POWER SYSTEMS, INC.
®
Owner’s Manual
100 and 200 Amp
“V” Type and “Y”Type
Transfer Switch
Models: 09227-0, 09228-0,
09229-0, and 09230-0
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
you use a procedure, work method or operating technique Generac does not specifically recommend, you
must satisfy yourself that it is safe for you and others.
You also must make sure the procedure, work
method or operating technique that you choose 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 you to
special instruction about a particular operation that
may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are
as follows:
After this heading, you can read instructions that,
if not strictly complied with, will result in personal
injury or property damage.
After this heading, you can read instructions that,
if not strictly complied with, may result in personal
injury or property damage.
After this heading, you can read instructions that, if
not strictly complied with, could result in damage to
equipment and/or property.
NOTE:
After this heading, you can 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 you and 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
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
Section2—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 Mechanisms ......................................4
2.4.2 3-Pole Mechanisms ......................................4
2.5 Connecting Start Circuit Wires ................................5
2.6 Auxiliary Contacts ..................................................5
2.7 Optional Accessories ..............................................5
Section 3 — Operation..................................................................5
3.1 Functional Tests and Adjustments ..........................6
3.2 Functional Tests ......................................................6
3.3 Manual Operation....................................................6
3.3.1 “V” Type Transfer Switches ..........................6
3.3.2 “Y” Type Transfer Switches ..........................7
3.4 Voltage Checks ........................................................7
3.5 Generator Tests Under Load ..................................8
Section 4 – Notes ..........................................................................9
Section 5 – Wiring Diagrams & Electrical
Schematics ..............................................................10
Section 6 – Exploded Views & Parts Lists ............................14
Section7–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 you must work 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.
2 Generac®Power Systems, Inc.
Section 1 — General Information
Generac “V” Type and “Y” 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 pre-packaged transfer switch is designed to use
with pre-packaged standby generator control panels.
It is used for transferring critical electrical loads from
a NORMAL (utility) power source to a STANDBY
(emergency generator) power source. Such a transfer
of loads occurs automatically when the NORMAL
power source fails or is subsequently reduced and
the STANDBY source voltage and frequency have
reached an acceptable level. The transfer switch prevents electrical feedback between two different power
sources (such as the NORMAL and STANDBY
sources) and, for that reason, codes require it in all
standby electric system installations.
Once the transfer is completed, the STANDBY power
source then powers electrical loads connected to the
transfer switch. When NORMAL source voltage above
an acceptable (preset) level has been restored, circuit
board action in the pre-packaged control panel initiates re-transfer back to NORMAL power source. After
this re-transfer, the circuit board signals to open the
start circuit to the generator, which shuts down the
engine. The circuit board is then "armed" and ready
for the next drop in NORMAL source voltage.
NOTE:
Keep in mind the pre-packaged transfer switch is
without any kind of electronic controls. It receives
signals solely from circuit boards contained in the
prepackaged control panel.
1.3 TRANSFER SWITCH DATA PLATE
Affixed permanently to the transfer switch door is a
DATA PLATE. Use the transfer switch only within the
specific limits shown on the DATA PLATE and on
other decals and labels that may be affixed to the
switch. This prevents damage to equipment, possible
injury to personnel, and provides long and troublefree life for the equipment.
When requesting information or ordering parts for
this equipment, make sure to include all information
from the DATA PLATE.
When requesting information or ordering parts for this
equipment, make sure to include all information from
the DATA PLATE.
Record your 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) 1 type.
NEMA 1 type enclosures primarily provide protection
against contact with the enclosed equipment and
against a limited amount of falling dirt.
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 you make a copy of the SAFETY RULES and post them near the transfer switch.
Also, be sure to read all instructions and information
you may find on tags, labels and decals affixed to the
equipment.
Two publications that outline the safe use of transfer
switches are the following:
• National Electrical Code
• UL 1008, STANDARD FOR SAFETY-AUTOMATIC
TRANSFER SWITCHES
MODEL #
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.
• 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.
Attach any lifting device to the transfer switch mounting holes or brackets only. DO NOT LIFT THE
SWITCH AT ANY OTHER POINT.
2.3 MOUNTING
Transfer switch components are generally mounted
in a standard NEMA 1 type enclosure (Figure 2.1).
Other options are available such as NEMA 34 and
NEMA 12.
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. 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 normal (Utility)
and standby (generator) 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.
Section2—Installation
Generac “V” Type and “Y” Type Transfer Switch
09
32
6.72
59
T
Figure 2.1 — Mounting Dimensions for Enclosures
92
62
0725.0
63
S
!
DANGER
14.
7.
20.
MOUNTING DIMENSIONS - 100 AMP,2-POLE UNI
19.37
19.
15.
7
MOUNTING DIMENSIONS - 200 & 400 AMP UNIT
7.
24.
4 Generac®Power Systems, Inc.
2.4.1 2-POLE MECHANISMS
These switches (Figures 2.2 and 2.3) 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 2.2 — 100 Amp 2-pole Transfer
Mechanism
Figure 2.3 — 200 Amp 2-pole Transfer
Mechanism
2.4.2 3-POLE MECHANISMS
This switch (Figure 2.4) is also 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 2.4 — 3-Pole Transfer Mechanism
Solderless, screw-type terminal lugs are standard.
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. If ALUMINUM conductors are used, apply corrosion inhibitor to conductors. After tightening terminal lugs, carefully wipe away any excess corrosion
inhibitor.
All power cables should enter the switch next to
transfer mechanism terminals. Standard terminal
lugs on the transfer mechanism are solderless,
screw-type.
Connect power source load conductors to clearly
marked transfer mechanism terminal lugs as follows
(Figure 2.5 on page 5):
1. Connect NORMAL (utility) power source cables to
switch terminals N1, N2, N3, etc.
2. Connect STANDBY source power cables to trans-
fer switch terminals E1, E2, E3, etc.
3. Connect customer LOAD leads to switch termi-
nals T1, T2, T3, etc.
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.
Tighten terminal lugs to the following torques:
100 Amp Switch: 50 INCH-POUNDS
200 Amp Switch: 250 INCH-POUNDS
Make sure to maintain proper electrical 1/2-inch
clearance between live metal parts and grounded
metal.
◆
Section2—Installation
Generac “V” Type and “Y” Type Transfer Switch
Generac®Power Systems, Inc. 5
Section2—Installation
Generac “V” Type and “Y” Type Transfer Switch
2.5 CONNECTING START CIRCUIT
WIRES
Control system interconnections (Figure 2.5) consist
of UTILITY 1 and 2, LOAD 1 and 2; 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:
NOTE:
The preceding start circuit connections apply to
the standard 2-wire start system only Your transfer
switch may be equipped with a 3-wire connection
system.
2.6 AUXILIARY CONTACTS
If desired, you can access a set of Auxiliary Contacts
on the Transfer Switch to operate customer accessories, remote advisory lights, or remote annunciator
devices. A suitable power source must be connected
to the COMMON (C) terminal. The contacts labeled 1,
2 and 3 (Figure 2.6) are connected at the factory for
operation of transfer switch advisory lights. Contacts
4, 5 and 6 are available for customer use.
Figure 2.6 — Auxiliary Contact Schematic
Auxiliary contacts are rated 15 amperes at 125, 250 or
480 volts AC; 0.5 ampere at 125 volts DC; 0.25 ampere
at 250 volts DC. DO NOT EXCEED THE RATED
VOLTAGE AND CURRENT OF THE CONTACTS.
Contact operation is shown in the following chart:
2.7 OPTIONAL ACCESSORIES
Note any optional accessories that may be installed
on the transfer switch or are to be installed in the
standby electric system in conjunction with the
switch. Complete the necessary connections for these
accessories.
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.
1,161 to 1,850 feet (565m) No. 12 AWG.
-
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1
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2
2
3
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Figure 2.5 — Transfer Switch Interconnections (Drawing #79963-B)
Switch Position
Utility Standby
Common (4) to Normally Closed (6) Closed Open
Common (4) to Normally Closed (5) Open Closed
REMOTE TES
SWITCH (OPTIONAL
- OPEN SWITCH TO TEST
SWITCH TYPE, SPS
ELECTRICAL RATINGS
2A @ 250Vac MIN
TILIT
PPL
N3, E3 AND T3 NO
ED ON SINGLE PHA
YSTEM
WIT
TILITY 1
TILITY 2
AD 1
AD 2
4
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NEUTRA
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NOTE
POWER LEADS AND
TRAN
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LEADS MUST B
RUN IN TW
DIFFERENT CONDUIT
E
AC GENERAT
NTROL PANE
TILITY
TILITY
LOAD
2
1
NEUTRA
NNECTI
6 Generac®Power Systems, Inc.
3.1 FUNCTIONAL TESTS AND
ADJUSTMENTS
Following transfer switch installation and interconnection, inspect the entire installation carefully. A
competent, qualified electrician should make the
inspection.
The installation should comply strictly with all applicable codes, standards, laws and regulations. All
electrical connections must be correct and in compliance with applicable codes and standards.
Make sure the standby generator is ready. This
includes checking engine oil level, coolant level, fuel
supply, batteries and other items specified in the
OWNER'S MANUAL for specific generators.
Complete all functional tests as outlined in the FUNCTIONAL TESTS section. Do this before placing the
transfer switch into service.
3.2 FUNCTIONAL TESTS
Following transfer switch installation, the entire
standby electric system should be inspected and tested. Have all necessary adjustments completed at this
time. Functional tests of the transfer switch include
these tests: (a) Manual Operation, (b) Voltage Checks
and (c) Electric Operation.
To avoid damaging the transfer switch, perform
functional tests In the exact order given.
Before proceeding with functional tests, read and be
sure you understand all instructions in this section.
Also, read the instructions and information on tags
and decals affixed to the transfer switch. Note any
options and accessories that might be installed or
provided with the switch and review their operation.
DO NOT ATTEMPT MANUAL OPERATION OF THE
TRANSFER SWITCH UNTIL AFTER ALL POWER
VOLTAGE SUPPLIES TO THE SWITCH HAVE BEEN
TURNED OFF. FAILURE TO TURN OFF POWER
VOLTAGE SUPPLIES MAY RESULT IN DANGEROUS AND POSSIBLE FATAL ELECTRICAL SHOCK.
3.3 MANUAL OPERATION
The pre-packaged transfer switch has a choice of two
transfer mechanisms - the "V" type (Model 9227-0)
and the "Y" type (Models 9228, 9229 and 9230).
3.3.1 “V” TYPE TRANSFER SWITCHES
Test manual operation for “V” type transfer switches
as follows:
1. Check that the generator's Auto/Off/Manual
switch has been set to OFF position.
2. Turn OFF the UTILITY power supply to the transfer switch, using whatever means provided (such
as the UTILITY source main line circuit breaker).
3. Set the generator's main circuit breaker to its
OFF or OPEN position.
FAILURE TO TURN OFF ALL A POWER VOLTAGE
SUPPLIES TO THE TRANSFER SWITCH BEFORE
ATTEMPTING MANUAL OPERATION RESULTS IN
EXTREMELY HAZARDOUS AND POSSIBLY FATAL
ELECTRICAL SHOCK.
4. Remove the manual transfer handle from the
enclosure.
5. Place open slot of the manual transfer handle on
the small tab of the transfer switch operating
lever (Figure 3.1).
6. Pull manual transfer handle downward, then
move it back to original position. If handle is
down, LOAD is connected to UTILITY power
source. If handle is up, LOAD is connected to
STANDBY power.
7. Move the transfer switch main contacts to both
positions several times. Leave the transfer switch
in the UTILITY position and connect LOAD to the
UTILITY power source (manual operation lever is
up).
Figure 3.1 — Transfer Switch Operation
(“V” Type)
◆
Section 3 — Operation
Generac “V” Type and “Y” Type Transfer Switch
!
DANGER
DANGER
Generac®Power Systems, Inc. 7
3.3.1 “Y” TYPE TRANSFER SWITCHES
A manual handle was shipped with the transfer
switch. Test manual operation for “Y” type transfer
switches as follows (Figure 3.2):
1. Check that the generator's Auto/Off/Manual
switch has been set to OFF position.
2. Attach the square opening of the manual handle
over the square shaft at lower right corner of
transfer mechanism.
3. Move the manual handle UP. When movement
stops at NEUTRAL, return handle to its original
position and actuate again.
4. Observe the changeover display on transfer
mechanism as follows:
• If utility arrow is aligned with GREEN band, load
is connected to UTILITY (normal) power source.
• If STANDBY arrow is aligned with GREEN band,
LOAD is connected to STANDBY (emergency)
source.
5. Repeat steps 3 and 4 several times, being sure the
switch main contacts actuate normally to all positions.
6. When certain that switch operates normally, actuate the main contacts to their UTILITY (normal)
source.
NOTE:
LOAD must be connected to UTILITY source
before proceeding. That is, the GREEN BAND
must be next to the UTILITY arrow and the RED
band must be next to the STANDBY arrow.
Figure 3.2 — Manual Operation of “Y” Type
Transfer Switch
3.4 VOLTAGE CHECKS
1. Turn ON the UTILITY power supply to the transfer switch with whatever means provided (such as
the UTILITY maim line circuit breaker).
PROCEED WITH CAUTION. THE TRANSFER
SWITCH IS NOW ELECTRICALLY HOT. CONTACT
WITH LIVE TERMINALS RESULTS IN EXTREMELY
HAZARDOUS AND POSSIBLY FATAL ELECTRICAL
SHOCK.
2. With an accurate AC voltmeter, check for correct
voltage across terminal lugs N1 and N2; N1 to
NEUTRAL; and finally N2 to NEUTRAL (Figure
2.5 on Page 5).
3. When certain that UTILITY supply voltage is correct
and compatible with transfer switch ratings, turn
OFF the UTILITY supply to the transfer switch.
4. On the generator panel, set the Auto/Off/Manual
switch to MANUAL position. The generator
should crank and start.
5. Let the generator stabilize and warm up at noload for at least five minutes.
6. Set the generator's main circuit breaker (CBI ) to
its ON or CLOSED position.
PROCEED WITH CAUTION. A GENERATOR OUTPUT VOLTAGE IS NOW BEING DELIVERED TO
TRANSFER SWITCH TERMINALS. CONTACT WITH
LIVE TERMINALS RESULTS IN EXTREMELY DANGEROUS AND POSSIBLY FATAL ELECTRICAL
SHOCK.
7. With an accurate AC voltmeter and frequency
meter, check the no-load, voltage and frequency
meter at transfer switch terminal lugs E1, E2 and
NEUTRAL. Readings should be as follows:
a. Frequency ........................61-63 Hz
b. Terminals E1 and E2 ......242-253 volts
c. Terminal E1 to Neutral ....121-126 volts
d. Terminal E2 to Neutral ....121-126 volts
8. Set the generator's main circuit breaker (CBI ) to
its OFF or OPEN position.
9. To shut down the generator, set its
Auto/Off/Manual switch to OFF position.
NOTE:
Do NOT proceed until generator AC output voltage
and frequency are correct and within stated limits.
If the no-load voltage is correct but no-load frequency is incorrect, the engine governed speed
probably requires adjustment. If no-load frequency is correct but voltage is not, the voltage regulator may require adjustment.
◆
Section 3 — Operation
Generac “V” Type and “Y” Type Transfer Switch
DANGER
DANGER
8 Generac®Power Systems, Inc.
3.5 GENERATOR TESTS UNDER LOAD
1. Set the generator's main circuit breaker to its
OFF or OPEN position.
2. Manually actuate the transfer switch main contacts to their STANDBY position.
3. To start the generator, set the Auto/Off/Manual
switch to MANUAL. When engine starts, let it stabilize for a few minutes.
4. Turn the generator's main circuit breaker to its
ON or CLOSED position. The generator now powers all LOAD circuits. Check generator operation
under load as follows:
• Turn ON electrical loads to the full rated
wattage/amperage capacity of the generator. DO
NOT OVERLOAD.
• With maximum rated load applied, check voltage
and frequency across transfer switch terminals
E1 and E2. Voltage should be greater than 230
volts; frequency should be greater than 58 Hz.
• Let the generator run under rated load for at
least 30 minutes. With unit running, listen for
unusual noises, vibration, overheating, etc., that
might indicate a problem.
5. When checkout under load is complete, set main
circuit breaker of the generator to its OFF or
OPEN position.
6. Let the generator run at no-load for several minutes. Then, shut down by setting the
Auto/Off/Manual switch to its OFF position.
7. With the manual transfer handle, move the
switch's main contacts back to their utility position, i.e., load connected to utility power supply.
Handle and operating lever of transfer switch
should be in down position.
8. Turn on the utility power supply to transfer
switch, using whatever means provided (such as
a utility main line circuit breaker). The utility
power source now powers the loads.
9. Set the generator's Auto/Off/Manual switch to its
AUTO position. The system is now set for fully
automatic operation.
Section 3 — Operation
Generac “V” Type and “Y” Type Transfer Switch
Generac®Power Systems, Inc. 9
Section4—Notes
Generac “V” Type and “Y” Type Transfer Switch
O
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10 Generac®Power Systems, Inc.
Section5—Electrical Schematics and Wiring Diagrams
Interconnection Diagram - Drawing No. 074106-A
N
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TILITY
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OPTIONAL
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SWITCH TYPE
ELECTRICAL RATINGS
PEN
-
Section5—Electrical Schematics and Wiring Diagrams
200 Amp, 2-Pole Transfer Switch - Drawing No. 074498-B
Generac®Power Systems, Inc. 11
6
6
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RAN
N.
ITI
DIA
T
IL
END
ATIN
T
E
R A
T
NTA
-
R
T
ACTUATOR
NTA
H
WIT
FER
TRANSFER
LS3 - LIMIT SWITCHES
LS2
- TRAN
T
R - RELAY
S1
CUSTOMER CONNECTION
S - TERMINAL STRIP
HEMATI
2
1
2
3
6
6
G
CO
C
S
S
O
S
S
C
U
O
194
23
N1A
N
T
T
6
6
6
S
C
G
G
G
RAM
S
CO
C
O
C
U
G
CO
S
S
S
C
CO
C
O
,
Y
,
(
)
Section5—Electrical Schematics and Wiring Diagrams
3-Pole Transfer Switch - Drawing No. 074499-B
12 Generac®Power Systems, Inc.
DIA
2
4
2
1
2
E1
4
IRIN
RAM
DIA
T
N
2
2
2
2
2
TILITY
4
WN WITH
H IN
H
WIT
T
4
TE:
NTA
LL
FER
RAN
N.
ITI
1
HEMATI
ED
2
1
T
R
T
IL
NTA
END
H
3 PHASE UTILIT
ATIN
T
E
2
R A
T
NTA
-
CUSTOMER CONNECTION
WIT
FER
TRANSFER
- TRAN
T
M - POWER MONITOR
R - RELAY
S - TERMINAL STRIP
S1,LS2,LS3 - LIMIT SWITCHES, ACTUATOR
Section5—Electrical Schematics and Wiring Diagrams
Transfer Switch - Drawing No. 081222-B
Generac®Power Systems, Inc. 13
G
G
,
(
)
U
OC
,
R
,
,
,
,
,
,
O
S
C
G
S
S
S
C
CO
C
O
(
)
(
)
CO
C
S
S
O
S
S
C
U
6
G
6
B
1
A
6
194
UTILITY
LO
UTILITY
O
23
)
S
)
RAM
DIA
IRIN
T
4
C1
2
C2
4
4
4
AD 2
AD 1
L
2
1
2A
END
E
RAM
DIA
12
HEMATI
T
B
2
1
R1
4
4
R
T
NTA
H
UTILITY CLOSING
STANDBY CLOSING
WIT
FER
TRANSFER
- TRAN
T
1- SOLENOID COIL
2- SOLENOID COIL
R - RELAY
TILITY
WN WITH
H IN
H
WIT
T
NTA
FER
TE:
LL
RAN
ACTUATOR
CUSTOMER CONNECTION
5A SENSING
F4-FUSE
F3
XB1- LIMIT SWITCHES
VR2 - VARISTO
F2
A1
R1
1
S - TERMINAL STRIP
N.
ITI
K
TRAL BL
B - NE
5
0
3
618
0
92326
0
0
L
L
DECA
L
L
0
3
4
5
Section 6 — Exploded Views and Parts Lists
Transfer Switch - Drawing No. 078589-H
14 Generac®Power Systems, Inc.
DECA
1
1
1
1
1
DECA
DECA
1
4
2
2
1
4
2
Generac®Power Systems, Inc. 15
ITEM PART NO. QTY. DESCRIPTION
1 62642 1 SWITCH TRANSFER-#79953
62677 1 SWITCH TRANSFER-#79953-A
64198 1 SWITCH TRANSFER-#79953-B
2 C2267 4 M5-.8 x 12 SWAGEFORM HHC
3 49226 6 WASHER, LOCK-M5
4 23897 4 WASHER, FLAT-M5
5 57073 1 LUG, NEUTRAL
6 27628 1 NUT, HEX .375-16
7 22131 1 WASHER, LOCK 3/8"
8 C2266 2 M5-.8 x 16 SWAGEFORM PPH
9 79954 1 DECAL, SWITCH RATING-#79953
79955 1 DECAL, SWITCH RATING #79953-A
79956 1 DECAL, SWITCH RATING-#79953-B
10 63552 9 DEVICE, ANTI-ROTATION-#79953
11 62684 9 LUG, SOLDERLESS-#79953
12 62704 4 LUG, SOLDERLESS-#79953-A
62704 6 LUG, SOLDERLESS-#79953-B
13 63378 5 HOLD DOWN, TIE WRAP
14 74991 1 DECAL, MANUAL OPERATIONS
15 75353 1 DECAL, UL COMPONENT RECOGNITION
16 A2595 1 DECAL, TERMINAL STRIP
17 47822 1 STRIP, TERMINAL
18 A1661 2 POP RIVET
19 64113 1 STUD, WING
20 63321 1 HANDLE, TRANSFER SWITCH
21 57329 1 LUG, GROUND
22 63306 1 MONITOR, POWER 3-PHASE
23 61675 1 SOCKET, RELAY OCTAL
24 47411 4 M6-1.0 x 16 HHCS
25 22473 4 M6 FLAT WASHER
26 76063 1 ENCLOSURE
27** 75506 1 COVER, ENCLOSURE
28 79959 1 DECAL, UL INFORMATION
29** 79957 1 ASSEMBLY, WIRE HARNESS-#79953
79958-A 1 ASSEMBLY, WIRE HARNESS-#79953-A
79957-A 1 ASSEMBLY, WIRE HARNESS-#79953-B
30** 69254 4 CRIMPTITE
31 28739 5 WRAP, TIE
32 C2265 4 M4-.7 x 12 SWAGEFORM PPH
33 22264 4 WASHER, LOCK-M4
34 22985 2 WASHER, FLAT-M4
35 63617 1 RELAY, 12VDC 10A.
36 62702 2 LUG, SOLDERLESS-#79953-A
62702 3 LUG, SOLDERLESS-#79953-B
37 26902 - TAPTITE, #8 x 1/4"-#79953
26902 6 TAPTITE, #8 x 1/4"-#79953-A
26902 7 TAPTITE, #8 x 1/4"-#79953-B
38 22142 1 5/16" x 3/4" HHCS
39 27482 1 5/16" SHAKEPROOF WASHER
40 22129 1 5/16" LOCK WASHER
41 22259 1 5/16"-18 HEX NUT
42 67210A 1 DECAL, GROUND
43 22097 4 M6 LOCK WASHER
44 75506 1 COVER
Section 6 — Exploded Views and Parts Lists
Transfer Switch - Drawing No. 078589-H
16 Generac®Power Systems, Inc.
3
Y
P
8
9
6
8
5
6
6
3
6
R
)
L
L
L
0
3
L
L
5
9
8
6
)
Section 6 — Exploded Views and Parts Lists
Transfer Switch - Drawing No. 078589-H
1
4
4
TO RETAIN COVE
231
2
1
1
2
DECA
TERM. STRI
REF. ONL
DECA
-
2
DECA
BOTTOM POWER TERMINALS
4
4
DECA
2
1
POWER TERMINAL LUG ASSY
151
4
4
DECA
Generac®Power Systems, Inc. 17
ITEM PART NO. QTY. DESCRIPTION
1 79849 1 ENCLOSURE
2* 74975 1 COVER, ENCLOSURE
3 71340 1 SWITCH, TRANSFER 100A. 2-POLE
4 C2267 4 M5-.8 x 12 SWAGEFORM HHC
5 49226 4 M5 LOCK WASHER
6 51713 4 M5 FLAT WASHER
7 63617 1 RELAY, 12V. DC 10A.
8 27628 1 NUT, .375-16
9 C2265 2 M4-.7 x 12 SWAGEFORM PPH
10 A1661 2 POP RIVET
11 22264 6 #8 LOCK WASHER
12 38150 6 #8 FLAT WASHER
13** 75353 1 DECAL, UL COMPONENT RECOGNITION
14 57073 1 LUG, NEUTRAL
15 C2266 2 M5-.8 x 16 SWAGEFORM PPH
16 22152 8 WASHER, LOCK #10
17 64113 1 STUD, WING
18 77441 - HANDLE, TRANSFER SWITCH
19 77440 1 COVER, POWER TERMINAL
20 22131 1 WASHER, FLAT .375 NOM.
21 36932 6 PPHMS 10-32 x 1/4"
22 77033 6 LUG, SOLDERLESS
23 74138 2 MALE DISCONNECT ADAPTOR (BENT)
24 77052 2 MALE DISCONNECT ADAPTOR
25** 77029 1 DECAL, MANUAL OPERATIONS
26 A2595 1 DECAL, TERMINAL STRIP
27* 81238 1 HARNESS, WIRE
28** 77032 1 DECAL, TRANSFER SWITCH RATING
29** 77036 1 DECAL, UL INFORMATION
30 79840 1 COVER, RELAY & TERM. BLOCK
31 79846 4 STANDOFF HEX S/S
32 22471 4 HEX NUT #8-32
33 81221 1 DECAL, NAME PLATE UL
34 73591 4 FUSE HOLDER
35 73590 4 FUSE 2A. 600V.
36 47411 4 M6-1.0 x 16 HHCS
37 83736 1 DECAL, CSA
38 95282 1 DECAL, LIVE CIRCUIT WARNING
39 62684 1 LUG, GROUND
40 22142 1 5/16"-18 x 3/4" HHCS
41 27482 1 5/16" SHAKEPROOF WASHER
42 22129 1 5/16" LOCK WASHER
43 22259 1 5/16"-18 HEX NUT
44 67210A 1 DECAL, GROUND
45 A9457 1 DECAL, NEUTRAL
46 74975 1 COVER
47 C2212 4 M4-.7 x 16 SWAGEFORM PPH
48 22473 4 M6 FLAT WASHER
49 22097 4 M6 LOCK WASHER
Section 6 — Exploded Views and Parts Lists
Transfer Switch - Drawing No. 078589-H
Part No. 078590 Revision D (05/29/02) Printed in U.S.A.
Section7—Warranty
Generac “V” Type and “Y” Type Transfer Switch
GENERAC POWER SYSTEMS STANDARD TWO-YEAR LIMITED WARRANTY
FOR GENERAC TRANSFER SWITCH SYSTEMS
NOTE: ALL UNITS MUST HAVE A START-UP INSPECTION PERFORMED BY AN AUTHORIZED GENERAC DEALER.
For a period of 2 (two) years from the date of sale/start date, Generac Power Systems, Inc. will, at its option, repair or
replace any part(s) which, upon examination, inspection, and testing by Generac Power Systems or a Generac Power
Systems Authorized Warranty Service Facility, is found to be defective under normal use and service, in accordance with
the warranty schedule set forth below. Any equipment that the purchaser/owner claims to be defective must be returned
to, and examined by the nearest Generac Power Systems Authorized Warranty Service Facility. All transportation costs
under the warranty, including return to the factory, are to be borne and prepaid by the purchaser/owner. This warranty
applies only to Generac Power Systems Transfer Switch applications, as Generac Power Systems, Inc. have defined
Transfer Switch application, provided said Transfer Switch has been initially installed and inspected on-site by a Generac
Power Systems Authorized Service Dealer or branch thereof. A scheduled maintenance agreement with a local Authorized
Generac Power Systems Dealer is highly recommended to verify adequate service has been performed on the unit
throughout the warranty period.
WARRANTY SCHEDULE
• YEAR ONE — 100% (one hundred percent) coverage on mileage*, labor, and parts listed.
• ALL COMPONENTS
• YEAR TWO — 100% (one hundred percent) coverage on parts listed.
• ALL COMPONENTS — *PARTS ONLY
• *Travel allowance is limited to 300 miles maximum, or 7.5 hours maximum (per occurrence), round trip, to the nearest
authorized Generac Service Facility.
• A Generac Power Systems, Inc. Transfer Switch is highly recommended to be used in conjunction with the genset. If a
non Generac genset is substituted for use and directly causes damage to the Generac Transfer Switch, no warranty
coverage shall apply.
• All warranty expense allowances are subject to the conditions defined in Generac Power Systems Warranty, Policies, and
Procedures Flat Rate Manual.
• Units that have been resold are not covered under the Generac Power Systems Warranty, as this Warranty is not transferable.
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
1. Any unit built/manufactured prior to January 1, 2002.
2. Unit enclosure is only covered against rust or corrosion the first year of the warranty provision.
3. Costs of normal maintenance i.e. tune-ups, associated part(s), adjustments, loose/leaking clamps, installation and start-up.
4. Use of Non-Generac replacement part(s) will void the warranty in its entirety.
5. Any failure caused by contaminated fuels, oils, coolants/antifreeze or lack of proper fuels, oils or coolants/antifreeze.
6. Failures due, but not limited to, normal wear and tear, accident, misuse, abuse, negligence, or improper installation or
sizing.
7. Failures caused by any external cause or act of God such as collision, fire, theft, freezing, vandalism, riot or wars, lightning,
earthquake, windstorm, hail, volcanic eruption, water or flood, tornado, hurricane, terrorist acts or nuclear holocaust.
8. Products that are modified or altered in a manner not authorized by Generac Power Systems in writing.
9. Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in
repair or replacement of the defective part(s).
10. Failure due to misapplication, misrepresentation, or bi-fuel conversion.
11. Telephone, telegraph, teletype or other communication expenses.
12. Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific
unit warranty period.
13. Rental equipment used while warranty repairs are being performed i.e. rental generators, cranes, etc..
14. Overtime labor or more than one person performing repairs.
15. Any and all expenses incurred investigating performance complaints unless defective Generac materials and or workmanship were the direct cause of the problem.
16. *Engine coolant heaters (block-heaters), heater controls and circulating pumps after the first year.
17. *Starting batteries, fuses, light bulbs, and engine fluids, tires, brakes and overnight freight cost for replacement part(s).
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, SPECIFICALLY, GENERAC
POWER SYSTEMS MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may
not apply to you.
GENERAC POWER SYSTEMS ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED
ABOVE. IN NO EVENT SHALL GENERAC POWER SYSTEMS BE LIABLE FOR ANY INCIDENTAL, OR CONSEQUENTIAL
DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC POWER SYSTEMS, INC. NEGLIGENCE.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may
not apply to you. Purchaser/owner agrees to make no claims against Generac Power Systems, Inc. based on negligence.
This warranty gives you specific legal rights. You also may have other rights that vary from state to state.
GENERAC®POWER SYSTEMS, INC. • P.O. BOX8•WAUKESHA, WI 53187
PH: (262) 544-4811 • FAX: (262) 544-4851
Bulletin 0166260SBY / Printed in USA 5.02
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