Generac Power Systems Switch 004635 2 User Manual

®
POWER SYSTEMS, INC.  
Owner’s Manual  
GTS “WType  
Automatic  
Transfer Switch  
200 Amp, 250 Volts  
Model Nos. 004635-1  
004635-2  
This manual should remain with the unit.  
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Table of Contents  
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 nonconduct-  
ing 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 cir-  
cuit must be disabled before working on or around  
the generator or transfer switch. Turn the genera-  
tor’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.  
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Section 1 — General Information  
Generac GTS “W” Type Transfer Switch  
When requesting information or ordering parts for this  
equipment, make sure to include all information from  
the DATA DECAL.  
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 appli-  
cation, or improper procedures.  
Record the Model and Serial numbers in the space pro-  
vided below for future reference.  
MODEL #  
SERIAL #  
Every effort has been expended to make sure that the  
contents of this manual are both accurate and cur-  
rent. Generac, however, reserves the right to change,  
alter or otherwise improve the product at any time  
without prior notice.  
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.  
1.2 EQUIPMENT DESCRIPTION  
The automatic transfer switch is used for transfer-  
ring 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 EMER-  
GENCY source voltage and frequency have reached  
an acceptable level. The transfer switch prevents elec-  
trical 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.  
1.5 SAFE USE OF TRANSFER SWITCH  
Before installing, operating or servicing this equip-  
ment, 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 equip-  
ment.  
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.  
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  
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Section 2 — Installation  
Generac GTS “W” Type Transfer Switch  
2.4.1 2-POLE MECHANISM  
2.1 INTRODUCTION TO INSTALLATION  
This equipment has been wired and tested at the fac-  
tory. Installing the switch includes the following pro-  
cedures:  
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.  
• 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.  
Figure 2.1 — Typical 2-Pole Transfer Mechanism  
(200 Amp Shown)  
2.2 UNPACKING  
Carefully unpack the transfer switch. Inspect closely  
for any damage that might have occurred during ship-  
ment. 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 enclo-  
sure are in this manual. Enclosures are typically  
wall-mounted. See “Mounting Dimensions” on page 8.  
2.4.2 3-POLE MECHANISM  
Handle transfer switches carefully when  
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).  
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.  
Figure 2.2 — Typical 3-Pole Transfer Mechanism  
(200 Amp Shown)  
2.4 CONNECTING POWER SOURCE  
AND LOAD LINES  
DANGER  
Make sure to turn OFF both the UTILITY  
(Normal) and EMERGENCY (Standby genera-  
tor) 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 volt-  
age power supply lines causes extremely haz-  
ardous, possibly lethal, electrical shock.  
Wiring diagrams and electrical schematics are pro-  
vided in this manual. Power source and load connec-  
tions are made at a transfer mechanism, inside the  
switch enclosure.  
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Section 2 — Installation  
Generac GTS “W” Type Transfer Switch  
Solderless, screw-type terminal lugs are standard.  
The conductor size range is as follows:  
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:  
Switch Rating  
Wire Range  
200A  
#4-400 MCM  
Conductor sizes must be adequate to handle the max-  
imum 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.  
MAXIMUM WIRE LENGTH  
RECOMMENDED WIRE  
SIZE  
460 feet (140m)  
No. 18 AWG.  
No. 16 AWG.  
No. 14 AWG.  
No. 12 AWG.  
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 con-  
ductors are used, apply corrosion inhibitor to con-  
ductors. 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.  
461 to 730 feet (223m)  
731 to 1,160 feet (354m)  
1,161 to 1,850 feet (565m)  
2.6 AUXILIARY CONTACTS  
If desired, there are Auxiliary Contacts on the trans-  
fer 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.  
All power cables should enter the switch next to the  
transfer mechanism terminals.  
Contact operation is shown in the following chart:  
Switch Position  
Utility  
Open  
Closed  
Standby  
Closed  
Open  
Use a torque wrench to tighten the conduc-  
tors, being sure not to overtighten, or dam-  
age to the switch base could occur. If under-  
Common to Normally Open  
Common to Normally Closed  
!
tightened, a loose connection would result,  
causing excess heat which could damage the  
switch base.  
NOTE:  
Auxiliary Contacts are rated 10 amps at 125 or  
250 volts AC. DO NOT EXCEED THE RATED  
VOLTAGE AND CURRENT OF THE CONTACTS.  
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).  
Figure 2.3 – Auxiliary Contacts  
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.  
Optional  
Auxiliary Contact  
(Actuated)  
Side views shown in Utility position  
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.  
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Section 3 — Operation  
Generac GTS “W” Type Transfer Switch  
3.2.1 CLOSE TO NORMAL SOURCE SIDE  
3.1 FUNCTIONAL TESTS AND  
Before proceeding, verify the position of the switch by  
observing window A” in Figure 3.1 on page 6. If win-  
dow A” reads “ON”, the contacts are closed in the  
normal position, no further action is required. If it  
reads “OFF”, proceed with Step 1.  
ADJUSTMENTS  
Following transfer switch installation and intercon-  
nection, inspect the entire installation carefully. A  
competent, qualified electrician should inspect it.  
The installation should comply strictly with all appli-  
cable codes, standards, and regulations. When  
absolutely certain the installation is proper and cor-  
rect, complete a functional test of the system.  
Step 1: With the handle attached to the actuating  
shaft, move handle in the direction of the  
arrow on the switch cover until it stops — DO  
NOT FORCE. Release handle slowly to allow  
the spring in the switch box to relax. “ON”  
now appears in Window A” and “OFF”  
appears in Window “B”.  
Perform functional tests in the exact order  
presented in this manual, or damage to the  
switch could be done.  
!
3.2.2 CLOSE TO EMERGENCY SOURCE SIDE  
IMPORTANT: Before proceeding with functional  
tests, read and make sure you understand all  
instructions and information in this section. 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.  
Before proceeding, verify the position of the switch by  
observing window “B” in Figure 3.1 on page 6. If win-  
dow “B” reads “ON”, the contacts are closed in the  
EMERGENCY (Standby) position. No further action  
is required. If it reads “OFF”, proceed with Step 1.  
Step 1: With the handle attached to the actuating  
shaft, move the handle in the direction of the  
arrow on the switch cover until it stops - DO  
NOT FORCE. Release handle slowly to allow  
the spring in the switch box to relax. “OFF”  
now appears in Window A” and “ON” appears  
in Window “B”.  
3.2 MANUAL OPERATION  
DANGER  
Do NOT manually transfer under load.  
Disconnect transfer switch from all power  
sources by approved means, such as a main  
!
3.2.3 RETURN TO NORMAL SOURCE SIDE  
Manually actuate switch to return Window A” to the  
“ON” position.  
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:  
3.3 VOLTAGE CHECKS  
1. Turn ON the UTILITY power supply to the trans-  
fer switch with whatever means provided (such as  
the UTILITY maim line circuit breaker).  
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 what-  
ever means provided (such as the main line cir-  
cuit breakers).  
3. Note position of transfer mechanism main con-  
tacts by observing display windows in A” and “B”  
in Figure 3.1 on page 6 as follows:  
• Window A” ON, Window “B” OFF - LOAD termi-  
nals (T1, T2, T3) are connected to utility termi-  
nals (N1, N2, N3).  
DANGER  
PROCEED WITH CAUTION. THE TRANSFER  
SWITCH IS NOW ELECTRICALLY HOT. CONTACT  
WITH LIVE TERMINALS RESULTS IN EXTREMELY  
HAZARDOUS AND POSSIBLY FATAL ELECTRI-  
CAL SHOCK.  
2. With an accurate AC voltmeter, check for correct  
voltage.  
Single-phase utility supply:  
• Window A” OFF, Window “B” ON - LOAD termi-  
nals (T1, T2, T3) are connected to emergency ter-  
minals (E1, E2, E3).  
Measure across ATS terminal lugs N1 and N2; N1  
to NEUTRAL and N2 to NEUTRAL.  
Three-phase utility supply:  
Measure across ATS terminal lugs N1 to N2, N2  
to N3, and N1 to N3.  
Measure across ATS terminal lugs N1 to NEU-  
TRAL, N2 to NEUTRAL, and N3 to NEUTRAL.  
Do not use excessive force when operating  
the transfer switch manually or the manual  
handle could be damaged.  
!
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Section 3 — Operation  
Generac GTS “W” Type Transfer Switch  
Figure 3.1 — Actuating Transfer Switch  
3. When certain that UTILITY supply voltage is cor-  
rect and compatible with transfer switch ratings,  
turn OFF the UTILITY supply to the transfer  
switch.  
4. On the generator panel, set the AUTO-OFF-  
MANUAL switch to MANUAL position. The gener-  
ator should crank and start.  
Single-phase generator supply:  
Measure across ATS terminal lugs E1 to E2; E1  
to NEUTRAL and E2 to NEUTRAL.  
a. Frequency ......................................60-62 Hz  
b. Terminals E1 to E2 ........................240-246 VAC  
c. Terminals E1 to NEUTRAL ............120-123 VAC  
d. Terminals E2 to NEUTRAL ............120-123 VAC  
Three-phase generator supply:  
5. Let the generator stabilize and warm up at no-  
load for at least five minutes.  
Measure across ATS terminal lugs E1 to E2, E2  
to E3 and E1 to E3.  
6. Set the generator's main circuit breaker (CB1) to  
its ON or CLOSED position.  
Measure across ATS terminal lugs E1 to NEU-  
TRAL, E2 to NEUTRAL and E3 to NEUTRAL.  
a. Frequency ......................................60-62 Hz  
b. Terminals E1-E2, E2-E3, E1-E3 ....208-212 VAC  
c. Terminals E1-N, E2-N, E3-N ..........120-122 VAC  
It will also be necessary to verify that the phase rota-  
tion of the utility matches the phase rotation of the  
generator. This can be done by using a phase rotation  
indicator.  
DANGER  
PROCEED WITH CAUTION. GENERATOR OUT-  
PUT VOLTAGE IS NOW BEING DELIVERED TO  
TRANSFER SWITCH TERMINALS. CONTACT  
WITH LIVE TERMINALS RESULTS IN EXTREMELY  
DANGEROUS AND POSSIBLY FATAL ELECTRI-  
CAL SHOCK.  
7. With an accurate AC voltmeter and frequency  
meter, check the no-load, voltage and frequency.  
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Section 3 — Operation  
Generac GTS “W” Type Transfer Switch  
Turn ON electrical loads to the full rated  
wattage/amperage capacity of the generator.  
DO NOT OVERLOAD.  
Failure to do so may result in damage to cer-  
tain rotary equipment.  
With maximum rated load applied, check  
voltage and frequency across transfer switch  
terminals E1 and E2. Voltage should be  
greater than 230 volts; frequency should be  
greater than 59 Hz.  
!
8. Set the generator’s main circuit breaker (CB1) to  
its OFF or OPEN position.  
9. Set the Auto/Off/Manual switch to the OFF posi-  
tion to shut down the generator.  
NOTE:  
Let the generator run under rated load for at  
least 30 minutes. With unit running, listen for  
unusual noises, vibration, overheating, etc.,  
that might indicate a problem.  
Do NOT proceed until generator AC output voltage  
and frequency are correct and within stated limits.  
If the no-load voltage is correct but no-load fre-  
quency is incorrect, the engine governed speed  
probably requires adjustment. If no-load frequen-  
cy is correct but voltage is not, the voltage regula-  
tor may require adjustment.  
5. When checkout under load is complete, set main  
circuit breaker of the generator to the OFF or  
OPEN position.  
6. Let the generator run at no-load for several  
minutes. Then, shut down by setting the AUTO-  
OFF-MANUAL switch to its OFF position.  
7. Move the switch's main contacts back to the  
UTILITY position. For example, load connected to  
utility power supply. Refer to Manual Operation  
on page 5. Handle and operating lever of transfer  
switch should be in down position.  
8. Turn on the utility power supply to transfer  
switch, using whatever means provided (such as  
a utility main line circuit breaker). The utility  
power source now powers the loads.  
3.4 GENERATOR TESTS UNDER LOAD  
1. Set the generator's main circuit breaker to its  
OFF or OPEN position.  
2. Manually actuate the transfer switch main con-  
tacts to their emergency (Standby) position.  
Refer to Manual Operation on page 5.  
3. To start the generator, set the AUTO-OFF-  
MANUAL switch to MANUAL. When engine starts,  
let it stabilize for a few minutes.  
4. Turn the generator's main circuit breaker to the  
ON or CLOSED position. The generator now pow-  
ers all LOAD circuits. Check generator operation  
under load as follows:  
9. Set the generator's AUTO-OFF-MANUAL switch to  
its AUTO position. The system is now set for fully  
automatic operation.  
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Section 4 — Mounting Dimensions  
Generac GTS “W” Type Transfer Switch  
Mounting Dimensions – Drawing No. 0D3714-B  
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Section 5 — Electrical Data  
Generac GTS “W” Type Transfer Switch  
Interconnection Diagram - Drawing No. 074106-B  
A D 2  
A D 1  
2
1
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Section 5 — Electrical Data  
Generac GTS “W” Type Transfer Switch  
200 Amp, 2-pole Switch – Drawing No. 0D3819-A  
TR  
1
F1  
F2  
N1  
N2  
126  
N1A  
N1A  
7
N2A  
N2A  
126  
N1A  
A1  
B1  
T1 T2  
205  
LS1  
2
3
5
6
LS3  
6
RED  
TR  
9
N2A  
WHITE  
1
4
E1  
LS2  
A2  
GTS  
B2  
E1  
E2  
N2A  
23  
23  
B
LEGEND  
TR  
A
C
- CONTACTOR ACTUATING COIL  
GTS - TRANSFER SWITCH CONTACTOR  
TR - RELAY, TRANSFER  
194  
194  
TS - TERMINAL STRIP (CUSTOMER CONNECTION)  
LS1,LS2,LS3 - LIMIT SWITCHES, ACTUATOR  
F1,F2 - FUSE 5A SENSING  
NOTES:  
ALL CONTACTS SHOWN WITH  
TRANSFER SWITCH IN UTILITY  
POSITION.  
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Section 5 — Electrical Data  
Generac GTS “W” Type Transfer Switch  
200 Amp, 2-pole Switch – Drawing No. 0D3819-A  
N2A  
N2A  
N1A  
N1A  
N1  
N2  
GTS  
N1A  
E1  
T1  
E2  
T2  
N2A  
E2  
N2A  
205  
N2A  
E1  
126  
N1A  
N1A  
126  
TR  
205  
A
B
7
9
1
3
N2A  
194  
N1A  
23  
205  
E1  
23  
194  
N1A  
N2A  
N1A  
N1A  
N2A  
F2  
23  
194  
N1  
23  
N2  
194  
TS  
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Section 5 — Electrical Data  
Generac GTS “W” Type Transfer Switch  
200 Amp, 3-pole Switch – Drawing No. 0D3818-A  
TR  
1
PM  
F1  
F2  
1
8
N1  
N2  
126  
N1B  
N1B  
N1A  
7
N2A  
N1B  
3
4
N2A  
N2A  
PM  
5
126  
N3  
N1B  
A1  
B1  
T1 T2  
205  
LS1  
2
3
5
6
LS3  
6
RED  
TR  
9
N2A  
WHITE  
1
4
E1  
LS2  
A2  
GTS  
B2  
E1  
E2  
N2A  
23  
23  
B
LEGEND  
TR  
A
C
- CONTACTOR ACTUATING COIL  
GTS - TRANSFER SWITCH CONTACTOR  
194  
194  
PM - POWER MONITOR, 3 PHASE UTILITY  
TR - RELAY, TRANSFER  
TS - TERMINAL STRIP (CUSTOMER CONNECTION)  
LS1,LS2,LS3 - LIMIT SWITCHES, ACTUATOR  
F1,F2 - FUSE 5A SENSING  
NOTES:  
1.) ALL CONTACTS SHOWN WITH  
TRANSFER SWITCH IN UTILITY  
POSITION.  
2.) FOR SINGLE PHASE OPERATION,  
ADD JUMPER WIRE FROM PM  
TERMINALS 1 TO 8.  
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Section 5 — Electrical Data  
Generac GTS “W” Type Transfer Switch  
200 Amp, 3-pole Switch – Drawing No. 0D3818-A  
N2A  
N2A  
N3  
N1B  
N1B  
N1  
N2  
N3  
GTS  
E1  
T1  
E2  
T2  
E3  
T3  
N2A  
N1B  
N3  
E2  
N2A  
205  
N2A  
E1  
126  
N1B  
N1B  
126  
TR  
N2A  
205  
A
B
7
9
1
3
6
194  
23  
205  
23  
E1  
N1B  
N1B  
194  
N3  
N3  
N1A  
7
N1B  
N2A  
2
1
8
5
N3  
N2A  
23  
F2  
PM  
N2A  
194  
3
4
6
N1B  
N1  
N2  
N3  
N2A  
N1B  
N2A  
N2A  
TS  
®
Generac Power Systems, Inc. 13  
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