Generac Power Systems Switch 09227 0 User Manual

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POWER SYSTEMS, INC.  
Owner’s Manual  
100 and 200 Amp  
“VType and “YType  
Transfer Switch  
Models: 09227-0, 09228-0,  
09229-0, and 09230-0  
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 you must work 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 Mechanisms ......................................4  
2.4.2 3-Pole Mechanisms ......................................4  
2.5 Connecting Start Circuit Wires................................5  
2.6 Auxiliary Contacts ..................................................5  
2.7 Optional Accessories ..............................................5  
Section 3 — Operation..................................................................5  
3.1 Functional Tests and Adjustments ..........................6  
3.2 Functional Tests ......................................................6  
3.3 Manual Operation....................................................6  
3.3.1 “V” Type Transfer Switches ..........................6  
3.3.2 “Y” Type Transfer Switches ..........................7  
3.4 Voltage Checks ........................................................7  
3.5 Generator Tests Under Load ..................................8  
Section 4 – Notes ..........................................................................9  
Section 5 – Wiring Diagrams & Electrical  
• 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. For that purpose,  
a SAFETY DISCONNECT is provided inside the  
transfer switch. Always set that switch to its MAN-  
UAL position before working on the equipment.  
Then place a “DO NOT OPERATE” tag on the  
transfer switch and on the generator.  
Schematics ..............................................................10  
Section 6 – Exploded Views & Parts Lists ............................14  
Section 7 – Warranty..................................................Back Cover  
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Section 1 — General Information  
Generac “V” Type and “Y” Type Transfer Switch  
1.1 INTRODUCTION  
1.3 TRANSFER SWITCH DATA PLATE  
Affixed permanently to the transfer switch door is a  
DATA PLATE. Use the transfer switch only within the  
specific limits shown on the DATA PLATE and on  
other decals and labels that may be affixed to the  
switch. This prevents damage to equipment, possible  
injury to personnel, and provides long and trouble-  
free life for the equipment.  
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.  
When requesting information or ordering parts for  
this equipment, make sure to include all information  
from the DATA PLATE.  
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.  
When requesting information or ordering parts for this  
equipment, make sure to include all information from  
the DATA PLATE.  
Record your Model and Serial numbers in the space  
provided below for future reference.  
1.2 EQUIPMENT DESCRIPTION  
The pre-packaged transfer switch is designed to use  
with pre-packaged standby generator control panels.  
It is used for transferring critical electrical loads from  
a NORMAL (utility) power source to a STANDBY  
(emergency generator) power source. Such a transfer  
of loads occurs automatically when the NORMAL  
power source fails or is subsequently reduced and  
the STANDBY source voltage and frequency have  
reached an acceptable level. The transfer switch pre-  
vents electrical feedback between two different power  
sources (such as the NORMAL and STANDBY  
sources) and, for that reason, codes require it in all  
standby electric system installations.  
MODEL #  
SERIAL #  
1.4 TRANSFER SWITCH ENCLOSURE  
The standard switch enclosure is  
a
National  
Electrical Manufacturer's Association (NEMA) 1 type.  
NEMA 1 type enclosures primarily provide protection  
against contact with the enclosed equipment and  
against a limited amount of falling dirt.  
Once the transfer is completed, the STANDBY power  
source then powers electrical loads connected to the  
transfer switch. When NORMAL source voltage above  
an acceptable (preset) level has been restored, circuit  
board action in the pre-packaged control panel initi-  
ates re-transfer back to NORMAL power source. After  
this re-transfer, the circuit board signals to open the  
start circuit to the generator, which shuts down the  
engine. The circuit board is then "armed" and ready  
for the next drop in NORMAL source voltage.  
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 you make a copy of the SAFE-  
TY RULES and post them near the transfer switch.  
Also, be sure to read all instructions and information  
you may find on tags, labels and decals affixed to the  
equipment.  
NOTE:  
Keep in mind the pre-packaged transfer switch is  
without any kind of electronic controls. It receives  
signals solely from circuit boards contained in the  
prepackaged control panel.  
Two publications that outline the safe use of transfer  
switches are the following:  
• National Electrical Code  
• UL 1008, STANDARD FOR SAFETY-AUTOMATIC  
TRANSFER SWITCHES  
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Section 2 — Installation  
Generac “V” Type and “Y” Type Transfer Switch  
2.1 INTRODUCTION TO INSTALLATION  
This equipment has been wired and tested at the fac-  
tory. Installing the switch includes the following pro-  
cedures:  
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.  
!
• Mounting the enclosure.  
• Connecting power source and load leads.  
• Connecting the generator start circuit.  
• Installing/connecting any options and accessories.  
Testing functions.  
Install the transfer switch as close as possible to the  
electrical loads that are to be connected to it. To pre-  
vent switch distortion, level all mounting points. If  
necessary, use washers behind mounting holes to  
level the unit.  
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 tran-  
sit.  
2.4 CONNECTING POWER SOURCE  
AND LOAD LINES  
DANGER  
Check that all packing material is completely  
removed from the switch prior to installation.  
Make sure to turn OFF both the normal (Utility)  
and standby (generator) 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.  
Attach any lifting device to the transfer switch mount-  
ing holes or brackets only. DO NOT LIFT THE  
SWITCH AT ANY OTHER POINT.  
2.3 MOUNTING  
Transfer switch components are generally mounted  
in a standard NEMA 1 type enclosure (Figure 2.1).  
Other options are available such as NEMA 34 and  
NEMA 12.  
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.  
Figure 2.1 — Mounting Dimensions for Enclosures  
14.32  
19.92  
1.1  
7.09  
6.72  
7.63  
2.12  
15.62  
20.59  
19.37  
25.07  
24.07  
MOUNTING DIMENSIONS - 200 & 400 AMP UNITS  
MOUNTING DIMENSIONS - 100 AMP,2-POLE UNIT  
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Section 2 — Installation  
Generac “V” Type and “Y” Type Transfer Switch  
Figure 2.4 — 3-Pole Transfer Mechanism  
2.4.1 2-POLE MECHANISMS  
These switches (Figures 2.2 and 2.3) are used with a  
single phase system, when the single phase NEU-  
TRAL line is to be connected to a Neutral Lug and is  
not to be switched.  
Figure 2.2 — 100 Amp 2-pole Transfer  
Mechanism  
Solderless, screw-type terminal lugs are standard.  
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.  
Before connecting wiring cables to terminals, remove  
any surface oxides from the cable ends with a wire  
brush. If ALUMINUM conductors are used, apply cor-  
rosion inhibitor to conductors. After tightening ter-  
minal lugs, carefully wipe away any excess corrosion  
inhibitor.  
Figure 2.3 — 200 Amp 2-pole Transfer  
Mechanism  
All power cables should enter the switch next to  
transfer mechanism terminals. Standard terminal  
lugs on the transfer mechanism are solderless,  
screw-type.  
Connect power source load conductors to clearly  
marked transfer mechanism terminal lugs as follows  
(Figure 2.5 on page 5):  
1. Connect NORMAL (utility) power source cables to  
switch terminals N1, N2, N3, etc.  
2. Connect STANDBY source power cables to trans-  
fer switch terminals E1, E2, E3, etc.  
3. Connect customer LOAD leads to switch termi-  
nals T1, T2, T3, etc.  
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.  
2.4.2 3-POLE MECHANISMS  
N
This switch (Figure 2.4) is also 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.  
Tighten terminal lugs to the following torques:  
100 Amp Switch: 50 INCH-POUNDS  
200 Amp Switch: 250 INCH-POUNDS  
Make sure to maintain proper electrical 1/2-inch  
clearance between live metal parts and grounded  
metal.  
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Section 2 — Installation  
Generac “V” Type and “Y” Type Transfer Switch  
Figure 2.5 — Transfer Switch Interconnections (Drawing #79963-B)  
00  
NEUTRAL  
CONNECTION  
N3, E3 AND T3 NOT  
USED ON SINGLE PHASE  
SYSTEMS  
E1  
CB2  
E2  
TRANSFER  
SWITCH  
NEUTRAL  
LUG  
E3  
UTILITY 1  
UTILITY 2  
LOAD 2  
NOTE:  
23  
POWER LEADS AND  
TRANSFER SWITCH  
LEADS MUST BE  
194  
RUN IN TWO  
DIFFERENT CONDUITS.  
REMOTE TEST  
SWITCH (OPTIONAL)  
- OPEN SWITCH TO TEST -  
SWITCH TYPE, SPST  
ELECTRICAL RATINGS,  
2A @ 250Vac MIN.  
AC GENERATOR  
CONTROL PANEL  
Figure 2.6 — Auxiliary Contact Schematic  
2.5 CONNECTING START CIRCUIT  
WIRES  
Control system interconnections (Figure 2.5) 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:  
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)  
Auxiliary contacts are rated 15 amperes at 125, 250 or  
480 volts AC; 0.5 ampere at 125 volts DC; 0.25 ampere  
at 250 volts DC. DO NOT EXCEED THE RATED  
VOLTAGE AND CURRENT OF THE CONTACTS.  
Contact operation is shown in the following chart:  
NOTE:  
The preceding start circuit connections apply to  
the standard 2-wire start system only Your transfer  
switch may be equipped with a 3-wire connection  
system.  
Switch Position  
Utility  
Closed  
Open  
Standby  
2.6 AUXILIARY CONTACTS  
Common (4) to Normally Closed (6)  
Common (4) to Normally Closed (5)  
Open  
If desired, you can access a set of Auxiliary Contacts  
on the Transfer Switch to operate customer acces-  
sories, remote advisory lights, or remote annunciator  
devices. A suitable power source must be connected  
to the COMMON (C) terminal. The contacts labeled 1,  
2 and 3 (Figure 2.6) are connected at the factory for  
operation of transfer switch advisory lights. Contacts  
4, 5 and 6 are available for customer use.  
Closed  
2.7 OPTIONAL ACCESSORIES  
Note any optional accessories that may be installed  
on the transfer switch or are to be installed in the  
standby electric system in conjunction with the  
switch. Complete the necessary connections for these  
accessories.  
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Section 3 — Operation  
Generac “V” Type and “Y” Type Transfer Switch  
3.1 FUNCTIONAL TESTS AND  
3.3 MANUAL OPERATION  
The pre-packaged transfer switch has a choice of two  
transfer mechanisms - the "V" type (Model 9227-0)  
and the "Y" type (Models 9228, 9229 and 9230).  
ADJUSTMENTS  
Following transfer switch installation and intercon-  
nection, inspect the entire installation carefully. A  
competent, qualified electrician should make the  
inspection.  
3.3.1 “V” TYPE TRANSFER SWITCHES  
N
Test manual operation for “V” type transfer switches  
as follows:  
The installation should comply strictly with all appli-  
cable codes, standards, laws and regulations. All  
electrical connections must be correct and in compli-  
ance with applicable codes and standards.  
1. Check that the generator's Auto/Off/Manual  
switch has been set to OFF position.  
2. Turn OFF the UTILITY power supply to the trans-  
fer switch, using whatever means provided (such  
as the UTILITY source main line circuit breaker).  
3. Set the generator's main circuit breaker to its  
OFF or OPEN position.  
Make sure the standby generator is ready. This  
includes checking engine oil level, coolant level, fuel  
supply, batteries and other items specified in the  
OWNER'S MANUAL for specific generators.  
Complete all functional tests as outlined in the FUNC-  
TIONAL TESTS section. Do this before placing the  
transfer switch into service.  
DANGER  
FAILURE TO TURN OFF ALL A POWER VOLTAGE  
SUPPLIES TO THE TRANSFER SWITCH BEFORE  
ATTEMPTING MANUAL OPERATION RESULTS IN  
EXTREMELY HAZARDOUS AND POSSIBLY FATAL  
ELECTRICAL SHOCK.  
3.2 FUNCTIONAL TESTS  
Following transfer switch installation, the entire  
standby electric system should be inspected and test-  
ed. Have all necessary adjustments completed at this  
time. Functional tests of the transfer switch include  
these tests: (a) Manual Operation, (b) Voltage Checks  
and (c) Electric Operation.  
4. Remove the manual transfer handle from the  
enclosure.  
5. Place open slot of the manual transfer handle on  
the small tab of the transfer switch operating  
lever (Figure 3.1).  
6. Pull manual transfer handle downward, then  
move it back to original position. If handle is  
down, LOAD is connected to UTILITY power  
source. If handle is up, LOAD is connected to  
STANDBY power.  
7. Move the transfer switch main contacts to both  
positions several times. Leave the transfer switch  
in the UTILITY position and connect LOAD to the  
UTILITY power source (manual operation lever is  
up).  
To avoid damaging the transfer switch, perform  
!
functional tests In the exact order given.  
Before proceeding with functional tests, read and be  
sure you understand all instructions in this section.  
Also, read the instructions and information on tags  
and decals affixed to the transfer switch. Note any  
options and accessories that might be installed or  
provided with the switch and review their operation.  
DANGER  
Figure 3.1 — Transfer Switch Operation  
(“V” Type)  
DO NOT ATTEMPT MANUAL OPERATION OF THE  
TRANSFER SWITCH UNTIL AFTER ALL POWER  
VOLTAGE SUPPLIES TO THE SWITCH HAVE BEEN  
TURNED OFF. FAILURE TO TURN OFF POWER  
VOLTAGE SUPPLIES MAY RESULT IN DANGER-  
OUS AND POSSIBLE FATAL ELECTRICAL SHOCK.  
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Section 3 — Operation  
Generac “V” Type and “Y” Type Transfer Switch  
3.3.1 “Y” TYPE TRANSFER SWITCHES  
A manual handle was shipped with the transfer  
switch. Test manual operation for “Y” type transfer  
switches as follows (Figure 3.2):  
N
3.4 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. Check that the generator's Auto/Off/Manual  
switch has been set to OFF position.  
2. Attach the square opening of the manual handle  
over the square shaft at lower right corner of  
transfer mechanism.  
3. Move the manual handle UP. When movement  
stops at NEUTRAL, return handle to its original  
position and actuate again.  
DANGER  
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 across terminal lugs N1 and N2; N1 to  
NEUTRAL; and finally N2 to NEUTRAL (Figure  
2.5 on Page 5).  
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.  
4. Observe the changeover display on transfer  
mechanism as follows:  
• If utility arrow is aligned with GREEN band, load  
is connected to UTILITY (normal) power source.  
• If STANDBY arrow is aligned with GREEN band,  
LOAD is connected to STANDBY (emergency)  
source.  
5. Repeat steps 3 and 4 several times, being sure the  
switch main contacts actuate normally to all posi-  
tions.  
5. Let the generator stabilize and warm up at no-  
load for at least five minutes.  
6. When certain that switch operates normally, actu-  
ate the main contacts to their UTILITY (normal)  
source.  
6. Set the generator's main circuit breaker (CBI ) to  
its ON or CLOSED position.  
NOTE:  
DANGER  
LOAD must be connected to UTILITY source  
before proceeding. That is, the GREEN BAND  
must be next to the UTILITY arrow and the RED  
band must be next to the STANDBY arrow.  
PROCEED WITH CAUTION. A GENERATOR OUT-  
PUT VOLTAGE IS NOW BEING DELIVERED TO  
TRANSFER SWITCH TERMINALS. CONTACT WITH  
LIVE TERMINALS RESULTS IN EXTREMELY DAN-  
GEROUS AND POSSIBLY FATAL ELECTRICAL  
SHOCK.  
Figure 3.2 — Manual Operation of “Y” Type  
Transfer Switch  
7. With an accurate AC voltmeter and frequency  
meter, check the no-load, voltage and frequency  
meter at transfer switch terminal lugs E1, E2 and  
NEUTRAL. Readings should be as follows:  
a. Frequency ........................61-63 Hz  
b. Terminals E1 and E2 ......242-253 volts  
c. Terminal E1 to Neutral ....121-126 volts  
d. Terminal E2 to Neutral ....121-126 volts  
8. Set the generator's main circuit breaker (CBI ) to  
its OFF or OPEN position.  
9. To shut down the generator, set its  
Auto/Off/Manual switch to OFF position.  
NOTE:  
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.  
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Section 3 — Operation  
Generac “V” Type and “Y” Type Transfer Switch  
5. When checkout under load is complete, set main  
3.5 GENERATOR TESTS UNDER LOAD  
1. Set the generator's main circuit breaker to its  
OFF or OPEN position.  
circuit breaker of the generator to its OFF or  
OPEN position.  
6. Let the generator run at no-load for several min-  
utes. Then, shut down by setting the  
Auto/Off/Manual switch to its OFF position.  
7. With the manual transfer handle, move the  
switch's main contacts back to their utility posi-  
tion, i.e., load connected to utility power supply.  
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 con-  
tacts to their STANDBY position.  
3. To start the generator, set the Auto/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:  
• Turn ON electrical loads to the full rated  
wattage/amperage capacity of the generator. DO  
NOT OVERLOAD.  
• 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 58 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.  
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 — Notes  
Generac “V” Type and “Y” Type Transfer Switch  
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Section 5 — Electrical Schematics and Wiring Diagrams  
Interconnection Diagram - Drawing No. 074106-A  
A D 2  
A D 1  
T I L I T Y 2  
T I L I T Y 1  
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Section 5 — Electrical Schematics and Wiring Diagrams  
200 Amp, 2-Pole Transfer Switch - Drawing No. 074498-B  
2
1
2
1
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Section 5 — Electrical Schematics and Wiring Diagrams  
3-Pole Transfer Switch - Drawing No. 074499-B  
2
1
2
1
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Section 5 — Electrical Schematics and Wiring Diagrams  
Transfer Switch - Drawing No. 081222-B  
A D 2  
A D L 1  
2
1
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