Generac Power Systems GenTran 6295 Instruction sheet

Installation Guidelines
For
Manual Transfer Switches
6295-6296 / 6378-6380
This manual should remain with the unit.
This manual must be used in conjunction
with the appropriate owner’s manual.
*NOT INTENDED FOR USE IN CRITICAL
LIFE SUPPORT APPLICATIONS.
*ONLY QUALIFIED ELECTRICIANS OR
CONTRACTORS SHOULD ATTEMPT
INSTALLATION!

ii Transfer Switch Installation Guidelines
Forward
Thank you for purchasing a Generac Manual Transfer Switch to safely connect a portable generator to your home or busi-
ness (single phase). Use where the main electrical panel is located indoors. This product is suitable for service entrance
equipment.
READ THIS MANUAL THOROUGHLY. This manual has been prepared to familiarize personnel involved with the
installation of transfer switches with the manufacturer’s installation requirements. Information and instructions con-
tained herein are not intended to replace or supersede, local, state, or national safety, electrical, and building codes
pertaining to such installations. Applicable laws, codes, and standards must always take precedence over the recom-
mendations contained herein. Always check with the local Authority Having Jurisdiction (AHJ) for the codes or stan-
dards that apply.
Only authorized dealers or qualified, competent installation contractors or electricians thoroughly familiar with applica-
ble codes, standards, and regulations should install this transfer switch. The installation must be in strict compliance
with all codes, standards, and regulations.
It is not intended that this manual be used by any unqualified person for the purpose of installing a transfer switch.
Installation, inspection, and testing of the system must be attempted only by competent, qualified electricians or instal-
lation contractors who are familiar with the equipment and with all installation codes and requirements.
It would be impossible to provide details for every installation configuration. For this reason, much of the information in
this manual is general in nature. Illustrations of typical installations are not intended to serve as specific installation
plans, but may be used in the planning and design process when considering the selection and purchase of a genera-
tor set for standby power applications. Always have the unit specific drawings and manuals on hand before beginning
any installation.
If a portable generator is used to power electrical load circuits normally powered by a utility
power source, it is required by code to install a transfer switch. The transfer switch must
effectively isolate the electrical system from the utility distribution system when the generator
is operating. Failure to isolate an electrical system by such means may result in damage to the
generator and may also result in injury or even death to utility power workers due to backfeed
of electrical energy.
After the transfer switch has been installed, do nothing that might render the installation in non-
compliance with codes, standards, and regulations. Every effort was made to ensure that the
information in this manual was both accurate and complete at the time it was released. However,
the manufacturer reserves the right to change, alter, or otherwise improve this product at any
time without notice.
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WARNING!
California Proposition 65
Engine exhaust and some of its constituents are known to the state of California to cause cancer,
birth defects, and other reproductive harm.
WARNING!
California Proposition 65
This product contains or emits chemicals known to the state of California to cause cancer,
birth defects, and other reproductive harm.

Table of Contents
Transfer Switch Installation Guidelines iii
Section 1 Safety
1.1 Introduction .......................................................................................................................... 1
1.2 Safety Rules .......................................................................................................................... 1
1.3 General Hazards ................................................................................................................... 2
1.4 Electrical Hazards ................................................................................................................ 2
1.5 Fire Hazards .......................................................................................................................... 3
1.6 Explosion Hazards ............................................................................................................... 3
1.7 Standards Index ................................................................................................................... 3
Section 2 Installation
2.1 What is Included in this Carton: ......................................................................................... 4
2.2 Tools and Items Needed for Installation: ........................................................................... 4
2.3 Optional Items for Installation: ...........................................................................................4
2.4 Specifications ....................................................................................................................... 5
2.5 Planning Your Installation ................................................................................................... 5
2.6 Installation Procedure ......................................................................................................... 6
Section 3 Operation
3.1 Using Your Transfer Switch ................................................................................................ 9
Table of Contents
Forward ....................................................................................................................ii

Table of Contents
iv Transfer Switch Installation Guidelines
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Transfer Switch Installation Guidelines 1
Section 1 Safety
1.1 — Introduction
Thank you for purchasing a Generac Manual Transfer Switch to safely connect a portable generator to your home or busi-
ness (single phase only). Use where the main electrical panel is located indoors. This product is suitable for service entrance
equipment.
Read this manual thoroughly.If any portion is not understood, contact the nearest Authorized Generac Service
Dealer for clarification. Only authorized dealers or qualified, competent installation contractors or electricians thor-
oughly familiar with applicable codes, standards, and regulations should install this transfer switch.These individuals
are trained/qualified service technicians familiar with the control systems and available options, and also have full
access to drawings, publications, and other information required for a successful installation.The installation must be in
strict compliance with all codes, standards, and regulations.
1.2 — Safety Rules
Throughout this publication, DANGER, WARNING, CAUTION, and NOTE boxes are used to alert personnel to special
instructions about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe them
carefully. They indicate:
Indicates a hazardous situation or action that, if not avoided, will result in death or serious
injury.
Indicates a hazardous situation or action that, if not avoided, could result in death or seri-
ous injury.
Indicates a hazardous situation or action that, if not avoided, could result in minor or mod-
erate injury.
NOTE: Notes provide additional information important to a procedure or component.
These safety warnings cannot eliminate the hazards they indicate. Observing safety precautions and strict compliance
with the special instructions while performing the action or service are essential to preventing accidents.
Four commonly used safety symbols accompany DANGER, WARNING, and CAUTION boxes and the type of informa-
tion each indicates:

Safety
2Transfer Switch Installation Guidelines
This symbol points out important safety information that, if not followed, could
endanger personnel and/or property.
This symbol represents the potential for an Explosion Hazard.
This symbol represents the potential for a Fire Hazard.
This symbol represents the potential for an Electrical Shock Hazard.
SAVE THESE INSTRUCTIONS. This manual contains important instructions that should be
followed during installation of the transfer switch. The manufacturer suggests that these
safety rules be copied and posted in potential hazard areas. Safety should be stressed
to all installers, operators, potential operators, and service and repair technicians for
this equipment.
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 not all-inclusive. If using a procedure, work method, or oper-
ating technique the manufacturer does not specifically recommend, ensure that it is safe for others. Also make sure the
procedure, work method, or operating technique used does not result in unsafe conditions.
1.3 — General Hazards
•For safety reasons, the manufacturer recommends that this equipment be installed, serviced, and repaired by an
Authorized Service Dealer or other competent, qualified electrician or installation technician who is familiar with
all applicable codes, standards, and regulations.
•Ensure that the transfer switch is installed, operated, and serviced in accordance with the manufacturer’s instruc-
tions and recommendations. Following installation, do nothing that might render the unit unsafe or in noncompli-
ance.
•Keep the area around the transfer switch clean and uncluttered. Remove any materials that could become haz-
ardous.
•When working on this equipment, remain alert at all times. Never work on the equipment when physically or men-
tally fatigued.
•Inspect the portable generator regularly, and promptly repair or replace any worn or damaged components using
only factory approved parts and procedures.
1.4 — Electrical Hazards
•All generators produce dangerous electrical voltages and can cause fatal electrical shock. Utility power delivers
extremely high and dangerous voltages to the transfer switch as well as the generator when it is in operation.
Avoid contact with bare wires, terminals and other connections. Ensure all covers, guards, and barriers are in
place, and that they are properly secured and/or locked before operation. If work must be done around an oper-
ating unit, stand on an insulated, dry surface to reduce potential shock hazard.
•Do not handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet.
DANGEROUS ELECTRICAL SHOCK MAY RESULT.
•If it is necessary to stand on metal or concrete while installing, operating, servicing, or repairing this equipment,
lay down a dry wooden platform and cover with insulated mats before beginning.
•Verify that the portable generator is properly grounded.
•Wire gauge sizes of electrical wiring, cables, and cord sets must be adequate to handle the maximum electrical
current (ampacity) to which it will be subjected.
•Before installing or servicing equipment, verify that all power voltage supplies are positively turned off at their
sources. Failure to do so can result in hazardous and possibly fatal electrical shock.
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Safety
Transfer Switch Installation Guidelines 3
•Connecting a portable generator to an electrical system normally supplied by an electric utility is by means of the
transfer switch so as to isolate the generator’s electric system from the electric utility distribution system when
the portable generator is operating. Failure to isolate the two electric system power sources from each other by
such means will result in damage to the portable generator and may also result in injury or death to utility power
workers due to backfeed of electrical energy.
•In case of 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. AVOID DIRECT CONTACT WITH THE VICTIM. Use
a nonconducting implement, such as a dry rope or board, to free the victim from the live conductor. If the victim is
unconscious, apply first aid and get immediate medical help.
•Do not wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in electric shock,
or may get caught in moving parts resulting in injury.
1.5 — Fire Hazards
•Keep a fire extinguisher near the portable generator and transfer switch at all times. Keep the extinguisher prop-
erly charged and be familiar with its use. Direct any questions to the local fire department.
NOTE: DO NOT use any carbon tetra-chloride type fire extinguishers. These fire extinguishers emit toxic fumes
and the liquid can damage wiring insulation.
1.6 — Explosion Hazards
•Do not smoke around the generator. Immediately wipe up any fuel or oil spills. Ensure that no combustible mate-
rials are left in the generator compartment, or on or near the generator, as FIRE or EXPLOSION may result.
Keep the area surrounding the generator clean and free of debris.
•All types of fuels are potentially FLAMMABLE and/or EXPLOSIVE and must be handled with care. Inspect the
fuel system frequently and correct any leaks immediately. Be sure fuel supply lines are properly installed, purged,
and leak tested before placing the generator set into service.
1.7 — Standards Index
Be sure the transfer switch is in strict compliance with all applicable local, state, and federal laws, codes, and regula-
tions pertaining to such installations. Always use the current version or edition of the applicable law, code, and regula-
tion as it applies to the local jurisdiction.

Installation
4Transfer Switch Installation Guidelines
Section 2 Installation
2.1 — What is Included in this Carton:
• Manual Transfer Switch with wire harness, conduit, fittings and wire connectors (10 or 12)
• Wire Harness, pre-assembled
• 30 amp or 50 amp Aluminum Power Inlet Box (Models 6295-6296 only)
• 10 Foot Power Cord (Models 6295-6296 only)
• Flanged Inlet (inside models 6378 and 6380 only)
• Installation Manual and Warranty Registration card
2.2 — Tools and Items Needed for Installation:
• 5/16” nut driver, 2-1/8” hole saw (if flush mounting)
• Screwdrivers, straight blade and Phillips
• Electric drill, drill bits, wallboard saw
• Wire cutter/stripper
• Safety eye goggles
• Anchors and screws to mount transfer switch to wall/wallboard
• New, 2-pole 60 Amp or 100 Amp, 240V circuit breaker to install in main load center – same manufacturer as existing load center
• Insulated building wire (4-wire, also known as 3-wire plus ground) and conduit to connect between power inlet box and transfer switch
Compatible Circuit Breakers:
Siemens/Murray QT, QPH, HQP, QPF (GFCI), QPHF, QFP, QE, QEH, QAF (Arc Fault), QP (Surge Protector)
Cutler-Hammer Series BD, BR, BQ, GFC
Challenger Type A, C, HAGF
Square D Series HOM (Homeline)
GE Series THQL
2.3 — Optional Items for Installation:
• Arc-fault, GFCI or Surge protection circuit breakers. If Arc-fault, GFCI or Surge protection circuit breakers are used as the branch circuit pro-
tector in the main load center, they MUST be used in the manual transfer switch. You may be able to re-use your existing AFCI, GFCI and
Surge protection circuit breakers in the manual transfer switch. See list of compatible breakers.
• Wire, fittings and conduit to connect the Power Inlet Box to the transfer switch.
• White, green, black and red THHN or MTW wire, 10 AWG, 300V rated (if breaker configuration is modified or expanded.
• Switched Neutral Kit (Model 6297). If your portable generator has the neutral bonded to the frame of the generator AND 240V “full-power”
receptacle is GFCI protected, you will need to install this accessory with your transfer switch to avoid nuisance tripping of the GFCI breaker
on the generator.
NOTE: ON NEUTRAL BONDED GENERATORS: Some portable generators are intended for use on jobsites, and therefore are subject to
OSHA regulations for GFCI protection on all receptacles. These "contractor grade" generators have their neutral wire bonded to the
ground wire to pass OSHA inspection on job sites, and when connected to a transfer switch, this may cause nuisance tripping of the
generator GFCI breaker. If you’re using a neutral bonded generator to power a house or building through a transfer switch, then deter-
mine if the neutral bond wire on the generator can be disabled without voiding the warranty, preferably by a dealer or a qualified elec-
trician. NOTE: After this action, the generator will no longer pass OSHA inspection on job sites. Consult the manufacturer of your
generator to determine if the neutral bond can be removed. If it can be disabled, then no modifications to your transfer switch installa-
tion are needed. If the neutral bond cannot be disabled or voids the generator warranty, you must install a Switched Neutral Kit (SNK)
accessory with your transfer switch.

Installation
Transfer Switch Installation Guidelines 5
NOTE: If Ground Fault Circuit Interrupters (GFCI), Arc Fault Circuit Interrupters (AFCI), or Surge Protector Circuit Breakers were used
as the branch circuit protector in the main load center, they MUST be used in the transfer switch. GFCI and AFCI breakers require an
isolated neutral connected from the load to the GFCI or AFCI. The load neutral needs to be connected with a wire nut to a 3-6 foot piece
of white wire, run through the harness conduit to the transfer switch and connected to the “load neutral” lug or pigtail on the GFCI or
ACFI breaker. Because GFCI and AFCI circuit breakers can take up more than one space, the overall maximum number of circuits may
be reduced from the number shown. Not all brands of GFCI and Arc Fault breakers will fit.
2.5 — Planning Your Installation
1. Determine the appliances, circuits or equipment you want to operate with generator power during a power out-
age, such as:
2. Determine the amps required for each appliance by reading the label on the appliance. IMPORTANT: No appli-
ance should have an amperage rating that exceeds the GEN MAIN breaker rating in the transfer switch (See
Table 1). The total amperage of all circuits can exceed the generator rating, but not all circuits will be able to be
used concurrently.
3. Assign the circuit # in the load center to a circuit (A2, B2, etc.) in the transfer switch matching the size of the cir-
cuit breaker in the load center to the circuit breaker in the transfer switch. Once you’ve determined which cir-
cuits you want to connect and the appropriate amperage, you will be ready to begin installing your transfer
switch.
4. The location of your load center/electrical panel in your home or business will determine where the transfer
switch will be installed. Refer to Figure 1. In addition to the transfer switch, this kit includes a generator cord
and power inlet box. You will use the generator cord to connect your generator to the power inlet box outdoors.
Whether your load center is in a basement, interior room or garage, we recommend installing power inlet box
on the exterior of your house or building to avoid running generator cord through a door or window.
5. Determine where you will install the power inlet box on an exterior wall at least 5 feet from any openings
(doors, windows, vents, etc.). See Figure 1.
2.4 — Specifications
Model 6295 or 6378 6296 or 6380
# Circuits Provided on Transfer Switch 10 12
Maximum # Circuits 16 16
REQUIRED BREAKER FOR MAIN LOAD CENTER
(not included)
60 amp 2-pole 100 amp 2-pole
Utility Main Breaker 60 amp 2-pole 100 amp 2-pole
Generator Main Breaker 30 amp 2-pole 60 amp 2-pole
Breakers Provided with Unit 3 – 15 amp 1-pole
3 – 20 amp 1-pole
1 – 20 amp 2-pole
1 – 30 amp 2-pole
3 – 15 amp 1-pole
3 – 20 amp 1-pole
1 – 20 amp 2-pole
1 – 30 amp 2-pole
1 – 50 amp 2-pole
Maximum Generator Watts 7500 continuous / 9000 surge 12500 continuous / 18000 surge
Maximum Generator Amps 30 Amps 60 amps
Voltage 125/250 Volts 125/250 Volts
NEMA Type Enclosure 1 – Indoor Only 1 – Indoor Only
NEMA Configuration of Male Inlet in Power Inlet Box NEMA L14-30 CS-6365
Phase 11
Minimum Gauge Cord Size 10/4 AWG 6/4 AWG
❑Refrigerator/Freezer ❑Water Heater ❑Security System
❑Furnace Blower (gas/oil only) ❑Garage Door Opener ❑Sump Pump
❑TV / Radio ❑Microwave, Coffee Maker ❑Computer, Fax and Printer, Phone
❑Lighting ❑Well Pump ❑Aquarium

Installation
6Transfer Switch Installation Guidelines
Figure 1: TYPICAL INSTALLATION
2.6 — Installation Procedure
PLEASE READ THIS MANUAL IN ITS ENTIRETY BEFORE ATTEMPTING TO UNPACK, ASSEMBLE, INSTALL,
OPERATE OR MAINTAIN THIS EQUIPMENT. HAZARDOUS VOLTAGES ARE PRESENT INSIDE TRANSFER SWITCH
ENCLOSURES THAT CAN CAUSE DEATH OR SEVERE PERSONAL INJURY. FOLLOW PROPER INSTALLATION,
OPERATION AND MAINTENANCE PROCEDURES TO AVOID HAZARDOUS VOLTAGES.
Table 1: CIRCUIT WORKSHEET
Circuit 6295 or 6378 6296 or 6380 Appliance(s) or Circuits
A1 NA 50A
B1 NA 50A
A2 30A 30A
B2 30A 30A
A3 NA 20A
B3 NA 20A
A4 15A 20A
B4 20A 15A
A5 15A 20A
B5 20A 20A
A6 20A 15A
B6 15A 15A
A7 20A NA
B7 20A NA
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