Generac Switch 004635 3 User Manual

®
POWER SYSTEMS, INC.  
Owner’s Manual  
GTS “HSType  
Automatic  
Transfer Switch  
Models: 004635-3  
(200 Amp, 250 Volts)  
and 004678-2  
(100 Amp, 250Volts)  
This manual should remain with the unit.  
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Table of Contents  
• 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 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  
2.5 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 ........................4  
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 ....................................6  
Section 4 – Notes................................................................7  
Section 5 – Installation Diagram....................................8  
Section 6 – Electrical Data ..............................................9  
Section 7 – Exploded Views & Parts Lists..................12  
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. Then place a “DO  
NOT OPERATE” tag on the transfer switch and on  
the generator. Remove the Negative (Neg) or (–) bat-  
tery cable.  
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Section 1 — General Information  
Generac GTS “HS” Type Transfer Switch  
1.1 INTRODUCTION  
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.  
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 DECAL.  
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.  
Record the Model and Serial numbers in the space pro-  
vided below for future reference.  
ASSEMBLY #  
SERIAL #  
1.2 EQUIPMENT DESCRIPTION  
The automatic transfer switch is used for transfer-  
ring electrical load from a UTILITY (NORMAL) power  
source to a 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.  
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 not damaged by the formation of ice on the  
enclosure.  
The transfer switch consists of a transfer mecha-  
nism, a relay control, and a terminal strip for con-  
nection of sensing wires.  
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 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 equipment.  
This switch is suitable for control of motors, electric  
discharge lamps, tungsten filament and electric heat-  
ing 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.  
Two publications that outline the safe use of transfer  
switches are the following:  
The transfer switch is for use in optional standby sys-  
tems only.  
• NFPA 70; National Electrical Code  
• UL 1008, STANDARD FOR SAFETY-AUTOMATIC  
TRANSFER SWITCHES  
The transfer switch is suitable for use on a circuit  
capable of 10,000 rms symmetrical amperes, 240  
VAC when protected by a circuit breaker without an  
adjustable short time response or by fuses.  
®
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Section 2 — Installation  
Generac GTS “HS” 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 power source and load leads.  
• Connecting the generator start circuit.  
• Connecting any auxiliary contact (if needed)  
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 “Installation Diagram”, Section 5.  
Solderless, screw-type terminal lugs are standard.  
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 dam-  
aged.  
Switch  
Rating  
100A  
Wire  
Range  
#14-1/0 AWG  
#6-250 MCM  
Conductor Tightening  
Torque  
!
50 in-lbs.  
275 in-lbs.  
200A  
Conductor sizes must be adequate to handle the max-  
imum 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.  
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.  
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.  
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 volt-  
age power supply lines causes extremely haz-  
ardous, possibly lethal, electrical shock.  
All power cables should enter the switch next to the  
transfer mechanism terminals.  
Use a torque wrench to tighten the conduc-  
tors, being sure not to over tighten, or dam-  
age to the switch base could occur. If not  
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.  
!
tightened enough, a loose connection would  
result, causing excess heat which could dam-  
age the switch base.  
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Section 3 — Operation  
Generac GTS “HS” Type Transfer Switch  
Connect power source load conductors to clearly  
marked transfer mechanism terminal lugs as follows  
IMPORTANT: Before proceeding with functional  
tests, read and make sure all instructions and infor-  
mation in this section are 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.  
1. Connect UTILITY (NORMAL) power source cables  
to switch terminals N1, N2.  
2. Connect EMERGENCY (STANDBY) source power  
cables to transfer switch terminals E1, E2.  
3. Connect customer LOAD leads to switch termi-  
nals T1, T2.  
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.  
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  
!
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.  
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:  
2.5 CONNECTING START CIRCUIT  
WIRES  
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 the moveable contact carrier  
arm.  
Control system interconnections (Section 6) 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  
• Manual operation handle towards the top of  
switch mechanism - LOAD terminals (T1, T2) are  
connected to UTILITY terminals (N1, N2).  
• Manual operation handle towards the bottom of  
switch mechanism - LOAD terminals (T1, T2) are  
connected to EMERGENCY terminals (E1, E2).  
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)  
NOTE:  
When this ATS is used with an air-cooled genera-  
tor, the LOAD 1 and LOAD 2 wires are not used.  
Do not use excessive force when operating  
the transfer switch manually or damage could  
be done to the manual handle.  
3.1 FUNCTIONAL TESTS AND  
!
ADJUSTMENTS  
Following transfer switch installation and inter-  
connection, inspect the entire installation careful-  
ly. 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.  
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 position, no further action is  
required. If the handle is DOWN, proceed with Step  
1.  
Step 1: With the handle inserted into the actuating  
shaft, move handle UP. Be sure to hold on to  
the handle as it will move quickly after the  
center of travel.  
Perform functional tests in the exact order  
presented in this manual, or damage could be  
!
done to the switch.  
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Section 3 — Operation  
Generac GTS “HS” Type Transfer Switch  
Figure 3.1 — Actuating Transfer Switch  
Attach handle to actuating shaft.  
NOTE: Return handle to  
storage position in enclosure  
when finished with manual transfer.  
Move handle  
Move handle  
DOWN for the  
EMERGENCY  
(standby)  
UP for the  
NORMAL  
position.  
position.  
3.2.2 CLOSE TO EMERGENCY SOURCE SIDE  
DANGER  
Before proceeding, verify the position of the switch by  
observing the position of the manual operation han-  
dle 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, pro-  
ceed with Step 1.  
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.  
Step 1: With the handle inserted into the actuating  
shaft, move the handle DOWN. Be sure to  
hold on to the handle as it will move quickly  
after the center of travel.  
Single-phase utility supply:  
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.  
3.2.3 RETURN TO NORMAL SOURCE SIDE  
Manually actuate switch to return manual operating  
handle to the UP position.  
4. On the generator panel, set the AUTO-OFF-  
MANUAL switch to MANUAL position. The gener-  
ator should crank and start.  
3.3 VOLTAGE CHECKS  
1. Turn ON the UTILITY power supply to the trans-  
fer switch with whatever means provided (such as  
the UTILITY main line circuit breaker).  
5. Let the generator stabilize and warm up at no-  
load for at least five minutes.  
6. Set the generator's main circuit breaker (CB1) to  
its ON or CLOSED position.  
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Section 3 — Operation  
Generac GTS “HS” Type Transfer Switch  
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. 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 pow-  
ers all LOAD circuits. Check generator operation  
under load as follows:  
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.  
Single-phase generator supply:  
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  
8. Set the generator’s main circuit breaker (CB1) to  
its OFF or OPEN position.  
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 and frequency should  
be greater than 59 Hertz.  
9. Set the AUTO/OFF/MANUAL switch to the OFF  
position to shut down the generator.  
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.  
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.  
5. When checkout under load is complete, set main  
circuit breaker of the generator 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 (Section 3.2). Handle and operating  
lever of transfer switch should be in UP 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.  
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 GTS “HS” Type Transfer Switch  
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Section 4 — Notes  
Generac GTS “HS” Type Transfer Switch  
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Section 4 — Notes  
Generac GTS “HS” Type Transfer Switch  
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Section 5 — Installation Diagram  
Generac GTS “HS” Type Transfer Switch  
Drawing No. 0E7081  
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Section 6 — Electrical Data  
Generac GTS “HS” Type Transfer Switch  
Transfer Switch Interconnections  
4
A D 1  
T I L I T Y 2  
T I L I T Y 1  
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Section 6 — Electrical Data  
Generac GTS “HS” Type Transfer Switch  
Electrical Schematic - Drawing No. 0E6093-A  
TR  
F1  
1
UTILITY 1  
126  
E1  
N1A  
N1  
7
TB1  
E1  
B
A
N1A  
N2A  
ATS  
NO  
NC  
NC  
NO  
XB1  
COM  
XA1  
COM  
E2  
VR1  
VR2  
N2A  
C1  
C2  
F3  
F4  
F2  
LOAD 1  
LOAD 2  
A
T1A  
T1  
T2  
TB3  
TB4  
B
TR  
T2A  
6
9
205  
E2  
UTILITY 2  
N2A  
N2  
TB2  
TB5  
NEUTRAL *  
(OPTIONAL)  
NB  
00  
23  
23  
B
A
TB6  
* - NOT USED WITH PREPACKAGED STANDBY GENERATORS  
194  
194  
LEGEND  
TB7  
ATS  
TRANSFER SWITCH CONTACTOR  
SOLENOID COIL (UTILITY CLOSING)  
SOLENOID COIL (STANDBY CLOSING)  
RELAY, TRANSFER  
C1  
C2  
NOTE:  
TR  
ALL CONTACTS SHOWN WITH  
TRANSFER SWITCH IN UTILITY  
POSITION.  
TB  
TERMINAL STRIP (CUSTOMER CONNECTION)  
LIMIT SWITCHES, ACTUATOR  
FUSE, 5A  
XA1,XB1  
F1,2,3 & 4  
VR1,VR2  
NB  
VARISTOR  
NB - NEUTRAL BLOCK  
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Section 6 — Electrical Data  
Generac GTS “HS” Type Transfer Switch  
Electrical Schematic - Drawing No. 0E6093-A  
N2A  
N1A  
N2A  
126  
N1A  
N2A  
(C1)  
N2A  
A
XA1  
ATS  
XB1  
E1  
B
(C2)  
E2  
205  
N1A  
T1A  
126  
T2A  
TR  
E2  
1
3
B
9
6
N1A  
194  
E2  
23  
205  
N2A  
N1A  
E2  
23  
N2A  
N2A  
194  
NEUTRAL BLOCK  
N2A  
N1A  
T2A  
F4  
N1A  
T1A  
23  
F2  
F3  
00  
194  
* - NOT USED WITH PREPACKAGED  
STANDBY GENERATORS  
N1  
T1  
N2  
T2  
00  
Y
Z
47822-T  
3
4
5
6
7
CUSTOMER CONTROL  
CONNECTIONS  
TB  
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