Gen-Tran R200660 PowerStay Transfer Switches Instruction Manual

Gen-Tran R200660 PowerStay Transfer Switches

Product Information

The Outdoor Manual Transfer Switches are designed for use with models R200660, R300660, R301060, R501210, and R601210. These transfer switches are intended for surface mounting outdoors or indoors. They allow you to safely and easily switch between utility power and generator power during a power outage It is important to note that Gen/Tran transfer switches should be installed by a professional electrician who is familiar with electrical wiring and codes, as well as experienced in working with generators. Incorrect installation may result in accidents, damages, or personal injury. Gen/Tran accepts no responsibility for such incidents. When using the generator and transfer switch for larger appliances, such as electric water heaters, clothes dryers, electric ranges, and small air conditioners, it is essential to check the labels on the appliances to ensure that they do not exceed the rating of the generator. No appliance should have an amperage rating that exceeds the GENERATOR MAIN rating in the transfer switch.

Product Usage Instructions

1. Planning Your Installation:
   • Determine the appliances, circuits, or equipment you want to operate with generator power during a power outage.
   • Complete the provided worksheet to determine the amps required for each appliance and assign circuit numbers in both the load center and the manual transfer switch.
2. Installation Procedure:
   • Ensure safety by turning off the MAIN circuit breaker in the load center before starting the installation. Remember that the wiring ahead of the MAIN is still HOT even when the main circuit breaker is off.
   • Mount the transfer switch outdoors or indoors, following the provided instructions.
   • Connect the transfer switch to the main load center using the provided wire harness through one of the two knockouts (KO’s) provided in the bottom of the manual transfer switch. If necessary, a 1 or 1-1/4 KO can be cut in the lower side of the enclosure.
   • Make sure all connections are secure and properly tightened.
   • Reinstall the load center cover and turn on the MAIN breaker, followed by all circuit breakers in both boxes.
   • Turn on the UTILITY MAIN in the manual transfer switch and check that power is restored to all appliances.
3. Hard-wired Generator Connection:
   • For Model R601210, it must be hardwired to the generator.
   • Models R200660, R300660, R301060, and R501210 are equipped with power inlets for generator connection.

Specifications

Model #| UTILITY MAIN breaker, Included| GEN MAIN breaker, included| Max Load per Circuit| Max Load Combined| Max Watts @ 250 Volt| Max Watts @ 125 Volt| Max 1-pole Circuits | Max 2-pole Circuits | NEMA Config. of Inlet| Min. gauge Cord Size
---|---|---|---|---|---|---|---|---|---|---
R200660| Yes| Yes| –| –| –| –| –| –| –| –
R300660| Yes| Yes| –| –| –| –| –| –| –| –
R301060| Yes| Yes| –| –| –| –| –| –| –| –
R501210| Yes| Yes| –| –| –| –| –| –| –| –
R601210| Yes| Yes| –| –| –| –| –| –| –| –
MODEL #| R300660**| R200660| R301060| R501210| R601210
---|---|---|---|---|---
UTILITY MAIN breaker, Included| 60 Amp| 60 Amp| 60 Amp| 100 Amp| 100 Amp
GEN MAIN breaker, included| 20 Amp| 20 Amp| 30 Amp| 50 Amp| 60 Amp
Max Load per Circuit| As marked| As marked| As marked| As marked| As marked
Max Load Combined| 30 Amp| 20 Amp| 30 Amp| 50 Amp| 60 Amp
Max Watts @ 250 Volt| N/A| 5000| 7500| 12,500| 15,000
Max Watts @ 125 Volt| 3750| 5000| 7500| 12,500| 15,000
Max 1-pole Circuits | 16| 16| 16| 16| 16
Max 2-pole Circuits | 0| 8| 8| 8| 8
NEMA Config. of Inlet| L5-30| L14-20| L14-30| CS6375| N/A
Min. gauge Cord Size| 10/3 wire| 12/4 wire| 10/4 wire| 6/4 wire| none

Note: If Ground Fault Circuit Interrupters (GFCI) circuit breakers, Arc Fault Circuit Interrupters, or Surge Protector Circuit Breakers were used as the branch circuit protector in the main load center, they MUST be used in the Power Stay unit . Because these circuit breakers typically take up more than one space, the overall maximum number of circuits may be reduced from the number shown. Contact Gen/Tran for more information on these circuit breaker types.
Special Note on R300660: This unit is designed and rated for 125 volt use only, and only single pole circuit breakers should be used in this unit. The maximum combined load should not exceed 3750 watts.

INSTALLATION AND OPERATING INSTRUCTIONS

Warning: Gen/Tran transfer switches should be installed by a professional electrician familiar with electrical wiring and codes, and experienced in working with generators. Gen/Tran accepts no responsibility for accidents, damages or personal injury caused by incorrect installation. These transfer switches are intended for surface mounting outdoors or indoors.
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 “GENERATOR MAIN” rating in the transfer switch.
Thank you for purchasing the finest manual transfer switch available today. Gen/Tran’s PowerStay® Manual Transfer Switches are designed to safely connect generators to load centers in homes and light commercial buildings (single phase only) for standby power applications. Features include:

• Generator Main and Utility Main are mechanically interlocked preventing utility or generator power back feed
• Full branch circuit protection with Siemens® circuit breakers
• Pre-assembled wire harness for easy connection to the load center
• Optional GFCI, Arc Fault or Surge Protection circuit breakers to further protect your home and electronic equipment (Available from GenTran)
• High Corrosion-resistant aluminum cabinet

Tools Needed for Installation:

• ¼” and 11/32 nut drivers
• Straight blade and Phillips screwdriver
• Electric drill
• Wire cutter/stripper

Other Items Needed:

• NEW 2-pole, 240V Breaker to mount in main load center – amperage to match utility breaker (see specifications Table I for Utility Main Breaker size – should be manufactured by same as Main load center).
• Anchors and screws to mount switch to wall
• Additional wire connectors if switch is “hard-wired”. See Table 2 for correct size.
• May need 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. See Table 3 for compatible breakers. (Available through Gen/Tran).
• Power Cord to connect generator to switch.

Typical Outdoor Installation:

Planning Your Installation

1. Determine the appliances, circuits or equipment you want to operate with generator power during a power outage, such as:
   • Furnace
   • TV / Radio
   • Refrigerator
   • Cordless Telephone
   • Freezer
   • Garage Door Opener
   • Microwave Oven
   • Water Heater
   • Well Pump
   • Security System
   • Sump Pump
   • Computer, Fax and Printer
   • Lighting
   • Range
2. Complete the following worksheet.: (Refer to TABLE 1 for maximum circuits your manual transfer switch will transfer)
3. Determine the amps required for each appliance using the circuit breaker rating in the load center. No appliance should have an amperage rating that exceeds the “GENERATOR MAIN” rating in the transfer switch. The total amperage of all circuits can exceed the generator rating, but not all circuits will be able to be used concurrently.
4. Assign the circuit # in the load center and in the manual transfer switch, matching the size of the circuit breaker in the load center to the circuit breaker in the transfer switch. Once you’ve completed the worksheet below, you will be ready to begin installing the manual transfer switch.

PLANNING WORKSHEET

Installation Procedure:
IMPORTANT: Please read this entire procedure before beginning installation. WARNING: For SAFETY, turn OFF the MAIN circuit breaker in the load center BEFORE starting installation. Remember, the wiring ahead of the MAIN is still HOT, even when the main circuit breaker is off.

For Surface- Installation – “Plug-in” Generator Connection (Models R200660, R300660, R301060, R501210):

1. Transfer switch can be installed on either the left or right side of the main load center. Transfer switch is provided with 21-1/2” of flexible conduit. The connection to the main load center, using the provided wire harness, must be made through one of the two (2) knockouts (KO’s) provided in the bottom of the manual transfer switch. The wire harness should enter the main load center in one of the bottom or lower side knockouts. A 1” or 1-1/4” KO can be cut in the lower side of the enclosure if necessary.
2. Remove the cover of the main load center and the transfer switch. The conduit may be cut to a convenient length. Attach connectors to the conduit. After attaching the flexible conduit to both boxes through the KOs, hold the transfer switch away from the load center against the wall on which it is to be mounted and mark the holes on the wall for the anchoring screws. Be sure NOT to stress the flexible conduit, as it will break. (NOTE: Mounting on LEFT side of existing load center is preferred method. Mounting to right side of existing load center and routing flexible conduit may interfere with generator cord connection into transfer switch. Reducing washers (not provided) may be needed if using 2” KO on the bottom left.
3. After mounting the transfer switch to the wall, you are ready to terminate the wires in the manual transfer switch. Fish the bundle of wires provided through the conduit. Strip each wire in the wire harness approximately 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 on the label on the cover of the transfer switch with the appliance on that circuit per the planning worksheet. The unmarked BLACK wires in the harness are inserted into the Utility 2-pole breaker in the transfer switch. Attach the WHITE wire to the insulated neutral bar inside the transfer switch, and attach the GREEN wire to the ground bar. Reinstall the dead front to the transfer switch. Cover may be re-installed and padlocked, if desired.
4. RECHECK TO BE SURE THE MAIN CIRCUIT BREAKER HAS BEEN TURNED OFF. The wires from the harness entering the load center can now be terminated. Remove the wires of the appliances/loads that have been assigned to circuits in the transfer switch from the breakers in the load center. Cut the harness wires to a convenient length and strip off approximately 5/8” and connect with the provided wire connectors (see wire connector chart) using the appropriate labeled wire from the transfer switch. The unmarked BLACK wires in the harness are to be inserted into the NEW 2 pole breaker (as required in the Other Items Needed section). Remove two adjacent single pole breakers from which the appliance/load wires were removed. The 2-pole breaker should be located in a bus bar location where two adjacent full size single pole circuit breakers were removed. 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 load center cover, and turn ON the MAIN breaker. Then turn ON ALL circuit breakers in both boxes. Turn on the UTILITY MAIN in the manual transfer switch. Check that power is restored to all appliances.

For “Hard-wired” Generator Connection:

1. Model R601210 must be hardwired to the generator. Models R200660, R300660, R301060, and R501210 are equipped with power inlets which can be disconnected when hardwiring is desired. The wires from the inlet can be removed from the “GEN MAIN” breaker and the neutral and ground bars. Then run the wires from the generator to the same locations that you removed from the power inlet. The inlet can remain in place – to cover the hole in the bottom of the enclosure OR you may order a knockout closer from 1-888-GEN-TRAN.

Operating Your PowerStay® Manual Transfer Switch and Generator

Transferring from Utility Power to Generator Power:

1. Move generator outdoors. WARNING: Operating a generator indoors or in a garage could result in injury or death.
2. Insert the male connector of the Power Cord into the correct outlet on the generator.
3. Plug in the female connector of the Power Cord to the inlet on the bottom of the PowerStay Manual Transfer Switch. Turn all circuit breakers in the transfer switch to their OFF position.
4. Start the generator outdoors, following the procedures described in the generator’s owner’s manual furnished by the manufacturer. 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”. It may be necessary to alternate the use of larger loads (furnace motors, well pumps, freezers, etc.) to avoid overloading the generator. Try to “balance” the loads on each “phase” (A and B). To promote generator life, loads should be balanced so that the wattage is within about 1000 watts of the other on each phase.
5. Test your circuits by determining 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.

Transferring from Generator Power to Utility Power:

1. On the transfer switch, turn Generator MAIN breaker OFF and turn Utility MAIN breaker ON.
2. Turn ON any branch circuit breakers in the transfer switch that are OFF.
3. Shut down the generator, following the procedures in the generator Owner’s Manual.
4. Unplug the power cord from the generator and then the power inlet.
5. Cool off the generator and store in a dry, secured location.
6. 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 supplying generator power to the transfer switch.

Wire Connector Usage Chart:

Compatible Circuit Breaker Types:

• Siemens QP, QT, QPH, HQP, QPF, QPHF, QFP, QE, QEH
• Westinghouse Series BD, BR, BQ, GFC
• Challenger Type A, C, HAGF
• Square D Series HOM
• GE Series THQL

Compatible GFCI, Arc-Fault/ Surge Protection Circuit Breakers:

• Siemens: QPF (GFCI), QAF (Arc Fault), QP (Surge Protector)

Circuit ID for Model R501210

Gen/Tran Corporation
P.O. Box 1001, Alpharetta, GA 30009-1001
Toll Free: 1-888-GEN-TRAN
Fax: 770-552-7756
www.gen-tran.com
© 2002 Gen-Tran Corporation. All Rights Reserved. PowerStay is a registered trademark of Gen-Tran Corporation.

References

• Generac Power Systems - Power Equipment and Generator Manufacturer
• Manual-Hub.com – Free PDF manuals!

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