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How to wire transfer switch |
| Use only 600 volt wire. Lamp cord, extension cords are not rated 600 volt. Use copper wire only. Aluminum wire is fire risk and should be avoided or installed by professional. 30 amp breaker use 10 gauge / 120-240 volt 30 amp outlet can be installed on 30 amp breaker only/ use 10 gauge wire ... cannot be connected to 15-20-40 amp breaker.  Orange/ #10 gauge wire, with ground ... 30 amp capacity. Safe maximum: 30 x 80% = 24 amps. Buy: 10-2 gauge/ 30 amp 10-3/ 30 amp Southwire electric tools |
Yellow
12 gauge 20 amp 120 volt 20 amp outlet can be installed on 20 amp breaker, but not 15 amp breaker/ use 12 ga wire. ... cannot be connected to 30-40 amp breaker. 1  Yellow/ #12 gauge wire, with ground ... 20 amp capacity. Safe maximum 16 amps. Buy: 12-2 gauge/ 20 amp 12-3/ 20 amp NMB is house wiring UF is underground Rolls of stranded wire HOOK UP Wires |
White
14 gauge 15 amp 120 volt 15 amp outlet, AFCI, GFCI, timer, switch etc can be installed on 15 or 20 amp breaker. Never connect 15 gauge wire to 20-30-40 amp breaker.  White/ #14 gauge wire, with ground ... 15 amp capacity. Safe maximum 12 amps. Buy: 14-2 gauge/ 15 amp 14-3/ 15 amp NMB is house wiring UF is underground |
| 50-60
amp breaker use 6 gauge / 240 volt 50 outlet can be installed on 50 amp breaker only  Buy: 6-2 wire Southwire electric tools NMB is house wiring UF is underground |
40-50
amp breaker use 8 gauge / 240 volt 40 amp outlet can be installed on 40 or 50 amp breaker only  Buy: 8-2 wire Southwire electric tools NMB is house wiring UF is underground |
  Copper ground wire. Every device, load, metal enclosure etc must be grounded. Ground wire must be continuous throughout installation, never switched on-off, never used as a Neutral wire. Generally ... use same size as other wire in circuit Buy: 12 gauge copper ground wire Ground wire Green ground wire Ground pigtails Ground rods/ ground clamps at Amazon |
 Non metallic flexible cables must carry ground wire, but do not have hazard of short circuit causing injury from shock. Armored steel cable can be used as a grounded connection, and will protect wires from damage. Metal can be energized from an insulation failure. All conduit ...metal, plastic ... flexible and rigid ... must be attached to structure, and attached to enclosures, boxes. Movement, damage and deterioration are major cause of electrical failure. Buy: Non-metallic flexible conduit Power whip Armored cable Southwire armored cable cutter Pull boxes |
 Electrical tools must be insulated. Always best to disconnect power, but insulation failure, lack of proper grounding, grounded neutral, lack of GFCI, out-of-code wiring, generator operating without transfer switch, and other problems still pose a risk to anyone working on electric power ... even when breaker is off. Buy: Electrician tools kits KLEIN TOOLS Tools kits IRWIN tools KNIPEX Telephone cable knife Low Voltage Mounting Bracket for Telephone |
Push-on wire connectors in place of twist-on connectorsBuy:Push on wire connectors Amazon Red 3P connector for 10-14 gauge wire Lever connectors for stranded wire at Amazon HOOK UP Wires |
 Protect wiring from damage Use nipper instead of pliers or screwdriver for removing staples (and nails). Do not damage cable or wires inside cable. -Code says: Cable SHALL BE secured without damage to the outer covering. NEC sec. 336-15 Buy End cutting nippers at Amazon |
  Electrically insulated tools When removing insulation from wire, do NOT score or put cuts on surface of copper wire. Doing so increases resistance and heat on wire and creates possible weak point. Buy tools: KLEIN TOOLS Wire strippers at Amazon Electric Wire Stripping Machine Linesman pliers Utility knife at Amazon |
 Multimeters Voltage is tested across two separate wires. Ohms or resistance is tested across both ends of same wire. Amperage is tested along one or two points on same wire. Buy: Analog multimeter Multimeters at Amazon Klein multimeter Electric testers at Amazon Clampmeter for testing amp flow on line |
 GFCI circuit breaker A GFCI circuit breaker will protect all boxes on circuit. Circuit must be grounded. Ground wire must be continuous and connected to each piece of equipment. White wire on circuit breaker must be connected to Neutral busbar inside the breaker panel. Buy GFCI circuit breakers |
Push down 1" wide Push down breaker Plug-in breaker Buy single-pole: Choose from 15 to 60 amp Eaton CL series Siemens 15-60 amp Single-pole tandem breaker Tandem breakers |
Push down 2" wide Push down breaker Plug-in breakers Buy double-pole: Choose from 15 to 125 amp Choose from 15 amp to 200 amp Eaton CL series circuit breaker Siemens circuit breaker Double pole GFCI |
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30 amp Transfer
switch Safe maximum of 30 amp service is 24 amps. The single breakers in this transfer switch are 15 amp, with 14 gauge wire... DO NOT use 15 amp for a 20 amp circuit in the main breaker panel, unless wires are changed to 12 gauge.. The double breaker in this transfer switch is 20 amp. Maximum wire size that is supplied with this transfer switch is 12 gauge ... both these are too small for residential water heater unless you a) replace transfer switch wire and breaker to 30 amp and 10 gauge or b) Replace water heater elements with 3500 watt and change main service panel breaker to 20 amp. Why you need transfer switch Purpose is to switch power OFF on specific breakers when you connect generator to household breaker panel.. When power goes out on the grid, any electricity that you generate can go backwards to the power company transformer and be converted to high voltage on the distribution wires. The existance of electricity of these wires is a danger to anyone coming into contact with the line, including linemen trying to do repairs. The situation slows repair and increase cost. As a result, a transfer switch is required to shut off home-generated power from reaching the main breaker panel and then out to the grid wires. Same requirement is true for home-generated solar power: it must be connected to equipment that automatically disconnects grid connection when grid power is OFF. When you need transfer switch Whenever you connect generator to any wire that is connected to main breaker panel. You can run a generator and plug in tools etc without a transfer switch. Buy Transfer switch at Amazon Resources: Reliance 31406CRK manual/pdf |
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50 amp Transfer
switch Safe maximum of 50 amp service is 48 amps. This product is supplied with a combination of 15- and 20-amp circuit breakers. Maximum two 30 amp double-pole breakers can be installed in the A and B positions.  To remove a circuit breaker, remove the circuit breaker compartment cover, unscrew the terminal screw in the breaker to be removed, removed the wire, tilt the top of the circuit breaker towards you and lift up and out. Reverse the procedure to install another breaker. In addition, positions A and B (but only these positions) will accommodate 30-amp circuit breakers. Buy 510 series 50 amp 10 circuit 12500 max 5 double breakers 1" conduit 12 gauge wires supplied 514 series 50 amp 10 circuit 12500 watt Buy double-pole breaker: Choose from 15 to 125 amp Resources: Reliance 510 manual/pdf |
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You
can run a generator and
plug in tools etc without a transfer switch as long as home-generated
power is not connected to any household wiring 120 and 240 volt generators are used for homes and construction businesses etc Check the total wattage output, portability vs need If you are connecting the power to main breaker panel, you MUST turn off main breaker and disconnect from power company service ... or use a transfer switch. Buy Generators at Amazon Resources How to wire 240 volt outlets |
| SAFETY:
Portable generators release more carbon monoxide—which is
particularly dangerous because it is odorless and invisible—than most
cars.... the fumes will get into house from garage Symptoms: First symptom of CO carbon monoxide poisoning is lethargy and headaches that disappear when you leave the house. Prolonged exposure can kill whole family. Call plumber immediately to check vent, clean burner and combustion chamber, check gas pressure, and What to do in event of CO poisioning: 1) Move affected people to fresh air. Lay on side... not on back or they will suffocate 2) Call for medical help. 3) Open windows and doors. 4) Call plumber to test and repair vents. 5) Install CO detector. 6) Maintain water heater once per year as shown in product manual Buy: Carbon monoxide detectors at Amazon |
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 Twist-lock plug will not pull out of receptacle |
Twist
lock plug for extension cord that plugs into generator Install 20 or 30 amp as needed. X Y terminals go to either Hot wire. W is always Neutral. G is always ground. These are standard markings for 240 volt plugs and outlets. Connect X to one hot busbar inside the transfer switch, connect Y to other hot busbar, ground and Neutral to respective terminals Buy: Leviton 2711/ 125-250 volt/ 20-30 amp/ 3 pole Resources How to wire subpanel How to wire 240 volt outlets, plugs, switches Difference between single-phase and 3-phase |
| Image below shows main
breaker panel without transfer switch In a time of power outage, it is very important that generators are not sending power to the main panel, because that power will travel backwards out the main breaker and re-energize the distribution lines that enter house. If the main distribution lines are still energized, that can be dangerous and slow the rate of repairs. |
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| Image below shows Transfer switch
installed When generator is OFF, the transfer switch breaker is pushed one direction. Power leaves from the main breaker panel, travels through the transfer switch breaker, and then goes to 120-240V load. When generator is ON, the transfer switch breaker is pushed the other direction. Power leaves the main panel breaker and travels to the transfer switch breaker .... but cannot go farther, so the transfer switch effectively turns off any power that could come from breaker, and turns off any chance of generator energizing the breaker panel and power company wires. When generator is ON power from the generator leaves the transfer switch breaker and travels to the load. Each main panel breaker that is wired into the transfer switch will operate the same. The transfer switch only designated loads that are connected as illustrated below. |
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| Image
below shows how to toggle
water heater from 240 volt to 120 volt Works any time, not just when the generator is on. If your transfer switch does not have 30 amp breaker it is a problem UNLESS you change elements to 3500 watt, in which case water heater will work fine with 20 amp. The math: Volts x amps = watts. 4500 watt element divided by 240 volt = 18.75 amp So technically a 20 amp breaker is sufficient for 4500 watt water heater, except when applying the 80% safe maximum used to calculate loads today. 20 amp breaker x 80% = 16 amp maximum ...; which means 20 amp breaker is undersized slightly. 30-amp 3-way switch (SPDT switch) can be added to the circuit so you can toggle 240 volt water heater to 120 volt. Works for ordinary residential water heater, but not heaters with electronic circuit board, electronic thermostat, This means the diagram will not work for tankless, heat pump, energy smart etc. Reducing to 120 volt reduces heat time by a factor of 4, so typical tank will heat 4+ gallons per hour at 120 volt .... gives you some hot water and more generator capacity to run lights, water well pump, grandpa's oxygen machine etc. Adding a 30 amp SPST switch to either wire going to water heater will let you turn off heater completely. Caution: You can toggle any time when generator is running as long as generator loads are relatively balanced. Balanced load: a residential generator produces two out-of-phase 120 volt legs, with 240V potential across both legs. If you draw too much power off one leg, it causes disturbance in the magnetic field around the generator, and alters the waveform of electricity ... which can affect electronic devices inside house, and overheat generator. All 240 volt loads are automatically balanced because they draw from both legs, but imbalance occurs when pulling power off 1 leg. If you want to use the 120 volt strategy, set up your balanced generator loads to accommodate the change, usually within a range of 80% watt rating of generator. Buy SPST: Leviton 3032 30 amp switch at Amazon Leviton 30 amp switch at Amazon 30 amp switches at Amazon |
 3-way switch wiring |
DPDT switch wiring |
| Image below shows best way to
toggle
water heater from 240 volt to 120 volt Works any time, not just when the generator is on. If your transfer switch does not have 30 amp breakers it is no problem if you're connecting 120 volt, but IS a slight problem for 240 volt ... UNLESS you change elements to 3500 watt, in which case water heater will work fine with 20 amp. The math: Volts x amps = watts. 4500 watt element divided by 240 volt = 18.75 amp So technically a 20 amp breaker is sufficient for 4500 watt water heater, except when applying the 80% safe maximum used to calculate loads today. 20 amp breaker x 80% = 16 amp maximum ...; which means 20 amp breaker is undersized slightly. 30-amp DPDT 3-way switch with center off solves all the problems with imbalance, toggling between voltages, and turning off heater entirely. Bang done right. But this design takes more breaker spaces in the transfer switch and requires dedicated 30 amp breaker in the main panel. Works for ordinary residential water heater, but not heaters with electronic circuit board, electronic thermostat. This means the diagram will not work for tankless, heat pump, energy smart etc. Buy double-pole double throw 30 amp 2 DPDT switch with center off 2 DPDT switch with center off Resources: 30 amp switch controls water heater How to change 240V water heater to 120V Figure volts amps watts How to wire 240 volt outlets Generators What is 3-phase |
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 For certainty, always Test switch terminals using continuity tester before wiring. 24 amp safe maximum |
Toggle
water heater between 120Volt and 240Volt 30 amp 2 pole DPDT switch with center off Use diagram that comes with device. Diagram shown might be different from your switch. Check terminals for continuity using multimeter. 120 volt Hot and Neutral connect to A1 A2 in either order, or you can connect to B1 B2. Water heater must be connected to L1 L2 Max 4500 watt non-simultaneous water heater Use 240Volt when electric prices are lower, and faster recovery is needed. Use 120Volt during peak prices when less hot water is used Buy 2 DPDT switch with center off Buy Multimeter Connect 120Volt wires as Hot and Neutral. Black connects to 120Volt circuit breaker and White connects to neutral busbar. Connect 240Volt wires as Hot1 and Hot2. Both wires connect to 240Volt breaker.  Buy DPDT 30 amp switch w center off 2 DPDT switch with center off at Amazon 2 DPDT switch with center off at Amazon |
| 30 amp switches | 30 amp double-pole | 30 amp DPDT | Ordinary 15-20 amp switches | 15 amp pilot light switch |
 Single-pole/ 2-pole on-off switches Buy: 30 amp 2-pole switch 30 amp industrial grade |
 Heavy duty double-pole switches to turn off both hot wires in 240 volt circuit Buy: 30 amp motor switch 40 amp motor switch |
Buy: 30 amp DPDT switch Resource: Use this switch to toggle water heater between 120-240 volt |
 Ordinary 15-20 amp toggle switch Buy: 15 amp switch 20 amp switch |
 Indicator light shows when Load is ON Buy: Pilot light switch Resource: How to wire pilot light switch |
| Risk
to motors and HVAC from generator Generator can cause low voltage and phase fluctuations. The problem of low voltage and phase fluctuation (lower voltage on one wire and not the other) do not affect resistance loads like light bubs or electric water heater, except to make them burn at dimmer capacity. However low voltage and phase fluctuations do affect inductive loads like contactors, relays, motors, pumps, HVAC causing problems such as chatter on contactors and relays, and lower rotation speed on motor, causing higher temperatures, and burning out the motor or shortening motor lifespan. |
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 Larger image |
IMC492 Single-phase Voltage
monitor Household power 120-240 volt is single phase. Voltage monitor Protect motors and equipment from low voltage. Adjustable voltage range Caution: select monitor voltage to match incoming Line voltage Select amp rating of contactor to match amp rating of Load (motor, pump etc) Select matching contactor voltage and coil voltage range Undervoltage on contactor coil will cause chattering and malfunction, Overvoltage on coil will melt coil. Buy: Single phase 95-270 volt range 3-phase 80-300 volt range ICM phase monitor Siemens monitoring relay Resources: Fuseholders Contactors Surge protector Difference between surge and ground Difference between single phase and 3-phase IMC492 manual Siemens .pdf |
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Locking plugs/ twist lock Nema L5 (look at bottom of graphic for Nema category) is same configuration for 20P or 30P/ use for 15, 20 or 30 amp Nema L6 is same configuration for 20P or 30 P/ use for 15, 20, 30 amp Nema L14, 4-pole is same configuration for 20P or 30P/ use for 20 or 30 amp 125 volt 3-wire has silver, brass and green screws 250 volt 3-wire has brass, brass, and green screws Buy: Leviton 2611/ 125 volt/ 15-20-30 amp/ 3-pole Leviton 2621/ 250 volt/ 20-30 amp/ 3-pole Leviton 2711/ 125-250 volt/ 20-30 amp/ 3 pole Resources: Locking plug Wiring diagrams |
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 Image: Bill R |
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Resources How to wire 240 volt outlets |
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Water
heater can be controlled directly with 30 Amp switch.
Use green color-coded 30 Amp switch and & 10 gauge wire. Buy 30 amp switches: 30 amp switches 30 amp single pole switch 30 amp double pole switch 30 amp 3-way switch 30 amp switches at Amazon Resource: Control 240 volt with switch |
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Toggle
water heater between 120 volts and 240
volts Use DPDT 30 amp with center off Ordinary 30 amp 3-way switch will do same job, but without center off Slower heating during peak electric pricing can save money where hot water is still needed during peak pricing. Buy double-pole double throw 30 amp 2 DPDT switch with center off at Amazon 2 DPDT switch with center off at Amazon Resources: How to convert water heater to 120Volts See wiring diagram See off-peak water heater options |
 Elements |
 Contactors/ relays |
 Z-wave/ wifi |
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Buy Electronic parts Industrial supplies Tools and home improvement Home and garden Hayward pool Pentair pool Southwire electric |
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Buy
Tools DEWALT Black and Decker Stanley SKIL Makita Porter-Cable Bosch Irwin Hand tools Klein hand tools Fluke electrical testing Dremel hobby tools Campbell Hausfeld air powered Tekton automotive Powerbuilt automotive Saws and saw blades |
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Resource: Compare box timers DPDT timers Intermatic Control water heater w/ Z-wave |
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Resource: Intermatic control centers: and parts Digital control centers and parts Tork control centers and parts Subpanels All control centers and parts Enclosures |
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Resource: Programmable timers Countdown timers Off delay timers On delay timers Timer modules Din rail Twin & one-shot Woods Intermatic Tork |
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Recirculation systems |
 | Buy
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