Generac ATS 004635-3 User Manual
Automatic Transfer Switch
Owner’s Manual
ATS “HS” Type
Models: 004635-3
(200 Amp, 250 Volts)
and 004678-2
(100 Amp, 250 Volts)
This manual should remain with the unit.
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:
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.
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.
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!
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.
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!
!
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DANGER
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Table of Contents
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 Decal......................................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
Section 3 — Operation ......................................................4
3.1 Functional Tests & Adjustments ..............................4
3.2 Manual Operation ....................................................4
3.2.1 Close to Normal Source Side ........................4
3.2.2 Close to Emergency Source Side....................5
3.2.3 Return to Normal Source Side ......................5
3.3 Voltage Checks..........................................................5
3.4 Generator Tests Under Load ....................................6
Section 4 – Notes................................................................7
Section 5 – Installation Diagram..................................10
Section 6 – Electrical Data ............................................11
Section 7 – Exploded Views & Parts Lists ..................14
Section 8 – Warranty/Service........................Back Cover
• 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. Then place a “DO
NOT OPERATE” tag on the transfer switch and on
the generator. Remove the Negative (Neg) or (–) battery cable.
For authorized service,
reference the dealer locator
number found inside the
generator owner’s manual.
2
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 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 transfer mechanism, a relay control, and a terminal strip for connection of sensing wires.
This switch is suitable for control of motors, electric
discharge lamps, tungsten filament and electric heating equipment and the tungsten load does the switch
rating.
The transfer switch is for use in optional standby systems only.
The transfer switch is suitable for use on a circuit
capable of 10,000 rms symmetrical amperes, 240
VAC when protected by a circuit breaker without an
adjustable short time response or by fuses.
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 and
is not damaged 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
MODEL #
SERIAL #
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)
• 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
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 will result in an
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 singlephase 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
(200 Amp Shown)
Solderless, screw-type terminal lugs are standard.
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 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.
Use a torque wrench to tighten the conductors, being sure not to over tighten, 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.
!
Section 2 — Installation
GTS “HS” Type Transfer Switch
Switch Wire Conductor Tightening
Rating Range Torque
100A #14-1/0 AWG 50 in-lbs.
200A #6-250 MCM 275 in-lbs.
UTILITY LUGS
!
DANGER
UTILITY
CLOSING
COIL
GENERATOR
LUGS (E1 & E2)
GENERATOR
CLOSING
COIL
LOAD LUGS (T1 & T2)
4
Section 3 — Operation
ATS “HS” Type Transfer Switch
Connect power source load conductors to clearly
marked transfer mechanism terminal lugs as follows
1. Connect UTILITY (NORMAL) power source cables
to switch terminals N1, N2.
2. Connect EMERGENCY (STANDBY) source power
cables to transfer switch terminals E1, E2.
3. Connect customer LOAD leads to switch termi-
nals 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 (Section 6) consist
of UTILITY 1 (N1) and UTILITY 2 (N2), LOAD 1 (T1)
and LOAD 2 (T2), and leads 23 and 194 when used
in conjunction with some water-cooled generators.
Recommended wire gauge sizes for this wiring
depends on the length of the wire, as recommended
below:
NOTE:
If there are no matching terminal connections for
LOAD 1 (T1) and LOAD 2 (T2) in the generator
control panel, do not connect these wires. Failure
of the control board will occur if connected.
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
presented 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
Do NOT manually transfer under load.
Disconnect transfer switch from all power
sources by approved means, such as a 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 and EMERGENCY
power supplies to the transfer switch, with whatever means provided (such as the main line circuit breakers).
3. Note position of transfer mechanism main contacts by observing the moveable contact carrier
arm.
• Manual operation handle towards the top of
switch mechanism - LOAD terminals (T1, T2) are
connected to UTILITY terminals (N1, N2).
• Manual operation handle towards the bottom of
switch mechanism - LOAD terminals (T1, T2) are
connected to EMERGENCY terminals (E1, E2).
Do not use excessive force when operating
the transfer switch manually or damage could
be done to the manual handle.
3.2.1 CLOSE TO NORMAL SOURCE SIDE
Before proceeding, verify the position of the switch by
observing the position of manual operation handle in
Figure 3.1. If the handle is UP, the contacts are closed
in the NORMAL position, no further action is
required. If the handle is DOWN, proceed with Step
1.
Step 1: With the handle inserted into the actuating
shaft, move handle UP. Be sure to hold on to
the handle as it will move quickly after the
center of travel.
◆
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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.
DANGER
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