Installation Guidelines
For
Manual Transfer Switches 6379 / 6381
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 Transfer Switch to safely connect a portable generator to up to 16 circuits in your
home or business (single phase only) for standby power applications. This product is recommended for installations
where the main electrical panel is located outdoors.
Product features include:
• Generator Main and Utility Main are mechanically interlocked preventing utility and generator from powering the circuits at the same
time
• Full branch circuit protection with Siemens® circuit breakers
• Pre-assembled wire harness for easy connection to the load center
• Transfer switch can be exp anded to up to 16 circuit s using st andar d
interchangeable type circuit breakers
• Provision to accept GFCI, Arc Fault or Surge Protection circuit
breakers to further protect your home and electronic equipment
(sold separately)
• High Corrosion-resistant aluminum NEMA 3R enclosure
• Subfeed lugs provided to feed additional downstream panels or to
expand beyond 16 circuits
• Accepts a Switched Neutral Kit (Model 6297 is only valid for use with
MTS. See note below on Neutral Bonded Generators.
Note: There is no 50 Amp rated Switched Neutral Kit for use with
Transfer Switch 6381.
• Power inlet provided for convenient cord connection from generator
Only authorized dealers or qualified, competent installation contractors or electricians thoroughly familiar with applicable codes, standards, and regulations should inst all this standby electric power system. The installation must be in strict
compliance with all codes, standards, and regulations.
It would be impossible to provide details for every inst alla tion con f iguration . For th is rea son, mu ch of the in fo rmation 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.
ii Transfer Switch Installation Guidelines
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 dea th 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 such codes, standards, and regulations. Every effort was made to ensure that
the information in this manual was both accurate and co mplete 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.
NOTE TO INSTALLER: Please leave this guide with the consumer for future reference. READ THIS MANUAL IN ITS
ENTIRETY BEFORE ATTEMPTING TO INSTALL THIS EQUIPMENT.
Generac® transfer switches should be installed by a professional electrician familiar with electrical wiring and
codes, and experienced in working with generators. Generac accepts no responsibility for accidents, damages or
personal injury caused by incorrect installation. This transfer switch is intended for surface mounting OUTDOORS.
Our transfer switches are UL listed to UL Standard 1008 and meet the criteria of National Electrical code Article
702.6 for Optional Standby Systems.
If using the generator and transfer switc h for larger appliance s, such as electric w ater heaters, cl othes dryers , electric ranges and small air conditioners, check the labels on the appliances to be sure they do NOT exceed the rating
of the generator. No appliance should have an amperage rating that exceeds the individual breaker rating in the
transfer switch (30 or 50 Amps).
Transfer Switch Installation Guidelines iii
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iv 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 Required Tools....................................................................................................................................... 5
2.2 Specifications.......................................................................................................................................... 5
2.3 Transfer Switch Installation ................................................................................................................ 5
2.4 Wiring Diagram .................................................................................................................................... 6
Section 3 Operation
3.1 When a Power Failure Occurs ............................................................................................................. 7
3.2 When Utility Power is Restored........................................................................................................... 7
Section 4 Wiring Diagram......................................................................................................9
Transfer Switch Installation Guidelines iv
Table of Contents
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v Transfer Switch Installation Guidelines
Section 1 Safety
$
!
+
1.1 — Introduction
Thank you for purchasing a Generac Transfer Switch to safely connect a portable generator to a single circuit in your
home or business (single phase only) for sta n db y power applications. Product features include:
• Generator Main and Utility Mains mechanically interlocked to prevent utility and generator from feeding circuit at the same time
• This transfer switch is intended to be surface mounted next to an existing load center and wired to one circuit breaker in the main panel.
Read this manual thoroughly. If any portion is not understood, contact the nearest Authorized Generac Service
Dealer for clarification. 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.
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. Ob servin g safe ty pr ecautio ns and strict compliance
with the special instructions while performing the ac tion or se rvic e ar e es sen tia l to pr ev en tin g ac cide n ts.
Four commonly used safety symbols accompany DANGER, WARNING, and CAUTION boxes and the type of
information each indicates: 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.
Transfer Switch Installation Guidelines 1
Safety
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 rep aired 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 prompt ly rep air or re place any worn o r damaged comp onent s 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 pote ntial shock hazard.
• Do not handle any kind of electrical device while standing in water, while barefoot, or while hand s 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.
• 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.
2 Transfer Switch Installation Guidelines
Safety
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 em it toxic fumes
and the liquid can damage wiring insulation.
1.6 — Explosion Hazards
• 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.
Generac transfer switches should be installed by a professional electrician familiar with electrical wiring and
codes, and experienced in working with generators. Generac accepts no responsibility for accidents, damages or
personal injury caused by incorrect installation. This transfer switch is intended for surface mounting OUTDOORS.
Our transfer switches are UL listed to UL Standard 1008 and meet the criteria of National Electrical code Article
702.6 for Optional Standby Systems.
If using the generator and transfer switc h for larger appliance s, such as electric w ater heaters, cl othes dryers , elec-
tric ranges and small air conditioners, check the labels on the appliances to be sure they do NOT exceed the rating
of the generator. No appliance should have an amperage rating that exceeds the individual breaker rating in the
transfer switch (30 or 50 amps).
Transfer Switch Installation Guidelines 3
Safety
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4 Transfer Switch Installation Guidelines
Installation
Section 2 Installation
2.1 — What is Included in this carton
• Manual Transfer Switch with wire harness, conduit, fittings and wire connectors
• Installation Manual and Warranty Registration card
2.2 — Tools Needed for Most Installations
• ¼” and 11/32” nut drivers
• Straight blade and Phillips screwdriver
• Electric drill
• Wire cutter/stripper
• Safety eye goggles and gloves
• NEW 2-pole, 250 volt Breaker to mount in main load center – see specifications in Table I – manufactured by same
as Main load center
• Anchors and screws to mount transfer switch to wall
2.3 — Compatible Circuit Breaker Types
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
2.4 — 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 protector 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.
• Power Cord to connect generator to transfer switch.
• White, green, black and red THHN or MTW wire, 10 A W G, 300V rated (if breaker configuration is modified or
expanded).
• Switched Neutral Kit (SNK or Generac 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 a SNK 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
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. When connected to a transfer
switch this may cause nuisance tripping of the generator GFCI breaker. When using a neutral bonded generator to power a house or building through a transfer switch consult the manufacturer of the generator (local
authorized service dealer) to determine if th e neu tra l- ground bo nd wire on th e ge nera tor can be removed without voiding the warranty. If it can be removed then no modifications to the transfer switch installation are
needed. If the neutral-ground bond cannot be removed, or voids the generator warranty, you MUST install a
Switched Neutral Kit (SNK, Model 6297) MTS model 6379 may use this Switched Neutral Kit. There is no
Switched Neutral Kit for the 50 Amp rated Transfer Switch 6381. NOTE: Removal of the neutral-ground bond
should be performed only by an authorized generator se rvice dealer or qualif ied electrician. If the neutral bond
is removed the generator will no longer pass OSHA inspection on job sites.
Transfer Switch Installation Guidelines 5
Installation
2.5 — Specifications
Table 1: SPECIFICATIONS
Model 6379 6381
Max Generator Size in Watts 7500 rated / 9300 surge 12500 rated / 15000 surge
UTILITY MAIN breaker, Included 60 Amp 100 Amp
GEN MAIN breaker, included 30 Amp 50 Amp
Branch Circuit Breakers Provided from Factory 3 – 15 amp 1-pole
3 – 20 amp 1-pole
1 – 20 amp 2-pole
1 – 30 amp 2-pole
Max Load Combined 30 Amp 50 Amp
Max Watts @ 250 Volts 7500 12,500
NEMA Type Enclosure NEMA 3R NEMA 3R
Configuration of Male Inlet NEMA L14-30 CS6365
Max 1-pole Circuits* / Max 2-pole Circuits* 16 / 8 16 / 8
Min. gauge Cord Size 10/4 wire 6/4 wire
Required Main Breaker in load Center (installer pro-
vided)
2-pole 60 amp 2-pole 100 amp
3 – 15 amp 1-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) circuit breakers, Arc Fault Circuit Interrupters, 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. Because these circuit
breakers typically take up more than one space, the overall maximum number of circuits may be reduced from the number shown.
2.6 — Planning Your Installation
1. Determin e the appliances, circuits or equipment you want to operate with generator power during a power out-
age, such as:
• Refrigerator/Freezer • Garage Door Opener • Computer, Fax and Printer, Phone
• Furnace Blower (gas/oil only) • Microwave, Coffee Maker • Medic al Device(s)
• TV / Radio • Well / Septic Pump • Aquarium
• Lighting • Security System
• Water Heater • Sump Pump
2. Determin e the amp s required fo r each appliance by reading the label on the a pplia nce. IMPORTANT: No appli-
ance 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 cir-
cuit 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.
6 Transfer Switch Installation Guidelines
Table 2: CIRCUIT WORKSHEET
Installation
Circuit 6379 6381
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
Appliance(s) or Circuits
2.7 — Installation Procedure
HAZARDOUS VOLTAGES ARE PRESENT INSIDE TRANSFER SWITCH ENCLOSURES THAT CAN CAUSE DEAT H
OR SEVERE PERSONAL INJURY. FOLLOW PROPER INSTALLATION, OPERATION AND MAINTENANCE PROCEDURES TO AVOID HAZARDOUS VOLTAGES.
TURN OFF THE MAIN CIRCUIT BREAKER IN THE LOAD CENTER BEFORE STARTING INSTALLATION.
2.7.1— TRANSFER SWITCH INSTALLATION:
1. Transfer switch can be installed on either the left or right side of the main load center. Transfer switch is provided with 21-1/2” of flexible conduit. The connection to the main load center, using the provided wire harness,
must be made through one of the two (2) knockouts (KO’s) provided in the bottom of the manual transfer
switch. The wire harness should enter the main load center in one of the bottom or lower side knockouts. A 1”
or 1-1/4” KO can be cut in the lower side of the enclosure if necessary.
2. Remove the cover of the main load center and the transfer switch. Cut the conduit to a convenient length or
use as is. Attach connectors to the conduit. After attaching the flexible conduit to both boxes through the KOs,
hold the transfer switch away from the load center against the wall on which it is to be mounted and mark the
holes on the wall for the anchoring screws. Be sure NOT to stress the flexible conduit, as it will break. (NOTE:
Mounting on LEFT side of existing load center is preferred method. Mounting to right side of existing load center and routing flexible conduit may interfere with generator cord connection into transfer switch. Reducing
washers (not provided) may be needed if using 2” KO on the bottom left.
Transfer Switch Installation Guidelines 7
Installation
3. After mounting the transfer switch to the wall, you are ready to terminate the wires in the manual transfer
switch. Fish the bundle of wires provided through the conduit. Strip each wire in the wire harness approximately 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 on the label on the cover of the transfer
switch with the appliance on that circuit per the planning worksheet. The unmarked BLACK wires in the harness are inserted into the Utility 2-pole breaker in the transfer switch. Attach the WHITE wire to the insulated
neutral bar inside the transfer switch, and atta ch the GREEN wir e to the ground bar. Reinstall the dead front to
the transfer switch. Cover may be re-installed and padlocked, if desi re d.
4. RECHECK TO BE SURE THE MAIN CIRCUIT BREAKER HAS BEEN TURNED OFF. The wires from the harness entering the load center can now be terminated. Remove the wires of the appliances/loads that have
been assigned to circuits in the transfer switch from the b reakers in the load center. Cut the harness wires to a
convenient length and strip off approximately 5/8” and connect with the provide d wire connectors (see wire
connector chart) using the appropriate labeled wire from the transfer switch. The unmarked BLACK wires in
the harness are to be inserted into the NEW 2 pole breaker (as required in the Other Items Needed section).
Remove two adjacent single pole breakers from which the appliance/load wires were removed. The 2-pole
breaker should be located in a bus bar location where two adjacent full size single pole circuit breakers were
removed. 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 load center cover, and turn ON the MAIN breaker. Then turn ON ALL circuit breakers in both
boxes. Turn on the UTILITY MAIN in the manual transfer switch. Check that powe r is restored to all appliances.
2.7.2— 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 requirement s, 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.
8 Transfer Switch Installation Guidelines
Section 3 Operation
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.
3.1 — Transferring from Utility Power to Generator Power:
1. Move generator outdoors.
2. Insert the male plug of the Power Cord into the 125/250 volt receptacle on the generator.
3. Plug in the fe male con nector of th e Po we r Cord to th e inlet on the bottom of the transfer switch. Turn all circuit
breakers in the transfer switch to their OFF position.
4. Sta rt the generator outdoors, following the procedures described in the generator’s owner’s manual furnished
by the manufacturer. 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”. It may be necessary to alternate the use of larger loads (furnace motors, well pumps, freezers, etc.) to avoid overloading the
generator. Try to “balance” the loads on each “phase” (A and B). To properly load the generato r and not cause
damage to the electrical windings, loads should be balanced so that the wattage is within a maximum of 1000
watts of the other on each leg/phase.
5. Test your circuits by determining 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.
3.2 — Transferring from Generator Power to Utility Power:
1. On the transfer switch, turn Generator MAIN breaker OFF and turn Utility MAIN breaker ON.
2. Turn ON any branch circuit breakers in the transfer switch that are OFF.
3. Shut do wn the generator, following the procedures in the generator Owner’s Manual.
4. Unplu g the power cord from the generator and then the power inlet.
5. Cool off the generator and store in a dry, secured location.
6. 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 supplying generator power to the transfer switch.
Transfer Switch Installation Guidelines 9
Operation
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10 Transfer Switch Installation Guidelines
Section 4 Wiring Diagram
CIRCUIT ID FOR MODEL 6381
(Model 6381 shown)
Transfer Switch Installation Guidelines 11
Wiring Diagram
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12 Transfer Switch Installation Guidelines
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