Reliance Controls Transfer Switch: Installation and Operating Instructions – Part II

In the last issue we have talked in details about the Reliance Controls transfer switch and its importance in power backup system (Part I). In this part we will discuss the installation and operating instructions of Reliance Controls Transfer Kit Model 3006 HDK in details using illustrated figures and videos.     

INSTALLATION INSTRUCTIONS

A.  Mounting the Transfer Switch

1.  Position the transfer switch so that its bottom center is about 18 inches from the bottom center of your load center. The end of the flexible conduit whip should be lined up with a 3/4" knockout hole on the bottom of your load center (Figure 1).

Figure 1

2.  Mark the position of the holes on the four external feet with a pencil.

3.   Anchor the transfer switch to the wall with four appropriate anchors (with a flange of at least 3/8").

NOTE: Do not attempt to bend the flexible conduit whip beyond its structural capabilities.

B.  Connecting the Flexible Conduit Whip to Your Load Center

1. Set up battery-powered lighting to clearly illuminate your work area.

2.   Turn off the main utility breaker (Figure 2).

Figure 2

3.   Remove the cover of your load center. Keep in mind that the wires on the utility side of the main breaker are still live and if contacted could cause serious injury or death. If available, use a non-contact voltage detector to insure that the power is off on the non-utility side of the main breaker.

4.  Remove the appropriate knockout hole in the bottom of your load center with a screwdriver and hammer. (See step A-1 above.)

5.   Insert all of the wires extending from the end of the flexible conduit whip through the knockout hole. Snap the conduit connector attached to the whip into the knockout hole.

C.  Connecting the Neutral and Ground Wire

1.   Find the white wire (Neutral) and the green wire (ground) among the wires from the transfer switch that you have inserted into the load center.

2.  Strip approximately 5/8” from the end of the white wire. Locate the neutral bar and partially unscrew a terminal screw on the bar. Insert the stripped end of the wire into the side of the bar under the screw and retighten the screw. (Figure 3)

3. Locate the ground bar. (It should be labeled.) Connect the green wire to the ground bar in the same way as in step #2. In service entrance load centers, the ground bar and neutral bar are frequently the same; if so, the ground and neutral wires can be connected to either.

Figure 3

D.  Installing 120 Volt Circuits

This section provides instructions for connecting the wires from your transfer switch to the circuit breakers in your load center which control your appliances.

You should refer to the load planning you did previously to insure that side #1 and side #2 of the transfer switch are balanced. Wire the circuits, starting with toggle Switch A. If a selected circuit is part of a multi-wire branch circuit, insure the other branch circuit that shares the neutral is also connected to the transfer switch. The two circuits must be connected to opposing legs (phases) of the generator power and a handle tie must be installed on the switch handles so that both legs are transferred at the same time.

If you will not be installing any 240 Volt or multi-wire circuits, remove the factory-installed handle tie(s) on the unit by loosening the setscrews on the tie. Let's assume that, according to your load balancing plan, you will use Switch A to supply power to the refrigerator. (Figure 4)

Figure 4

1.Turn off the refrigerator circuit breaker. Disconnect the wire that is attached to the circuit breaker.

2.   Find the black and red wires from the transfer switch marked A.

3.   Cut the red wire at a length convenient for it to reach to the refrigerator circuit breaker. Strip 5/8” from the end of the wire. Connect the red wire to the refrigerator circuit breaker and retighten the screw on the breaker.

4.   Cut the black wire from the transfer switch to a length convenient for attaching it to the wire you removed from the refrigerator circuit breaker in #1. Strip 5/8” from the end of the wire.

5. Insert both wires—the one removed from the refrigerator circuit breaker and the black wire for Switch A—into a yellow wire connecter. Tighten the connection and push the connected wires back into the wiring compartment of the load center.

This completes the connection of Switch A for your refrigerator. Label Switch A as “REFRIGERATOR” on the identification pad on top of the transfer switch.

6. Repeat Steps 1 through 5 for each of the remaining switches on your transfer switch according to your load balancing plan, taking into account the following:

•   See the next section for installing 240-Volt Circuits

•  Remember to “Balance the Load”, dividing appliances with higher wattages between the left and right side of the transfer switch

E.  Installing 240 Volt Circuits

Reliance Controls 6-Circuit Transfer switch (In Kit) is shipped from the factory with one installed handle tie on two adjacent circuits.

Let’s assume that, according to your set-up plan, Switches C & D on the 6-Circuit transfer switch will be used to supply power to your well pump, a 240 Volt appliance. (Figure 5)

1.   Find the two red and the two black wires marked C & D.

2. Turn off the double pole breaker for the well pump in the load center.

Figure 5

3. Disconnect the two installed wires on the double pole breaker.

4.   Cut the two red wires from Switches C & D at a length convenient for them to reach to the double pole breaker. Strip 5/8” from the end of each red wire. Connect both red wires to the double pole circuit breaker in place of the wires you just removed from that breaker. It doesn’t matter in what order.

5.  Cut the black wires marked C & D to a length convenient to reach to the wires you removed from the double pole breaker in #3. Strip 5/8” from the end of each wire.

6.   Connect one of the wires you removed from the double pole breaker in #3 with one of the black wires (either C or D) with a yellow wire connector. Similarly, connect the other wire you removed with the remaining black wire with a wire connector.

F.Completing the Installation of the Transfer Switch

When you have wired all of the circuits from the transfer switch into your load center and have properly installed the green and white wires to ground the unit, you have finished the installation. (Figure 6) Just a few more steps to wrap things up.

Figure 6

1.   Replace the cover of the load center.

2.   If you have not already done so, fill in the chart on the top of the transfer switch to identify your emergency circuits and the toggle switches they correspond to.

3. Do not turn the main and individual circuit breakers in your load center back on until you have installed all other transfer switch components in Sections G, H and I which follow.

G.  Installing and Wiring the Outdoor Power Inlet Box (included in kit)

Since you will be operating your generator outdoors in a location remote from your electrical load center, it is recommended that you install an outdoor power inlet box on an exterior wall of your house.

Because it is hardwired directly to your transfer switch, the power inlet box gives you the flexibility to locate your generator just about anywhere outside away from a door or a window.

Reliance Controls Power Inlet Boxes are UL listed and can be used with the following generator and building wire sizes:

To install a Reliance Power Inlet Box (Figure 7):

1.   Loosen the screw at the bottom front of the box and lift off the cover.

2.   Choose which knockout hole on the box is most convenient to where you will be running the building wire into your house. Remove the knockout with a screwdriver and hammer.

Figure 7

3. Plan to run enough building wire (check electrical codes for the need for conduit) to reach your transfer switch, allowing extra length for ease of wiring at the transfer switch end.

4.   Using approved wiring methods, place a cable or conduit connector (check codes) in the inlet box knockout hole and run enough building wire into the box to allow easy wiring. Tighten the connector.

5. Mount the back plate of the power inlet box where it will be convenient. Use the three holes in the plate.

6.   Strip 5/8” from each building wire lead. Loosen the green grounding screw on the inside of the box and insert the stripped end of the building wire ground under one side of the grounding screw and retighten.

7.   On the bottom of the inlet plug, insert the white wire into the hole marked “W” and tighten the screw on the side of the plug. Do the same with the red wire into the hole marked “X” and the black wire into the hole marked “Y”.

8.   Replace the cover of the power inlet box and tighten the screw.

H.Wiring the Power Inlet Box to the Transfer Switch

All Reliance Controls transfer switches are designed to allow hardwiring between the outdoor power inlet box and the transfer switch’s internal wiring compartment. This installation is the most efficient, eliminates the need for longer generator power cords running through your home to your transfer switch and eliminates the need for an additional junction box. To hardwire your transfer switch to the building wire from the power inlet box (Figure 8A and 8B):

               Figure 8A                          Figure 8B

1. Remove the front bottom wiring compartment cover plate of the transfer switch by unscrewing the two screws securing the plate and then pulling out on the bottom of the plate. Once the plate is removed, the wire leads necessary to connect the incoming building wire can be easily accessed.

2.   Punch out the knockout hole on the side of the transfer switch wiring compartment.

3.   Using approved wiring methods, place a cable or conduit connector (check electrical codes) in the knockout hole, and pull enough building wire into the inside of the wiring compartment to provide sufficient working length. Tighten the connector.

4. Connecting the Wattmeters: Thread the black building wire through the transformer ring attached to the left wattmeter before connecting it to the black transfer switch wire. Likewise thread the red building wire through the transformer ring attached to the right wattmeter before connecting it to the red transfer switch wire. Connect the green to green and white to white wires with a red connector. Do not thread these wires through the transformer rings (Figure 8B).

5.   Complete the wiring by pushing the wires back into the unit, putting the wiring compartment cover back in place and replacing the screws that hold the cover plate.

I.Installing an Optional Power Inlet on your Transfer Switch (not necessary in kit installation)

Although such an installation is not necessary with the Power Transfer Kit, your Reliance Controls transfer switch is unique in that it allows the installation of an accessory power inlet which allows you to plug your generator directly into your transfer switch using a longer power cord. Use this option only if the transfer switch is installed outdoors where it is sheltered from the elements.

To install a power inlet on your transfer switch (Figures 9A-9C):

Figures 9

1.   Purchase Reliance Flanged Power Inlet model number L1420F for a 20 Amp inlet to accommodate 20 Amp power cords and small generators up to 5000 watts, or L1430F for a 30 Amp inlet to accommodate 30 Amp power cords and generators up to 30 Amp. If you choose to, you may also use the 30 Amp power Inlet from the Reliance PB30 Power Inlet Box (supplied with the kit).

2.   Remove the plastic Reliance logo panel located on the right side of the wiring compartment cover to reveal the hole for the power inlet. One screw holds this plate on the bottom.

3.   Remove the entire wiring compartment plate by removing the other bottom screw and pulling out on the bottom of the plate.

4.   If your transfer switch has wattmeters, make sure that the black wire from the transfer switch is threaded through the transformer ring connected to the left wattmeter, and the red wire from the transfer switch is threaded through the transformer ring connected to the right wattmeter.

5.   Insert the power inlet into the hole in the wiring compartment plate and fasten it with the two smaller screws included with the inlet. Do not refasten the longer bottom screw at this time.

6.   On the underside of the inlet, insert the white wire into the hole marked “W” and tighten the screw on the side of the plug. Do the same with the red wire into the hole marked “X”, the black wire into the hole marked “Y” and the green wire into the hole marked “G”.

7.   Replace the wiring compartment panel with the two screws you removed in steps #2 and #3, inserting the longer screw through the bottom of the flanged inlet plug.

J.   Finishing Up

According to your individual installation requirements, after you have completed all the steps necessary in Sections G through I, complete the system installation by doing the following:

1.  Turn on all of the circuit breakers in your load center.

2.   Turn on the main breaker.

3.   Position all switches on the transfer switch to the LINE position.

4. IMPORTANT! In order to insure that all wiring connections have been properly completed and that your system functions properly under generator power, it is important to test each circuit before turning on any devices or appliances connected to that circuit. Correct voltage output can and should be checked with a voltage meter at any convenient electrical outlet on each branch circuit that is wired through the transfer switch. This should be done under generator power with the appropriate circuit breaker switch in the “GEN” position.

OPERATING INSTRUCTIONS

You want your generator to be ready when you need it – so, it is important to perform the following steps once a month:

•   Start and run generator power through your transfer switch circuits.

•     Keep your fuel tank filled with fresh fuel.

With your Reliance Controls transfer switch installed, it is not necessary to turn off any of your load center breakers when starting your generator, even when utility power is fully functional. This is because the double throw break-before-make action of the transfer switch prevents feeding generator power to the utility and, conversely, prevents feeding utility power back to your generator.

A. Transferring from Utility Power to Generator  Power in an Emergency

1. Make sure that all switches on the Reliance Controls transfer switch are in the LINE position.

2.   Plug the male end of your power cord into the generator. NOTE: If your generator has only 20 Amp 125/250 V output receptacles, replace the 30 Amp male end of the power cord with the 20 Amp male plug end supplied in the kit. See installation instructions with the 20 Amp plug.

3. Plug the female end of your power cord into either the outdoor power inlet box or directly into the transfer switch, depending on how you installed your system.

4.   Start your generator outdoors and let it warm to a point where it is running evenly.

5. Turn the toggle switches on your Reliance transfer switch to the GEN position one at a time.

If you have a Reliance transfer switch with wattmeters, you can monitor the wattage load on your generator.

B.  Transferring back to Utility Power When the Power Is Restored

1. Move all switches on the Reliance Controls transfer switch back to the LINE position.

2.   Turn off your generator.

3.    Unplug your power cord and store it.