Briggs & Stratton CH6EGNSYS Series, CH10EGNSYS Series, CH630EGNSYS Series, CH1050EGNSYS Series, 695061 Series Operating & Installation Instructions Manual

Manual Transfer Switch

Model Series Covered

In This Manual

CH6EGNSYS

CH10EGNSYS

CH630EGNSYS

CH1050EGNSYS

695061
695062

695511
695571

CONTENTS OF PACKAGE

• Manual Transfer Switch NEMA 1
Indoor use only

• Inlet Box NEMA 3R - Rainproof

• 10ft. powercord

*8 ft. power cord supplied with 695511 and

CH105OEGNSYS

REQUIRED MATERIAL

SUPPLIED BY INSTALLER

See listing on page 6.

Operating & Installation

Instructions

Read and follow all Safety Information and Instructions

before installation and first use of this product.
Keep these instructions for future reference.

Failure to follow instructions could result in serious
injury or death. The safety alert symbol is used to

identify safety information about hazards which can

result in personal injury or death.
WARNING: Engines give off carbon monoxide, an

odorless, colorless, poison gas. Do not start or run
engine in enclosed area, even if doors or windows

are open.

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THE OPERATING AND INSTALLATION INSTRUCTIONS CONTAIN SAFETY INFORMATION TO:

• Make you aware of hazards associated with the utility power to generator manual transfer switch

• Inform you of the risk of injury associated with those hazards, and

• Tell you how to avoid or reduce the risk of injury.

_$ SHOCK indicates a hazard which, if not avoided, could result in death or serious injury.

• To reduce the risk of electrical shock, the main circuit breaker must be turned OFF
while the house load center cover is removed.

_i, WARNING !_ &

This product must be installed in compliance with local residential wiring and electrical codes by a

licensed electrician or qualified professional. Neither Cutler-Hammer nor Briggs & Stratton are
responsible for damaged equipment, accidents, or personal injury caused by incorrect installation.

FORM MS-6356-11/00

PRINTED IN US.A.

(ENGLISH, FRENCH CANADIAN, MEXICAN SPANISH)

Power Cable

7

" Inlet Box

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House Load Center

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Generator J

JunotionBoxJ

Manual Transfer Switch j

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Figure 1. System Component Location

,_ WARNING: GENERAL SAFETY INFORMATION

1. A licensed electrician or qualified professional must
install the generator manual transfer switch.

2. During installation, the installer is required to remove
the cover panel of the house load center.

'_/_ To reduce the risk of electrical shock, the main circuit

breaker must be turned OFF while the load center
cover panel is removed.

3. Always place the manual transfer switch circuit break-
ers in the OFF position before connecting the generator

to the system.

4. BEFORE starting the generator, plug the power cord

from the generator into the inlet box outside the house.

BEFORE disconnecting the power cord from the inlet
box, shut the generator OFE

GENERATOR COMPATIBILITY

Only use a generator that is factory equipped with the correct

NEMA 4-prong receptacle. DO NOT use a generator equipped

with a 3-prong 240V receptacle.

OPERATION

The manual transfer switch is equipped with two sets of cir-
cuit breakers ("GEN" and "LINE") and a selection switch.

The "GEN" circuit breakers provide power from the genera-
tor to the load devices wired to the manual transfer switch.

The "LINE" circuit breakers provide utility power from the

house load center circuit breakers to the load devices wired

to the manual transfer switch.

The selection switch allows the circuit breakers for either
the generator power "GEN" or the utility power "LINE" to be

turned on to provide power to the selected house loads.
The manual transfer switch will not allow utility line power

and generator power to be connected to a load device at
the same time.

A

WARNING: Any device having a test operation that
is to be performed by the owner should NOT be
tested while both the utility power and generator

power are operating at the same time.
If a multiwire circuit having a shared neutral wire

exists, inadvertent overloading of the neutral wire
may occur.

Utility line power being restored while the generator power
is being used will not affect the generator. When utility

power is restored, follow the Switch to Utifity Powerinstruc_
tions.

_, ARNING: To prevent accidental electrical connec-

tion when operating the selection switch, ALL of the
manual transfer switch circuit breakers must be

placed in the OFF position.

SWITCH TO GENERATOR POWER:

,_ WARNING: Ensure the generator is outdoors, in

proper working condition and connected to the inlet

box.

1. Start the generator following procedures provided from
the generator manufacturer.

2. Ensure the inlet box circuit breaker is in the ON posi-
tion. Refer to Figure 1.

3. Place ALL of the utility "LINE" circuit breakers (A) in the
OFF position. Refer to Figure 2.

2

4. Move the selection switch (B) from the utility LINE set-
ting to the GENERATOR setting.

NOTE: This will mechanically prevent the manual transfer
switch "LINE" circuit breakers from being placed in the ON

_osition.

5. Place the desired generator "GEN" circuit breakers (C)
in the ON position.

IMPORTANT: If there is a delay before switching to genera-
tor power during an extended power outage, most or all of

the load devices being powered through the manual trans-
fer switch may start at the same time. To avoid possible

overload damage to the generator, alternate placing loads
on each of the 120 VAC legs of the generator. This is

accomplished by turning the generator circuit breakers ON
one at a time, alternating between the upper and lower cir-

cuit breakers of the manual transfer switch.

Examples:

On the 6 circuit manual transfer switch: Turn on an

upper circuit breaker (labeled "A","B" or "C"), then a

lower circuit breaker (labeled "D", "E" or "F"). Continue
alternating for remaining circuit breakers.

On the 10 circuit manual transfer switch: Turn on an
upper circuit breaker (labeled "A" through "E'), then a

lower circuit breaker (labeled "F" through "J"). Continue
alternating for remaining circuit breakers.

CAUTION: Watch the watt meters (D) to ensure that the
loads do not exceed the rated output of the generator. Main-

tain balanced loads where each of the watt meters stay at

approximately the same level.
Most portable generators do not have the capacity to han-

dle all of the loads that have been wired through the manual

transfer switch at the same time.
Alternate device loads such as a refrigerator and furnace to

avoid exceeding the power output of the generator.

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Manual Transfer Switch

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Figure 2. Manual Transfer Switch Controls

(10 Circuit Model Shown)

SWITCH TO UTILITY POWER:

1, Place the manual transfer switch "GEN" circuit breakers

(C) in the OFF position.

2. Move the selection switch (B) from the GENERATOR
setting to the utility LINE setting.

3. Place all of the manual transfer switch "LINE" circuit
breakers (A) in the ON position.

4. Shut off the generator and disconnect the power cord to

the inlet box.

Testing:

Periodically switch from normal utility power to generator

power following the procedures above. This will help famil-
iarize the operator with the switching procedures and verify

that the manual transfer switch is operating properly.
Testing will also verify that the devices listed on the labels

are still connected through the listed circuits.

INSTALLATION PROCEDURE

Before Installation:

CAUTION: Determine the load draw requirements of devices
that will be operated through the manual transfer switch.
Loads can be determined using a clamp-on ammeter to mea-

sure actual loads; determined from data plates on each
appliance; or, estimated from the reference guide below.

Balance loads between the two 120 VAC legs of the manual
transfer switch. Refer to schematics.

IMPORTANT: NO load placed through a circuit in the manual

transfer switch should exceed the rating of that circuit breaker.

NOTE: Some electric motors require more than two times
more power for starting than operating. This initial draw only

lasts for a few seconds. Allow for the high starting load draw
in determining load requirements. The load draws given in

the reference guide are approximate load draws for typical

appliances. Refer to the data plates or service literature of

appliances for specific information of that appliance.

REFERENCE GUIDE

LOAD DEVICE

Range Burner (one)
Electric Blanket

Electric Fry Pan
Freezer

Furnace Blower (1/3 HP)
Light Bulb (75 W)

Light Bulb (100 W)
Microwave

Radio
Refrigerator

Sump Pump (1/2 HP)
Television

Well Pump (Shallow)
Well Pump (Deep)

Non-Listed Device Load

APPROXIMATE LOAD DRAW

1500W - 6.25A @240V
1200W - 10A @ 120V
1500W - 12.5A @ 120V

BOOW- 6.7A @ 120V
BOOW- 6.7A @ 120V (1500W - 12.5A starting)

75W- 0.63A @ 120V (for each bulb)
100W - 0.85A @ 120V (for each bulb)

?50W - 6.25A @ 120V
50W-200W - 0.5A - 1.7A @ 120V

B00W - 6.7A @ 120V

1000W - 8.3A @ 120V (2200W- 18.3A starting/
100W-500W - 0.85A -4.2A @ 120V

1000W - 8.3A @ 120V (2200W - 18.3A starting)

_000W - 8.3A @ 240V (4000W - 16.7A starting)
Determine the wattage or amp draw of the

device. Use the formula: Watts = Volts X Amps.

Manual Transfer Switch Installation:

1. Ensure that there is a proper space next to the house
load center toproperly mount the manual transfer switch.
The manual transfer switchcan be mounted either to the

right or to the leftof the load center. Refer to Figure 3.

IMPORTANT: After locating the place to mount the manual
transferswitch, rotatethe flexible conduit connector (A) on the

bottomor the manual transfer switchto either the left or right.

The connector rotates past the rear edge ofthe manual trans-
fer switch box and cannot be rotated properly after the man-

ual transfer switchis mounted tothe wall. Toavoid damage to
thewires in the flexible conduit, Do not rotate more than 180°.

NOTE: The flexible conduit connector is designed to rotate
on the manual transfer switch box without opening the box.

After installation the conduit connector will remain loose.

f

House Load Center

r-oJunction Box

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Figure 3. Manual Transfer Switch Placement

2. Secure the manual transfer switch to the wall.

3. Place the load center main circuit breaker (B) in the
OFF position.

4. Locate an appropriate 1" knockout on the load center.

Wires on the utility lineside of the main circuit breakers
remain electrically "hot". Contact with these wires must be

avoided as dangerous or fatal electrical shock will occur.

5. Remove the knockout previously located on the load
center. Feed all wires from the manual transfer switch

conduit through the knockout hole. Secure the flexible
conduit end connector to the load center.

6. Install the ground (Grn) wire into the load center ground
terminal strip. Refer to Figure 7.

7. Install the neutral lead (Wht) into the load center neutral
terminal strip.

NOTE: Figure 7 shows a typical house load center. The neu-
tral and ground terminal strips may be separate, tied
together, or there may be only one terminal strip. Follow local

and national electrical codes when installing and securing
the neutral and ground wires from the manual transfer switch.

Junction Box and Inlet Box Installation:

1. Route the flexible conduit on the left side of the manual
transfer switch to the desired location to mount a junc-,

tion box. Refer to Figure 4.

2. Mount a junction box to the wall.

3. Feed the four wires from the manual transfer switch
through a knockout in the junction box and secure the

flexible conduit connector to the junction box.

Junction Box

Figure 4. Junction Box Mounting

4. Carefully plan a route from the junction box to the out-

door location where the inlet box will be installed.

NOTE: The conduit may be connected to the inlet box

through the back or either side. Determine where the con-
duit will be connected before routing conduit.

5. Install a (3/4") conduit from the junction box to the
desired location for the inlet box.

6. Remove the front cover of the inlet box and remove the
two (2) screws securing the inside panel assembly.

NOTE: The circuit breaker and receptacle are secured to

the inside cover. Do not remove them from the cover.

7. Mount the inlet box on the outside wall of the house.

A TTENTION: Important Mounting instructions!

The 50 amp inlet box must be mounted a minimum
of 30 inches above the horizontal surface adjacent

to the mounting wall.

8.

9,

Secure the conduit from the junction box to the inlet box

in a manner that meets all local and national code
requirements and maintains the weather resistant

integrity of the inlet box. Use only U.L listed rain tight or

liquid tight conduit hubs. Install hubs and conduit
according to the hub manufacturer's instructions.

Run four electrical wires from the inlet box to the junc-

tion box. Check local and national electrical codes to
determine proper wire gauge.

4

Junction Box

I Inlet Box \

Figure 5. Junction Box Wiring (Typical)

J

10. Connect and secure the wires inside of the junction
box. Refer to Figure 5.

_Pre-wfred from

receptacle to
circuit breakers

Inlet Box

t..==-1

G - Ground

W - Neutral

X - 120 VAC
Y - 120 VAC

TopView _

Pre-wired from

(_) receptacle to

ground connectio_

Grn

FrontView

Figure 6, Inlet Box Wiring (Prewired)

J

11. Connect the ground wire from the junction box to the
Green ground wire (A) in the inlet box (secured to the

front panel of the inlet box) with an appropriate wire
terminal. Refer to Figure 6.

12. Connect the neutral wire to the open receptacle "W"
terminal (B) in the inlet box.

13. Connect the two load wires from the junction box to the
circuit breakers (C) in the inlet box.

14. Install the inlet box inner panel and secure with the

screw removed earlier.

Wiring 120 Volt Circuits:

1. Determine the power circuit in the load center that will

be connected to the "A" circuit breaker in the manual

transfer switch.

CAUTION: When selecting cimuits to wire through the man-
ual transfer switch, DO NOT select circuitswired through a

GFCI in the load center. Wiring a GFCl through the manual
transfer switch will disable the GFCI when generator power
is being used.

A ARNING: Ensure that any selected circuitsthatare part of a multiwire branch circuits are wired on

opposing legs (phases) to prevent inadvertent over-
load of the neutral wire.

F

House Load Center

To Manual Transfer Switch

Figure 7. Load Center Wiring (Typical)

2. Placetheloadcentercircuitbreakerforthatcircuitto
theOFFposition.Disconnectthe"A"loadwirefromthat

circuitbreaker.RefertoFigure7.

3. Locatethelabeled"A"Blackand"A"Redwiresfrom
themanualtransferswitch.Routethosewirestothe

selectedcircuitbreaker.Trimandstripthe"A"wiresto
anappropriatelength.

4. Connectthewire("A"loadwire)disconnectedinstep2
tothe"A"Blackwirewithanappropriatewireconnector.

5. Connectthe"A"Redwirefromthemanualtransfer
switchtotheselectedcircuitbreakerintheloadcenter.

6. Determinethepowercircuitthatwillbeconnectedto

"B"circuitbreakerinthemanualtransferswitch.

7. Followsteps2through5forthe"B"circuit.Repeatwith
allotherselected120VACcircuits.

Wiring 240 Volt Circuit:

NOTE: The ganged 240V circuit breaker may be used as

two individual 120V circuit breakers. However, if one of the

120V circuit line loads "trips" a circuit breaker, both of the
ganged circuit breakers will "trip".

1.

Turn the load center 240V circuit breakers (two ganged

120V circuit breakers typically) for the selected circuit to

the OFF position. Disconnect the house load wires from
the circuit breakers. Refer to Figure 7.

For 6 circuit manual transfer switch:

2. Locate the "C" and "D" Black and "C" and "D" Red wires
from the manual transfer switch. Route the two "C" and

two "D" wires to the circuit breakers for the selected

240V circuit. Refer to Figure 7.

3. Trim and strip each of the two "C" and two "D" wires to

an appropriate length.

4. Connect and secure the disconnected house load wires
to the "C" and "D" Black wires from the manual transfer

switch with appropriate wire connectors.

5. Connect the "C" and "D" Red wires from the manual
transfer switch to the selected circuit breakers in the

toad center.

For 10 circuit manual transfer switch:

2. Locate the "E" and "F" Black and "E" and "F" Red wires
from the manual transfer switch. Route the two "E" and

two "F" wires to the circuit breakers for the selected
240V circuit. Refer to Figure 7.

3. Trim and strip each of the two "E" and two "F" wires to
an appropriate length.

4. Connect and secure the disconnected house load wires
to the "E" and "F" Black wires from the manual transfer
switch with appropriate wire connectors.

5. Connect the "E" and "F" Red wires from the manual
transfer switch to the selected circuit breakers in the
load center.

6. Install and secure the house load center cover.

7. Label all circuits on the front of the manual transfer
switch with the name (function) of the connected load

device.

A

CAUTION: When connecting house circuits to the
20A Generator side circuits ("C&D" on the 6 circuit
system; "D," "E&F" and "G" on the 10 circuit, 50A

system), care should be taken to not connect these
Transfer Switch circuits into 15 Amp house circuits.

SPECIFICATIONS

CH6EGNSYS CH10EGNSYS

Model

695061 695062

Max. Load per circuit (generator/lin_ 15-20/20A 15-20/20A
Max. Load - Watts (generator) 4800W 7200W

Max. Load - Amps (generator) 40A 60A
Number of 1 Pole Circuits (120 VAC) 4 8
Number of 2 Pole Circuits 1 1

120/240 VAC)

CH630EGNSYS CHI050EGNSYS

Model

695571 695511

iMax. Load per circuit (generatodline - 15-20/20A 15-20/20A
;Max. Load - Watts (generator) 7200W 12,000W

k,lax. Load - Amps (generator) 60A 100A
Number of 1 Pole Circuits (120 VAC) 4 8
Number of 2 Pole Circuits 1 1

(120/240 VAC)

i •

REQUIRED MATERIAL SUPPLIED BY
INSTALLER

• Junction Box

• Conduit (Inlet box to junction box)

• Conduit Connectors (Conduit from inlet box to junction
box)

Electrical Wire (Inlet box to junction box)

• Wire Nuts

• Screws and anchoring items used to secure the manual
transfer switch, junction box and inlet box

TROUBLESHOOTING

Problem Possible Cause Possible Solution

Generator slows down when loads 1. Generator is overloaded 1. Check watt meters to determine possible over-

!are connected, loads. Turn circuit breakers OFF to balance or

reduce loads.

Generator runs but no power to 1. Check and reset circuit breakers in inlet box.
load devices.

Only some load devices work on

lenerator power.

Unable to turn manual transfer
switch circuit breakers ON.

240V manual transfer switch circuit
breaker trips.

1. Inlet box cimuit breakers are notin the ON
position.

2. Manual transfer switch selector is in incorrect
position and/or circuit breakers are in incorrect

position.

3. Poor or no connection between generator and
inlet box.

4. Generator circuit breaker(s) "tripped."

1. Manual transfer switch circuitbreaker(s) are OFF

2. Load devices are not plugged into connected
circuit outlets.

1. Selection switch is in incorrect position.

1. One or both of the 120V lines is overloaded or
shorted to ground.

2. Check manual transfer switch for correct selec-

tion switch position ("GEN") and/or turn circuit
breakers ON.

3. Check power cord and connections between
generator and inlet box.

4. Reset generator circuit breaker(s).

1. Check circuit breakers.

2. Verify that load devices are plugged into cor-

rsctoutlets.

1. Verify selection switch is placed in proper posi-
tion. Set circuit breakers.

1. Determine which line(s) is overloaded or
shorted. Disconnect load or correct short.

NOTE: If one of the 120V load circuits trips the
circuit breaker, both of the tied circuit breakers
will trip.

No power to the load device when 1. The house load center circuit breaker orthe 1. Check both the house load center circuit
the manual transfer switch selector manual transfer switch circuit breaker for that breaker and the manual transfer switch circuit

is in "LINE" operation (generator load device is tripped, breaker that the load device is powered
OFF and not being used), through.

Limited Warranty

Cuttler-Hammer Inc. warrants that the Cutler-Hammer/Briggs & Stratton Manual Power Transfer Switches (CH6EGNSYS/695061,
CH10EGNSYS/695062, CH630EGNSYS/695571 and CH1050EGNSYS/695511) and power inlet boxes, and power cords and flange kits

(695520, 695521, 695522, 695523, 695649, CH6EGENCORD, CH6EGEN10CORD, CH6EGEN25CORD, CH10EGEN25CORD, 695514,
695066, 695067, CHEGENFKIT, CH6EGENPIB and CH10EGENPIB) will be free from failure due to defects in workmanship and material for
a period of 5 years from date of purchase by the original retail purchaser under normal care and proper usage in a residential installation.

In the event the product fails to comply with this warranty Cutler-Hammer lec. will, at its option, repair or replace the defective product, or
component(s) or part(s) thereof. To obtain warranty service the original retail purchaser should return the product to the place of pur-
chase or deliver the product prepaid to Cutler-Hammer Inc. at the address set forth below. Proof of purchase in the form of a receipt or

invoice which is evidence that the unit is within the warranty period must be presented to obtain warranty service.

Notice requirements and limitations applicable to Cutler-Hammer Inc. warranties are:
A. This warranty does not cover failure or damage due to improper storage, installation, operation, maintenance, alteration, repair, acci-

dent, misuse, abuse or negligence. This warranty does not cover reimbursement for labor, transportation, gaining access, removal,
installation, temporary power, or any other expenses which may be incurred in connection with repair or replacement.

B. REPAIR OR REPLACEMENT AS PROVIDED UNDER THIS WARRANTY IS THE EXCLUSIVE REMEDY OF THE PURCHASER

AND THE LIMIT OF THE LIABILITY OF CUTLER-HAMMER INC. WiTH RESPECT TO THIS PRODUCT, WHETHER IN CON-
TRACT, IN TORT (INCLUDING NEGLIGENCE OR STRICT LIABILITY) OR OTHERWISE. CUTLER-HAMMER INC. DISCLAIMS

ALL OTHER WARRANTIES, INCLUDING WITHOUT LIMITATION, ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FIT-

NESS FOR A PARTICULAR PURPOSE. IN NO EVENT WILL CUTLER-HAMMER INC. BE LIABLE FOR ANY OTHER DAMAGES,

WHETHER DIRECT, INCIDENTAL, CONSEQUENTAL OR OTHERWISE.

C. With respect to products purchased by consumers ofthe United States for personal use, the implied warranties, including but not lim-

ited to the warranties of merchantability and of fitness for a particular purpose, are not excluded but are limited to the duration of the
applicable warranty period. Some states do not allow limitations on the duration of an implied warranty, so the above limitation may

not apply to buyer. Similarly, some states do not allow the exclusion or limitation of incidental or consequential damages, so the
above excision or limitation may not apply to buyer. This warranty gives buyer specific legal rights, and buyer may also have other

rights which may vary from state to state.

This warranty covers residential use of Cutler-Hammer/Briggs & Stratton Manual Power Transfer Switches and excludes any commercial
applications.

CUTLER-HAMMER INC.

1000 CHERRINGTON PARKWAY

MOON TOWNSHIP, PENNSYLVANIA 15108

www.briggsandstratton.com

1-800-356-1243

www.ch.cutler-hammer.com

7

SCHEMATICS

f

Flexible Conduit to

Junction Box

SCHEMATIC

(6 Circuit Model)

Manual Transfer Switch

Inlet Box Receptacle

240 VAC

Flexible Conduit to

House Load Center

F

Red Wires

A

G-Ground f

W - Neutral
X - 120 VAC
Y - 120 VAC

F

Black Wires

Grn
Wht

Rating:
A through C - 120VAC

D through F - 120VAC

C and D - 240VAC

Figure 9. Schematic, 6 Circuit Model

J

F

/

SCHEMATIC

(10 Circuit Model)

Flexible Conduit to

Junction Box

Manual Transfer Switch

E

Flexible Conduit to
House Load Center

Inlet Box Receptacle

240 VAC

_- 120_VAC --="

\@/

G - Ground
W - Neutral
X - 120 VAC
Y - 120 VAC

Red Wires

A

Black Wires

A

Grn

Wht

Rating:

A through E - 120VAC

F through J - 120VAC
E and F - 240VAC

Figure 10. Schematic, 10 Circuit Model