Kohler RSB Series Instruction Manual

Automatic Transfer Switches
Operation
Model:
RSB
Intelligent Transfer Switch
150--225 Amps
Electrical Controls:
MPACt550
TP-6487 8/07a

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
Accessory Number Accessory Description

Table of Contents
TP-6487 8/07 Table of Contents 3
Product Identification Information 2............................................................
Safety Precautions and Instructions 5........................................................
Introduction 7...............................................................................
List of Related Materials 7.....................................................
Nameplate 7.................................................................
Model Code 8................................................................
Service Assistance 9........................................................................
Section 1 Description 11.....................................................................
1.1 Transfer Switch Description 11.............................................
1.2 Intelligent Transfer Switch 11..............................................
FCC Statement 11.............................................................
1.3 Specifications 12.........................................................
Section 2 Operation 13.......................................................................
2.1 Introduction 13..........................................................
2.2 Pushbuttons and Indicators 13.............................................
2.3 Source Sensing 14.......................................................
2.4 Sequence of Operation 14................................................
2.4.1 Time Delays 15..................................................
2.4.2 Load Control 15..................................................
2.4.3 Load Shed 15...................................................
2.5 Faults 15...............................................................
2.5.1 Failure to Acquire Standby Source Warning 15.......................
2.5.2 Failure to Transfer Warning 15.....................................
2.5.3 Auxiliary Switch Fault 15..........................................
2.6 Controller Reset 15......................................................
2.6.1 Fault Reset 15...................................................
2.6.2 Alarm Silence 15.................................................
2.6.3 Controller Reset 15...............................................
2.7 Running a Test 16........................................................
2.7.1 Unloaded Test 16................................................
2.7.2 Loaded Test 16..................................................
2.8 Exerciser 16.............................................................
2.8.1 Unloaded Exercise 17............................................
2.8.2 Loaded Exercise 17..............................................
2.8.3 Stopping Exercise Run 17.........................................
2.8.4 Resetting Exerciser 17............................................
Section 3 Scheduled Maintenance 19..........................................................
3.1 Introduction 19..........................................................
3.2 Testing 20..............................................................
3.2.1 Weekly Generator Set Exercise 20.................................
3.2.2 Monthly Automatic Control System Test 20..........................
3.3 Inspection and Service 20.................................................
3.3.1 General Inspection 20............................................
3.3.2 Other Inspections and Service 21..................................
3.4 Service Schedule 22.....................................................

Table of Contents, continued
TP-6487 8/07Table of Contents4
Section 4 Accessories 23.....................................................................
4.1 Accessory Board 23......................................................
4.1.1 Accessory Board Audible Alarm 23.................................
4.1.2 Accessory Board Time Delay Adjustment Switches 24................
4.1.3 Accessory Board DIP Switches 24..................................
4.2 Load Shed Kit 25........................................................
Appendix A Abbreviations 27..................................................................

TP-6487 8/07 5Safety Precautions and Instructions
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,orsubstantial
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
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.
WARNING
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
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.
DANGER
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.

TP-6487 8/076 Safety Precautions and Instructions
Airborne particles.
Can cause severe injury or
blindness.
Wear protective goggles and clothing
when using power tools, hand tools,
or compressed air.
WARNING Notice
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.

TP-6487 8/07 7Introduction
Introduction
This manual provides operation instructions for the
KohlerrModel RSB Intelligent Transfer Switch with
MPACt550 electrical controls.
Information in this publication represents data available
at the time of print. Kohler Co. reserves the right to
change this literature and the products represented
without notice and without any obligation or liability
whatsoever.
Read this manual and carefully follow all procedures
and safety precautions to ensure proper equipment
operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section at the
beginning of this manual. Keep this manual with the
equipment for future reference.
The equipment service requirements are very important
to safe and efficient operation. Inspect parts often and
perform required service at the prescribed intervals.
Obtain service from an authorized service distributor/
dealer to keep equipment in top condition.
TP-6486
Figure 1 Intelligent Transfer Switch
List of Related Materials
Separate manuals cover the installation of the Type 1
and Type 3R load centers and the transfer switch
conversion kit. Figure 2 lists the available manuals and
part numbers.
Document Part Number
Installation Instructions, QO Indoor Load
Center (Type 1) TP-6493
Installation Instructions, QO Outdoor
Load Center (Type 3R) TP-6494
Installation Manual, Model RSB Intelligent
Transfer Switch Conversion Kit TP-6486
Figure 2 Related Documents
Nameplate
A nameplate attached to the transfer switch 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.
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. Copy the model
designation into the spaces in the Model Code chart and
use the chart to interpret the model designation.
TRANSFER SWITCH
GM21291-E
1
2
3
1. Model designation
2. Serial number
3. Factory-installed accessory numbers
MATERIAL
FOR EMERGENCY SYSTEMS
TRANSFER SWITCH
TYPE ENCLOSURE
MFG. DATE
POLES
WIRES
AMPS
HERTZ
BAR CODE
PHASE
VOLTS
SERIAL NO.
MODEL
ACCESSORIES:
FOR EMERGENCY SYSTEMS
LISTED
R
Figure 3 Typical Transfer Switch Nameplate

TP-6487 8/078 Introduction
Model Code
Record the transfer switch model designation in the boxes below. The transfer switch model designation defines
characteristics and ratings as explained in the accompanying chart.
KohlerrModel Designation Key
This chart explains the Kohlerrtransfer switch model designation system. The
sample model designation shown is for a Model RSB Intelligent Transfer Switch
with MPACt550 electrical controls rated at 240 volts/60 Hz, 2 poles, 3 wires,
and solid neutral in a type 1 enclosure with a 200 amp main circuit breaker, a 125
amp generator circuit breaker, and no load shed modules.
Model
R: Kohler
Electrical Controls
G: MPACt550 (Microprocessor ATS Controls)
Number of Poles/Wires
Enclosure
0150 0200 0225 0000 [
RSB-GFNA-0200-0125-N
SAMPLE MODEL DESIGNATION
Mechanism
SB: Intelligent Transfer Switch, Service Entrance Rated
Load Shed
N: No Load Shed Modules
S: With Load Shed Modules
F: 240 Volts/60 Hz
Voltage/Frequency
N: 2-pole, 3-wire, solid neutral
A: Type 1 Complete
B: Conversion Kit for Type 1 Indoor
Load Center (no enclosure) *
C: Type 3R Complete
D: Conversion Kit for Type 3R Outdoor
Load Center (no enclosure) *
Enclosure
Main Circuit Breaker Rating, in Amps:
0050
0060
0070
0080
0090
00100
0125
Generator Circuit Breaker Rating, in Amps:
* Order a conversion kit for locations that already have a Square DrGenerator-Ready Intelligent Load Center installed.
[Conversion kits are available without a main circuit breaker for installations that already include a type QOM main circuit breaker with control taps
.
Note: Load centers do not include branch circuit breakers. Obtain Square Drtype QO breakers locally as required for the application.
RSB--GFN
M
a
in Bre
a
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a
ting Gener
a
tor Circuit Bre
a
ker R
a
ting
L
o
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d Shed

TP-6487 8/07 9Service Assistance
Service Assistance
For professional advice on generator set power
requirements and conscientious service, please contact
your nearest Kohler distributor or dealer.
DConsult the Yellow Pages under the heading
Generators—Electric.
DVisit the Kohler Power Systems website at
KohlerPower.com.
DLook at the labels and stickers on your Kohler product
or review the appropriate literature or documents
included with the product.
DCall toll free in the US and Canada 1-800-544-2444.
DOutside the US and Canada, call the nearest regional
office.
Headquarters Europe, Middle East,Africa
(EMEA)
Kohler Power Systems
ZI Senia 122
12, rue des Hauts Flouviers
94517 Thiais Cedex
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-6487 8/0710 Service Assistance
Notes

TP-6487 8/07 11Section 1 Description
Section 1 Description
1.1 Transfer Switch Description
An automatic transfer switch (ATS) transfers electrical
loads from a normal source of electrical power to a
standby source when the normal source voltage or
frequency falls below an acceptable level. The normal
source is typically utility power. The standby source is
usually a generator set.
When the normal source fails, the ATS signals the
standby source generator set to start. When the
standby source reaches acceptable levels and
stabilizes, the ATS transfers the electrical load to the
standby source.
The ATS continuously monitors the normal source and
transfers the load back when the normal source returns
and stabilizes. After transferring the load back to the
normal source, the ATS removes the generator start
signal, allowing the generator set to shut down.
Figure 1-1 shows a typical power system block diagram.
Transfer
Mechanism
To Load
Automatic Transfer Switch
Electrical
Controls
Normal
(Utility)
Power
Standby
(Generator)
Power Generator
Start Generator
TS-003
Figure 1-1 Typical ATS Block Diagram
1.2 Intelligent Transfer Switch
The Model RSB Intelligent Transfer Switch is intended
for use in an optional standby power system to allow a
homeowner to switch between utility and generator
power by means of an integrated automatic transfer
mechanism.
The MPACt550 controller monitors utility power for
interruptions. When utility power is lost, the controller
signals the generator set to start. The transfer
mechanism switches pre-determined electrical
components to the generator.
When utility power is restored, the MPACt550
controller commands the transfer mechanism to switch
the electrical load back to the utility and shuts down the
generator set.
The Intelligent Transfer Switch is available in two
enclosures, accommodating up to 40 (Type 1) or 28
(Type 3R) branch circuits selected by the user for
backup power. It is suitable for service entrance or
sub-panel use.
FCC Statement
This transfer equipment has been tested and found to
comply with the limits for a Class B digital device,
pursuant to Part 15 of the FCC Rules. These limits are
designed to provide reasonable protection against
harmful interference in a residential installation. This
transfer equipment generates and can radiate radio
frequency energy and, if not installed and used in
accordance with the instructions, may cause harmful
interference to radio communications. However, there
is no guarantee that interference will not occur in a
particular installation.
If this transfer equipment does cause harmful
interference to radio or television reception, the user is
encouraged to try to correct the interference by one or
more of the following measures:
DReorient or relocate the receiving antenna.
DIncrease the separation between the transfer
equipment and the receiver.
DConnect the receiver into an outlet on a different
circuit.
DConsult the receiver dealer or an experienced radio/
TV technician for help.
DDo not make changes or modifications to the transfer
equipment that are not expressly approved by Kohler
Co. Any changes or modifications may result in the
loss of authority to operate the equipment.

TP-6487 8/0712 Section 1 Description
1.3 Specifications
Enclosure Type Rating, Amps Load Center Weight, kg (lb) HxWxD,mm(in.)
NEMA 1 150–225 40 circuits 11.40 (25.0) 1000 x 362 x 95 (39.37 x 14.25 x 3.74)
NEMA 3R 100–200 28 circuits 19.10 (42.0) 858 x 375 x 115 (33.78 x 14.76 x 4.53)
Figure 1-2 Weights and Dimensions
Item Specifications
Type 1 enclosure, 150–225 amp. Maximum rating of generator circuit breaker is 125 amp.
For indoor installation, flush or surface mount. Up to 40 branch circuits.
Enclosures and ratings Type 3R enclosure, 150–200 amp. Maximum rating of generator circuit breaker is
125 amp. For indoor or outdoor installation, padlockable. Up to 28 branch circuits.
150, 200, and 225 amp models are suitable for service entrance use.
Two-pole, single-phase open-transition transfer mechanism.
T
r
a
n
s
f
e
r
m
e
c
h
a
n
i
s
m
240 VAC 60 Hz.
Trans
f
er mechanism Solid neutral.
Manually operable.
Operating temperature –10°to 60°C(14°to 140°F) with derating
–10°to 40°C(14°to 104°F) without derating.
Storage temperature –40°to 85°C (–40°to 185°F).
Humidity 5%--95% noncondensing.
Altitude 0--2000 m (0--6560 ft.).
Vibration and shock (shipping) ISTA-tested per ASTM 4169-1A.
UL listed per UL 67, Enclosed Panelboards.
Certifications, codes, and
s
t
a
n
d
a
r
d
s
Tested to UL 1008, Standard for Automatic Transfer Switches for Use in Optional Standby
Systems.
standards NFPA 70, National Electrical Coder, Article 702.
NEMA Standard IC10-1993, AC Automatic Transfer Switches.
IEC 61000-4-2, 2001, Electrostatic Discharge, Level 3.
IEC 61000-4-3, 2002, Radiated Immunity, Level 2.
IEC 61000-4-4, 2001, EFT/Burst Immunity, Severity Level 3.
EMI/EMC immunity IEC 61000-4-5, 2001, Surge Immunity, Severity Level 4.
E
M
I
/
E
M
C
i
m
m
u
n
i
t
y
IEC 61000-4-6, 2003, Conducted RF Immunity, Level 2.
FCC Part 15, Radiated Emissions, Class B.
FCC Part 15 using CISPR 11 Conducted Emissions, Class B.
Figure 1-3 Specifications

TP-6487 8/07 13Section 2 Operation
Section 2 Operation
2.1 Introduction
Red and green LEDs on the transfer switch controls
indicate which sources are available, show which
source is connected to the load, and flash to indicate
fault conditions. Pushbuttons allow you to start and stop
the generator set (with or without transferring the load)
and set the exercise timer. See Figure 2-1.
The transfer switch uses factory-default settings for time
delays, voltage and frequency pickup and dropout, and
other system settings. An optional accessory board
allows changes to the time delays and exerciser settings
and provides connections for remote test and remote
exercise inputs. See Section 4.1 for information on the
accessory board.
2.2 Pushbuttons and Indicators
Figure 2-1 identifies the controller pushbuttons and LED
indicators.
The LEDs light steadily or flash to indicate different ATS
conditions as shown in Figure 2-2. See Section 2.5 for
more information on fault conditions.
tp6345
Utility Source Position LED
Utility Source Available LED
Generator Position LED
Generator Source Available LED
Test Button Exercise Button
Figure 2-1 User Interface Panel
Condition LED Indication
Utility source power available Utility Source Available LED lights steadily.
Load connected to utility power Utility Source Position LED lights steadily.
Generator set power available GEN Source Available LED lights steadily.
Load connected to the generator set GEN Position LED lights steadily.
Loaded test GEN Available and GEN Position LEDs flash on 1 second, off 1 second.
Unloaded test GEN Available LED flashes on 1 second, off 1 second.
Loaded exercise GEN Available and GEN Position LEDs flash on 0.5 second, off 2 seconds.
Unloaded exercise GEN Available LED flashes on 0.5 second, off 2 seconds.
Failure to acquire standby source fault GEN Available LED flashes 2 times/second.
Failure to transfer fault GEN or Utility Source Position LED flashes 2 times/second.
Auxiliary switch failure fault GEN Position and Utility Source Position LEDs flash 2 times/second.
Figure 2-2 LED Indication

TP-6487 8/0714 Section 2 Operation
2.3 Source Sensing
The transfer switch controller monitors the utility power
source voltage and initiates the transfer sequence if the
source voltage falls below the voltage dropout setting.
Retransfer is initiated when the utility source rises above
the voltage pickup settings and remains stable for at
least 6 minutes. See Figure 2-3.
Source Sensing
Single-phase voltage sensing, both sources ±5%
Line-line frequency sensing, standby source ±2%
Undervoltage dropout 80%
Undervoltage pickup 85%
Voltage dropout time 0.5 sec
Underfrequency dropout 90%
Underfrequency pickup 96%
Frequency dropout time 1sec.
Figure 2-3 Source Sensing
2.4 Sequence of Operation
Figure 2-4 illustrates the transfer sequence when the
normal source fails and Figure 2-5 illustrates the
sequence when it returns. Time delays before load
transfer prevent nuisance transfers during brief power
interruptions.
Total transfer time depends on the generator set engine
cranking time and other factors. Events such as the
failure of the generator set to start can change the
sequence of operation.
If the standby source fails and the normal source is not
available, the transfer switch controller powers down
until one of the sources returns.
Transfer will not occur if one of the source circuit
breakers opens on a fault.
The time delay option board allows time delay
adjustments. See Section 4.1.
Transfer time delay from normal to
standby source (3 sec.) *
* The time delay option board allows adjustment of these
time delays. See Section 4.1.
Engine start time delay (3 sec) *
Normal power source voltage falls below
80% of nominal
Undervoltage dropout time delay,
0.5 seconds (fixed)
Load shed circuit breakers open
Load control contact opens
Generator set engine crank and start
Command to transfer to the standby source
Figure 2-4 ATS Sequence of Operation, Transfer to
Standby
Retransfer from standby to normal time delay
(5 min.) *
Command to transfer to the normal source
Time delay engine cooldown (5 min.) *
Engine start signal removed
Normal power source voltage rises above
85% of nominal
* The time delay option board allows adjustment of these
time delays. See Section 4.1.
Load control contact closes
Load shed circuit breakers close
Figure 2-5 ATS Sequence of Operation, Retransfer
to Normal

TP-6487 8/07 15Section 2 Operation
2.4.1 Time Delays
The controller time delays are shown in Figure 2-6. For
adjustable time delays, install the accessory board. See
Section 4.1.
Description Time Delay
Engine Start 3sec.
Transfer from Normal to Standby 3sec.
Retransfer from Standby to Normal 5min.
Engine Cooldown 5min.
Exercise Time Duration 20 min.
Failure to Acquire Standby 75 sec.*
* Allows for three 15 sec. engine starting attempts separated by
15 sec. rest periods.
Figure 2-6 Time Delays
2.4.2 Load Control
The load control contact is closed when the transfer
switch is in the Normal position. The contact opens
when the Normal source is lost to allow disconnection of
a load. The load connected to the load control contact is
not powered by the standby source. The load control
step in the sequence of operation is shown in
Figure 2-4.
2.4.3 Load Shed
The optional load shed kit allows disconnection of
selected loads before transfer to the generator set.
Remote-controlled circuit breakers connected to the
optional load shed module(s) open before transfer to the
generator set. After transfer back to the utility source,
the remote-controlled circuit breakers close.
2.5 Faults
The LEDs on the controller’s user interface flash as
shown in Figure 2-2 to indicate various fault conditions.
Contact an authorized distributor/dealer for service if the
fault persists.
2.5.1 Failure to Acquire Standby
Source Warning
The Failure to Acquire Standby Source fault occurs if the
transfer switch does not sense voltage from the
generator set within 78 seconds after signalling the
generator set to start. Check the generator set
operation and the connections from the generator set to
the ATS in the case of this fault.
The Failure to Acquire Standby Time Delay is set for 78
seconds to match the crank cycle of the Kohler
generator set controller.
The fault clears when the system acquires the standby
source.
2.5.2 Failure to Transfer Warning
The Failure to Transfer warning occurs if a signal to
transfer is sent to the contactor and the position-
indicating contacts do not indicate a complete transfer.
The controller will attempt to transfer three times before
indicating the fault. If the transfer switch is in the Normal
position, the Engine Cooldown time delay is executed
and then the engine start contacts open to stop the
generator set.
Reset the controller to clear the fault condition. See
Section 2.6.
2.5.3 Auxiliary Switch Fault
An Auxiliary Switch fault occurs if the controller is unable
to determine the transfer switch position. If the transfer
switch is in the Normal position, the Engine Cooldown
time delay is executed and then the engine start
contacts open to stop the generator set.
Reset the controller to clear the fault condition. See
Section 2.6.
2.6 Controller Reset
2.6.1 Fault Reset
Always identify and correct the cause of a fault condition
before clearing the faults from the ATS controller. Press
and hold the Exercise and Test buttons for
approximately 3 seconds until the LEDs flash to clear all
faults and warnings. Warnings reset automatically with
a change in the source availability or a signal to transfer.
2.6.2 Alarm Silence
If the transfer switch is equipped with a time delay option
board, pressing both buttons for 3 seconds will also
silence the alarm horn.
2.6.3 Controller Reset
Press and hold both buttons for 6 seconds to reset the
controller to its original state at powerup.

TP-6487 8/0716 Section 2 Operation
Note: Resetting the controller clears the exerciser
setting. Set the exercise time and day as
described in Section 2.8 after resetting the
controller.
2.7 Running a Test
Follow the instructions below to start and stop a loaded
or unloaded test. Once started, a test sequence will
continue to run until ended by the operator as described
in the procedures below.
If the standby source fails during a test run and the
normal source is available, the load is transferred back
to the Normal source and the test function is
deactivated. The standby source available LED stops
flashing when the standby source is no longer available.
See Figure 2-1 for the location of the Test button.
2.7.1 Unloaded Test
During an unloaded test, the generator set starts and
runs, but the electrical load is not transferred to the
standby source.
To start an unloaded test:
DPress and hold the Test button for 3 seconds. The
standby source available LED flashes.
DAfter the engine start time delay, the generator set
starts. (The load is not transferred.)
DThe Generator Available LED flashes at 1 Hz.
To end the test:
DPress and hold the test button for 2 seconds.
DThe generator set stops.
DThe Generator Available LED stops flashing when
the standby source is no longer available.
2.7.2 Loaded Test
During a loaded test, the generator set starts and runs.
The ATS transfers the electrical load from the normal
source to the standby source. At the signal to end the
test, the ATS transfers the load back to the normal
source before signalling the generator set to stop.
Note: If the optional load shed kit is installed, the loads
connected to the remote-controlled circuit
breakers will be turned off during a loaded test.
To start a loaded test:
DPress and hold the Test button for 6 seconds, until the
standby source available and standby position LEDs
flash.
DAfter the engine start time delay, the generator starts.
The Generator Available LED flashes at 1 Hz.
DThe load control contact opens.
DThe optional load shed circuit breakers open.
DAfter the normal-to-standby time delay, the ATS
transfers the load to the standby source.
To end the test:
DPress and hold the test button for 2 seconds.
DAfter the standby-to-normal time delay, the ATS
transfers the load back to the normal source.
DThe load control contact closes.
DThe optional load shed circuit breakers close.
DAfter the engine cooldown time delay, the generator
set stops.
DThe Generator Available LED stops flashing when
the standby source is no longer available.
2.8 Exerciser
Follow the instructions below to set the exercise timer to
automatically start and run the generator set for
20 minutes every week. The exerciser can be set for
loaded or unloaded exercise runs. The factory settings
fortheexerciseraresummarizedinFigure2-7.
Exerciser
Parameter Setting
Frequency * Weekly
Duration * 20 minutes
Type Unloaded: Hold Exercise button for 3--5
seconds
Loaded: Hold Exercise button for 6+
seconds
* The time delay option board allows adjustment of these
parameters.
Figure 2-7 Exerciser Settings
The time delay option board allows setting the exerciser
for biweekly exercise runs and adjustment of the
exercise run duration from 5 to 50 minutes. See
Section 4.1.

TP-6487 8/07 17Section 2 Operation
2.8.1 Unloaded Exercise
During an unloaded exercise, the generator set runs but
the electrical load is not transferred from the normal
source to the generator set.
Press and hold the Exercise button for approximately 3
seconds to start an unloaded exercise and set the time
and date of the next exercise run.
To start an unloaded exercise AND set the
exercise timer:
On the day and time that you want the exercise to run
every week (for example, at 1 p.m. every Tuesday):
DPress and hold the Exercise button for 3--5 seconds,
until the GEN Available LED flashes.
DThe generator set starts.
DThe GEN available LED continues to flash
throughout the exercise run to indicate an unloaded
exercise.
DAfter approximately 20 minutes, the ATS signals the
generator set to stop.
The timer is now set to run an unloaded exercise at the
same time and day every week.
2.8.2 Loaded Exercise
During a loaded exercise, the generator set runs and the
ATS transfers the electrical load to the generator set.
Note: If the optional load shed kit is installed, the loads
connected to the remote-controlled circuit
breakers will be turned off during a loaded
exercise.
To start a loaded exercise AND set the exercise
timer:
On the day and time that you want the exercise to run
every week (for example, at 1 p.m. every Tuesday):
DPress and hold the Exercise button for at least 6
seconds, until both the GEN available and GEN
position LEDs flash.
DThe generator set starts.
DThe optional load shed circuit breakers open.
DThe ATS transfers the load to generator set.
DThe GEN available and GEN position LEDs continue
to flash throughout the exercise run to indicate a
loaded exercise.
DAfter approximately 20 minutes, the ATS transfers the
load back to the normal source.
DThe optional load shed circuit breakers close.
DThe ATS signals the generator set to stop.
The timer is now set to run a loaded exercise at the same
time and day every week.
If the standby source fails during an exercise run and the
normal source is available, the load is transferred back
to the Normal source. The standby source available
LED stops flashing, and the Failure to Acquire Standby
Source alarm is activated.
2.8.3 Stopping Exercise Run
If it is necessary to stop the generator set during an
exercise run, press and hold the exercise button for 2
seconds. Ending the current exercise period early does
not affect future exercise runs.
2.8.4 Resetting Exerciser
To set a new exercise time and day, just follow the
instructions for setting the exerciser, above. The
exerciser will then be reset for the new time and day.
To clear the exerciser setting, press and hold the
Exercise and Test buttons for at least 6 seconds.

TP-6487 8/0718 Section 2 Operation
Notes

TP-6487 8/07 19Section 3 Scheduled Maintenance
Section 3 Scheduled Maintenance
3.1 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 3.4 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.
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.
WARNING
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.
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.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
Moving parts.
WARNING
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.

TP-6487 8/0720 Section 3 Scheduled Maintenance
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.
3.2 Testing
3.2.1 Weekly Generator Set Exercise
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 standby power system. See Section 2.7
for test instructions and Section 2.8 for instructions to set
the exerciser.
Optional accessories allow adjustment of the exercise
schedule and duration. See Sections 2.8 and NO TAG.
Refer to the generator set operation manual for exercise
recommendations.
3.2.2 Monthly Automatic Control
System Test
Test the transfer switch’s automatic control system
monthly. See Section 2.7 for the test procedure.
DVerify that the expected sequence of operations
occurs as the switch transfers the load to the standby
source when a preferred source failure occurs or is
simulated.
DObserve the indicator LEDs included on the transfer
switch to check their operation.
DWatch and listen for signs of excessive noise or
vibration during operation.
DAfter 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 and signals the
generator set to shut down after a cooldown period.
3.3 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.
3.3.1 General Inspection
External Inspection. Keep the transfer switch clean
and in good condition by performing a weekly general
external inspection of the transfer switch 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
clothorbrush.
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 any worn,
missing, or broken external components with
manufacturer-recommended replacement parts.
Contact a local authorized distributor/dealer for specific
part information and ordering.