Installation Guidelines
For
Manual Transfer Switches
6295-6296 / 6378-6380
NOT INTENDED FOR USE IN CRITICAL
*
*
This manual should remain with the unit.
This manual must be used in conjunction
with the appropriate owner’s manual.
LIFE SUPPORT APPLICATIONS.
ONLY QUALIFIED ELECTRICIANS OR
CONTRACTORS SHOULD ATTEMPT
INSTALLATION!
Forward
WARNING!
California Proposition 65
Engine exhaust and some of its constituents are known to the state of California to cause cancer,
birth defects, and other reproductive harm.
WARNING!
California Proposition 65
This product contains or emits chemicals known to the state of California to cause cancer,
birth defects, and other reproductive harm.
Thank you for purchasing a Generac Manual Transfer Switch to safely connect a portable generator to your home or business (single phase). Use where the main electrical panel is located indoors. This product is suitable for service entrance
equipment.
READ THIS MANUAL THOROUGHLY. This manual has been prepared to familiarize personnel involved with the
installation of transfer switches with the manufacturer’s installation requirements. Information and instructions contained herein are not intended to replace or supersede, local, state, or national safety, electrical, and building codes
pertaining to such installations. Applicable laws, codes, and standards must always take precedence over the recommendations contained herein. Always check with the local Authority Having Jurisdiction (AHJ) for the codes or standards that apply.
Only authorized dealers or qualified, competent installation contractors or electricians thoroughly familiar with applicable codes, standards, and regulations should install this transfer switch. The installation must be in strict compliance
with all codes, standards, and regulations.
It is not intended that this manual be used by any unqualified person for the purpose of installing a transfer switch.
Installation, inspection, and testing of the system must be attempted only by competent, qualified electricians or installation contractors who are familiar with the equipment and with all installation codes and requirements.
It would be impossible to provide details for every installation configuration. For this reason, much of the information in
this manual is general in nature. Illustrations of typical installations are not intended to serve as specific installation
plans, but may be used in the planning and design process when considering the selection and purchase of a generator set for standby power applications. Always have the unit specific drawings and manuals on hand before beginning
any installation.
If a portable generator is used to power electrical load circuits normally powered by a utility
power source, it is required by code to install a transfer switch. The transfer switch must
effectively isolate the electrical system from the utility distribution system when the generator
is operating. Failure to isolate an electrical system by such means may result in damage to the
generator and may also result in injury or even death to utility power workers due to backfeed
of electrical energy.
After the transfer switch has been installed, do nothing that might render the installation in noncompliance with codes, standards, and regulations. Every effort was made to ensure that the
information in this manual was both accurate and complete at the time it was released. However,
the manufacturer reserves the right to change, alter, or otherwise improve this product at any
time without notice.
ii Transfer Switch Installation Guidelines
Table of Contents
Table of Contents
Forward ....................................................................................................................ii
Section 1 Safety
1.1 Introduction .......................................................................................................................... 1
1.2 Safety Rules .......................................................................................................................... 1
1.3 General Hazards ................................................................................................................... 2
1.4 Electrical Hazards ................................................................................................................ 2
1.5 Fire Hazards .......................................................................................................................... 3
1.6 Explosion Hazards ............................................................................................................... 3
1.7 Standards Index ................................................................................................................... 3
Section 2 Installation
2.1 What is Included in this Carton: ......................................................................................... 4
2.2 Tools and Items Needed for Installation: ........................................................................... 4
2.3 Optional Items for Installation: ...........................................................................................4
2.4 Specifications ....................................................................................................................... 5
2.5 Planning Your Installation ................................................................................................... 5
2.6 Installation Procedure ......................................................................................................... 6
Section 3 Operation
3.1 Using Your Transfer Switch ................................................................................................ 9
Transfer Switch Installation Guidelines iii
Table of Contents
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iv Transfer Switch Installation Guidelines
Section 1 Safety
1.1 — Introduction
Thank you for purchasing a Generac Manual Transfer Switch to safely connect a portable generator to your home or business (single phase only). Use where the main electrical panel is located indoors. This product is suitable for service entrance
equipment.
Read this manual thoroughly. If any portion is not understood, contact the nearest Authorized Generac Service
Dealer for clarification. Only authorized dealers or qualified, competent installation contractors or electricians thoroughly familiar with applicable codes, standards, and regulations should install this transfer switch.These individuals
are trained/qualified service technicians familiar with the control systems and available options, and also have full
access to drawings, publications, and other information required for a successful installation.The installation must be in
strict compliance with all codes, standards, and regulations.
1.2 — Safety Rules
Throughout this publication, DANGER, WARNING, CAUTION, and NOTE boxes are used to alert personnel to special
instructions about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe them
carefully. They indicate:
Indicates a hazardous situation or action that, if not avoided, will result in death or serious
injury.
Indicates a hazardous situation or action that, if not avoided, could result in death or serious injury.
Indicates a hazardous situation or action that, if not avoided, could result in minor or moderate injury.
NOTE: Notes provide additional information important to a procedure or component.
These safety warnings cannot eliminate the hazards they indicate. Observing safety precautions and strict compliance
with the special instructions while performing the action or service are essential to preventing accidents.
Four commonly used safety symbols accompany DANGER, WARNING, and CAUTION boxes and the type of information each indicates:
Transfer Switch Installation Guidelines 1
Safety
$
!
+
This symbol points out important safety information that, if not followed, could
endanger personnel and/or property.
This symbol represents the potential for an Explosion Hazard.
This symbol represents the potential for a Fire Hazard.
This symbol represents the potential for an Electrical Shock Hazard.
SAVE THESE INSTRUCTIONS. This manual contains important instructions that should be
followed during installation of the transfer switch. The manufacturer suggests that these
safety rules be copied and posted in potential hazard areas. Safety should be stressed
to all installers, operators, potential operators, and service and repair technicians for
this equipment.
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 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 used does not result in unsafe conditions.
1.3 — General Hazards
• For safety reasons, the manufacturer recommends that this equipment be installed, serviced, and repaired by an
Authorized Service Dealer or other competent, qualified electrician or installation technician who is familiar with
all applicable codes, standards, and regulations.
• Ensure that the transfer switch is installed, operated, and serviced in accordance with the manufacturer’s instruc-
tions and recommendations. Following installation, do nothing that might render the unit unsafe or in noncompliance.
• Keep the area around the transfer switch clean and uncluttered. Remove any materials that could become haz-
ardous.
• When working on this equipment, remain alert at all times. Never work on the equipment when physically or men-
tally fatigued.
• Inspect the portable generator regularly, and promptly repair or replace any worn or damaged components using
only factory approved parts and procedures.
1.4 — Electrical Hazards
• All generators produce dangerous electrical voltages and can cause fatal electrical shock. Utility power delivers
extremely high and dangerous voltages to the transfer switch as well as the generator when it is in operation.
Avoid contact with bare wires, terminals and other connections. Ensure all covers, guards, and barriers are in
place, and that they are properly secured and/or locked before operation. If work must be done around an operating unit, stand on an insulated, dry surface to reduce potential shock hazard.
• Do not handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet.
DANGEROUS ELECTRICAL SHOCK MAY RESULT.
• If it is necessary to stand on metal or concrete while installing, operating, servicing, or repairing this equipment,
lay down a dry wooden platform and cover with insulated mats before beginning.
• Verify that the portable generator is properly grounded.
• Wire gauge sizes of electrical wiring, cables, and cord sets must be adequate to handle the maximum electrical
current (ampacity) to which it will be subjected.
• Before installing or servicing equipment, verify that all power voltage supplies are positively turned off at their
sources. Failure to do so can result in hazardous and possibly fatal electrical shock.
2 Transfer Switch Installation Guidelines
• Connecting a portable generator to an electrical system normally supplied by an electric utility is by means of the
transfer switch so as to isolate the generator’s electric system from the electric utility distribution system when
the portable generator is operating. Failure to isolate the two electric system power sources from each other by
such means will result in damage to the portable generator and may also result in injury or death to utility power
workers due to backfeed of electrical energy.
• In case of 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. 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.
• Do not wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in electric shock,
or may get caught in moving parts resulting in injury.
1.5 — Fire Hazards
• Keep a fire extinguisher near the portable generator and transfer switch at all times. Keep the extinguisher prop-
erly charged and be familiar with its use. Direct any questions to the local fire department.
NOTE: DO NOT use any carbon tetra-chloride type fire extinguishers. These fire extinguishers emit toxic fumes
and the liquid can damage wiring insulation.
1.6 — Explosion Hazards
Safety
• Do not smoke around the generator. Immediately wipe up any fuel or oil spills. Ensure that no combustible mate-
rials are left in the generator compartment, or on or near the generator, as FIRE or EXPLOSION may result.
Keep the area surrounding the generator clean and free of debris.
• All types of fuels are potentially FLAMMABLE and/or EXPLOSIVE and must be handled with care. Inspect the
fuel system frequently and correct any leaks immediately. Be sure fuel supply lines are properly installed, purged,
and leak tested before placing the generator set into service.
1.7 — Standards Index
Be sure the transfer switch is in strict compliance with all applicable local, state, and federal laws, codes, and regulations pertaining to such installations. Always use the current version or edition of the applicable law, code, and regulation as it applies to the local jurisdiction.
Transfer Switch Installation Guidelines 3
Installation
Section 2 Installation
2.1 — What is Included in this Carton:
• Manual Transfer Switch with wire harness, conduit, fittings and wire connectors (10 or 12)
• Wire Harness, pre-assembled
• 30 amp or 50 amp Aluminum Power Inlet Box (Models 6295-6296 only)
• 10 Foot Power Cord (Models 6295-6296 only)
• Flanged Inlet (inside models 6378 and 6380 only)
• Installation Manual and Warranty Registration card
2.2 — Tools and Items Needed for Installation:
• 5/16” nut driver, 2-1/8” hole saw (if flush mounting)
• Screwdrivers, straight blade and Phillips
• Electric drill, drill bits, wallboard saw
• Wire cutter/stripper
• Safety eye goggles
• Anchors and screws to mount transfer switch to wall/wallboard
• New, 2-pole 60 Amp or 100 Amp, 240V circuit breaker to install in main load center – same manufacturer as existing load center
• Insulated building wire (4-wire, also known as 3-wire plus ground) and conduit to connect between power inlet box and transfer switch
Compatible Circuit Breakers:
Siemens/Murray QT, QPH, HQP, QPF (GFCI), QPHF, QFP, QE, QEH, QAF (Arc Fault), QP (Surge Protector)
Cutler-Hammer Series BD, BR, BQ, GFC
Challenger Type A, C, HAGF
Square D Series HOM (Homeline)
GE Series THQL
2.3 — Optional Items for Installation:
• Arc-fault, GFCI or Surge protection circuit breakers. If Arc-fault, GFCI or Surge protection circuit breakers are used as the branch circuit pro-
tector in the main load center, they MUST be used in the manual transfer switch. You may be able to re-use your existing AFCI, GFCI and
Surge protection circuit breakers in the manual transfer switch. See list of compatible breakers.
• Wire, fittings and conduit to connect the Power Inlet Box to the transfer switch.
• White, green, black and red THHN or MTW wire, 10 AWG, 300V rated (if breaker configuration is modified or expanded.
• Switched Neutral Kit (Model 6297). If your portable generator has the neutral bonded to the frame of the generator AND 240V “full-power”
receptacle is GFCI protected, you will need to install this accessory with your transfer switch to avoid nuisance tripping of the GFCI breaker
on the generator.
NOTE: ON NEUTRAL BONDED GENERATORS: Some portable generators are intended for use on jobsites, and therefore are subject to
OSHA regulations for GFCI protection on all receptacles. These "contractor grade" generators have their neutral wire bonded to the
ground wire to pass OSHA inspection on job sites, and when connected to a transfer switch, this may cause nuisance tripping of the
generator GFCI breaker. If you’re using a neutral bonded generator to power a house or building through a transfer switch, then determine if the neutral bond wire on the generator can be disabled without voiding the warranty, preferably by a dealer or a qualified electrician. NOTE: After this action, the generator will no longer pass OSHA inspection on job sites. Consult the manufacturer of your
generator to determine if the neutral bond can be removed. If it can be disabled, then no modifications to your transfer switch installation are needed. If the neutral bond cannot be disabled or voids the generator warranty, you must install a Switched Neutral Kit (SNK)
accessory with your transfer switch.
4 Transfer Switch Installation Guidelines
Installation
2.4 — Specifications
Model 6295 or 6378 6296 or 6380
# Circuits Provided on Transfer Switch 10 12
Maximum # Circuits 16 16
REQUIRED BREAKER FOR MAIN LOAD CENTER
(not included)
Utility Main Breaker 60 amp 2-pole 100 amp 2-pole
Generator Main Breaker 30 amp 2-pole 60 amp 2-pole
Breakers Provided with Unit 3 – 15 amp 1-pole
Maximum Generator Watts 7500 continuous / 9000 surge 12500 continuous / 18000 surge
Maximum Generator Amps 30 Amps 60 amps
Voltage 125/250 Volts 125/250 Volts
NEMA Type Enclosure 1 – Indoor Only 1 – Indoor Only
NEMA Configuration of Male Inlet in Power Inlet Box NEMA L14-30 CS-6365
Phase 11
Minimum Gauge Cord Size 10/4 AWG 6/4 AWG
60 amp 2-pole 100 amp 2-pole
3 – 15 amp 1-pole
3 – 20 amp 1-pole
1 – 20 amp 2-pole
1 – 30 amp 2-pole
3 – 20 amp 1-pole
1 – 20 amp 2-pole
1 – 30 amp 2-pole
1 – 50 amp 2-pole
NOTE: If Ground Fault Circuit Interrupters (GFCI), Arc Fault Circuit Interrupters (AFCI), or Surge Protector Circuit Breakers were used
as the branch circuit protector in the main load center, they MUST be used in the transfer switch. GFCI and AFCI breakers require an
isolated neutral connected from the load to the GFCI or AFCI. The load neutral needs to be connected with a wire nut to a 3-6 foot piece
of white wire, run through the harness conduit to the transfer switch and connected to the “load neutral” lug or pigtail on the GFCI or
ACFI breaker. Because GFCI and AFCI circuit breakers can take up more than one space, the overall maximum number of circuits may
be reduced from the number shown. Not all brands of GFCI and Arc Fault breakers will fit.
2.5 — Planning Your Installation
1. Determine the appliances, circuits or equipment you want to operate with generator power during a power outage, such as:
❑ Refrigerator/Freezer ❑ Water Heater ❑ Security System
❑ Furnace Blower (gas/oil only) ❑ Garage Door Opener ❑ Sump Pump
❑ TV / Radio ❑ Microwave, Coffee Maker ❑ Computer, Fax and Printer, Phone
❑ Lighting ❑ Well Pump ❑ Aquarium
2. Determine the amps required for each appliance by reading the label on the appliance. IMPORTANT: No appliance should have an amperage rating that exceeds the GEN MAIN breaker rating in the transfer switch (See
Table 1). The total amperage of all circuits can exceed the generator rating, but not all circuits will be able to be
used concurrently.
3. Assign the circuit # in the load center to a circuit (A2, B2, etc.) in the transfer switch matching the size of the circuit breaker in the load center to the circuit breaker in the transfer switch. Once you’ve determined which circuits you want to connect and the appropriate amperage, you will be ready to begin installing your transfer
switch.
4. The location of your load center/electrical panel in your home or business will determine where the transfer
switch will be installed. Refer to Figure 1. In addition to the transfer switch, this kit includes a generator cord
and power inlet box. You will use the generator cord to connect your generator to the power inlet box outdoors.
Whether your load center is in a basement, interior room or garage, we recommend installing power inlet box
on the exterior of your house or building to avoid running generator cord through a door or window.
5. Determine where you will install the power inlet box on an exterior wall at least 5 feet from any openings
(doors, windows, vents, etc.). See Figure 1.
Transfer Switch Installation Guidelines 5
Installation
+
Figure 1: TYPICAL INSTALLATION
Table 1: CIRCUIT WORKSHEET
Circuit 6295 or 6378 6296 or 6380 Appliance(s) or Circuits
A1 NA 50A
B1
A2 30A 30A
B2 30A 30A
A3
B3
A4 15A 20A
B4 20A 15A
A5 15A 20A
B5 20A 20A
A6 20A 15A
B6 15A 15A
A7 20A
B7 20A
NA 50A
NA 20A
NA 20A
NA
NA
2.6 — Installation Procedure
PLEASE READ THIS MANUAL IN ITS ENTIRETY BEFORE ATTEMPTING TO UNPACK, ASSEMBLE, INSTALL,
OPERATE OR MAINTAIN THIS EQUIPMENT. HAZARDOUS VOLTAGES ARE PRESENT INSIDE TRANSFER SWITCH
ENCLOSURES THAT CAN CAUSE DEATH OR SEVERE PERSONAL INJURY. FOLLOW PROPER INSTALLATION,
OPERATION AND MAINTENANCE PROCEDURES TO AVOID HAZARDOUS VOLTAGES.
6 Transfer Switch Installation Guidelines
Installation
+
TURN OFF THE MAIN CIRCUIT BREAKER IN THE LOAD CENTER BEFORE STARTING INSTALLATION.
I. TRANSFER SWITCH INSTALLATION:
A: Surface Mount Installation Using Power Inlet Box (included in models 6295-6296):
1. Select a location on the left or right side of the Load Center to mount transfer switch, as it is provided with 24”
of flexible conduit. Remove the cover to the load center and the cover of the transfer switch, save the screws.
Measure and cut conduit to a length and snap provided fittings on ends. Locate and remove a knockout (KO)
on lower side of load center that matches the conduit fitting size on the wiring harness. After attaching the flexible conduit to both enclosures through one of the bottom or side KOs, hold the transfer switch in position
against the wall on which it is to be mounted, mark the holes on the wall for the anchoring screws and anchor
to wall (anchors not provided). Be sure NOT to stress the flexible conduit, as it may break. [NOTE: The Electrical Non-Metallic Tubing (ENT) provided is UL Listed and recognized by the National Electrical Code (NEC) for
this application. However, some local codes and inspectors may prohibit its use in buildings that exceed (3)
floors above grade.]
2. Fish the pre-assembled wire harness through the conduit. Strip each wire in the wire harness 5/8” and insert
and tighten the wires to the correspondingly marked circuit breakers in the transfer switch. As you attach each
marked wire to the circuit breaker, write the appliance name on the label on the transfer switch cover per the
TABLE 2 CIRCUIT WORKSHEET completed in Step 1. The unmarked BLACK wires in the harness are
inserted into the UTIL MAIN 2-pole breaker in the transfer switch. Attach the WHITE wire to the neutral bar
located on the right side and attach the GREEN wire to the ground bar located on the left side of the transfer
switch.
3. Install appropriately sized conduit, fittings and wire between the Power Inlet Box (Models 6295-6296 only)
mounted on the building exterior and the transfer switch, referring to Power Inlet Box Install Instructions below.
Locate and remove a KO on the right top or side of the transfer switch, pull wire into transfer switch enclosure
and secure wire with fitting. Install the green ground wire into the ground bar on the left, and install the white
neutral wire into neutral bar on the right. Using provided wiring connectors, connect black wire from PIB to
black wiring going to Meter “A”. Repeat for red wire from PIB to Meter “B”. Note: Models 6296 and 6380 use
current transformers (CTs) connected to the meters; pass the black wire from the PIB through the hole in the
CT connected to the “A” meter before connecting to the “GEN MAIN A” circuit breaker. Repeat for the red wire
from the PIB, passing through the hole in the CT connected to the “B” meter before connecting to the “GEN
MAIN B” circuit breaker. See FIGURE 2 WIRING DIAGRAM. Reinstall the cover to the transfer switch.
4. In the main Load Center, remove the wires from the breakers for the loads that will be relocated to the transfer
switch. Cut each harness wire to a convenient length, strip off 5/8” insulation and connect to the wires removed
from the breakers per TABLE 2 with the provided wire connectors. Remove two adjacent single pole breakers
from which the load wires were removed and install the NEW 60A or 100A 2-pole circuit breaker (as required in
the Other Items Needed section) in their place. Insert the unmarked BLACK wires from the harness into the
new circuit breaker. Terminate the WHITE and GREEN wire in the harness in an open position in the Neutral
and Ground bars respectively. If there is no separate ground bar, insert the GREEN wire into an open position
in the NEUTRAL bar, and tighten.
5. Reinstall the cover to the load center, and turn ON the MAIN breaker in the load center. Turn ON all branch circuit breakers in both panels. Turn ON the UTIL MAIN in the transfer switch. Check that power is restored to all
appliances. Transfer switch installation is complete.
B. Flush Mounting in New Construction (unfinished walls) Using Power Inlet Box (included in 6295-6296):
1. Install the transfer switch at the same time as the main load center, in adjacent wall stud openings (the transfer
switch enclosure is 14.25” wide and will fit in standard 16” wall framing). Remove the transfer switch dead front
cover, save the screws. Knock out the appropriate mounting slots on the sides of the enclosure and secure to
framing with nails or screws; be sure the front edge of the enclosure extends forward to be flush with the thickness of the finished wallboard.
2. Mark and drill a 2 1/8” diameter hole in the stud between the main load center and the transfer switch, lining up
with the lowest side KO in the load center and near the bottom center KO in the transfer switch. Remove the
KO’s, cut the provided conduit to length, snap on the provided fittings to the conduit, push the conduit through
the drilled hole and install the conduit assembly to the KO openings in the main load center and transfer switch.
Transfer Switch Installation Guidelines 7
Installation
3. Complete Section A #3 above. Cut a piece of cardboard to 14.5” x 12.5”, using the 4 screws removed in Section A #1, attach the cardboard to the front of the transfer switch.
4. After the walls have been finished and painted, remove the cardboard cover and complete the installation as
described in Sections A: #2, #4 and #5. NOTE: To simplify installation, all conductors for the branch circuits can
be terminated directly into the transfer switch instead of the main load center, eliminating the need to install the
harness wires between the main load center and transfer switch for each circuit.
C. Flush Mounting in Retrofit Construction (finished walls) Using Power Inlet Box (included in 6295-6296):
1. Remove the dead front cover from the main load center and the transfer switch, save the screws.
2. Determine where to install the transfer switch (keep in mind the length and flexibility of the conduit provided
and where the generator wires will enter), Verify that there are no wires going through the side of the main load
center into the space where you want to mount the transfer switch. Use a “stud finder” to determine if you have
at least 14.25” between the studs to mount the transfer switch. Hold the transfer switch enclosure in the
desired position on the wall and mark the exact dimensions of the box. Set the enclosure aside and cut the
hole in the wallboard.
3. Remove a 1” or 1-¼” KO in the lower side (towards the hole cut in Step 2) of the load center. From the inside of
the main load center, drill a ¼” pilot hole through the stud in the center of the KO removed. Reach down inside
the hole cut in Step 2 and drill a 2 1/8” diameter hole in the stud using the pilot hole as a guide. Remove the
bottom center KO in the transfer switch, snap the fittings on the conduit, and attach the conduit assembly to the
transfer switch.
4. Remove one of the KO’s on the top of the transfer switch enclosure and install an appropriately sized fitting for
the incoming wires from the Power Inlet Box. Knock out the appropriate mounting slots on the sides of the
transfer switch enclosure.
5. Insert the transfer switch enclosure into the hole in the wallboard, inserting conduit fitting on attached conduit
assembly into the KO removed in Step 3. Fasten conduit fitting to main load center with locknut. Secure transfer switch enclosure to framing with nails or screws; be sure the front edge of the enclosure extends forward to
be flush with the finished wallboard.
6. Complete Sections A #2 through A #5 on page 5.
II. EXPANDING OR RECONFIGURING YOUR TRANSFER SWITCH:
This transfer switch ships from the factory with certain popular branch circuit breaker sizes. However, the circuit
breaker assortment can be modified to suit specific requirements, and this does not void the UL Listing. For example, if
the 2-pole 20 amp circuit breaker is not needed, it may be removed from the panel and replaced with any combination
of the following: two separate full size breakers, four tandem (half size) breakers, one full size and two tandems, or a
quad breaker. If additional circuit(s) are added, the installer is responsible for providing appropriately sized wire(s) for
each circuit.
III. INSTALLING THE POWER INLET BOX (Models 6295 and 6296 Only):
1. Remove the front cover of the power inlet box. Remove the 3 screws that secure the flanged inlet to the bottom
plate.
2. Mount the power inlet box on the outside of the building in a convenient location (minimum 24” above grade),
using the four holes provided in the back of the enclosure. Use sealant around the anchoring screws to keep
water from entering the box at these mounting holes. Using approved wiring methods, install the wiring through
one of the knockouts provided in the enclosure. Be sure to seal around the hole in the building where the conduit enters through the wall.
3. Extend wiring inside the power inlet box approx. 8” from the point of entrance. Attach green or bare ground
wire to green lead provided in power inlet box with wire nut (provided by installer). Strip and insert incoming
leads into terminals on flanged inlet. Insert white wire (neutral) into nickel-plated screw terminal or white marking on the flanged inlet.
4. Carefully fold wires into the enclosure and reattach the bottom assembly or inlet onto box with screws removed
earlier. Installation is complete.
8 Transfer Switch Installation Guidelines
Section 3 Operation
3.1 — Using Your Transfer Switch
NEVER run portable generators indoors or in garages, basements, or sheds. Portable generators should always
be used at least 5 feet away from windows, doors, vents, or any other opening. Carbon Monoxide (CO) from a generator is deadly and can kill you in minutes. Read and follow all generator directions before use.
A. Transferring from Utility Power to Generator Power:
1. Move generator outdoors.
2. Connect male plug of Power Cord into 125/250V receptacle on the generator. Turn ON circuit breaker for the
outlet plugged into.
3. Plug in female connector of the Power Cord to the Power Inlet Box or Flanged Inlet on top of transfer switch (if
installed). Turn all circuit breakers in the transfer switch to the OFF position.
4. Start the generator outdoors, following the procedures described in the generator’s owner’s manual. Turn ON
the GENERATOR MAIN circuit breaker in the transfer switch. Turn ON circuit breakers in the manual transfer
switch one at a time alternating from phase “A” and phase “B”. Watch the meters as you turn on successive circuits so that the meters do not continuously exceed the maximum wattage of the generator. It may be necessary to alternate the use of larger loads (furnace motors, well pumps, freezers, etc.) to avoid overloading the
generator. To promote generator life, loads should be balanced on Phase “A” and “B” so that the wattage reading on each meter is within about 1000 watts of the other.
5. Test your circuits by using the wattmeters or determine wattage from that shown on each appliance. Make a
note of any excessive loads which must be removed from a given circuit during generator operation in an
emergency. [Note: Wattmeters do not show power at very low levels.]
B. Transferring from Generator Power to Utility Power:
1. On the transfer switch, turn the GENERATOR MAIN breaker OFF. Then shut down the generator, following the
procedures in the generator Owner’s Manual.
2. On the transfer switch, turn the UTILITY MAIN breaker ON. Then Turn ON any branch circuit breakers in the
transfer switch that are OFF.
3. Unplug the power cord from the generator and the power inlet.
4. Cool off the generator and store in a dry, secured location.
To ensure that your generator will work properly when you need it, it is important to start and run your generator under
load regularly and keep the tank filled with fresh fuel. Perform the above steps at least ONCE A MONTH to keep the
generator properly “exercised.” It is not necessary to turn off any circuits in the MAIN load center when operating/
testing the transfer switch.
Transfer Switch Installation Guidelines 9
Operation
Models 6295/6378 (shown below) include a 2-pole 60 Amp
breaker for the Utility Main and a 2-pole 30 amp Generator
Main.
Models 6296/6380 include a 2-pole 100 amp Utility Main
and a 2-pole 60 amp Generator Main.
Figure 1: Wiring Diagrams:
10 Transfer Switch Installation Guidelines
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Operation
Transfer Switch Installation Guidelines 11
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