the RXT enclosure.
I
c. Connect power relays, HVAC connections, and
120 VAC power to the LCM asI described in
TT 1574.
10. Install the ATS enclosure cover, j
11. Check that the generator set is OFF.
I
12. Reconnect the utility power to the transfer switch.
13. Reconnect the generator set engine starting
battery, negative (-) lead last.
14. Reconnect utility power to the generator set.
TP-6807 7/16
2
DO NOT
CONNEC
T
90773
T132: DO NOT CONNECT
1. P11: Install jumper across pins 1 and 2 to disable load
management
2. Connect RBUS communication cable to P10 on the
combined board.
Note: DO NOT connect power relays, HVAC relays,
or current transformer to the combined board.
Connect to the LCM as described in the LCM
instruction sheet.
Figure 2-20 Combined Interface/ Load Management
Board Connections with LCM
Section 2 Installation 27
2.9 Optional Load Control
Connection
Connector P11 on the standard 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 2-21 for the location of load control
connector P11. See Figure 2-22 for contact ratings,
connection, and wire size information.
Note: For load add and load shed operation based on
generator capacity, use the load shed kit or the
combined interface/load management board.
See Sections 1.4.2, 2.7, and 3.4 for more
information about load management.
B a
HU W EL1 LL P13
1
P12
INTERFACE BOARD
i
K3
IN 1
P11 P10 RBUS
00N1R0 2 1 A B PNR Cdll
1 GM80663
1. Load control connection P11
Figure 2-21 Load Control Connection, Standard
Interface Board
2.10 Accessory Module
Connections
For connection of the optional programmable interface
module (PIM), refer to the instructions provided with the
module and to the generator set installation manual.
2.11 Test and Exercise
Refer to the generator set Operation Manual for
instructions to test the power system operation and to
setthe RDC2 or DC2 controller for weekly exercise runs
to keep the power system in good operating condition.
2.12 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.
Terminal Block
Connection
Designation III
Description
Contact Rating
Wire Size
P11
P11-1
LCi
Load Control Output
10 A @ 250 VAC
1 A @ 30 VDC
#12-18 AWG
P11-2
LC2
Figure 2-22 Load Control Contact P11 Connections
28 Section 2 Installation I TP-6807 7/16