Owner’s Manual
100 Amp “V”Type
Transfer Switch
Models:
9227-2
4678-1
This manual should remain with the unit.
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Table of Contents
• 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.
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
• Never work on this equipment while physically or
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
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.
Section 4 – Notes ............................................7
Section 5 – Electrical Data ............................8
Section 6 – Exploded Views and
Parts Lists........................................................9
Section 7 – Warranty ....................Back Cover
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Section 1 — General Information
Generac 100 Amp Transfer Switch
1.1 INTRODUCTION
1.3 TRANSFER SWITCH RATINGS
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.
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.
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.
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.
1.2 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.
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.
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.
Two publications that outline the safe use of transfer
switches are the following:
• National Electrical Code
• UL 1008, STANDARD FOR SAFETY-AUTOMATIC
TRANSFER SWITCHES
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.
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Section 2 — Installation
Generac 100 Amp Transfer Switch
2.1 INTRODUCTION TO INSTALLATION
This equipment has been wired and tested at the facto-
ry. Installing the switch includes the following proce-
dures:
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.
• 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.
2.4 CONNECTING POWER SOURCE AND
LOAD LINES
DANGER
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.
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.
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.
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.
2.3 MOUNTING
Transfer switch components are generally mounted in a
standard NEMA 1 type enclosure (Figure 2.1).
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.
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 2.2 — 100 Amp 2-Pole Transfer Mechanism
BRIDGE
RECTIFIER
Figure 2.1 — Mounting Dimensions for Enclosures
N1 N2
VARISTOR
UTILITY
CLOSING COIL
363.8mm [14.32"]
53.4mm [2.10"]
257.0mm [10.12"]
LIMIT SWITCH XA1
MANUAL TRANSFER LEVER
LIMIT SWITCH XB1
E1
514.1mm [20.24"]
GENERAC
TRANSFER
SWITCH
STANDBY
488.7mm [19.24"]
E2
CLOSING COIL
VARISTOR
WARNING MORE THAN ONE
-
LIVE CIRCUIT - SEE DIAGRAM
12.7mm [0.50"]
AV TISSEMENT - PLUS
D'UN CIRCUIT SOUS TENSION
OIR LE SCHEMA
E
R
-
V
BRIDGE
RECTIFIER
NEUTRAL
T1
T2
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.
**ALL DIMENSIONS IN:
MILLIMETERS (INCHES)
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Section 2 — Installation
Generac 100 Amp Transfer Switch
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.
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
All power cables should enter the switch next to trans-
fer mechanism terminals.
Connect power source load conductors to clearly on the length of the wire, as recommended below:
marked transfer mechanism terminal lugs as follows
MAXIMUM WIRE LENGTH
RECOMMENDED WIRE
SIZE
(Figure 2.3).
1. Connect NORMAL (utility) power source cables to
switch terminals N1 and N2.
460 feet (140m)
730 feet (223m)
1,160 feet (354m)
No. 18 AWG.
No. 16 AWG.
No. 14 AWG.
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.
Figure 2.3 — Transfer Switch Interconnections (Drawing No. C3921)
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Section 3 — Post Installation Start-Up Adjustments
Generac 100 Amp Transfer Switch
3.1 FUNCTIONAL TESTS AND
ADJUSTMENTS
DANGER
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.
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.
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).
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.
Figure 3.1 — Transfer Switch Operation (“V” Type)
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.
DANGER
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.
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Section 3 — Post Installation Start-Up Adjustments
Generac 100 Amp Transfer Switch
3.3 TRANSFER SWITCH VOLTAGE
3.4 GENERATOR TESTS UNDER LOAD
1. Set the generator’s main circuit breaker to its OFF
or OPEN position.
CHECKS
1. Turn ON the UTILITY power supply to the transfer
switch with whatever means provided (such as the
UTILITY main line circuit breaker).
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.
DANGER
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).
• 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.
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. When checkout under load is complete, set the gen-
erator’s main circuit breaker to its OFF or OPEN
position.
6. Set the generator’s main circuit breaker (CB1) to its
ON or CLOSED 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.
DANGER
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.
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.
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.
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Section 4 — Notes
Generac 100 Amp Transfer Switch
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Section 5 — Electrical Data
Electrical Schematic – Drawing No. 81222-B
1 9 4
2 3
L O A D 2
L O A D 1
U T I L I T Y 2
U T I L I T Y 1
B
A
7
9
6
1
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Section 6 — Exploded Views and Parts Lists
Transfer Switch – Drawing No. C3909-A
A
A A A
A
A
DECAL
ENCLOSURE
A A A
A
A
A
DECAL
A
A
A
DECAL
DETAIL B-B
(GROUND LUG ASSEMBLY)
A
A
3
4
A
5
6
7
9
10
A
A
A
A
DECAL
11 12
A
A
A
8
1
2
3
4
1
2
13
14
A
A
A
A
A
(BOTTOM POWER TERMINALS)
A
A
DECAL
L
B
B
A A
A
5
6
7
8
A
A
A
A
TERM. STRIP
REF. ONLY
A
DECAL
DETAIL A-A
(POWER TERMINAL LUG ASSEMBLY)
A
1 2 3 4 5 6 7
A
A
NOTE:
TIGHTEN ITEM #24 TO 24-30 IN.LBS
A
A
A
DECAL
DECAL
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
C2259
74975
42568
22473
22097
C2237
74908
63617
24940
73591
73590A
57073
66849
27628
22131
64113
77441
62684
24912
A1658
C2630
40213B
A1661
36932
22152
1
1
4
4
4
1
4
1
6
4
4
1
2
1
1
1
-
1
1
1
1
4
2
6
6
ENCLOSURE
26
27
28
29*
30
31
32
77033
74138
77052
81238
63378
28739
75353
6
2
2
1
2
2
1
LUG, SOLDERESS
COVER, ENCLOSURE
HHCS M6-1.0 x 20
M6 FLAT WASHER
M6 LOCK WASHER
SWITCH, TRANSFER 100A 2-POLE, 250V
M5-0.8 x 10 TAPTITE
RELAY, 12V-DC 10A
#8-32 x 1/2" TAPTITE
FUSE HOLDER
FUSE 5A 600V
LUG, NEUTRAL
M5-0.8 x 16 TAPTITE
NUT, .375-16
WASHER, FLAT .375 NOM.
STUD, WING
MALE DISCONNECT ADAPTOR (BENT)
LUG, 0.25"-TAB, #10-SCREW
HARNESS, WIRE
CABLE TIE HOLDER
TIE WRAP, 4"
DECAL, UL COMPONENT
RECOGNITION
DECAL, MANUAL OPERATION
DECAL, TERMINAL STRIP
DECAL, TRANSFER SWITCH RATING
(9222-3)
33
34
35
A9517
A2595
77030
1
1
1
77032
1
DECAL, TRANSFER SWITCH RATING
(9227-2)
36**
37
38***
39
77036
83736
95282
81221
1
1
1
1
DECAL, TEST SEQUENCE
DECAL, CSA(NOT FOR SALE)
DECAL, LIVE CIRCUIT WARNING
DECAL, NAMEPLATE UL (NOT FOR
SALE)
HANDLE, TRANSFER SWITCH
LUG, GROUND
1/4"-20 x 5/8" TAPTITE
LOCK WASHER 1/4" SPECIAL
COVER, RELAY & TERMINAL BLOCK
STANDOFF 1-3/8" NYLON
POP RIVET
40
41
67210A
A9457
1
1
DECAL, GROUND
DECAL, NEUTRAL
* NOT SHOWN
** INSIDE OF COVER
*** OUTSIDE OF COVER
PPHMS #10-32 x 1/4"
WASHER, LOCK #10
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Section 7 — Warranty
Generac 100 Amp Transfer Switch
GENERAC POWER SYSTEMS STANDARD TWO-YEAR LIMITED WARRANTY
FOR GENERAC TRANSFER SWITCH SYSTEMS
For a period of 2 (two) years from the date of sale, Generac Power Systems, Inc. will, at its option, repair or replace any
part(s) which, upon examination, inspection, and testing by Generac Power Systems or a Generac Power Systems
Authorized Warranty Service Dealer, is found to be defective under normal use and service, in accordance with the war-
ranty schedule set forth below. Any equipment that the purchaser/owner claims to be defective must be examined by the
nearest Generac Power Systems Authorized Warranty Service Dealer. All transportation costs under the warranty, includ-
ing return to the factory, are to be borne and prepaid by the purchaser/owner. This warranty applies only to Generac
Power Systems Transfer Switch applications, as Generac Power Systems, Inc. have defined Transfer Switch application.
WARRANTY SCHEDULE
• YEAR ONE — 100% (one hundred percent) coverage labor, and parts listed.
• ALL COMPONENTS
• YEAR TWO — 100% (one hundred percent) coverage on parts listed.
• ALL COMPONENTS — *PARTS ONLY
• A Generac Power Systems, Inc. Transfer Switch is highly recommended to be used in conjunction with the genset. If a
non Generac genset is substituted for use and directly causes damage to the Generac Transfer Switch, no warranty
coverage shall apply.
• All warranty expense allowances are subject to the conditions defined in Generac Power Systems Warranty, Policies, and
Procedures Flat Rate Manual.
• Units that have been resold are not covered under the Generac Power Systems Warranty, as this Warranty is not transferable.
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
1. Any unit built/manufactured prior to January 1, 2002.
2. Unit enclosure is only covered against rust or corrosion the first year of the warranty provision.
3. Costs of normal maintenance i.e. tune-ups, associated part(s), adjustments, loose/leaking clamps, installation and start-up.
4. Use of Non-Generac replacement part(s) will void the warranty in its entirety.
5. Damage related to rodent infestation
6. Failures due, but not limited to, normal wear and tear, accident, misuse, abuse, negligence, or improper installation or
sizing.
7. Failures caused by any external cause or act of God such as collision, fire, theft, freezing, vandalism, riot or wars, lightning,
earthquake, windstorm, hail, volcanic eruption, water or flood, tornado, hurricane, terrorist acts or nuclear holocaust.
8. Products that are modified or altered in a manner not authorized by Generac Power Systems in writing.
9. Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in
repair or replacement of the defective part(s).
10. Failure due to misapplication, or misrepresentation.
11. Telephone, cellular phone, facsimile, internet access or other communication expenses.
12. Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific
unit warranty period.
13. Rental equipment used while warranty repairs are being performed.
14. Overtime labor.
15. Expenses related to “customer instruction” or troubleshooting where no manufacturing defect is found.
16. Overnight freight costs for replacement part(s).
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, SPECIFICALLY, GENERAC
POWER SYSTEMS MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICU-
LAR PURPOSE. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may
not apply to you.
GENERAC POWER SYSTEMS ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED
ABOVE. IN NO EVENT SHALL GENERAC POWER SYSTEMS BE LIABLE FOR ANY INCIDENTAL, OR CONSEQUENTIAL
DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC POWER SYSTEMS, INC. NEGLIGENCE.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may
not apply to you. Purchaser/owner agrees to make no claims against Generac Power Systems, Inc. based on negligence.
This warranty gives you specific legal rights. You also may have other rights that vary from state to state.
GENERAC® POWER SYSTEMS, INC.
P.O. BOX 297
WHITEWATER, WI 5319087
Part No. C3908
Revision B (12/11/02)
Printed in U.S.A.
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