Generac 005036-0 User Manual
Automatic Transfer Switch
Owner’s Manual
ATS Service Entrance
HS Type Transfer Switch
Models: 005036-0, 100 Amp, 250 Volts
and 004945-1, 200 Amp, 250 Volts
This manual should remain with the unit.
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS - This manual contains important instructions that should be
followed during installation and maintenance of the generator and batteries.
SAVE THESE INSTRUCTIONS! Read the following information carefully before attempting to
install, operate or service this equipment. Also read the instructions and information on tags,
decals, and labels that may be affixed to the transfer switch. Replace any decal or label that
is no longer legible.
DANGER! Connection of a generator to an electrical system normally supplied by an electric
utility shall be by means of suitable transfer equipment so as to isolate the electric system
from utility distribution system when the generator is operating (Article 701 Legally Required
Standby Systems or Article 702 Optional Standby Systems, as applicable). Failure to isolate
electric system by these means may result in damage to generator and may result in injury
or death to utility workers due to backfeed of electrical energy.
Generac Power Systems, Inc., hereafter referred to as
the “manufacturer”, cannot anticipate every possible
circumstance that might involve a hazard. The warnings in this manual, and on tags and decals affixed
to the unit are, therefore, not all-inclusive. If using
a procedure, work method or operating technique
the manufacturer does not specifically recommend,
ensure that it is safe for others. Also make sure the
procedure, work method or operating technique chosen does not render the transfer switch unsafe.
Throughout this publication, and on tags and decals
affixed to the generator, DANGER, WARNING,
CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular operation that may be hazardous if performed incorrectly
or carelessly. Observe them carefully. Their definitions are as follows:
DANGER
After this heading, read instructions that, if not
strictly complied with, will result in personal injury, including without limitation, death, or property
damage.
After this heading, read instructions that, if not
strictly complied with, may result in personal injury or property damage.
After this heading, read instructions that, if not
strictly complied with, could result in damage to
equipment and/or property.
NOTE:
After this heading, read explanatory statements
that require special emphasis.
These safety warnings cannot eliminate the hazards
that they indicate. Common sense and strict compliance with the special instructions while performing
the service are essential to preventing accidents.
Four commonly used safety symbols accompany the
DANGER, WARNING and CAUTION blocks. The type
of information each indicates follows:
This symbol points out important safety infor-
mation that, if not followed, could endanger
personal safety and/or property.
This symbol points out potential explosion haz-
ard.
This symbol points out potential fire hazard.
This symbol points out potential electrical shock
hazard.
GENERAL HAZARDS
• Any AC generator that is used for backup power if
a NORMAL (UTILITY) power source failure occurs,
must be isolated from the NORMAL (UTILITY)
power source by means of an approved transfer
switch. Failure to properly isolate the NORMAL
and STANDBY power sources from each other may
result in injury or death to electric utility workers,
due to backfeed of electrical energy.
• Improper or unauthorized installation, operation,
service or repair of the equipment is extremely
dangerous and may result in death, serious personal injury, or damage to equipment and/or personal property.
• Extremely high and dangerous power voltages are
present inside an installed transfer switch. Any
contact with high voltage terminals, contacts or
wires will result in extremely hazardous, and possibly LETHAL, electric shock. DO NOT WORK ON
THE TRANSFER SWITCH UNTIL ALL POWER
VOLTAGE SUPPLIES TO THE SWITCH HAVE
BEEN POSITIVELY TURNED OFF.
Table of Contents
• Competent, qualified personnel should install,
operate and service this equipment. Adhere strictly
to local, state and national electrical and building
codes. When using this equipment, comply with
regulations the National Electrical Code (NEC),
CSA Standard; C22.1 Canadian Electric Code and
Occupational Safety and Health Administration
(OSHA) have established.
• Never handle any kind of electrical device while
standing in water, while barefoot, or while hands or
feet are wet. DANGEROUS ELECTRICAL SHOCK
MAY RESULT.
• Jewelry conducts electricity and wearing it may
cause dangerous electrical shock. Remove all jewelry (such as rings, watches, bracelets, etc.) before
working on this equipment.
• If work must be done on this equipment while
standing on metal or concrete, place insulative
mats over a dry wood platform. Work on this
equipment only while standing on such insulative
mats.
• Never work on this equipment while physically or
mentally fatigued.
• Keep the transfer switch enclosure door closed
and bolted at all times. Only qualified personnel
should be permitted access to the switch interior.
• In case of an accident caused by electric shock,
immediately shut down the source of electrical
power. If this is not possible, attempt to free the
victim from the live conductor but AVOID DIRECT
CONTACT WITH THE VICTIM. Use a nonconducting implement, such as a dry rope or board, to free
the victim from the live conductor. If the victim is
unconscious, apply first aid and get immediate
medical help.
• When an automatic transfer switch is installed for
a standby generator set, the generator engine may
crank and start at any time without warning. To
avoid possible injury that might be caused by such
sudden start-ups, the system’s automatic start circuit must be disabled before working on or around
the generator or transfer switch. For that purpose,
a SAFETY DISCONNECT is provided inside the
transfer switch. Always set that switch to its OFF
position before working on the equipment. Then
place a “DO NOT OPERATE” tag on the transfer
switch and on the generator. Remove the Negative
(Neg) or (–) battery cable.
Safety Rules .........................................Inside Front Cover
Section 1 — General Information ...................................2
1.1 Introduction............................................................. 2
1.2 Equipment Description ........................................... 2
1.2.1 Transfer Switch Mechanism .......................... 2
1.2.2 Service Disconnect Circuit Breaker ............... 2
1.3 Transfer Switch Data Decal ..................................... 2
1.4 Transfer Switch Enclosure ...................................... 3
1.5 Safe Use Of Transfer Switch .................................... 3
Section 2 — Installation ....................................................3
2.1 Introduction to Installation ...................................... 3
2.2 Unpacking ............................................................... 3
2.3 Mounting ................................................................. 3
2.4 Connecting Power Source and Load Lines ............... 3
2.5 Connecting Start Circuit Wires ................................ 4
Section 3 — Operation .......................................................4
3.1 Functional Tests & Adjustments .............................. 4
3.2 Manual Operation .................................................... 4
3.2.1 Close to Normal Source Side ........................ 5
3.2.2 Close to Emergency Source Side ................... 5
3.2.3 Return to Normal Source Side ...................... 5
3.3 Voltage Checks ......................................................... 6
3.4 Generator Tests Under Load ................................... 6
Section 4 – Installation Diagram ....................................7
Section 5 – Electrical Data ...............................................8
Section 6 – Exploded Views & Parts Lists ..................12
Section 7 – Notes .............................................................16
Section 8 – Warranty ...................................... Back Cover
For authorized service,
reference the dealer locator
number found in the generator
owner’s manual.
1
Section 1 — General Information
ATS “HS” Type Transfer Switch
1.1 INTRODUCTION
This manual has been prepared especially for the
purpose of familiarizing personnel with the design,
application, installation, operation and servicing of
the applicable equipment. Read the manual carefully
and comply with all instructions. This will help to
prevent accidents or damage to equipment that might
otherwise be caused by carelessness, incorrect application, or improper procedures.
Every effort has been expended to make sure that the
contents of this manual are both accurate and current. The manufacturer, however, reserves the right
to change, alter or otherwise improve the product at
any time without prior notice.
1.2 EQUIPMENT DESCRIPTION
The automatic transfer switch is used for transferring electrical load from a UTILITY (NORMAL) power
source to an EMERGENCY (STANDBY) power source.
Such a transfer of electrical loads occurs automatically when the UTILITY power source has failed or is
substantially reduced and the EMERGENCY source
voltage and frequency have reached an acceptable
level. The transfer switch prevents electrical feedback
between two different power sources (such as the
UTILITY and EMERGENCY sources) and, for that
reason, codes require it in all standby electric system
installations.
The transfer switch consists of a transfer mechanism, service disconnect circuit breaker, a relay
control, fuses, and a terminal strip for connection of
sensing wires.
This transfer switch is suitable for use as service
entrance equipment.
1.2.1 TRANSFER SWITCH MECHANISM
These switches (Figure 1.1) are used with a singlephase system, when the single-phase NEUTRAL line
is to be connected to a Neutral Lug and is not to be
switched.
Solderless, screw-type terminal lugs are standard.
Switch Wire Conductor Tightening
Rating Range Torque
100A #14-1/0 AWG 50 in-lbs.
200A #6-250 MCM 275 in-lbs.
This transfer switch is suitable for control of motors,
electric discharge lamps, tungsten filament and electric heating equipment where the sum of motor full
load ampere ratings and the ampere ratings of other
loads do not exceed the ampere rating of the switch
and the tungsten load does not exceed 30 percent of
the switch rating.
2
Figure 1.1 — Typical ATS Transfer Mechanism
UTILITY LUGS
UTILITY
CLOSING
COIL
GENERATOR
LUGS (E1 & E2)
GENERATOR
CLOSING
COIL
LOAD LUGS (T1 & T2)
This transfer switch is for use in optional standby
systems only.
This transfer switch is suitable for use on a circuit
capable of 10,000 rms symmetrical amperes, 240
VAC maximum.
1.2.2 SERVICE DISCONNECT CIRCUIT
BREAKER
The service disconnect circuit breaker for the 100
amp models are:
• Siemens, Type BQ, 2-pole
• 120/240VAC, 100A
• 50/60 Hertz
• Heating, Air Conditioning and Refrigeration (HACR)
rated
• Wire range: #1 - #8 AWG.
• The conductor tightening torque is 50 in-lbs.
The service disconnect circuit breaker for the 200
amp models are:
• Siemens, Type QN, 2-pole
• 120/240VAC, 200A
• 50/60 Hertz
• Heating, Air Conditioning and Refrigeration (HACR)
rated
• Wire range: 300 KCMIL - 4 AWG
• The conductor tightening torque is 250 in-lbs.
1.3 TRANSFER SWITCH DATA DECAL
A DATA DECAL is permanently affixed to the transfer
switch enclosure. Use this transfer switch only with
the specific limits shown on the DATA DECAL and
on other decals and labels that may be affixed to the
switch. This will prevent damage to equipment and
property.
Section 2 — Installation
GTS “HS” Type Transfer Switch
When requesting information or ordering parts for this
equipment, make sure to include all information from
the DATA DECAL.
Record the Model and Serial numbers in the space
provided below for future reference.
MODEL #
SERIAL #
1.4 TRANSFER SWITCH ENCLOSURE
The standard switch enclosure is a National
Electrical Manufacturer’s Association (NEMA) 3R
type. NEMA 3R type enclosures primarily provide
a degree of protection against falling rain and sleet
and is undamaged by the formation of ice on the
enclosure.
1.5 SAFE USE OF TRANSFER SWITCH
Before installing, operating or servicing this equipment, read the SAFETY RULES (inside front cover)
carefully. Comply strictly with all SAFETY RULES to
prevent accidents and/or damage to the equipment.
The manufacturer recommends that a copy of the
SAFETY RULES are posted near the transfer switch.
Also, be sure to read all instructions and information
found on tags, labels and decals affixed to the equipment.
Two publications that outline the safe use of transfer
switches are the following:
• NFPA 70; National Electrical Code
• UL 1008, STANDARD FOR SAFETY-AUTOMATIC
TRANSFER SWITCHES
2.1 INTRODUCTION TO INSTALLATION
This equipment has been wired and tested at the
factory. Installing the switch includes the following
procedures:
• Mounting the enclosure.
• Connecting power source and load leads.
• Connecting the generator sensing and transfer
relay circuits.
• Connecting any auxiliary contact (if needed)
• Testing functions.
2.2 UNPACKING
Carefully unpack the transfer switch. Inspect closely
for any damage that might have occurred during shipment. The purchaser must file with the carrier any
claims for loss or damage incurred while in transit.
Check that all packing material is completely removed
from the switch prior to installation.
2.3 MOUNTING
Mounting dimensions for the transfer switch enclosure are in this manual. Enclosures are typically
wall-mounted. See “Installation Diagram”, Section 5.
Handle transfer switches carefully when install-
ing. Do not drop the switch. Protect the switch
against impact at all times, and against construction grit and metal chips. Never install a transfer
switch that has been damaged.
This transfer switch is mounted in a NEMA 3R enclosure. It can be mounted outside or inside and should
be based on the layout of installation, convenience
and proximity to the utility supply and load center.
Install the transfer switch as close as possible to the
electrical loads that are to be connected to it. Mount
the switch vertically to a rigid supporting structure.
To prevent switch distortion, level all mounting
points. If necessary, use washers behind mounting
holes to level the unit.
2.4 CONNECTING POWER SOURCE
AND LOAD LINES
DANGER
Make sure to turn OFF both the UTILITY
(NORMAL) and EMERGENCY ( STANDBY) power
supplies before trying to connect power source
and load lines to the transfer switch. Supply
voltages are extremely high and dangerous.
Contact with such high voltage power supply lines causes extremely hazardous, possibly
lethal, electrical shock.
Wiring diagrams and electrical schematics are provided in this manual.
Two suggested installation methods are shown. One
for new installations and/or retrofit and one for retrofit.
NOTE:
All installations must comply with national, state
and local codes. It is the responsibility of the
installer to perform an installation that will pass
the final electrical inspection.
The utility supply connection is made at the circuit
breaker terminals. The generator supply and customer load connections are made at the transfer switch
mechanism, inside the switch enclosure.
3
Section 3 — Operation
ATS “HS” Type Transfer Switch
Conductor sizes must be adequate to handle the
maximum current to which they will be subjected to,
based on the 75°C column of tables, charts, etc. used
to size conductors. The installation must comply fully
with all applicable codes, standards and regulations.
Before connecting wiring cables to terminals, remove
any surface oxides from the cable ends with a wire
brush. All power cables must enter the enclosure
through the knockouts. If not using the knockouts,
entry must be at or below knockouts. If ALUMINUM
conductors are used, apply corrosion inhibitor to
conductors. Tighten terminal lugs to the torque
values as noted in Section 1.2.2, and on the decal
located on the inside of the door. After tightening terminal lugs, carefully wipe away any excess corrosion
inhibitor.
Use a torque wrench to tighten the conduc-
tors, being sure not to overtighten, or damage
to the switch base could occur. If not tightened
enough, a loose connection would result, causing excess heat which could damage the switch
base.
Connect power source load conductors to clearly
marked transfer mechanism terminal lugs as follows
1. Connect UTILITY (NORMAL) power source cables
to circuit breaker.
2. Connect EMERGENCY (STANDBY) source power
cables to transfer switch terminals E1, E2.
3. Connect customer LOAD leads to switch terminals T1, T2.
Conductors must be properly supported, of approved
insulative qualities, protected by approved conduit,
and of the correct wire gauge size in accordance with
applicable codes.
Be sure to maintain proper electrical clearance
between live metal parts and grounded metal. Allow
at least 1/2 inch for 100-400 amp circuits.
2.5 CONNECTING START CIRCUIT
WIRES
Control system interconnections consist of N1 and
N2, T1 and T2, and leads 23 and 194. Control system
interconnection leads must be run in a conduit that
is separate from the AC power lead. Recommended
wire gauge sizes for this wiring depends on the length
of the wire, as recommended below:
MAXIMUM WIRE LENGTH RECOMMENDED WIRE
SIZE
460 feet (140m) No. 18 AWG.
461 to 730 feet (223m) No. 16 AWG.
731 to 1,160 feet (354m) No. 14 AWG.
1,160 to 1,850 feet (565m) No. 12 AWG.
4
NOTE:
When this ATS is used with an air-cooled generator, the LOAD 1 and LOAD 2 wires are not used.
3.1 FUNCTIONAL TESTS AND
ADJUSTMENTS
Following transfer switch installation and interconnection, inspect the entire installation carefully. A competent, qualified electrician should
inspect it. The installation should comply strictly
with all applicable codes, standards, and regulations. When absolutely certain the installation is
proper and correct, complete a functional test of
the system.
Perform functional tests in the exact order pre-
sented in this manual, or damage could be done
to the switch.
IMPORTANT: Before proceeding with functional tests,
read and make sure all instructions and information
in this section are understood. Also read the information and instructions of labels and decals affixed
to the switch. Note any options or accessories that
might be installed and review their operation.
3.2 MANUAL OPERATION
DANGER
Do NOT manually transfer under load.
Disconnect transfer switch from all power sources by approved means, such as the main circuit
breaker(s).
A manual HANDLE is shipped with the transfer
switch. Manual operation must be checked BEFORE
the transfer switch is operated electrically. To check
manual operation, proceed as follows:
1. Turn the generator’s AUTO/OFF/MANUAL switch
to OFF.
2. Turn OFF both UTILITY (service disconnect cir-
cuit breaker) and EMERGENCY (generator main
line to circuit breaker) power supplies to the
transfer switch.
3. Turn the GENERATOR DISCONNECT SWITCH
to the OFF position.
4. Note position of transfer mechanism main con-
tacts by observing the moveable contact carrier
arm. This can be viewed through the long narrow
slot in the inside cover of the ATS. The top of the
moveable contact carrier arm is yellow to be easily identified.
• Manual operation handle in the UP position LOAD terminals (T1, T2) are connected to UTILITY terminals (N1, N2).
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