Generac Power Systems Switch 04635 0 User Manual

®
POWER SYSTEMS, INC.  
Owner’s Manual  
GTS “WType  
Automatic  
Transfer Switch  
200 Amp, 250 Volts  
Model 04635-0  
This manual should remain with the unit.  
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Table of Contents  
• 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.  
Safety Rules..........................................Inside Front Cover  
Section 1 — General Information ..................................2  
1.1 Introduction ............................................................2  
1.2 Equipment Description ............................................2  
1.3 Transfer Switch Data Plate ......................................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  
2.5 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 ........................6  
3.2.2 Close to Emergency Source Side....................6  
3.2.3 Return to Normal Source Side ......................6  
3.3 Voltage Checks..........................................................6  
3.4 Generator Tests Under Load ....................................7  
Section 4 – Mounting Dimensions ................................8  
Section 5 – Electrical Data ..............................................9  
Section 6 – Exploded Views & Parts Lists..................12  
Section 7 – 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
nonconducting implement, such as a rope or  
board, to free the victim from the live conductor. If  
the victim is unconscious, apply first aid and get  
immediate medical help.  
• When an automatic transfer switch is installed for  
a standby generator set, the generator engine may  
crank and start at any time without warning. To  
avoid possible injury that might be caused by such  
sudden start-ups, the system’s automatic start  
circuit must be disabled before working on or  
around the generator or transfer switch. For that  
purpose, a SAFETY DISCONNECT is provided  
inside the transfer switch. Always set that switch  
to its MANUAL 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.  
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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  
application, or improper procedures.  
Record the Model and Serial numbers in the space  
provided below for future reference.  
ASSEMBLY #  
SERIAL #  
Every effort has been expended to make sure that the  
contents of this manual are both accurate and  
current. Generac, however, reserves the right to  
change, alter or otherwise improve the product at any  
time without prior notice.  
1.4 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  
transferring critical electrical load from a UTILITY  
(Normal) power source to  
a
EMERGENCY  
(STANDBY) power source. Such a transfer of  
electrical loads occurs automatically when the  
UTILITY power source has failed or is substantially  
reduced and the EMERGENCY source voltage and  
frequency have reached an acceptable level. The  
transfer switch prevents electrical feedback between  
two different power sources (such as the UTILITY  
and EMERGENCY sources) and, for that reason,  
codes require it in all standby electric system  
installations.  
1.5 SAFE USE OF TRANSFER SWITCH  
Before installing, operating or servicing this  
equipment, read the SAFETY RULES (inside front  
cover) carefully. Comply strictly with all SAFETY  
RULES to prevent accidents and/or damage to the  
equipment. Generac recommends that a copy of the  
SAFETY RULES be posted near the transfer switch.  
Also, be sure to read all instructions and information  
found on tags, labels and decals affixed to the  
equipment.  
The transfer switch consists of a solid state  
intelligence circuit, a transfer mechanism and a  
control panel.  
Two publications that outline the safe use of transfer  
switches are the following:  
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.  
• 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  
Wiring diagrams and electrical schematics are  
provided in this manual. Power source and load  
connections are made at a transfer mechanism,  
inside the switch enclosure.  
2.1 INTRODUCTION TO INSTALLATION  
This equipment has been wired and tested at the  
factory. Installing the switch includes the following  
procedures:  
• Mounting the enclosure.  
2.4.1 2-POLE MECHANISM  
• Connecting power source and load leads.  
• Connecting the generator start circuit.  
• Connecting any auxiliary contact (if needed)  
• Installing/connecting any options and accessories.  
Testing functions.  
These switches (Figure 2.1) are used with a single  
phase system, when the single phase NEUTRAL line  
is to be connected to a Neutral Lug and is not to be  
switched.  
Figure 2.1 — Typical 2-Pole Transfer Mechanism  
(100 Amp Shown)  
2.2 UNPACKING  
Carefully unpack the transfer switch. Inspect closely  
for any damage that might have occurred during  
shipment. The purchaser must file with the carrier any  
claims for loss or damage incurred while in transit.  
Check that all packing material is completely  
removed from the switch prior to installation.  
2.3 MOUNTING  
Mounting dimensions for the transfer switch  
enclosure are in this manual. Enclosures are  
typically wall-mounted. See “Mounting Dimensions”.  
Handle transfer switches carefully when  
installing. Do not drop the switch. Protect the  
switch against impact at all times, and against  
!
construction grit and metal chips. Never  
install a transfer switch that has been  
damaged.  
Solderless, screw-type terminal lugs are standard.  
The conductor size range is as follows:  
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.  
Switch Rating  
Wire Range  
200A  
#4-400 MCM  
Conductor sizes must be adequate to handle the  
maximum current to which they will be subjected;  
based on the 75°C column of tables, charts, etc. used  
to size conductors. The installation must comply fully  
with all applicable codes, standards and regulations.  
2.4 CONNECTING POWER SOURCE  
AND LOAD LINES  
DANGER  
Before connecting wiring cables to terminals, remove  
any surface oxides from the cable ends with a wire  
brush. All power cables should enter the switch next  
to transfer mechanism terminals. If ALUMINUM  
conductors are used, apply corrosion inhibitor to  
conductors. Tighten terminal lugs to the torque  
values as noted on the decal located on the inside of  
the door. After tightening terminal lugs, carefully wipe  
away any excess corrosion inhibitor.  
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 supply lines causes extremely  
hazardous, possibly lethal, electrical shock.  
All power cables should enter the switch next to the  
transfer mechanism terminals.  
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Section 2 — Installation  
Generac GTS “W” Type Transfer Switch  
2.6 AUXILIARY CONTACTS  
If desired, there are Auxiliary Contacts on the  
transfer switch to operate customer accessories,  
remote advisory lights, or remote annunciator  
devices. A suitable power source must be connected  
to the COMMON (C) terminal. See Figure 2.3.  
Use a torque wrench to tighten the  
conductors, being sure not to overtighten, or  
damage to the switch base could occur. If  
undertightened, a loose connection would  
result, causing excess heat which could  
damage the switch base.  
!
Contact operation is shown in the following chart:  
Switch Position  
Connect power source load conductors to clearly  
marked transfer mechanism terminal lugs as follows  
Utility  
Open  
Standby  
Closed  
Open  
Common to Normally Open  
Common to Normally Closed  
1. Connect UTILITY (NORMAL) power source cables  
to switch terminals N1, N2.  
Closed  
2. Connect EMERGENCY (STANDBY) source power  
cables to transfer switch terminals E1, E2.  
3. Connect customer LOAD leads to switch  
terminals Load 1, Load 2. (Load 1 and Load 2 are  
used with liquid-cooled units only.)  
NOTE:  
Auxiliary Contacts are rated 10 amps at 125 or  
250 volts AC. DO NOT EXCEED THE RATED  
VOLTAGE AND CURRENT OF THE CONTACTS.  
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.  
Figure 2.3 – Auxiliary Contacts  
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; at least  
one inch for circuits over 400 amps.  
Optional  
Auxiliary Contact  
(Actuated)  
2.5 CONNECTING START CIRCUIT  
WIRES  
Side views shown in Utility position  
Control system interconnections consist of UTILITY  
1 and 2, LOAD 1 and 2 (liquid-cooled units only); 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:  
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)  
1,161 to 1,850 feet (565m)  
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Section 3 — Operation  
Generac GTS “W” Type Transfer Switch  
3.1 FUNCTIONAL TESTS AND  
3.2 MANUAL OPERATION  
DANGER  
ADJUSTMENTS  
Following transfer switch installation and  
interconnection, inspect the entire installation  
carefully. A competent, qualified electrician  
should inspect it. The installation should comply  
strictly with all applicable codes, standards, and  
regulations. When absolutely certain the  
installation is proper and correct, complete a  
functional test of the system.  
Do NOT manually transfer under load.  
Disconnect transfer switch from all power  
sources by approved means, such as a 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:  
1. Turn the generator’s AUTO-OFF-MANUAL switch  
to OFF.  
Perform functional tests in the exact order  
2. Turn OFF both UTILITY and EMERGENCY  
power supplies to the transfer switch, with  
whatever means provided (such as the main line  
circuit breakers).  
3. Note position of transfer mechanism main  
contacts by observing display windows in A” and  
“B” in Figure 3.1 as follows:  
• Window A” ON, Window “B” OFF - LOAD  
terminals (T1, T2) are connected to UTILITY  
terminals (N1, N2).  
presented in this manual, or the switch could  
be damaged.  
!
IMPORTANT: Before proceeding with functional  
tests, read and make sure all instructions and  
information in this section is understood. 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.  
Figure 3.1 — Actuating Transfer Switch  
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Section 3 — Operation  
Generac GTS “W” Type Transfer Switch  
• Window A” OFF, Window “B” ON - LOAD  
terminals (T1, T2) are connected to  
EMERGENCY terminals (E1, E2).  
Single-phase utility supply:  
Measure across ATS terminal lugs N1 and N2; N1  
to NEUTRAL and N2 to NEUTRAL.  
3. When certain that UTILITY supply voltage is  
correct 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  
generator should crank and start.  
Do not use excessive force when operating  
the transfer switch manually or the manual  
handle could be damaged.  
!
3.2.1 CLOSE TO NORMAL SOURCE SIDE  
5. Let the generator stabilize and warm up at no-  
Before proceeding, verify the position of the switch by  
observing window A” in Figure 3.1. If window A”  
reads “ON”, the contacts are closed in the NORMAL  
position, no further action is required. If it reads  
“OFF”, proceed with Step 1.  
load for at least five minutes.  
6. Set the generator's main circuit breaker (CB1) to  
its ON or CLOSED position.  
DANGER  
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”.  
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.  
7. With an accurate AC voltmeter and frequency  
meter, check the no-load, voltage and frequency.  
Single-phase generator supply:  
3.2.2 CLOSE TO EMERGENCY SOURCE SIDE  
Before proceeding, verify the position of the switch by  
observing window “B” in Figure 3.1. If window “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.  
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  
It will also be necessary to verify that the phase  
rotation of the utility matches the phase rotation of  
the generator. This can be done by using a phase  
rotation indicator.  
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”.  
3.2.3 RETURN TO NORMAL SOURCE SIDE  
Manually actuate switch to return Window A” to the  
“ON” position.  
Failure to do so may result in damage to  
certain rotary equipment.  
!
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  
position to shut down the generator.  
NOTE:  
3.3 VOLTAGE CHECKS  
1. Turn ON the UTILITY power supply to the  
transfer switch with whatever means provided  
(such as the UTILITY maim line circuit breaker).  
DANGER  
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  
frequency is incorrect, the engine governed speed  
probably requires adjustment. If no-load  
frequency is correct but voltage is not, the voltage  
regulator may require adjustment.  
PROCEED WITH CAUTION. THE TRANSFER  
SWITCH IS NOW ELECTRICALLY HOT. CONTACT  
WITH LIVE TERMINALS RESULTS IN EXTREMELY  
HAZARDOUS AND POSSIBLY FATAL  
ELECTRICAL SHOCK.  
2. With an accurate AC voltmeter, check for correct  
voltage.  
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Section 3 — Operation  
Generac GTS “W” Type Transfer Switch  
5. When checkout under load is complete, set main  
circuit breaker of the generator to its OFF or  
OPEN position.  
3.4 GENERATOR TESTS UNDER LOAD  
1. Set the generator's main circuit breaker 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 connected to  
utility power supply. Refer to Manual Operation.  
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.  
2. Manually actuate the transfer switch main  
contacts to their EMERGENCY (STANDBY)  
position. Refer to Manual Operation.  
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 its  
ON or CLOSED position. The generator now  
powers all LOAD circuits. Check generator  
operation under load as follows:  
Turn ON electrical loads to the full rated  
wattage/amperage capacity of the generator.  
DO NOT OVERLOAD.  
9. Set the generator's AUTO-OFF-MANUAL switch to  
its AUTO position. The system is now set for fully  
automatic operation.  
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.  
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.  
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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  
Transfer Switch Interconnections - Drawing No. 079963-B  
4
A D 1  
T I L I T Y 1  
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Section 5 — Electrical Data  
Generac GTS “W” Type Transfer Switch  
Transfer Switch Interconnections - Drawing No. 074106-A  
4
A D 1  
T I L I T Y 2  
T I L I T Y 1  
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Section 5 — Electrical Data  
Generac GTS “W” Type Transfer Switch  
Wiring Diagram - 200 Amp, 2-pole Switch – Drawing No. 0D3819  
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