Generac 04635-0 User Manual
Owner’s Manual
GTS “W”T ype
Automatic
Transfer Switch
200 Amp, 250 Volts
Model 04635-0
®
POWER SYSTEMS, INC.
This manual should remain with the unit.
Generac®Power Systems, Inc.
Generac cannot possibly anticipate every possible cir
cumstance 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
Generac 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:
After this heading, read instructions that, if not
strictly complied with, will result in personal
injury, including 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
information that, if not followed, could endanger
personal safety and/or property of others.
This symbol points out potential explosion hazard.
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.
• 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.
!
!
IMPORTANT SAFETY INSTRUCTIONS
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.
!
!
!
!
DANGER
!
Table of Contents
Generac®Power Systems, Inc. 1
Safety Rules..........................................Inside Front Cover
Section 1 — General Information ..................................2
1.1 Introduction ............................................................2
1.2 Equipment Description ............................................2
1.3 Transfer Switch Data Plate ......................................2
1.4 Transfer Switch Enclosure ......................................2
1.5 Safe Use Of Transfer Switch ....................................2
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
2.4.1 2-Pole Mechanism ..........................................3
2.5 Connecting Start Circuit Wires ................................4
2.6 Auxiliary Contacts ....................................................4
Section 3 — Operation ......................................................5
3.1 Functional Tests & Adjustments ..............................5
3.2 Manual Operation ....................................................5
3.2.1 Close to Normal Source Side ........................6
3.2.2 Close to Emergency Source Side....................6
3.2.3 Return to Normal Source Side ......................6
3.3 Voltage Checks..........................................................6
3.4 Generator Tests Under Load ....................................7
Section 4 – Mounting Dimensions ................................8
Section 5 – Electrical Data ..............................................9
Section 6 – Exploded Views & Parts Lists ..................12
Section 7 – Warranty ......................................Back Cover
• Because jewelry conducts electricity, 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 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 MANUAL 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.
2 Generac®Power Systems, Inc.
Section 1 — General Information
Generac GTS “W” 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. Generac, 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 critical electrical load from a UTILITY
(Normal) power source to a 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 solid state
intelligence circuit, a transfer mechanism and a
control panel.
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.
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.
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;
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. Generac recommends that a copy of the
SAFETY RULES be 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
ASSEMBLY #
SERIAL #
Generac®Power Systems, Inc. 3
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 start circuit.
• Connecting any auxiliary contact (if needed)
• Installing/connecting any options and accessories.
• 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 “Mounting Dimensions”.
Handle transfer switches carefully when
installing. 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.
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
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. Power source and load
connections are made at a transfer mechanism,
inside the switch enclosure.
2.4.1 2-POLE MECHANISM
These switches (Figure 2.1) are used with a single
phase system, when the single phase NEUTRAL line
is to be connected to a Neutral Lug and is not to be
switched.
Figure 2.1 — Typical 2-Pole Transfer Mechanism
(100 Amp Shown)
Solderless, screw-type terminal lugs are standard.
The conductor size range is as follows:
Conductor sizes must be adequate to handle the
maximum current to which they will be subjected;
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 should enter the switch next
to transfer mechanism terminals. If ALUMINUM
conductors are used, apply corrosion inhibitor to
conductors. Tighten terminal lugs to the torque
values as noted on the decal located on the inside of
the door. After tightening terminal lugs, carefully wipe
away any excess corrosion inhibitor.
All power cables should enter the switch next to the
transfer mechanism terminals.
Section 2 — Installation
Generac GTS “W” Type Transfer Switch
Switch Rating Wire Range
200A #4-400 MCM
!
DANGER
Loading...