Generac Power Systems 4678-1 Manual de usuario

Owner’s Manual

100 Amp “V” Type

Transfer Switch

Models:

9227-2

4678-1

This manual should remain with the unit.

Generac®Power Systems, Inc.

Generac cannot possibly anticipate every possible cir

cumstance 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, you

must satisfy yourself that it is safe for you and others.

You also must make sure the procedure, work

method or operating technique that you choose 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 you to

special instruction about a particular operation that

may be hazardous if performed incorrectly or care-

lessly. Observe them carefully. Their definitions are

as follows:

After this heading, you can read instructions that,

if not strictly complied with, will result in personal

injury or property damage.

After this heading, you can read instructions that,

if not strictly complied with, may result in personal

injury or property damage.

After this heading, you can read instructions that, if

not strictly complied with, could result in damage to

equipment and/or property.

NOTE:

After this heading, you can 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 you and 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) 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 elec-

tric utility shall be by means of a double throw switch so as to isolate the electric system

from utility distribution system when the generator is operating (NEC 701). Failure to iso-

late electric system by these means results 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-1

Section 1 — General Information ................2

1.1 Introduction ................................................2

1.2 Equipment Description ................................2

1.3 Transfer Switch Ratings 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 ........................3-4

2.5 Connecting Start Circuit Wires ....................4

Section 3 — Post Installation Start-Up

and Adjustments ..........................................5

3.1 Functional Tests & Adjustments ..................5

3.2 Manual Operation ........................................5

3.3 Transfer Switch Voltage Checks ..................6

3.4 Generator Tests Under Load ........................6

Section 4 – Notes ............................................7

Section 5 – Electrical Data ............................8

Section 6 – Exploded Views and

Parts Lists........................................................9

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 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.

• 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. Always set the

Auto-Off-Manual switch to its OFF position before

working on the equipment. Then place a “DO NOT

OPERATE” tag on the transfer switch and on the

generator.

2 Generac®Power Systems, Inc.

Section 1 — General Information

Generac 100 Amp 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 careful-

ly 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 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. Such a trans-

fer 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.

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,

voltage sensor action in the pre-packaged control

panel initiates re-transfer back to NORMAL power

source. After this re-transfer, the controller signals

to open the start circuit to the generator, which shuts

down the engine. The controller is then “armed” and

ready for the next drop in NORMAL source voltage.

NOTE: Keep in mind the pre-packaged transfer

switch is without any kind of electronic controls. It

receives signals solely from the controller contained

in the pre-packaged control panel.

1.3 TRANSFER SWITCH RATINGS

DECAL

Affixed to the transfer switch door is a RATINGS

DECAL. Use the transfer switch only within the specif-

ic limits shown on the RATINGS DECAL and on other

decals and labels that may be affixed to the switch.

This prevents damage to equipment and possible

injury to personnel, and provides long and trouble-free

life for the equipment.

When requesting information or ordering parts for this

equipment, make sure to include all information from

the RATINGS DECAL.

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.

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.

Two publications that outline the safe use of transfer

switches are the following:

• National Electrical Code

• UL 1008, STANDARD FOR SAFETY-AUTOMATIC

TRANSFER SWITCHES

3 Generac®Power Systems, Inc.

2.1 INTRODUCTION TO INSTALLATION

This equipment has been wired and tested at the facto-

ry. Installing the switch includes the following proce-

dures:

• Mounting the enclosure.

• Connecting power source and load leads.

• Connecting control wiring.

• 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.

Attach any lifting device to the transfer switch mounting

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).

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.

Figure 2.1 — Mounting Dimensions for Enclosures

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 pre-

vent switch distortion, level all mounting points. If nec-

essary, use washers behind mounting holes to level the

unit.

2.4 CONNECTING POWER SOURCE AND

LOAD LINES

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 extreme-

ly high and dangerous. Contact with such high

voltage power supply lines causes extremely haz-

ardous, possibly lethal, electrical shock.

Wiring diagrams and electrical schematics are provided

in this manual. Power source and load connections are

made at a transfer mechanism, inside the switch enclo-

sure.

2.4.1 2-POLE MECHANISM

This switch (Figure 2.2) is used with a single phase sys-

tem, when the single phase NEUTRAL line is to be con-

nected 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 maxi-

mum current to which they will be subjected. The

installation must comply fully with all applicable codes,

standards and regulations.

NEUTR

BRIDGE

RECTIFIER

VARISTOR

UTILITY

CLOSING COIL

LIMIT SWITCH XA1

ANUAL TRANSFER LEVER

LIMIT SWITCH XB1

STANDBY

CLOSING COIL

VARISTOR

BRIDGE

RECTIFIER

N1 N2

T1 T2



DANGER

Section 2 — Installation

Generac 100 Amp Transfer Switch

SWITCH

TRANSFER

GENERAC

**ALL DIMENSIONS IN:

MILLIMETERS (INCHES)

- VOIR LE SCHEMA

D'UN CIRCUIT SOUS TENSION

AVERTISSEMENT - PLUS

LIVE CIRCUIT - SEE DIAGRAM

WARNING - MORE THAN ONE

257.0mm [10.12"]

363.8mm [14.32"]

53.4mm [2.10"]

12.7mm [0.50"]

514.1mm [20.24"]

488.7mm [19.24"]

4 Generac®Power Systems, Inc.

Before connecting wiring cables to terminals, remove

any surface oxides from the cable ends with a wire

brush. If ALUMINUM conductors are used, apply joint

compound to conductors. After tightening terminal

lugs, carefully wipe away any excess joint compound.

All power cables should enter the switch next to trans-

fer mechanism terminals.

Connect power source load conductors to clearly

marked transfer mechanism terminal lugs as follows

(Figure 2.3).

1. Connect NORMAL (utility) power source cables to

switch terminals N1 and N2.

2. Connect STANDBY source power cables to transfer

switch terminals E1 and E2.

3. Connect customer LOAD leads to switch terminals

T1 and T2.

Conductors must be properly supported, of approved

insulative qualities, protected by approved conduit, and

of the correct wire gauge size in accordance with appli-

cable codes.

Tighten the wire into lugs to the following torque:

• 100 Amp Switch: 50 Inch-Pounds

Make sure to maintain proper electrical 1/2 inch clear-

ance between live metal parts and grounded metal.

2.5 CONNECTING START CIRCUIT

WIRES

Control system interconnections (Figure 2.3) 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:

Section 2 — Installation

Generac 100 Amp Transfer Switch

Figure 2.3 — Transfer Switch Interconnections (Drawing No. C3921)

MAXIMUM WIRE LENGTH RECOMMENDED WIRE

SIZE

460 feet (140m) No. 18 AWG.

730 feet (223m) No. 16 AWG.

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

5 Generac®Power Systems, Inc.

3.1 FUNCTIONAL TESTS AND

ADJUSTMENTS

Following transfer switch installation and interconnec-

tion, inspect the entire installation carefully. A compe-

tent, qualified electrician should make the inspection.

The installation should comply strictly with all applica-

ble codes, standards, laws and regulations. All electri-

cal connections must be correct and in compliance with

applicable codes and standards.

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 Post

Installation Start-Up Adjustments section. Do this

before placing the transfer switch into service.

Functional tests of the transfer switch include these

tests: (a) Manual Operation, (b) Voltage Checks and (c)

Electric Operation.

To avoid damaging the transfer switch, perform

functional test 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.

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 possibly fatal electrical shock.

3.2 MANUAL OPERATION

Instructions for “V” type transfer switches: Test manu-

al operation as follows:

1. Check that the generator’s Auto-Off-Manual switch

has been set to the OFF position.

2. Turn Off the UTILITY power supply to the transfer

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.

Failure to turn OFF all power voltage supplies to

the transfer switch before attempting manual

operation results in extremely hazardous and pos-

sibly fatal electrical shock.

4. Remove the manual transfer handle from the enclo-

sure.

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. If handle is

down, LOAD is connected to STANDBY power

source. If handle is up, LOAD is connected to UTIL-

ITY power.

7. Move the transfer switch main contact to both posi-

tions several times. Leave the transfer switch in the

UTILITY position and connect LOAD to the UTILITY

power source (manual operation lever is up).

Figure 3.1 — Transfer Switch Operation (“V” Type)

DANGER

Section 3 — Post Installation Start-Up Adjustments

Generac 100 Amp Transfer Switch

6 Generac®Power Systems, Inc.

3.3 TRANSFER SWITCH VOLTAGE

CHECKS

1. Turn ON the UTILITY power supply to the transfer

switch with whatever means provided (such as the

UTILITY main line circuit breaker).

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 NEU-

TRAL; and, finally, N2 to NEUTRAL (see Wiring

Diagram on Page 8).

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.

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 output voltage

is now being delivered to transfer switch termi-

nals. 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 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 (CB1) to its

OFF or OPEN position.

9. To shut down the generator, set its Auto-Off-Manual

switch to its OFF position.

NOTE:

Do NOT proceed until generator AC output voltage

and frequency are correct and within stated lim-

its. If the no-load voltage is correct but no-load

frequency is incorrect, the engine governed speed

probably requires adjustment. If no-load frequen-

cy is correct but voltage is not, the voltage regu-

lator may require adjustment.

3.4 GENERATOR TESTS UNDER LOAD

1. Set the generator’s main circuit breaker to its OFF

or OPEN position.

2. Turn OFF utility power to the transfer switch.

3. Manually move the transfer switch main contacts to

their STANDBY position.

4. To start the generator, set the Auto-Off-Manual

switch to MANUAL. When engine starts, let it stabi-

lize for a few minutes.

5. 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.

• 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 the unit running, listen for

unusual noises, vibration, overheating, etc., that

might indicate a problem.

6. When checkout under load is complete, set the gen-

erator’s main circuit breaker to its OFF or OPEN

position.

7. Let the generator run at no-load for several minutes.

Then, shut down by setting the Auto-Off-Manual

switch to its OFF position.

8. With the manual transfer handle, move the switch’s

main contacts back to their utility position, i.e., load

connected to utility power supply. The handle and

operating lever of the transfer switch should be in

the up position.

9. Turn on the utility power supply to the transfer

switch, using whatever means provided (such as a

utility main line circuit breaker). The utility power

source now powers the loads.

10. Set the generator’s main circuit breaker to its ON or

CLOSED position.

11. Set the generator’s Auto-Off-Manual switch to its

AUTO position. The system is now set for fully

automatic operation.

DANGER

Section 3 — Post Installation Start-Up Adjustments

Generac 100 Amp Transfer Switch

7 Generac®Power Systems, Inc.

Section 4 — Notes

Generac 100 Amp Transfer Switch

N2A

WIRING DIAGRAM

TR - RELAY, TRANSFER

TS - TERMINAL STRIP (CUSTOMER CONNECTION)

NB - NEUTRAL BLOCK

VR1, VR2 - VARISTOR

F1, F2, F3, F4-FUSE, 5A SENSING

XA1, XB1- LIMIT SWITCHES, ACTUATOR

POSITION.

N1A

GTS

N2A

SCHEMATIC DIAGRAM

GTS - TRANSFER SWITCH CONTACTOR

C1- SOLENOID COIL (UTILITY CLOSING)

C2- SOLENOID COIL (STANDBY CLOSING)

ALL CONTACTS SHOWN WITH

TRANSFER SWITCH IN UTILITY

194

NOTE:

194 A

2323 B

VR1

XA1

XB1

205

126

N2A

LEGEND

T2A

VR2

T1A

N2A

N1 N2

F1 F2

N1A

N1A N2A

N1A

194

T2A

T1A

194

205

126

N1A N2A

205

N2A

N1A

194

UTILITY 2

LOAD 2

UTILITY 1

LOAD 1

194

T1A

T2A

(C2)

XB1

GTS

(C1)

XA1

N2A

8 Generac®Power Systems, Inc.

Section 5 — Electrical Data

Electrical Schematic – Drawing No. 81222-B

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