Generac Power Systems Switch 004945 1 User Manual

Automatic Transfer Switch  
Owner’s Manual  
ATS Service Entrance  
HS Type Transfer Switch  
Models: 005036-0, 100 Amp, 250 Volts  
and 004945-1, 200 Amp, 250 Volts  
This manual should remain with the unit.  
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Table of Contents  
• 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.  
• Jewelry conducts electricity and wearing it may  
cause dangerous electrical shock. Remove all jew-  
elry (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.  
Safety Rules .........................................Inside Front Cover  
Section 1 — General Information ...................................2  
1.1 Introduction............................................................. 2  
1.2 Equipment Description ........................................... 2  
1.2.1 Transfer Switch Mechanism.......................... 2  
1.2.2 Service Disconnect Circuit Breaker............... 2  
1.3 Transfer Switch Data Decal..................................... 2  
1.4 Transfer Switch Enclosure ...................................... 3  
1.5 Safe Use Of Transfer Switch.................................... 3  
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  
2.5 Connecting Start Circuit Wires ................................ 4  
Section 3 — Operation.......................................................4  
3.1 Functional Tests & Adjustments.............................. 4  
3.2 Manual Operation.................................................... 4  
3.2.1 Close to Normal Source Side ........................ 5  
3.2.2 Close to Emergency Source Side................... 5  
3.2.3 Return to Normal Source Side ...................... 5  
3.3 Voltage Checks......................................................... 6  
3.4 Generator Tests Under Load ................................... 6  
Section 4 – Installation Diagram....................................7  
Section 5 – Electrical Data...............................................8  
Section 6 – Exploded Views & Parts Lists..................12  
Section 7 – Notes .............................................................16  
Section 8 – Warranty ......................................Back Cover  
• 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 dry rope or board, to free  
the victim from the live conductor. If the victim is  
unconscious, apply first aid and get immediate  
medical help.  
• When an automatic transfer switch is installed for  
a standby generator set, the generator engine may  
crank and start at any time without warning. To  
avoid possible injury that might be caused by such  
sudden start-ups, the system’s automatic start cir-  
cuit must be disabled before working on or around  
the generator or transfer switch. For that purpose,  
a SAFETY DISCONNECT is provided inside the  
transfer switch. Always set that switch to its OFF  
position before working on the equipment. Then  
place a “DO NOT OPERATE” tag on the transfer  
switch and on the generator. Remove the Negative  
(Neg) or (–) battery cable.  
For authorized service,  
reference the dealer locator  
number found in the generator  
owner’s manual.  
1
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Section 1 — General Information  
ATS “HS” Type Transfer Switch  
Figure 1.1 — Typical ATS Transfer Mechanism  
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.  
UTILITY LUGS  
UTILITY  
CLOSING  
COIL  
Every effort has been expended to make sure that the  
contents of this manual are both accurate and cur-  
rent. The manufacturer, however, reserves the right  
to change, alter or otherwise improve the product at  
any time without prior notice.  
GENERATOR  
LUGS (E1 & E2)  
GENERATOR  
CLOSING  
COIL  
1.2 EQUIPMENT DESCRIPTION  
The automatic transfer switch is used for transfer-  
ring electrical load from a UTILITY (NORMAL) power  
source to an EMERGENCY (STANDBY) power source.  
Such a transfer of electrical loads occurs automati-  
cally 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.  
LOAD LUGS (T1 & T2)  
This transfer switch is for use in optional standby  
systems only.  
This transfer switch is suitable for use on a circuit  
capable of 10,000 rms symmetrical amperes, 240  
VAC maximum.  
1.2.2 SERVICE DISCONNECT CIRCUIT  
BREAKER  
The service disconnect circuit breaker for the 100  
amp models are:  
The transfer switch consists of a transfer mecha-  
nism, service disconnect circuit breaker, a relay  
control, fuses, and a terminal strip for connection of  
sensing wires.  
• Siemens, Type BQ, 2-pole  
• 120/240VAC, 100A  
• 50/60 Hertz  
This transfer switch is suitable for use as service  
entrance equipment.  
• Heating, Air Conditioning and Refrigeration (HACR)  
rated  
• Wire range: #1 - #8 AWG.  
• The conductor tightening torque is 50 in-lbs.  
1.2.1 TRANSFER SWITCH MECHANISM  
These switches (Figure 1.1) 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.  
The service disconnect circuit breaker for the 200  
amp models are:  
• Siemens, Type QN, 2-pole  
• 120/240VAC, 200A  
• 50/60 Hertz  
Solderless, screw-type terminal lugs are standard.  
Switch  
Rating  
100A  
Wire  
Range  
#14-1/0 AWG  
#6-250 MCM  
Conductor Tightening  
Torque  
50 in-lbs.  
• Heating, Air Conditioning and Refrigeration (HACR)  
rated  
• Wire range: 300 KCMIL - 4 AWG  
• The conductor tightening torque is 250 in-lbs.  
200A  
275 in-lbs.  
This transfer switch is suitable for control of motors,  
electric discharge lamps, tungsten filament and elec-  
tric heating equipment where the sum of motor full  
load ampere ratings and the ampere ratings of other  
loads do not exceed the ampere rating of the switch  
and the tungsten load does not exceed 30 percent of  
the switch rating.  
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.  
2
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Section 2 — Installation  
GTS “HS” Type Transfer Switch  
When requesting information or ordering parts for this  
equipment, make sure to include all information from  
the DATA DECAL.  
2.3 MOUNTING  
Mounting dimensions for the transfer switch enclo-  
sure are in this manual. Enclosures are typically  
wall-mounted. See “Installation Diagram”, Section 5.  
Record the Model and Serial numbers in the space  
provided below for future reference.  
MODEL #  
SERIAL #  
Handle transfer switches carefully when install-  
ing. Do not drop the switch. Protect the switch  
against impact at all times, and against construc-  
tion grit and metal chips. Never install a transfer  
switch that has been damaged.  
This transfer switch is mounted in a NEMA 3R enclo-  
sure. It can be mounted outside or inside and should  
be based on the layout of installation, convenience  
and proximity to the utility supply and load center.  
1.4 TRANSFER SWITCH ENCLOSURE  
The standard switch enclosure is a National  
Electrical Manufacturer’s Association (NEMA) 3R  
type. NEMA 3R type enclosures primarily provide  
a degree of protection against falling rain and sleet  
and is undamaged by the formation of ice on the  
enclosure.  
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.  
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.  
The manufacturer recommends that a copy of the  
SAFETY RULES are posted near the transfer switch.  
Also, be sure to read all instructions and information  
found on tags, labels and decals affixed to the equip-  
ment.  
2.4 CONNECTING POWER SOURCE  
AND LOAD LINES  
DANGER  
Make sure to turn OFF both the UTILITY  
(NORMAL) and EMERGENCY ( STANDBY) power  
supplies before trying to connect power source  
and load lines to the transfer switch. Supply  
voltages are extremely high and dangerous.  
Contact with such high voltage power sup-  
ply lines causes extremely hazardous, possibly  
lethal, electrical shock.  
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  
Wiring diagrams and electrical schematics are pro-  
vided in this manual.  
2.1 INTRODUCTION TO INSTALLATION  
This equipment has been wired and tested at the  
factory. Installing the switch includes the following  
procedures:  
Two suggested installation methods are shown. One  
for new installations and/or retrofit and one for ret-  
rofit.  
• Mounting the enclosure.  
NOTE:  
• Connecting power source and load leads.  
• Connecting the generator sensing and transfer  
relay circuits.  
• Connecting any auxiliary contact (if needed)  
Testing functions.  
All installations must comply with national, state  
and local codes. It is the responsibility of the  
installer to perform an installation that will pass  
the final electrical inspection.  
The utility supply connection is made at the circuit  
breaker terminals. The generator supply and custom-  
er load connections are made at the transfer switch  
mechanism, inside the switch enclosure.  
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.  
3
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Section 3 — Operation  
ATS “HS” Type Transfer Switch  
Conductor sizes must be adequate to handle the  
maximum current to which they will be subjected to,  
based on the 75°C column of tables, charts, etc. used  
to size conductors. The installation must comply fully  
with all applicable codes, standards and regulations.  
NOTE:  
When this ATS is used with an air-cooled genera-  
tor, the LOAD 1 and LOAD 2 wires are not used.  
3.1 FUNCTIONAL TESTS AND  
Before connecting wiring cables to terminals, remove  
any surface oxides from the cable ends with a wire  
brush. All power cables must enter the enclosure  
through the knockouts. If not using the knockouts,  
entry must be at or below knockouts. If ALUMINUM  
conductors are used, apply corrosion inhibitor to  
conductors. Tighten terminal lugs to the torque  
values as noted in Section 1.2.2, and on the decal  
located on the inside of the door. After tightening ter-  
minal lugs, carefully wipe away any excess corrosion  
inhibitor.  
ADJUSTMENTS  
Following transfer switch installation and inter-  
connection, inspect the entire installation care-  
fully. A competent, qualified electrician should  
inspect it. The installation should comply strictly  
with all applicable codes, standards, and regula-  
tions. When absolutely certain the installation is  
proper and correct, complete a functional test of  
the system.  
Perform functional tests in the exact order pre-  
Use a torque wrench to tighten the conduc-  
sented in this manual, or damage could be done  
tors, being sure not to overtighten, or damage  
to the switch.  
to the switch base could occur. If not tightened  
enough, a loose connection would result, caus-  
ing excess heat which could damage the switch  
base.  
IMPORTANT: Before proceeding with functional tests,  
read and make sure all instructions and information  
in this section are understood. Also read the infor-  
mation and instructions of labels and decals affixed  
to the switch. Note any options or accessories that  
might be installed and review their operation.  
Connect power source load conductors to clearly  
marked transfer mechanism terminal lugs as fol-  
lows  
1. Connect UTILITY (NORMAL) power source cables  
to circuit breaker.  
2. Connect EMERGENCY (STANDBY) source power  
cables to transfer switch terminals E1, E2.  
3. Connect customer LOAD leads to switch termi-  
nals T1, T2.  
3.2 MANUAL OPERATION  
DANGER  
Do NOT manually transfer under load.  
Disconnect transfer switch from all power sourc-  
es by approved means, such as the main circuit  
breaker(s).  
A manual HANDLE is shipped with the transfer  
switch. Manual operation must be checked BEFORE  
the transfer switch is operated electrically. To check  
manual operation, proceed as follows:  
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.  
1. Turn the generator’s AUTO/OFF/MANUAL switch  
to OFF.  
2. Turn OFF both UTILITY (service disconnect cir-  
cuit breaker) and EMERGENCY (generator main  
line to circuit breaker) power supplies to the  
transfer switch.  
2.5 CONNECTING START CIRCUIT  
WIRES  
Control system interconnections consist of N1 and  
N2, T1 and T2, 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:  
3. Turn the GENERATOR DISCONNECT SWITCH  
to the OFF position.  
4. Note position of transfer mechanism main con-  
tacts by observing the moveable contact carrier  
arm. This can be viewed through the long narrow  
slot in the inside cover of the ATS. The top of the  
moveable contact carrier arm is yellow to be eas-  
ily identified.  
• Manual operation handle in the UP position -  
LOAD terminals (T1, T2) are connected to UTIL-  
ITY terminals (N1, N2).  
MAXIMUM WIRE LENGTH  
RECOMMENDED WIRE  
SIZE  
460 feet (140m)  
No. 18 AWG.  
No. 16 AWG.  
No. 14 AWG.  
No. 12 AWG.  
461 to 730 feet (223m)  
731 to 1,160 feet (354m)  
1,160 to 1,850 feet (565m)  
4
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Section 3 — Operation  
ATS “HS” Type Transfer Switch  
Figure 3.1 — Actuating Transfer Switch  
Attach handle to  
the moveable contact  
carrier arm.  
NOTE: Return handle to  
storage position in enclosure  
when finished with manual transfer.  
Move handle UP for the  
NORMAL (UTILITY) position.  
Move handle DOWN for the  
STANDBY (EMERGENCY)  
position.  
• Manual operation handle in the DOWN posi-  
tion - LOAD terminals (T1, T2) are connected to  
EMERGENCY terminals (E1, E2).  
3.2.2 CLOSE TO EMERGENCY SOURCE SIDE  
Before proceeding, verify the position of the switch  
by observing the position of the manual operation  
handle in Figure 3.1. If the handle is DOWN, the  
contacts are closed in the EMERGENCY (STANDBY)  
position. No further action is required. If the handle  
is UP, proceed with Step 1.  
Do not use excessive force when operating the  
transfer switch manually or damage could be  
done to the manual handle.  
Step 1: With the handle inserted into the moveable  
contact carrier arm, move the handle DOWN.  
Be sure to hold on to the handle as it will  
move quickly after the center of travel.  
Step 2: Remove manual operating handle from move-  
able contact carrier arm. Return handle to  
storage bracket.  
3.2.1 CLOSE TO NORMAL SOURCE SIDE  
Before proceeding, verify the position of the switch by  
observing the position of manual operation handle in  
Figure 3.1. If the handle is UP, the contacts are closed  
in the NORMAL (UTILITY) position, no further action  
is required. If the handle is DOWN, proceed with Step  
1.  
3.2.3 RETURN TO NORMAL SOURCE SIDE  
Step 1: With the handle inserted into the moveable  
contact carrier arm, move handle UP. Be  
sure to hold on to the handle as it will move  
quickly after the center of travel.  
Step 2: Remove manual operating handle from move-  
able contact carrier arm. Return handle to  
storage bracket.  
Step 1: Manually actuate switch to return manual  
operating handle to the UP position.  
Step 2: Remove manual operating handle from move-  
able contact carrier arm. Return handle to  
storage bracket.  
5
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Section 3 — Operation  
ATS “HS” Type Transfer Switch  
NOTE:  
3.3 VOLTAGE CHECKS  
1. Turn ON the UTILITY power supply to the trans-  
fer switch using the service disconnect circuit  
breaker.  
Do NOT proceed until generator AC output volt-  
age and frequency are correct and within stated  
limits. If the no-load voltage is correct but no-load  
frequency is incorrect, the engine governed speed  
may require adjustment. If no-load frequency is  
correct but voltage is not, the voltage regulator  
may require adjustment.  
DANGER  
PROCEED WITH CAUTION. THE TRANSFER  
SWITCH IS NOW ELECTRICALLY HOT. CONTACT  
WITH LIVE TERMINALS RESULTS IN EXTREMELY  
HAZARDOUS AND POSSIBLY FATAL ELECTRICAL  
SHOCK.  
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 (Section 3.2).  
3. Tostartthegenerator, settheAUTO/OFF/MANUAL  
switch to MANUAL. When engine starts, let it sta-  
bilize for a few minutes.  
4. Turn the generator's main circuit breaker to its  
ON or CLOSED position. The generator now pow-  
ers all LOAD circuits. Check generator operation  
under load as follows:  
2. With an accurate AC voltmeter, check for correct  
voltage. Measure across ATS terminal lugs N1  
and N2. Also check N1 to NEUTRAL and N2 to  
NEUTRAL.  
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 gen-  
erator should crank and start.  
5. Let the generator stabilize and warm up at no-  
Turn ON electrical loads to the full rated watt-  
age/amperage capacity of the generator. DO  
NOT OVERLOAD.  
load for at least five minutes.  
6. Turn the GENERATOR DISCONNECT SWITCH  
to the ON position.  
With maximum rated load applied, check  
voltage and frequency across transfer switch  
terminals E1 and E2. Voltage should be  
greater than 230VAC and frequency should be  
greater than 59 Hertz.  
7. Set the generator's main circuit breaker (CB1) to  
its ON or CLOSED position.  
DANGER  
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.  
PROCEED WITH CAUTION. GENERATOR  
OUTPUT VOLTAGE IS NOW BEING DELIVERED  
TO TRANSFER SWITCH TERMINALS. CONTACT  
WITH LIVE TERMINALS RESULTS IN EXTREMELY  
DANGEROUS AND POSSIBLY FATAL ELECTRICAL  
SHOCK.  
5. When checkout under load is complete, set main  
circuit breaker of the generator to its OFF or  
OPEN position.  
8. With an accurate AC voltmeter and frequency  
meter, check the no-load, voltage and frequency.  
Measure across ATS terminal lugs E1 to E2. Also  
check E1 to NEUTRAL and E2 to NEUTRAL.  
a. Frequency.......................................60-62 Hertz  
b. Terminals E1 to E2 ........................240-246 VAC  
c. Terminals E1 to NEUTRAL.............120-123 VAC  
d. Terminals E2 to NEUTRAL.............120-123 VAC  
9. Set the generator’s main circuit breaker (CB1) to  
its 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 their  
UTILITY position. For example, LOAD connect-  
ed to UTILITY power supply. Refer to Manual  
Operation (Section 3.2). Handle and operating  
lever of transfer switch should be in UP posi-  
tion.  
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.  
10. Set the AUTO/OFF/MANUAL switch to the  
OFF position to shut down the generator.  
9. Set the generator's AUTO/OFF/MANUAL switch to  
its AUTO position.  
10. Set the GENERATOR DISCONNECT SWITCH to  
the ON position. The system is now set for fully  
automatic operation.  
6
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Section 4 — Installation Diagram  
ATS “HS” Type Transfer Switch  
Drawing No. 0F0016-B  
271mm[10.67"]  
26.5mm[1.04"]  
MOUNTING HOLES  
Ø6.3mm[Ø0.25"]  
0A6599tv  
0A6599tv  
561mm[22.09"  
597mm[23.50"]  
PADLOCK  
(CUSTOMER SUPPLIED)  
LOCATION  
0
34mm[1.34"]  
179.5mm[7.07"]  
KNOCKOUT SUITABLE  
FOR 3/4" & 1" CONDUIT SIZE  
KNOCKOUT SUITABLE FOR  
1", 1-1/4", 1-1/2" CONDUIT SIZE  
3 PLACES  
KNOCKOUT SUITABLE  
FOR 1", 1-1/4", 1-1/2" CONDUIT SIZE  
324mm[12.76"]  
7
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Section 5 — Electrical Data  
ATS “HS” Type Transfer Switch  
Transfer Switch Interconnections - Drawing No. 0F0017-A  
8
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