Generac 09230-0, 09229-0, 09228-0, 09227-0 User Manual
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
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