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Portable Generator
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Briggs & Stratton Portable Generator User Manual [en, es, fr]

Home Generator Systems
Installation & Operator’s Manual
Manual No. 203421GS Rev. - (10/17/07)
200 Amp Automatic Transfer Switch
with Service Disconnect & AC Power Control Module
™
Briggs & Stratton Power Products Group, LLC 900 North Parkway Jefferson, WI 53549
Copyright © 2007 Briggs & Stratton Power Products Group, LLC. All rights reserved. No part of this material may be reproduced or transmitted in any form by any means without the express written permission of Briggs & Stratton Power Products Group, LLC.
Thank you for your purchase of this Briggs & Stratton Power Products Automatic Transfer Switch. This product is intended for use with Briggs & Stratton Home Standby Generator sets and therefore may not function with generators produced by other manufacturers. Seek a qualified electrical professional to determine applicability of this equipment to generators aside from those manufactured by Briggs & Stratton. This is an optional home standby system which provides an alternate source of electric power and to serve loads such as a gas furnace, refrigeration and communication systems that, when stopped during any power outage, could cause discomfort, or the like. This product DOES NOT qualify for emergency standby as defined by NFPA 70 (NEC).
This manual contains safety information to make you aware of the hazards and risks associated with transfer switches and how to avoid them. Briggs & Stratton has made every effort to provide for a safe, streamlined and cost-effective installation. Each installation is unique, it is impossible to know of and advise of all conceivable procedures and methods by which installation might be achieved. We do not know all possible hazards and/or the results of each method or procedure. Save
these instructions for future reference.
This transfer switch requires installation before use. Refer to the Installation section of this manual for instructions on installation procedures. Only licensed electrical contractors should install transfer switches. Installations must strictly comply with all applicable federal, state and local codes, standards and regulations.
Where to Find Us
You never have to look far to find Briggs & Stratton support and service for your transfer switch. Consult your Yellow Pages. There are over 30,000 Briggs & Stratton authorized service dealers worldwide who provide quality service. You can also contact Briggs & Stratton Customer Service by phone at (800) 743-4115, or on the Internet at BRIGGSandSTRATTON.COM.
Transfer Switch
Model Number Revision Serial Number
Date Purchased
3
FrançaisEspañol
Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Owner Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installer Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Equipment Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Mounting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
System Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Supervisory Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Wiring Interconnections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Testing the Automatic Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Table of Contents
Important Safety Instructions
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
The safety alert symbol ( ) is used with a signal word (DANGER, CAUTION, WARNING), a pictorial and/or a safety message to alert you to hazards. DANGER indicates a hazard which, if not avoided, will result in death or serious injury. WARNING indicates a hazard which, if not avoided, could result in death or serious injury. CAUTION indicates a hazard which, if not avoided, might result in minor or moderate injury. NOTICE indicates a situation that could result in equipment damage. Follow safety messages to avoid or reduce the risk of injury or death.
The manufacturer cannot possibly anticipate every possible circumstance that might involve a hazard. The warnings in this manual, and the tags and decals affixed to the unit are, therefore, not all-inclusive. If you use a procedure, work method or operating technique that the manufacturer does not specifically recommend, you must satisfy yourself that it is safe for you and others. You must also make sure that the procedure, work method or operating technique that you choose does not render the transfer switch unsafe.
Save These Instructions
WARNING
Only qualified electricians should attempt installation of this system, which must strictly comply with applicable codes, standards and regulations.
WARNING
Failure to properly ground transfer switch can result in electrocution.
• DO NOT touch bare wires or receptacles.
• DO NOT use transfer switch with worn, frayed, bare or otherwise damaged wiring.
• DO NOT handle electrical cords while standing in water, while barefoot, or while hands or feet are wet.
• If you must work around a unit while it is operating, stand on an insulated dry surface to reduce shock hazard.
• DO NOT allow unqualified persons or children to operate or service transfer switch.
• In case of an accident caused by electrical shock, immediately shut down the source of electrical power and contact local authorities. Avoid direct contact with the victim.
WARNING
Low voltage wire cannot be installed in same conduit as power voltage wiring.
• Failure to follow above warning could cause personal injury, damage and/or malfunction of equipment.
WARNING
Transfer Switch contains hazardous voltage that can cause personal injury or death.
• Despite the safe design of the transfer switch, operating this equipment imprudently, neglecting its maintenance or being careless can cause possible injury or death.
NOTICE
Improper treatment of transfer switch can damage it and shorten its life.
• Use transfer switch only for intended uses.
• If you have questions about intended use, ask dealer or contact Briggs and Stratton Power Products.
• DO NOT expose transfer switch to excessive moisture, dust, dirt, or corrosive vapors.
• Remain alert at all times while working on this equipment. NEVER work on the equipment when you are physically or mentally fatigued.
• If connected devices overheat, turn them off and turn off their circuit breaker/fuse.
5
Introduction
Your Briggs & Stratton Transfer Switch is supplied with this combined “Installation and Operator’s Manual”. This is an important document and should be retained by the owner after the installation has been completed.
Every effort has been expended to make sure that the information in this manual is both accurate and current. However, the manufacturer reserves the right to change, alter or otherwise improve the system at any time without prior notice.
For the Home Owner
To help you make informed choices and communicate effectively with your installation contractor(s),
Read and understand the Owner Orientation Section
of this manual BEFORE contracting or starting your
transfer switch installation.
To arrange for proper installation, contact the store at which you purchased your Briggs & Stratton Transfer Switch, your dealer, or your utility power provider.
The Transfer Switch Warranty is VOID
unless the system is installed by a
licensed electrical professional.
Owner Orientation
The illustrations are for typical circumstances and are meant to familiarize you with the installation options available with your transfer switch.
Local codes, appearance, and distances are the factors that must be considered when negotiating with an installation professional. As the distance from the existing electrical service increases, compensation in wiring materials must be allowed for. This is necessary to comply with local codes and overcome electrical voltage drops.
The factors mentioned above will have a direct effect on the overall price of your transfer switch installation.
NOTE: Your installer must check local codes AND obtain
permits before installing the system.
• Read and follow the instructions given in this manual.
• Follow a regular schedule in caring for and using your transfer switch, as specified in the manual.
Installer Responsibilities
• Read and observe the safety rules.
• Read and follow the instructions given in this manual.
• Check federal, state and local codes and authority having jurisdiction, for questions on installation.
• Ensure generator is not overloaded with selected loads.
If you need more information about the transfer switch, call
(800) 743-4115, between 8:00 AM and 5:00 PM CT.
Equipment Description
The transfer switch is intended to transfer the entire load of normal residential installations when used with the supervisory contacts provided. The load is connected either to utility power (normal) or home standby power (generator). The transfer switch monitors utility and generator voltages and will automatically connect to the appropriate source of power.
This switch makes it easy for a licensed electrician to complete a home standby installation. The unit contains utility service disconnect circuit breaker, generator disconnect circuit breaker and automatic transfer switch in one enclosure. Service conduit and conductors can be wired directly from your meter to the transfer switch. A separate disconnect and associated wiring are not required when installed per applicable federal, state and local codes, standards and regulations.
Major components of the transfer switch are a 2 pole utility disconnect circuit breaker, a 2 pole generator disconnect circuit breaker, a 2 pole double throw transfer switch, control circuit board, fused utility terminals and interconnecting wiring. The control board also has two inputs for current transformers that sense generator current.
The transfer switch is solenoid-operated from utility or generator inputs and contain suitable mechanical and electrical interlock switches to eliminate the possibility of connecting the utility service to the generator output. It has ratings capable of switching full utility power into the residence. In addition, a manual override lever is provided for the transfer function.
The control circuit board has active circuits sensing utility and generator voltages. It creates a signal for the generator start-up, switch transfer and retransfer when utility is restored. The control board also contains red and green LED’s indicating the power sources available and two relay operated contacts that provide supervisory control of external loads.
Installation
Unpacking
Delivery Inspection
After removing the carton, carefully inspect the transfer switch components for any damage that may have occurred during shipment.
IMPORTANT: If loss or damage is noted at time of delivery, have the person(s) making delivery note all damage on the freight bill and affix his signature under the consignor's memo of loss or damage. If loss or damage is noted after delivery, contact the carrier for claim procedures. Missing or damaged parts are not warranted.
Shipment Contents
• Automatic Power Transfer Switch
• Installation and Operator’s Manual
• Current Transformers
Mounting Guidelines
The Automatic Transfer Switch is enclosed in a NEMA Type 3R enclosure suitable for indoor/outdoor use. Guidelines for mounting the Automatic Transfer Switch include:
• Install the switch on a firm, sturdy supporting structure.
• The switch must be installed with minimum NEMA 3R hardware for conduit connections.
• To prevent switch contact distortion, level and plumb the enclosure. This can be done by placing washers between the switch enclosure and the mounting surface.
• NEVER install the switch where any corrosive substance might drip onto the enclosure.
• Protect the switch at all times against excessive moisture, dust, dirt, lint, construction grit and corrosive vapors.
A typical installation of the Automatic Power Transfer Switch is depicted below. An alternative installation of the Automatic Power Transfer Switch is also depicted below. It is best if the transfer switch is mounted near the utility meter, either inside or outside. Discuss layout suggestions/ changes with the owner before beginning the system installation process.
Main
Breaker
Panel
Transfer
Switch w/
Service and
Generator
Disconnect
Hot Water
Heater
Air
Conditioner
Contactor
Generator
Watt -
Hourmeter
Typical
Branch Circuits
— — — — — — Control Wiring
Disconnect Switch
Main
Breaker
Panel
Transfer
Switch
Hot Water
Heater
Air
Conditioner
Contactor
Disconnect Switch
Generator
Watt -
Hourmeter
Branch Circuits
Emergency
Branch Circuits
— — — — — — Control Wiring
Emergency
Load Center
Alternate
System Setup
You must perform the following before operating the system:
• If generator is installed in an area regularly subjected to temperatures below 40°F (4°C), select a 50 second warm up time by moving jumper installed on JP2 from ‘20’ position to ‘50’ position.
• Set the DPSW1 and DPSW2 dipswitches on the control module to match the KW rating of the Home Standby Generator set as described in Setting Dipswitches.
Setting Dipswitches
Dipswitches are used to adjust control board operation based on generator capacity and fuel source. Sum of DSPW1 and DPSW2 are set to correspond to system kW rating. Dipswitch DPSW1 has units of 1,000 Watts; Dipswitch DPSW2 has units of 10,000 Watts.
IMPORTANT: Set only one switch to “On” position on each dipswitch.
The “On” position for the dipswitches is the switch number ON THE CONTROL BOARD, not on the switch. For example, on a 27,000 Watt generator that runs on natural gas (NG), set DPSW2 dipswitch 20 to “On” position. Set DPSW1 dipswitch 7 to “On” position. 20,000 plus 7000 equals 27,000 Watts.
Supervisory Control Wiring
1. Terminal strip on control module in transfer switch has four connections for customer use. There are two sets of “Normally Closed” contacts available. They will be activated when generator power is required. These can be used for supervisory control of large connected loads on generator. Loads will be allowed to operate if there is enough generator power available.
NOTE: There are two wireways provided to keep the supervisory loads separated from each other.
2. Terminals “A-A” on control module are rated for 24 VAC and air conditioner contactor control. Contacts are connected in series with the air conditioner contactor control circuit.
3. Terminals “B-B” on control module are rated for 1 Amp 125 VAC and installer supplied contactor to control a large load. Example: electric hot water heater. Contacts are connected in series with the contactor control circuit.
4. Tighten all wire connections/fasteners to proper torque. See inside transfer switch enclosure for proper torque values.
7
A A
Air Conditioner Contactor
24 VAC
B B
Contactor
Neutral
120 VAC
JP2
DPSW1
Dipswitch
CT1 & CT2
Connectors
Supervisory
Contacts
DPSW2
Dipswitch
NOTICE
Use extreme caution when setting dipswitches or damage to control board will result.
• Use a pencil or small piece of plastic to set the dipswitch.
• NEVER use a screwdriver or any type of metal object to set dipswitches.
Wiring Interconnections
All wiring must be the proper size, properly supported and protected by conduit.
Complete the following connections between the transfer switch, main distribution panel, utility power and generator, as shown on the next page.
High Voltage Wiring
1. Ensure utility power is turned OFF. Connect utility Service conductors to line side of transfer switch service disconnect circuit breaker.
2. Connect utility service Neutral conductor to the transfer switch “NEUTRAL” terminal.
3. Connect main breaker panel feeder conductors to transfer switch terminals marked “LOAD CONNECTION”.
4. Connect main breaker panel Neutral conductor to transfer switch “NEUTRAL” terminal.
5. Connect main breaker panel Ground conductor to the transfer switch “GND” terminal.
NOTE: Assure grounding electrode conductor is connected and bonded per applicable federal, state and local codes, standards and regulations.
6. Connect generator feeder conductors from the generator control panel to line side of transfer switch “GENERATOR” breaker. Each conductor should pass through hole of current transformer before making connection.
7. Plug in current transformer leads into “CT1” and “CT2” on control module.
8. Connect Neutral conductor from the generator control panel to the transfer switch “NEUTRAL” terminal.
9. Connect generator Ground conductor from the control panel to the transfer switch “GND” terminal.
NOTE: Assure generator equipment grounding conductor is connected per applicable federal, state and local codes, standards and regulations.
10. Connect generator “UTILITY 240 VAC” terminals to transfer switch “UTILITY 240 VAC” terminals. Use minimum #14 AWG conductors.
11. Tighten all wire connections/fasteners to proper torque. See inside transfer switch enclosure for proper torque values.
Low Voltage Wiring
1. Connect Tx Rx and Tx Rx Ground from the generator control panel to the GND and T/R on the transfer switch control board.
2. Tighten all wire connections/fasteners to proper torque. See inside transfer switch enclosure for proper torque values.
WARNING
Low voltage wire cannot be installed in same conduit as power voltage wiring.
• Failure to follow above warning could cause personal injury, damage and/or malfunction of equipment.
9
Main
Main Distribution Panel
Ground Bus
Neutral Bus
To Generator
Neutral Terminal
To Utility Meter
Supervisory
Contacts
Load Connection
Ground Terminal
Generator
Connection
Utility
Connection
Current
Transformers
240V Generator
Connection
Generator Tx Rx and
Tx Rx Ground Connection
Controls
Other than a Manual Override lever, there are no operator controls because this is an automatic transfer switch. The manual override is to be used only by licensed professionals.
Operation
To select automatic transfer operation, do the following:
1. Set utility service disconnect circuit breaker in transfer
switch to “On” position.
2. Set generator disconnect circuit breaker in transfer
switch to “On” position.
3. Set generator’s main circuit breaker to its “On” position.
4. Install 15 Amp fuse in control panel on generator.
5A. If generator is equipped with a system ON/OFF switch,
set switch to “ON” position.
B. If generator is equipped with a AUTO/OFF/MANUAL
switch, set switch to “AUTO” position.
The system will now be in automatic operation mode. When the generator is providing power to the transfer
switch, the controller is constantly monitoring generator power. If the air conditioner is called to run, and there is sufficient generator power available, the controller will close contacts “A-A” to air conditioner contactor. Contacts “B-B” will open before contacts A-A close. If loads are too great for generator, contacts A-A and/or B-B will open. When air conditioning is not needed, A-A will open. If enough power is available, B-B will close.
Testing the Automatic Transfer Switch
Turn the utility disconnect circuit breaker in the transfer switch, to the “Off” position. The automatic sequence will follow. To go back to utility power, turn the utility disconnect circuit breaker to the “On” position.
Utility Fail
The Home Standby Generator set senses when utility voltage is below 70 percent of nominal. Engine start sequence is initiated after 6 second time delay.
Engine Warm-Up
Time delay to allow for engine warm-up before transfer is fixed at 20 seconds or 50 seconds with removal of jumper on control board.
Transfer
Transfer from utility to generator supply occurs after voltage is above set levels. Minimum engine run time is 5 minutes after transfer.
Utility Pickup
Voltage pickup level is 80 percent of nominal voltage.
Retransfer
Retransfer from generator to utility supply is approximately 10 seconds after utility voltage supply is above pickup level and minimum run time is completed.
Engine Cool Down
Engine will run for 60 seconds after retransfer.
11
Troubleshooting
Problem Cause Correction
Automatic transfer switch does not transfer to generator
1. Generator breaker open.
2. Generator voltage not acceptable.
3. Generator disconnect circuit breaker open.
1. Reset generator circuit breaker.
2. Refer to generator manual.
3. Reset generator disconnect circuit breaker.
Automatic transfer switch does not transfer to utility
1. Utility disconnect circuit breaker open.
2. Utility voltage not acceptable.
1. Reset utility disconnect circuit breaker.
2. Wait for utility voltage to return to normal.
Generator is still running after switch transfers to utility power
Engine cool down period. Engine should stop after 1 minute.
Generator or supervised loads (air conditioner, etc.) are operating improperly when generator is supplying power
1. A-A or B-B contacts not operating correctly.
2. Too much load on generator.
3. Current transformer not connected.
4. Broken current transformer.
1. Check A-A or B-B contacts for proper operation and/or check control wiring to external load.
2. Decrease load to generator.
3. Plug CT connectors into control module.
4. Contact local Briggs & Stratton service center.
Generator is still running after utility power is restored
1. Minimum engine run time has not elapsed.
2. Fuse(s) in transfer switch is defective.
1. Wait five minutes for transfer switch to retransfer to utility power.
2. Check fuse(s) and replace if necessary.
Maintenance
The transfer switch is designed to be maintenance free under normal usage. However, inspection and maintenance checks should be made on a regular basis. Maintenance will consist mainly of keeping the transfer switch clean.
Visual inspections should be done at least once a month. Access to transfer switch must not be obstructed. Keep 3 feet (92 cm) clearance around transfer switch. Check for an accumulation of dirt, moisture and/or corrosion on and around the enclosure, loose parts/hardware, cracks and/or discoloration to insulation, and damaged or discolored components.
Exercise the transfer switch at least once every three months as described in the previous section Testing the Automatic Transfer Switch unless a power outage occurs and Home Generator System has gone through automatic sequence. Allow generator to run for at least 30 minutes.
Contact a licensed electrical professional to inspect and clean the inside of your transfer switch at least once a year.
Specifications UL® 1008 Listed Transfer Switch
Maximum Load Current: . . . . . . . . . . . . . . . . . . . .200 Amps
Rated AC Voltage . . . . . . . . . . . . . . . . . . . . . . . . . .250 Volts
Poles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50/60 Hz
Fault Current Rating . . . .25,000 RMS Symmetrical Amperes
Supervisory Contacts Rating:
A-A Terminals . . . . . . . . . . . . . . . . . . . . . . . . . .24 Volt AC
B-B Terminals . . . . . . . . . .1 Amp, 125 Volt AC, Pilot Duty
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 lbs.
Transfer Switch Schematic
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