Generac Power Systems 004635-1 Bedienungsanleitung

POWER SYSTEMS, INC.

Owner’s Manual

GTS “W” Type

Automatic

Transfer Switch

200 Amp, 250 Volts

Model Nos. 004635-1

004635-2

This manual should remain with the unit.

Generac®Power Systems, Inc.

Generac cannot possibly anticipate every possible

circumstance that might involve a hazard. The warn-

ings in this manual, and on tags and decals

affixed to the unit are, therefore, not all-inclusive. If

you use a procedure, work method or operating tech-

nique Generac does not specifically recommend, sat-

isfy yourself that it is safe for you and others. Also

must make sure the procedure, work method or

operating technique that is used does not render the

transfer switch unsafe.

Throughout this publication, and on tags and

decals affixed to the generator, DANGER, WARNING,

CAUTION and NOTE blocks are used to alert per-

sonnel to special instruction about a particular oper-

ation that may be hazardous if performed incorrectly

or carelessly. Observe them carefully. The definitions

are as follows:

After this heading, read instructions that, if not

strictly complied with, will result in personal injury

or property damage.

After this heading, read instructions that, if not

strictly complied with, may result in personal injury

or property damage.

After this heading, read instructions that, if not

strictly complied with, could result in damage to

equipment and/or property.

NOTE:

After this heading, read explanatory statements

that require special emphasis.

These safety warnings cannot eliminate the hazards

that they indicate. Common sense and strict compli-

ance with the special instructions while performing the

service are essential to preventing accidents.

Four commonly used safety symbols accompany the

DANGER, WARNING and CAUTION blocks. The type

of information each indicates follows:

This symbol points out important safety informa-

tion that, if not followed, could endanger personal

safety and/or property of others.

This symbol points out potential explosion hazard.

This symbol points out potential fire hazard.

This symbol points out potential electrical shock

hazard.

GENERAL HAZARDS

• Any AC generator that is used for backup power if

a NORMAL (utility) power source failure occurs,

must be isolated from the NORMAL (utility) power

source by means of an approved transfer switch.

Failure to properly isolate the NORMAL and

STANDBY power sources from each other may

result in injury or death to electric utility workers,

due to backfeed of electrical energy.

• Improper or unauthorized installation, operation,

service or repair of the equipment is extremely

dangerous and may result in death, serious per-

sonal injury, or damage to equipment and/or per-

sonal property.

• Extremely high and dangerous power voltages are

present inside an installed transfer switch. Any

contact with high voltage terminals, contacts or

wires will result in extremely hazardous, and pos-

sibly LETHAL, electric shock. DO NOT WORK ON

THE TRANSFER SWITCH UNTIL ALL POWER

VOLTAGE SUPPLIES TO THE SWITCH HAVE

BEEN POSITIVELY TURNED OFF.

• Competent, qualified personnel should install,

operate and service this equipment. Adhere strict-

ly to local, state and national electrical and build-

ing 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.

DANGER

Important Safety Instructions

Read the following information carefully before attempting to install, operate or service this

equipment. Also read the instructions and information on tags, decals, and labels that may

be affixed to the transfer switch. Replace any decal or label that is no longer legible.

DANGER! Connection of a generator to an electrical system normally supplied by an electric

utility shall be by means of suitable transfer equipment so as to isolate the electric system

from utility distribution system when the generator is operating (Article 701 Legally Required

Standby Systems or Article 702 Optional Standby Systems, as applicable). Failure to isolate

electric system by these means may result in damage to generator and may result in injury

or death to utility workers due to backfeed of electrical energy.

Table of Contents

Generac®Power Systems, Inc. 1

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

2.4.2 3-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 ........................5

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 ....................................7

Section 4 – Mounting Dimensions ................................8

Section 5 – Electrical Data ..............................................9

Section 6 – Exploded Views & Parts Lists ..................14

Section 7 – Warranty ......................................Back Cover

• 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.

• 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. Turn the genera-

tor’s AUTO-OFF-MANUAL switch to OFF. Turn the

generator’s main circuit breaker OFF. Then place a

“DO NOT OPERATE” tag on the transfer switch

and on the generator. Remove the Negative (Neg) or

(–) battery cable.

2 Generac®Power Systems, Inc.

Section 1 — General Information

Generac GTS “W” Type Transfer Switch

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.

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.

1.2 EQUIPMENT DESCRIPTION

The automatic transfer switch is used for transfer-

ring critical electrical load from a UTILITY (Normal)

power source to a EMERGENCY (Standby generator)

power source. Such a transfer of electrical loads

occurs automatically when the UTILITY power source

has failed or is substantially reduced and the EMER-

GENCY source voltage and frequency have reached

an acceptable level. The transfer switch prevents elec-

trical 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.

1.3 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.

When requesting information or ordering parts for this

equipment, make sure to include all information from

the DATA DECAL.

Record the Model and Serial numbers in the space pro-

vided below for future reference.

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.

1.5 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 a copy of the SAFETY RULES

are made and 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.

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

MODEL #

SERIAL #

Generac®Power Systems, Inc. 3

2.1 INTRODUCTION TO INSTALLATION

This equipment has been wired and tested at the fac-

tory. Installing the switch includes the following pro-

cedures:

• Mounting the enclosure.

• Connecting utility and generator power source leads.

• Connecting the load leads.

• Connecting the generator sensing leads.

• Connecting any auxiliary contact (if needed)

• Installing/connecting any options and accessories.

• Testing functions.

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 “Mounting Dimensions” on page 8.

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.

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.

2.4 CONNECTING POWER SOURCE

AND LOAD LINES

Make sure to turn OFF both the UTILITY

(Normal) and EMERGENCY (Standby genera-

tor) 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.

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.

2.4.1 2-POLE MECHANISM

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

(200 Amp Shown)

2.4.2 3-POLE MECHANISM

These switches (Figure 2.2) are used with a three

phase system, when the three phase NEUTRAL line is

to be connected to a NEUTRAL lug and is not to be

switched. It is also used with a single phase system

when the neutral is to be switched (NEUTRAL to be

connected to third pole).

Figure 2.2 — Typical 3-Pole Transfer Mechanism

(200 Amp Shown)

◆



DANGER

Section 2 — Installation

Generac GTS “W” Type Transfer Switch

4 Generac®Power Systems, Inc.

Solderless, screw-type terminal lugs are standard.

The conductor size range is as follows:

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. 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.

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 overtighten, or dam-

age to the switch base could occur. If under-

tightened, a loose connection would result,

causing excess heat which could damage the

switch base.

Connect power source load conductors to clearly

marked transfer mechanism terminal lugs as follows

1. Connect utility (NORMAL) power source cables to

switch terminals N1, N2, (N3).

2. Connect emergency (STANDBY) source power

cables to transfer switch terminals E1, E2, (E3).

3. Connect customer LOAD leads to switch termi-

nals T1, T2, T3.

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.

2.5 CONNECTING START CIRCUIT

WIRES

Control system interconnections (Page 11) 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:

2.6 AUXILIARY CONTACTS

If desired, there are Auxiliary Contacts on the trans-

fer 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.

Contact operation is shown in the following chart:

NOTE:

Auxiliary Contacts are rated 10 amps at 125 or

250 volts AC. DO NOT EXCEED THE RATED

VOLTAGE AND CURRENT OF THE CONTACTS.

Figure 2.3 – Auxiliary Contacts

Optional

Auxiliary Contact

(Actuated)

Side views shown in Utility position

Section 2 — Installation

Generac GTS “W” Type Transfer Switch

MAXIMUM WIRE LENGTH RECOMMENDED WIRE

SIZE

460 feet (140m) No. 18 AWG.

461 to 730 feet (223m) No. 16 AWG.

731 to 1,160 feet (354m) No. 14 AWG.

1,161 to 1,850 feet (565m) No. 12 AWG.

Switch Position

Utility Standby

Common to Normally Open Open Closed

Common to Normally Closed Closed Open

Switch Rating Wire Range

200A #4-400 MCM

Generac®Power Systems, Inc. 5

3.1 FUNCTIONAL TESTS AND

ADJUSTMENTS

Following transfer switch installation and intercon-

nection, inspect the entire installation carefully. A

competent, qualified electrician should inspect it.

The installation should comply strictly with all appli-

cable codes, standards, and regulations. When

absolutely certain the installation is proper and cor-

rect, complete a functional test of the system.

Perform functional tests in the exact order

presented in this manual, or damage to the

switch could be done.

IMPORTANT: Before proceeding with functional

tests, read and make sure you understand all

instructions and information in this section. 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.

3.2 MANUAL OPERATION

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.

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 display windows in “A” and “B”

in Figure 3.1 on page 6 as follows:

• Window “A” ON, Window “B” OFF - LOAD termi-

nals (T1, T2, T3) are connected to utility termi-

nals (N1, N2, N3).

• Window “A” OFF, Window “B” ON - LOAD termi-

nals (T1, T2, T3) are connected to emergency ter-

minals (E1, E2, E3).

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

Before proceeding, verify the position of the switch by

observing window “A” in Figure 3.1 on page 6. If win-

dow “A” reads “ON”, the contacts are closed in the

normal position, no further action is required. If it

reads “OFF”, proceed with Step 1.

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”.

3.2.2 CLOSE TO EMERGENCY SOURCE SIDE

Before proceeding, verify the position of the switch by

observing window “B” in Figure 3.1 on page 6. If win-

dow “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.

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.

3.3 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).

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.

Single-phase utility supply:

Measure across ATS terminal lugs N1 and N2; N1

to NEUTRAL and N2 to NEUTRAL.

Three-phase utility supply:

Measure across ATS terminal lugs N1 to N2, N2

to N3, and N1 to N3.

Measure across ATS terminal lugs N1 to NEU-

TRAL, N2 to NEUTRAL, and N3 to NEUTRAL.

DANGER

◆

DANGER

Section 3 — Operation

Generac GTS “W” Type Transfer Switch

6 Generac®Power Systems, Inc.

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 gener-

ator should crank and start.

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.

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; 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

Three-phase generator supply:

Measure across ATS terminal lugs E1 to E2, E2

to E3 and E1 to E3.

Measure across ATS terminal lugs E1 to NEU-

TRAL, E2 to NEUTRAL and E3 to NEUTRAL.

a. Frequency ......................................60-62 Hz

b. Terminals E1-E2, E2-E3, E1-E3 ....208-212 VAC

c. Terminals E1-N, E2-N, E3-N ..........120-122 VAC

It will also be necessary to verify that the phase rota-

tion of the utility matches the phase rotation of the

generator. This can be done by using a phase rotation

indicator.

DANGER

Section 3 — Operation

Generac GTS “W” Type Transfer Switch

Figure 3.1 — Actuating Transfer Switch

Generac®Power Systems, Inc. 7

Failure to do so may result in damage to cer-

tain 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 posi-

tion to shut down the generator.

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.

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 on page 5.

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 the

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 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.

5. When checkout under load is complete, set main

circuit breaker of the generator to the 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 the

UTILITY position. For example, load connected to

utility power supply. Refer to Manual Operation

on page 5. 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.

9. Set the generator's AUTO-OFF-MANUAL switch to

its AUTO position. The system is now set for fully

automatic operation.

Section 3 — Operation

Generac GTS “W” Type Transfer Switch

8 Generac®Power Systems, Inc.

Section 4 — Mounting Dimensions

Generac GTS “W” Type Transfer Switch

Mounting Dimensions – Drawing No. 0D3714-B

180 514

612 490

430

Values are in Millimeters

Note: Diameter of Mounting holes (A) is 6.35 MM

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