Generac Power Systems 004635-1 User Manual
POWER SYSTEMS, INC.
®
Owner’s Manual
GTS “W” Type
Automatic
Transfer Switch
200 Amp, 250 Volts
Model Nos. 004635-1
004635-2
This manual should remain with the unit.
Generac®Power Systems, Inc.
Generac cannot possibly 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
you use a procedure, work method or operating technique Generac does not specifically recommend, satisfy yourself that it is safe for you and others. Also
must make sure the procedure, work method or
operating technique that is used 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 instruction about a particular operation that may be hazardous if performed incorrectly
or carelessly. Observe them carefully. The definitions
are as follows:
After this heading, read instructions that, if not
strictly complied with, will result in personal injury
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.
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!
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.
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DANGER
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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 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
2.4.2 3-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 ........................5
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 ....................................7
Section 4 – Mounting Dimensions ................................8
Section 5 – Electrical Data ..............................................9
Section 6 – Exploded Views & Parts Lists ..................14
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. Turn the generator’s AUTO-OFF-MANUAL switch to OFF. Turn the
generator’s main circuit breaker OFF. 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 generator)
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.
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 a copy of the SAFETY RULES
are made and 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 #
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 utility and generator power source leads.
• Connecting the load leads.
• Connecting the generator sensing leads.
• 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” on page 8.
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 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.
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
(200 Amp Shown)
2.4.2 3-POLE MECHANISM
These switches (Figure 2.2) are used with a three
phase system, when the three phase NEUTRAL line is
to be connected to a NEUTRAL lug and is not to be
switched. It is also used with a single phase system
when the neutral is to be switched (NEUTRAL to be
connected to third pole).
Figure 2.2 — Typical 3-Pole Transfer Mechanism
(200 Amp Shown)
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Section 2 — Installation
Generac GTS “W” Type Transfer Switch
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DANGER
4 Generac®Power Systems, Inc.
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.
Use a torque wrench to tighten the conductors, being sure not to overtighten, or damage to the switch base could occur. If undertightened, 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
switch terminals N1, N2, (N3).
2. Connect emergency (STANDBY) source power
cables to transfer switch terminals E1, E2, (E3).
3. Connect customer LOAD leads to switch termi-
nals T1, T2, T3.
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 (Page 11) 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:
2.6 AUXILIARY CONTACTS
If desired, there are 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. See Figure 2.3.
Contact operation is shown in the following chart:
NOTE:
Auxiliary Contacts are rated 10 amps at 125 or
250 volts AC. DO NOT EXCEED THE RATED
VOLTAGE AND CURRENT OF THE CONTACTS.
Figure 2.3 – Auxiliary Contacts
Section 2 — Installation
Generac GTS “W” Type Transfer Switch
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.
Switch Position
Utility Standby
Common to Normally Open Open Closed
Common to Normally Closed Closed Open
Switch Rating Wire Range
200A #4-400 MCM
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Optional
Auxiliary Contact
(Actuated)
Side views shown in Utility position
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