Generac Switch 6378 User Manual

Installation and Operating Instructions  
MANUAL TRANSFER SWITCH - MODELS 6295-6296 and 6378-6380  
NOTE TO INSTALLER: Please leave this guide with the consumer for future reference. READ THIS MANUAL IN ITS ENTIRETY BEFORE ATTEMPTING TO INSTALL THIS EQUIPMENT.  
WARNING: Generac® transfer switches should be installed by a professional electrician familiar with electrical wiring and codes, and experienced in working with generators. Generac accepts  
no responsibility for accidents, damages or personal injury caused by incorrect installation. This transfer switch is intended for surface mounting INDOORS only. Our transfer switches are UL  
listed to UL Standard 1008 and meet the criteria of National Electrical code Article 702.6 for Optional Standby Systems. CAUTION: If using the generator and transfer switch for larger  
appliances, such as electric water heaters, clothes dryers, electric ranges and small air conditioners, check the labels on the appliances to be sure they do NOT exceed the rating of the  
generator. No appliance should have an amperage rating that exceeds the individual breaker rating in the transfer switch. CALIFORNIA PROPOSITION 65 WARNING: Engine exhaust and some  
of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm. This product may contain or emit chemicals known to cause cancer, birth  
defects and other reproductive harm.  
Thank you for purchasing a Generac Transfer Switch to safely connect  
a portable generator to the load center in your home or business  
(single phase only) for standby power applications. Product features  
Generator and Utility feeds mechanically interlocked to prevent dangerous utility or  
generator back feeding – thereby avoiding property damage and serious injury to  
electrical workers.  
Enclosure can be flush or surface mounted indoors.  
Pre-assembled wire harness with all wires clearly marked for easy connection to  
the load center.  
Transfer switch can be expanded to up to 16 circuits using standard  
interchangeable type circuit breakers. See Step 2, Section II.  
Accommodates GFCI and Arc-Fault breakers to meet the latest NEC requirements.  
Sufficient ground and neutral termination positions for all branch circuits  
Subfeed lugs provided to feed additional downstream panels or to expand beyond  
16 circuits.  
Dual wattmeters help you monitor and balance the loads on your generator,  
prolonging generator life.  
Safe generator connection – Install the Power Inlet Box in a convenience location  
outside for a quick cord connection to your generator.  
Accepts a Switched Neutral Kit (SNK). See Page 2 Note on Neutral Bonded  
Generators above Table 1.  
Model 6295 Kit Shown  
What is Included in this Carton:  
Manual Transfer Switch with wire harness, conduit, fittings and wire connectors (10 or 12)  
Wire Harness, pre-assembled  
30 amp or 50 amp Aluminum Power Inlet Box (Models 6295-6296 only)  
10 Foot Power Cord (Models 6295-6296 only)  
Installation Manual and Warranty Registration card  
Tools and Items Needed for Installation:  
1/4” nut driver, 2-1/8” hole saw (if flush mounting)  
Screwdrivers, straight blade and Phillips  
Electric drill, drill bits, wallboard saw  
Wire cutter/stripper  
Safety eye goggles  
Anchors and screws to mount transfer switch to wall/wallboard  
New, 2-pole 60 Amp or 100 Amp, 240V circuit breaker to install in main load center – same manufacturer as existing load center.  
4 gauge building wire and conduit to connect between power inlet box and transfer switch  
Compatible Circuit Breaker Types:  
Siemens/Murray QT, QPH, HQP, QPF (GFCI), QPHF, QFP, QE, QEH, QAF (Arc Fault), QP (Surge Protector)  
Cutler-Hammer Series BD, BR, BQ, GFC  
Challenger Type A, C, HAGF  
Square D Series HOM (Homeline)  
GE Series THQL  
Optional Items for Installation:  
Arc-fault, GFCI or Surge protection circuit breakers. If Arc-fault, GFCI or Surge protection circuit breakers are used as the branch circuit protector in the main load  
center, they MUST be used in the manual transfer switch. You may be able to re-use your existing AFCI, GFCI and Surge protection circuit breakers in the manual  
transfer switch. See list of compatible breakers.  
Wire, fittings and conduit to connect the Power Inlet Box to the transfer switch.  
White, green, black and red THHN or MTW wire, 10 AWG, 300V rated (if breaker configuration is modified or expanded.  
Switched Neutral Kit (SNK). If your portable generator has the neutral bonded to the frame of the generator AND 240V “full-power” receptacle is GFCI protected, you  
will need to install a SNK accessory with your transfer switch to avoid nuisance tripping of the GFCI breaker on the generator.  
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6295 or 6378  
6296 or 6380  
A: Surface Mount Installation Using Power Inlet Box (included in models 6295-6296)  
1. Select a location on the left or right side of the Load Center to mount transfer switch, as it is provided with 21.5” of flexible conduit. Remove the cover to the  
load center and the cover of the transfer switch, save the screws. Measure and cut conduit to a length and snap provided fittings on ends. Locate and remove  
a knockout (KO) on lower side of load center that matches the conduit fitting size on the wiring harness. After attaching the flexible conduit to both enclosures  
through one of the bottom or side KOs, hold the transfer switch in position against the wall on which it is to be mounted, mark the holes on the wall for the  
anchoring screws and anchor to wall (anchors not provided). Be sure NOT to stress the flexible conduit, as it may break. [NOTE: The Electrical Non-Metallic  
Tubing (ENT) provided is UL Listed and recognized by the National Electrical Code (NEC) for this application. However, some local codes and inspectors may  
prohibit its use in buildings that exceed (3) floors above grade.]  
2. Fish the pre-assembled wire harness through the conduit. Strip each wire in the wire harness 5/8” and insert and tighten the wires to the correspondingly  
marked circuit breakers in the transfer switch. As you attach each marked wire to the circuit breaker, write the appliance name on the label on the transfer  
switch cover per the TABLE 2 CIRCUIT WORKSHEET completed in Step 1. The unmarked BLACK wires in the harness are inserted into the UTIL MAIN 2-pole  
breaker in the transfer switch. Attach the WHITE wire to the neutral bar located on the right side and attach the GREEN wire to the ground bar located on the left  
side of the transfer switch.  
3. Install appropriately sized conduit, fittings and wire between the Power Inlet Box (Models 6295-6296 only) mounted on the building exterior and the transfer  
switch, referring to Power Inlet Box Install Instructions below. Locate and remove a KO on the right top or side of the transfer switch, pull wire into transfer  
switch enclosure and secure wire with fitting. . Install the green ground wire into the ground bar on the left, and install the white neutral wire into neutral bar on  
the right. Using provided wiring connectors, connect black wire from PIB to black wiring going to Meter “A”. Repeat for red wire from PIB to Meter “B”. Note:  
Models 6296 and 6380 use current transformers (CTs) connected to the meters; pass the black wire from the PIB through the hole in the CT connected to the  
“A” meter before connecting to the “GEN MAIN A” circuit breaker. Repeat for the red wire from the PIB, passing through the hole in the CT connected to the  
“B” meter before connecting to the “GEN MAIN B” circuit breaker. See FIGURE 2 WIRING DIAGRAM. Reinstall the cover to the transfer switch.  
4. In the main Load Center, remove the wires from the breakers for the loads that will be relocated to the transfer switch. Cut each harness wire to a convenient  
length, strip off 5/8” insulation and connect to the wires removed from the breakers per TABLE 2 with the provided wire connectors. Remove two adjacent  
single pole breakers from which the load wires were removed and install the NEW 60A or 100A 2-pole circuit breaker (as required in the Other Items Needed  
section) in their place. Insert the unmarked BLACK wires from the harness into the new circuit breaker. Terminate the WHITE and GREEN wire in the harness in  
an open position in the Neutral and Ground bars respectively. If there is no separate ground bar, insert the GREEN wire into an open position in the NEUTRAL  
bar, and tighten.  
5. Reinstall the cover to the load center, and turn ON the MAIN breaker in the load center. Turn ON all branch circuit breakers in both panels. Turn ON the UTIL  
MAIN in the transfer switch. Check that power is restored to all appliances. Transfer switch installation is complete.  
B. Flush Mounting in New Construction (unfinished walls) Using Power Inlet Box (included in 6295-6296):  
1. Install the transfer switch at the same time as the main load center, in adjacent wall stud openings (the transfer switch enclosure is 14.25” wide and will fit in  
standard 16” wall framing). Remove the transfer switch dead front cover, save the screws. Knock out the appropriate mounting slots on the sides of the  
enclosure and secure to framing with nails or screws; be sure the front edge of the enclosure extends forward to be flush with the thickness of the finished  
2. Mark and drill a 2 1/8” diameter hole in the stud between the main load center and the transfer switch, lining up with the lowest side KO in the load center and  
near the bottom center KO in the transfer switch. Remove the KO’s, cut the provided conduit to length, snap on the provided fittings to the conduit, push the  
conduit through the drilled hole and install the conduit assembly to the KO openings in the main load center and transfer switch.  
3. Complete Section IA3 above. Cut a piece of cardboard to 14.5” x 12.5”, using the 4 screws removed in step IIA1, attach the cardboard to the front of the  
transfer switch.  
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4. After the walls have been finished and painted, remove the cardboard cover and complete the installation as described in Sections IA2, 4 and 5. NOTE: To  
simplify installation, all conductors for the branch circuits can be terminated directly into the transfer switch instead of the main load center, eliminating the  
need to install the harness wires between the main load center and transfer switch for each circuit.  
C. Flush Mounting in Retrofit Construction (finished walls) Using Power Inlet Box (included in 6295-6296):  
1. Remove the dead front cover from the main load center and the transfer switch, save the screws.  
2. Determine where to install the transfer switch (keep in mind the length and flexibility of the conduit provided and where the generator wires will enter), Verify  
that there are no wires going thru the side of the main load center into the space where you want to mount the transfer switch. Use a “stud finder” to determine  
if you have at least 14.25” between the studs to mount the transfer switch. Hold the transfer switch enclosure in the desired position on the wall and mark the  
exact dimensions of the box. Set the enclosure aside and cut the hole in the wallboard.  
3. Remove a 1” or 1-¼” KO in the lower side (towards the hole cut in Step 2) of the load center. From the inside of the main load center, drill a ¼” pilot hole  
through the stud in the center of the KO removed. Reach down inside the hole cut in Step 2 and drill a 2 1/8” diameter hole in the stud using the pilot hole as a  
guide. Remove the bottom center KO in the transfer switch, snap the fittings on the conduit, and attach the conduit assembly to the transfer switch.  
4. Remove one of the KO’s on the top of the transfer switch enclosure and install an appropriately sized fitting for the incoming wires form the Power Inlet Box.  
Knock out the appropriate mounting slots on the sides of the transfer switch enclosure.  
5. Insert the transfer switch enclosure into the hole in the wallboard, inserting conduit fitting on attached conduit assembly into the KO removed in Step 3. Fasten  
conduit fitting to main load center with locknut. Secure transfer switch enclosure to framing with nails or screws; be sure the front edge of the enclosure  
extends forward to be flush with the finished wallboard.  
6. Complete Section IA2 thru 5 above.  
This transfer switch ships from the factory with certain popular branch circuit breaker sizes. However, the circuit breaker assortment can be modified to suit specific  
requirements, and this does not void the UL Listing. For example, if the 2-pole 20 amp circuit breaker is not needed, it may be removed from the panel and replaced  
with any combination of the following: two separate full size breakers, four tandem (half size) breakers, one full size and two tandems, or a quad breaker. If  
additional circuit(s) are added, the installer is responsible for providing appropriately sized wire(s) for each circuit.  
III. INSTALLING THE POWER INLET BOX (Included in Models 6295-6296)  
1. Remove the front cover of the Power inlet box. Remove the 3 screws that secure the flanged inlet to the bottom plate. For  
installations where side clearance exceeds 12” on both sides, remove the 4 screws that secure the bottom plate to the box.  
2. Mount the power inlet box on the outside of the building in a convenient location (minimum 24” above grade), using the four holes  
provided in the back of the enclosure. Use sealant around the anchoring screws to keep water from entering the box at these  
mounting holes. Using approved wiring methods, install the wiring through one of the knockouts provided in the enclosure. Be  
sure to seal around the hole in the building where the conduit enters through the wall.  
3. Extend wiring inside the power inlet box approx. 8” from the point of entrance. Attach green or bare ground wire to green lead  
provided in power inlet box with wire nut (provided by installer). Strip and insert incoming leads into terminals on flanged inlet.  
Insert white wire (neutral) into nickel-plated screw terminal or white marking on the flanged inlet.  
4. Carefully fold wires into the enclosure and reattach the bottom assembly or inlet onto box with screws removed earlier. Installation is complete.  
NEVER run portable generators indoors or in garages, basements, or sheds. Portable generators should always be used at least 5 feet away from windows, doors, vents, or any other  
opening. Carbon Monoxide (CO) from a generator is deadly and can kill you in minutes. Read and follow all generator directions before use.  
A. Transferring from Utility Power to Generator Power:  
1. Move generator outdoors. Connect male plug of Power Cord into 125/250V receptacle on the generator. Turn ON circuit breaker for the outlet plugged into.  
2. Plug in female connector of the Power Cord to the Power Inlet Box. Turn all circuit breakers in the transfer switch to their OFF position.  
3. Start the generator outdoors, following the procedures described in the generator’s owner’s manual.  
4. Turn ON the GENERATOR MAIN circuit breaker in the transfer switch. Turn ON circuit breakers in the manual transfer switch one at a time alternating from  
phase “A” and phase “B”. Watch the meters as you turn on successive circuits so that the meters do not continuously exceed the maximum wattage of the  
generator. It may be necessary to alternate the use of larger loads (furnace motors, well pumps, freezers, etc.) to avoid overloading the generator. To  
promote generator life, loads should be balanced on Phase “A” and “B” so that the wattage reading on each meter is within about 1000 watts of the other.  
5. Test your circuits by using the wattmeters or determine wattage from that shown on each appliance. Make a note of any excessive loads which must be  
removed from a given circuit during generator operation in an emergency. [Note: Wattmeters do not show power at very low levels.]  
B. Transferring from Generator Power to Utility Power:  
1. On the transfer switch, turn the GENERATOR MAIN breaker OFF. Then shut down the generator, following the procedures in the generator Owner’s Manual.  
2. On the transfer switch, turn the UTILITY MAIN breaker ON. Then Turn ON any branch circuit breakers in the transfer switch that are OFF.  
3. Unplug the power cord from the generator and the power inlet.  
4. Cool off the generator and store in a dry, secured location.  
To ensure that your generator will work properly when you need it, it is important to start and run your generator under load regularly and keep the tank filled with  
fresh fuel. Perform the above steps at least ONCE A MONTH to keep the generator properly “exercised.” It is not necessary to turn off any circuits in the MAIN  
load center when operating/testing the transfer switch.  
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Model 6295 (shown below) includes a 2-pole 60 Amp breaker for the  
Utility Main and a 2-pole 30 amp Generator Main.  
Model 6296 includes a 2-pole 100 amp Utility Main  
and a 2-pole 60 amp Generator Main.  
6295 / 6378  
Protected by US Patent No. US 6,861,596 B2  
Generac Power Systems, Inc.  
Toll Free: 1-888-GENERAC  
© 2012 Generac Power Systems, Inc. All Rights Reserved. GenTran and Generac are registered trademarks of Generac Power Systems, Inc.  
PN 500508 Rev A  
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