GENERAC 006852 Switch Homelink Upgradeable Manual Transfer Switch Owner’s Manual

GENERAC 006852 Switch Homelink Upgradeable Manual Transfer Switch

Product Information

Specifications

• Models: 006852 Switch, 006853 Switch, Cord and Resin Power Inlet Box, 006854 Switch, Cord and Aluminum Power Inlet Box, 006869 Manual to Automatic Upgrade Kit
• Owner’s Manual: Homelink Upgradeable Manual Transfer Switch 000961
• Warning: This product is not intended for critical life support applications
• California Proposition 65 Warning: Engine exhaust and some constituents may cause cancer, birth defects, and other reproductive harm

Introduction and Safety
Thank you for purchasing a Generac Power Systems Inc. product. This unit has been designed to provide high performance, efficient operation, and years of use when maintained properly.

Safety Rules
It is important to follow safety rules to ensure the safe operation of the product. Failure to adhere to these rules could result in death or serious injury.

Safety Symbols and Meanings
The product manual contains safety symbols that indicate specific hazards and precautions. It is important to understand the meanings of these symbols before operating the product.

General Information

Unpacking
When unpacking the product, ensure that all components are present and undamaged. If any parts are missing or damaged, contact Generac customer support for assistance.

Equipment Description
The Homelink Upgradeable Manual Transfer Switch includes the following components:

• Transfer Switch Mechanism
• Transfer Switch Data Decal
• Transfer Switch Enclosure
• Power Inlet Box (if equipped)

Transfer Switch Mechanism
The transfer switch mechanism is responsible for transferring power between the utility and the generator. It ensures a seamless transition during power outages.

Transfer Switch Data Decal
The transfer switch data decal contains important information about the switch, including its model number, serial number, and date of purchase. This information should be noted for future reference.

Transfer Switch Enclosure
The transfer switch enclosure houses the transfer switch mechanism and provides protection against environmental factors.

Power Inlet Box
If equipped, the power inlet box allows for a safe connection between the generator and the transfer switch. It is important to follow the provided instructions for proper installation and use of the power inlet box.

Safe Use of Transfer Switch
Follow the provided instructions for the safe use of the transfer switch. This includes proper grounding, installation, and operation procedures.

Load Management Options
The transfer switch may have load management options that allow you to prioritize certain circuits or appliances during power outages. Refer to the product manual for more information on load management capabilities and instructions.

Installation

Breakers Listed for Use
Ensure that the breakers used with the transfer switch are listed for use. Using incompatible breakers may result in malfunction or damage to the product.

Portable Generator Grounding Requirements
If using a portable generator with the transfer switch, ensure that proper grounding requirements are met. Failure to do so may result in electrical hazards.

Automatic Upgrade Kit Installation
If you have the Manual to Automatic Upgrade Kit (model number 006869), follow the provided instructions for installation. This kit allows for automatic transfer of power during outages.

Operation

Functional Tests
Perform functional tests on the transfer switch to ensure proper operation. Follow the instructions provided in the manual for conducting these tests.

Manual Operation
The transfer switch can be operated manually to switch between utility and generator power. Follow the manual’s instructions for manual operation procedures.

Drawings and Diagrams
The product manual includes installation and interconnection drawings and diagrams for reference. These provide visual guidance for proper installation and connection of the transfer switch.

Installation Drawing
Refer to Installation Drawing No. 0K8843-A for detailed instructions on installing the transfer switch.

Interconnection Drawings
There are two interconnection drawings available:

1. Interconnection Drawing No. 0K8845-A – Manual Transfer Connections
2. Interconnection Drawing No. 0K8844-C – Automatic Transfer Connections

Introduction and Safety

Introduction

Thank you for purchasing a Generac Power Systems Inc. product. This unit has been designed to provide high-performance, efficient operation, and years of use when maintained properly. Read this manual thoroughly and understand all of the instructions, cautions, and warnings before using this equipment. If any section of the manual is not understood, contact your nearest Independent Authorized Service Dealer, or contact Generac Customer Service at 1-888-436-3722, or www.generac.com with any questions or concerns.

The owner is responsible for proper maintenance and safe use of the equipment. Before operating or servicing this transfer switch:

1. Study all warnings in this manual and on the product carefully.
2. Become familiar with this manual and the unit before use.
3. Refer to the Assembly section of the manual for instructions on final assembly procedures. Follow the instructions completely.

Save these instructions for future reference. ALWAYS supply this manual to any individual that will use this machine.

THE INFORMATION CONTAINED HEREIN WAS BASED ON EQUIPMENT IN PRODUCTION AT THE TIME OF PUBLICATION. GENERAC RESERVES THE RIGHT TO MODIFY THIS MANUAL AT ANY TIME.

Safety Rules
The manufacturer cannot anticipate every possible circumstance that might involve a hazard. The warnings in this manual, and on tags and decals affixed to the unit are, therefore, not all inclusive. If using a procedure, work method or operating technique that the manufacturer does not specifically recommend, verify that it is safe for others. Also make sure the procedure, work method or operating technique utilized does not render the equipment unsafe.

Throughout this publication, and on tags and decals affixed to the transfer switch, DANGER, WARNING, and CAUTION blocks are used to alert personnel to special instructions about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are as follows:

1. DANGER
   Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

2. WARNING
   Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

3. CAUTION
   Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

4. NOTE :
   Notes contain additional information important to a procedure and will be found within the regular text of this manual.

These safety warnings cannot eliminate the hazards that they indicate. Common sense and strict compliance with the special instructions while performing the action or service are essential to preventing accidents.

Safety Symbols and Meanings

DANGER

• Electrocution. High voltage is present at transfer switch and terminals. Contact with live terminals will result in death or serious injury.
• Electrocution. Water contact with a power source, if not avoided, will result in death or serious injury.
• Electrocution. In the event of electrical accident, immediately shut power OFF. Use non-conductive implements to free victim from live conductor. Apply first aid and get medical help. Failure to do so will result in death or serious injury.
• Electrical backfeed. Use only approved switchgear to isolate generator when electrical utility is the primary power source. Failure to do so will result in death, serious injury, and equipment damage.
• Electrocution, equipment and property damage. Handle transfer switches carefully when installing. Never install a damaged transfer switch. Doing so could result in death or serious injury, equipment and property damage.
• Electrocution. Turn utility supply OFF before working on utility connections of the transfer switch. Failure to do so will result in death or serious injury.
  • Any voltage measurements should be performed with a meter that meets UL3111 safety standards, and meets or exceeds overvoltage class CAT III.
• Electrocution. Do not disable or modify the connection box door safety switch. Doing so will result in death or serious injury.
• Automatic start-up. Disconnect utility power and render unit inoperable before working on unit. Failure to do so will result in death or serious injury.

WARNING

• Only a trained and licensed electrician should perform wiring and connections to unit. Failure to follow proper installation requirements could result in death, serious injury, and damage to equipment or property. (000155)
• Consult Manual. Read and understand manual completely before using product. Failure to completely understand manual and product could result in death or serious injury.

General Information

Unpacking
Carefully unpack the transfer switch. Inspect closely for any damage that might have occurred during shipment. 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.

Equipment Description
The transfer switch is used for transferring critical electrical load from a UTILITY (NORMAL) power source to a GENERATOR (STANDBY) power source. The transfer switch prevents electrical feedback between two different power sources (such as the UTILITY and GENERATOR sources) and, for that reason, codes require it in all standby electric system installations. The transfer switch consists of a transfer mechanism, a control switch, and indicator lights. This UL listed transfer switch is for use in optional standby systems only (NEC article 702).

Transfer Switch 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 to be switched. The switched neutral provides compatibility with GFCI equipped generators. Solderless, screw-type terminal lugs are standard.

The conductor size range is as follows:

AWG

| 50 in-lbs

(5.6 Nm)

| 167°F (75°C)

This transfer switch is suitable for control of motors, electric discharge lamps, tungsten filament and electric heating 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.

A 50A-rated switch is suitable for use on circuits capable of delivering not more than 10,000 RMS symmetrical amperes, 250 VAC maximum, when protected by a 50A maximum circuit breaker (Siemens types QP or BQ) or 50A maximum circuit breaker (Square D Q2, Westinghouse CA-CAH, General Electric TQ2 and Siemens QJ2).

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. For future reference, record the Model and Serial numbers in the space provided on the front cover of this manual.

Transfer Switch Enclosure
The standard switch enclosure is a National Electrical Manufacturer’s Association (NEMA) UL Type 1 indoor enclosure.

Power Inlet Box (if equipped)
The Power Inlet Box (PIB) safely connects a portable generator to the manual transfer switch.

Two types of enclosure are available:

• Corrosion-resistant aluminum
• Non-metallic resin

The conductor size range is as follows:

PIB

Rating

| Wire Range| Conductor Tightening Torque| Lug Temp. Rating
---|---|---|---
30A| 1/0 – 14

AWG

| 50 in-lbs

(5.6 Nm)

| 167°F (75°C)

Safe Use of Transfer Switch

WARNING
Consult Manual. Read and understand manual completely before using product. Failure to completely understand manual and product could result in death or serious injury.

Before installing, operating or servicing this equipment, read the SAFETY RULES carefully. Comply strictly with all SAFETY RULES to prevent accidents and/or damage to the equipment.  The manufacturer recommends that a copy of the SAFETY RULES be posted near the transfer switch. Also, be sure to read all instructions and information found on tags, labels and decals affixed to the equipment. Publications that outline the safe installation and manufacturing of transfer switches are the following:

• NFPA 70; National Electrical Code
• UL 1008, STANDARD FOR SAFETY-AUTOMATIC TRANSFER SWITCHES
• UL67 Panel boards

NOTE : To ensure code compliance, it is essential to use the latest version of any standard that has been adapted by your local municipality.

Load Management Options
Loads can be managed using a smart power management system. The system can accommodate up to eight individual Smart Management Modules (SMM).*

NOTE : The SMM modules are self-contained and have individual built-in controllers.

*See SMM Module (available separately)

Installation

Mounting the Transfer Switch

DANGER

• Electrocution. Turn utility supply OFF before working on utility connections of the transfer switch. Failure to do so will result in death or serious injury.
• Equipment malfunction. Installing a dirty or damaged transfer switch will cause equipment malfunction and will result in death or serious injury.

WARNING
Only qualified service personnel may install, operate and maintain this equipment. Failure to follow proper installation requirements could result in death, serious injury, and damage to equipment or property.

Mounting dimensions for the transfer switch enclosure are in this manual. Enclosures are typically wall-mounted. See the Drawings and Diagrams section. This transfer switch is mounted in a NEMA 1 enclosure. It can be mounted indoors only and should be based on the layout of installation, convenience and proximity to the utility supply and load center.

IMPORTANT NOTE: Always adhere to local electrical codes during installation.

1. Locate transfer switch where the proper equipment and clear working space can be maintained.
2. Hold transfer switch against the mounting surface.
   • IMPORTANT NOTE : To eliminate the possibility of debris contamination, never drill inside the enclosure.
3. Drill the appropriate size holes for mounting hardware at marked hole locations.
4. Mount transfer switch to mounting surface with appropriate fasteners.

NOTE : The 1’ conduit can be installed on either side of the box through a removable plate.
NOTE : Transfer switch must be mounted vertically as shown in Figure 3-1.

Mounting the Power Inlet Box
Install the Power Inlet Box (PIB) in a location that ensures that the generator is at least 5 feet away from windows, doors or other openings such as dryer vents, or air conditioning units.

Remove front cover.

• For installations where side clearance is less than 12 inches on either side, remove the three (3) screws that secure the inlet to the bottom plate.
• For installations where side clearance exceeds 12 inches on both sides, remove the screw that secures the bottom plate to the box.
• For wiring entry into the back of the PIB, install the wiring through one of the provided knockouts, or drill an appropriate sized entry into the PIB.
• For wiring entry into the sides or top of the PIB, install the wiring through one of the provided knockouts, or drill an appropriate sized entry into the PIB.

NOTE : To maintain NEMA 3R rating, if entry is above the level of uninsulated live parts, use fittings listed for use in wet locations.

1. Mount the power inlet box on the outside of the building in a convenient location (minimum 24 inches above grade), using the four holes provided in the back of the cabinet.
2. Extend wiring inside the power inlet box approximately eight (8) inches from the point of entrance.
3. Attach the equipment grounding conductor to the green lead provided in power inlet box with wire nut (provided by installer).
   • NOTE : If used as a grounding conductor, the ground stud/pigtail in the non-metallic units is provided to ground metallic conduit when connecting to the non-metallic power inlet box.
4. Strip and insert incoming leads into terminals on power inlet. Insert white wire (neutral) into nickel plated screw terminal or white marking on the inlet.
5. Carefully fold wires into the enclosure and reattach the bottom assembly or inlet onto box with screw removed earlier.

Connecting Power Source and Load Lines

DANGER
Electrocution. Turn utility and emergency power supplies to OFF before connecting power source and load lines. Failure to do so will result in death or serious injury. (000116)

1. Installation and interconnection diagrams are provided in the Drawings and Diagrams section of this manual.
   NOTE : All installations must comply with national, state and local codes. It is the responsibility of the installer to perform an installation that will pass the final electrical inspection.

2. The utility supply, generator, and customer load connections are made at the transfer switch mechanism, inside the switch enclosure.

3. Conductor sizes must be adequate to handle the maximum 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.
   NOTE : If aluminum conductors are used, apply corrosion inhibitor to conductors. After tightening terminal lugs, carefully wipe away any excess corrosion inhibitor.

4. Tighten terminal lugs to the torque values as noted on the inside of the door.

CAUTION
Equipment damage. Verify all conductors are tightened to the factory specified torque value. Failure to do so could result in damage to the switch base.

Connect power source and load conductors to clearly marked terminal lugs on transfer mechanism as follows:

1. Install a 2-pole, 50 Amp breaker in the main distribution panel. This will be the utility (normal) power source for transfer switch.
2. Customer LOAD leads are pre-wired at the factory.

NOTE : 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.

Connecting Front Panel Wiring
Utilize the quick disconnect connector in the wiring harness to remove the front panel during service or installation. Verify that power and load lines are disconnected any time the front panel is removed.

Installing Branch Circuit

Conductors – USA Installations

1. Select which branch circuits will be protected by the generator in the normal power panel board.

2. Turn the circuit breaker in the normal power panel board to the off position.

3. Remove the ungrounded (hot) conductor from the circuit breaker and neutral conductor from the neutral terminal bar in the normal power panel board.
   NOTE: Multi-wire branch circuits must be connected to circuit breakers that are adjacent to each other. If the circuit to be protected is part of a multi- wire branch circuit, the entire multi-wire branch circuit must be relocated to the transfer switch panel board (See NEC 210.4). The branch circuit wiring can be removed from the normal power panel board and installed in the transfer switch panel board, or spliced onto new branch circuit wiring originating from the transfer switch panel board.

4. If the normal power panel board is being used as a junction box for the protected branch circuit conductors, install the 2 foot conduit, raceway(s), or other approved wiring method between the transfer switch panel board and normal power panel board.

5. Install properly sized branch circuit conductors between the transfer switch panel board to the branch circuit conductors to be protected by the transfer switch, if not using factory supplied wiring.

6. Use listed wire nuts or any other approved termination device to connect the branch circuit conductors.

7. Install the provided label on the existing panel board that indicates the location of the disconnecting means for the pass through conductors.

8. If the generator protected branch circuit conductors are being re-installed into the transfer switch panel board, punch the required sized hole(s) for the cable, conduit, or raceway.

9. Route the branch circuit conductors into the transfer switch and terminate the equipment ground conductor on the equipment ground terminal bar, the neutral on the neutral terminal bar, and the ungrounded (hot) on the circuit breaker terminal.

10. Size all conductors, raceways, conduits, and junction boxes, if required, to the applicable NEC code articles and follow the NEC installation requirements for the wiring method(s) selected.

NOTE : The two foot pre-wire whip can be shortened if needed or removed and replaced with field wiring. The factory installed branch circuits and circuit breakers can also be modified if needed. Follow all applicable electrical codes for any field modification.

Installations

1. Select which branch circuits will be protected by the generator in the normal power panel board. Turn the circuit breaker in the normal power panel board to the off position.
2. Remove the ungrounded (hot) conductor from the circuit breaker and neutral conductor from the neutral terminal bar in the normal power panel board.
   • NOTE : If the circuit to be protected is part of a multi-wire branch circuit, the entire multi-wire branch circuit must be relocated to the transfer switch panel board.
3. The Canadian Electric Code prohibits the use of the normal power panel board as a junction box, the generator protected branch circuit wiring must be relocated to a properly sized junction box, or reinstalled into the transfer switch panel board.
4. Punch the required sized hole(s) for the cable, conduit, or raceway into the transfer switch.
5. Route the branch circuit conductors into the transfer switch and terminate the equipment ground conductor on the equipment ground terminal bar, the neutral on the neutral terminal bar, and the ungrounded (hot) on the circuit breaker terminal.
6. Size all conductors, raceways, conduits, and junction boxes, if required, to the applicable CEC code articles and follow the CEC installation requirements for the wiring method(s) selected.

NOTE : The two foot pre-wire whip can be shortened if needed or removed and replaced with field wiring. The factory installed branch circuits and circuit breakers can also be modified if needed. Follow all applicable electrical codes for any field modification.

Installing Breakers

IMPORTANT NOTE: AFCI and GFCI circuit breakers are not provided by the factory. If the circuits to be protected require AFCI or GFCI protection, or both, then listed protection shall be provided by the installer.

The factory-supplied breakers can be changed by the installer. Install listed and labeled circuit breakers that are compatible with the transfer switch (See Breakers Listed for Use). Follow all applicable NEC and CEC code articles for any field modifications.

Breakers Listed for Use

1. Multi-listed for use with 1″ standard, tandem, GFCI and AFCI breakers from Siemens, Murray, Eaton and Square D.
2. Insert the tab on the breaker (A) into the hook on the bus (B).
3. Push the breaker into the bus until it snaps into place.

Portable Generator Grounding Requirements
The Upgradeable Manual Transfer Switch is designed for use with portable generators with a bonded neutral, and used as a separately derived system. A grounding system and a grounding electrode system shall be connected to the ground terminal on the portable generator. See NEC Article 250.30(A)(4) and (5) for code compliance.

Automatic Upgrade Kit Installation

1. Turn the normal power supply circuit breaker to the transfer switch to the OFF (open) position.
2. Remove the transfer switch cover, disconnect the control wiring to the cover, and verify that the electrical power has been turned off.
3. Disconnect the normal power feeder conductors, the generator feeder conductors, and the panelboard conductors from the transfer mechanism.
4. Remove the screw that holds the transfer mechanism in place (A in Figure 3-3), and remove the 3 pole transfer mechanism from the transfer switch.
5. Remove the lower left screw that secures the divider plate in the transfer switch (B in Figure 3-4).
6. Install the new automatic back plate in the transfer switch and secure to the transfer switch enclosure (C in Figure 3-4).
7. Remove the neutral conductor from the main lug on the neutral bar.
8. Terminate the normal power neutral to the main lug on the neutral bar (D in Figure 3-5).
9. Terminate the neutral conductor from the generator power feeder onto the neutral terminal bar in the transfer switch (E in Figure 3-5).
10. Terminate the normal power feeder conductors to N1 and N2 on the transfer mechanism (F in Figure 3-5).
11. Terminate the panelboard feeder conductors to T1 and T2 on the transfer mechanism (G in Figure 3-5).
12. Terminate the generator feeder conductors to E1 and E2 on the transfer mechanism (H in Figure 3-5).
13. Terminate generator control wiring to the N1, N2, T1, 23 and 194 terminals in the transfer switch (J in Figure 3-5).
14. Install the new panelboard cover and properly label all branch circuits.
15. See Section 4 Checking Automatic Operation (Automatic HSB Generator Only) to verify proper transfer switch and generator operation.

Operation

Functional Tests
Following transfer switch installation and interconnection, inspect the entire installation carefully. A competent, qualified electrician should inspect it. The installation should comply strictly with all applicable codes, standards, and regulations. When absolutely certain the installation is proper and correct, complete a functional test of the system.

CAUTION
Equipment damage. Perform functional tests in the exact order they are presented in the manual. Failure to do so could result in equipment damage. (000121)

IMPORTANT NOTE:
Before proceeding with functional tests, read and make sure all instructions and information in this section is 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.

Manual Operation

DANGER
Electrocution. Do not manually transfer under load. Disconnect transfer switch from all power sources prior to manual transfer. Failure to do so will result in death or serious injury, and equipment damage.

A manual handle is shipped with the transfer switch. See Figure 4-1. Manual operation must be checked BEFORE the transfer switch is operated electrically. To check manual operation, proceed as follows:

1. Verify generator is OFF.
2. Turn OFF both UTILITY (service disconnect circuit breaker) and STANDBY (generator main line circuit breaker) power supplies to the transfer switch.
3. Note position of transfer mechanism main contacts by observing the movable contact carrier arm.
   • Manual operation handle in the UP position – LOAD terminals (T1, T2) are connected to STANDBY terminals (E1, E2).
   • Manual operation handle in the DOWN position -LOAD terminals (T1, T2) are connected to UTILITY terminals (N1, N2).

CAUTION
Equipment damage. Do not use excessive force while manually operating the transfer switch. Doing so could result in equipment damage.

Transfer Mechanism Manual Operation
Before proceeding, verify the position of the switch by observing the position of manual operation handle in Figure 4-1. If the handle is DOWN, the contacts are closed in the NORMAL (UTILITY) position, no further action is required. If the handle is UP, proceed with Step 1.

1. With the handle inserted into the movable contact carrier arm, move handle DOWN. Be sure to hold on to the handle as it will move quickly after the center of travel.
2. Remove manual operating handle from movable contact carrier arm. Return handle to storage bracket.

Close to Generator Source Side
Before proceeding, verify the position of the switch by observing the position of the manual operation handle in Figure 4-1. If the handle is UP, the contacts are closed in the GENERATOR (STANDBY) position. No further action is required. If the handle is DOWN, proceed with Step 1.

1. With the handle inserted into the movable contact carrier arm, move the handle UP. Be sure to hold on to the handle as it will move quickly after the center of travel.
2. Remove manual operating handle from movable contact carrier arm. Return handle to storage bracket.

Return to Utility Source Side

1. Manually actuate switch to return manual operating handle to the DOWN position.
2. Remove manual operating handle from movable contact carrier arm. Return handle to storage bracket.

Voltage Checks

DANGER

• Electrocution. High voltage is present at transfer switch and terminals. Contact with live terminals will result in death or serious injury.
• Electrocution. Turn utility supply OFF before working on utility connections of the transfer switch. Failure to do so will result in death or serious injury.

Utility Voltage Checks

1. Turn ON the UTILITY power supply to the transfer switch using the breaker in main distribution panel.
2. With an accurate AC voltmeter, check for correct voltage.
3. Measure across MTS terminal lugs N1 and N2 (Approximately 240 VAC).
4. Measure across MTS terminal lugs N1 to N3 and N2 to N3 (Approximately 120 VAC).
5. Verify that UTILITY supply voltage is correct and compatible with the transfer switch ratings.

Generator Voltage Checks

1. Connect the generator to the transfer switch.
2. Start the generator.
3. With an accurate AC voltmeter and frequency meter, check the no-load, voltage and frequency. Measure across ATS terminal lugs E1 to E2; E1 to E3 and E2 to E3.
   Frequency| 58-63 Hz
   ---|---
   Terminals E1 to E2| 240-246 VAC
   Terminals E1 to E3| 120-123 VAC
   Terminals E2 to E3| 120-123 VAC
4. When certain that generator supply voltage is correct and compatible with the transfer switch ratings, turn OFF the generator supply to the transfer switch.
5. Set the generator main circuit breaker (CB1) to OFF or OPEN.
6. Shut down the generator.

NOTE : Do NOT proceed until generator AC output volt-age and frequency are correct and within stated limits.

Generator Tests Under Load

1. If so equipped, set the generator main circuit breaker to OFF or OPEN.
2. Turn OFF or OPEN all load circuits.
3. Set the utility service disconnect circuit breaker to OFF or OPEN.
4. Manually actuate the transfer switch main contacts to the Standby position. See Manual Operation.
5. Start the generator. When engine starts, let it stabilize for a few minutes.
6. The generator now powers all LOAD circuits. Check generator operation under load as follows:
7. Turn on electrical loads to the full rated wattage/amperage capacity of the generator. DO NOT OVERLOAD.
8. With maximum rated load applied, check voltage and frequency across transfer switch terminals E1 and E2. Voltage should be greater than 230 VAC (240 VAC system). Frequency should be greater than 58 Hz.
9. 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.
10. When generator tests under load are complete, turn OFF all load circuits.
11. Let the generator run at no-load for several minutes. Then, shut down the generator.
12. Manually move the main switch contacts back to the utility position.
13. Place the manual handle in its storage bracket.

Checking Electric Operation

(Portable Generator Only)
To check the system for proper electrical operation, proceed as follows:

1. Verify generator is OFF.
2. Connect the electrical harness six position quick connector (from the lights and rocker switch of the front panel) to the main harness of the transfer switch.
3. Install the front cover of the transfer switch with four (4) screws provided. See Figure 3.2.
4. Turn ON the utility power supply to the transfer switch, using the means provided (such as utility main line circuit breaker). The Utility Light will illuminate only if the transfer switch is in the Generator position, and utility voltage is present.
5. Press rocker button towards UTILITY direction (the transfer switch will not operate without utility voltage present). The Utility Light is now off and in normal operating condition (Utility voltage is present and transfer switch is in normal utility mode). Any loads will be energized via the power panel of the transfer switch.
6. Ensure the Generator Neutral and Ground are connected on the generator. The Generator should be properly tied to earth ground as local regulations require.
7. Connect the generator to the Generac Portable Inlet Box using the Generac Portable Power Cord.
8. Turn on the generator. The amber indicator light for Generator Power will illuminate on the front panel of the transfer switch any time generator voltage is available. The generator is now electrically isolated from any electrical connections beyond the transfer switch.
9. Press rocker button towards GENERATOR POWER direction. The Utility Light will illuminate to indicate utility voltage is available for transfer back to the utility. The generator light will continue to illuminate to indicate the presence of generator voltage. All loads through the transfer switch panel are now being supplied by the generator.
10. Turn OFF the utility power supply to the transfer switch, using the means provided (such as utility main line circuit breaker). The Utility Light will no longer be illuminated, as utility voltage is no longer present.
11. Confirm any loads being supplied by the transfer switch panel are energized by the generator.
12. Turn ON the utility power supply to the transfer switch, using the means provided (such as utility main line circuit breaker). The Utility Light will again illuminate.
13. Press rocker button towards UTILITY direction. The Utility Light will turn off. The transfer switch is now in its normal operating mode. All loads from the transfer switch panel are provided by the utility.
14. Let the generator run at no-load for several minutes. Then, shut down the generator. The Generator Power Light on the transfer switch will turn off.
15. Disconnect the generator portable power cord.
16. Store the generator as suggested by the manufacturer.
17. Transfer switch testing is complete and ready for use.

NOTE : The transfer switch requires electric power to operate with the rocker button. The transfer switch will not transfer to utility mode if the Utility Light is not illuminated prior to pressing the rocker button. The transfer switch will not transfer to generator mode if the Generator Light is not illuminated (this safeguards against acciden-tal transfer to the generator if generator power is not present).

Checking Automatic Operation

(Automatic HSB Generator Only)
To check the system for proper automatic operation, proceed as follows:

1. Verify generator is OFF.
2. Verify switch is de-energized.
3. Install front cover of the transfer switch.
4. Turn the utility power supply to the transfer switch ON, using the utility main line circuit breaker.
5. Set the generator main circuit breaker to ON.
6. On the generator panel, select AUTO. The system is now ready for automatic operation.
7. Turn utility power supply to the transfer switch OFF.

With the generator ready for automatic operation, the engine should crank and start when the utility source power is turned OFF after a ten second delay (factory default setting). After starting, the transfer switch should connect load circuits to the standby side after the engine warm-up delay. Let the system operate through its entire automatic sequence of operation.

With the generator running and loads powered by generator AC output, turn ON the utility power supply to the transfer switch. The following should occur:

• After approximately 15 seconds, the switch should transfer loads back to the utility power source.
• Approximately one minute after re-transfer, the engine should shut down.

With the generator in the AUTOMATIC mode, the system is now set for fully automatic operation.

Installation Summary

1. Verify the installation has been properly performed as outlined by the manufacturer and that it meets all applicable laws and codes.
2. Verify proper operation of the system as outlined in the appropriate installation and owner’s manuals.
3. Educate the end-user on the proper operation, maintenance and service call procedures.

Shutting Generator Down While Under Load

IMPORTANT NOTE: T o turn the generator OFF during utility outages to perform maintenance, or conserve fuel, follow these important steps:

To turn the generator OFF (while running in AUTO and Online):

1. Turn the main utility disconnect OFF.
2. Turn the main line circuit breaker (MLCB) on the generator to OFF (OPEN).
3. Turn the generator OFF.

NOTE : If turning the unit off for longer than 24 hours, remove the F1 fuse from the generator controller.

To turn the generator ON:

1. Reinstall F1 fuse if necessary.
2. Put the generator back into AUTO and allow to start and warm-up for a few minutes.
3. Set the MLCB on the generator to ON.

The system will now be operating in automatic mode. The main utility disconnect can be turned ON (CLOSED).

NOTE : To shut the unit off, this complete process must be repeated.

Drawings and Diagrams

Installation Drawing No. 0K8843-A

Interconnection Drawing No. 0K8845-A (Manual Transfer Connections)

Interconnection Drawing No. 0K8844-C (Automatic Transfer Connections)

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Part No. 0K9960 Rev. B 07/31/15 Printed in USA ©2015 Generac Power Systems, Inc. All rights reserved Specifications are subject to change without notice. No reproduction is allowed in any form without prior written consent from Generac Power Systems, Inc. Generac Power Systems, Inc. S45 W29290 Hwy. 59 Waukesha, WI 53189 1-888-GENERAC (1-888-436-3722) generac.com

FAQ’s

How do I register my Generac product?
You can register your Generac product at www.generac.com or by calling 1-888-GENERAC (888-436-3722).

Can this transfer switch be used for critical life support applications?

No, this product is not intended for critical life support applications. It is important to adhere to this warning to ensure safety.

What does the California Proposition 65 warning mean?

The warning indicates that the engine exhaust and some constituents of the product may cause cancer, birth defects, and other reproductive harm. It is important to take necessary precautions and follow safety guidelines.

References

• Generac Power Systems - Find My Manual, Parts List, and Product Support
• Manual-Hub.com – Free PDF manuals!

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