GENERAC
Portable Generator
™
Power Transfer System with Dual Load Manager
Owner’s Manual
CONTENTS:
Installation Instructions - - - - - - - - - - - -Page 1 through 12
Owner’s Operating Procedure - - - - - -Page 13 through 16
IMPORTANT
This product must be installed in compliance with local residential wiring and electrical codes by a
licensed electrician or qualified professional. Generac Portable Products is not responsible for
damaged equipment, accidents, or personal injury caused by incorrect installation.
Read this Safety Manual and Instructions BEFORE operating Power Transfer System.
DESCRIPTION
The Model 1403 Power Transfer System safely connects up to twelve essential household loads, such as the
furnace fan, freezer, refrigerator, water well pump, sump pump, lighting or outlet circuits to either the utility power
or a portable generator. In the event of a utility power failure, the homeowner can safely select devices to be
powered by an outdoor portable generator. Self-contained load meters assist the operator when managing power
loads. The power transfer system will not permit connection to both utility and generator power at the same time.
The Model 1403 Power Transfer System is easy for a licensed electrician or qualified professional to install, safe
for a homeowner to operate, and will work with 240 Volt AC generators factory equipped with a NEMA type
14-50R receptacle.
This manual contains important warnings and information. READ AND RETAIN FOR REFERENCE.
Model No. 1403-0 Power Transfer System Manual No. B4610 (Revision 2, 1/28/2000)
This symbol points out important safety instructions, which, if not followed, could endanger the personal safety and/or
property of yourself and others. Read and follow all instructions in the manual before attempting to operate this unit.
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Generac Portable Products Power Transfer System
Sum Loads from Data Plates
GENERAL SAFETY
INFORMATION
1. A licensed electrician or qualified professional
(referred to herein as “installer”) must install
the power transfer system per local code.
The installer inspects each desired device, notes
current consumption found on labels on each
appliance, then adds all loads on each circuit:
• The rated current of appliances and motors can
usually be found on a data plate or decal affixed to
the device.
2. During installation, the installer is required to
remove the cover from the building power
distribution panel (referred to herein as a ‘load
center’.) To reduce the risk of electrical shock, the
Main circuit breaker must be turned OFF while the
load center cover is removed.
• The rated wattage of lights can be taken from light
bulbs.
• Some electric motors, such as induction types,
require about three times more power for starting
than for running. This surge of power lasts for only a
few seconds when starting such motors. Be sure to
allow for this high starting load.
3. DO NOT OVERLOAD THE GENERATOR.
Overloading a generator in excess of its rated
wattage capacity will trip generator circuit
breakers.
Estimate Loads
The third method estimates total circuit loads based on
information given in Figure 1.
4. Always plug the connecting cord set into the
connection box and generator BEFORE starting
the generator. Always shut the generator down
before detaching the cord set.
Figure 1 — Load Reference Guide
APPLIANCE ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~LOAD DRAW
5. Portable generators attached to this Power
Transfer System must be operated outside, in
accordance with warnings and instructions found in
the generator’s Owner’s Manual.
Air Conditioner (12,000 BTU) ~ ~ ~ ~ ~(1700W) 7A@240V
Coffee Maker ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~(1000W) 8.4A@120V
*Electric Range (one element) ~ ~ ~(1500W) 6.3A@240V
Electric Blanket ~ ~ ~ ~ ~ ~ ~ ~ ~ ~(1500W) 12.5A@120V
Electric Skillet ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~(1250W) 10.5A@120V
*Freezer ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~(500W) 4.2A@120V
*Furnace Fan (1/3 HP) ~ ~ ~ ~ ~ ~ ~(1200W) 10A@120V
*Jet Pump ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~(800W) 3.4A@240V
Light Bulb ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~(100W) 0.9A@120V
Microwave Oven ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~(700W) 5.9A@120V
Oil Burner on Furnace ~ ~ ~ ~ ~ ~ ~ ~(300W) 2.5A@120V
Oil Fired Heater (30,000 BTU) ~ ~ ~ ~(150W) 1.3A@120V
Oil Fired Heater (85,000 BTU) ~ ~ ~ ~(225W) 1.9A@120V
Oil Fired Heater (140,000 BTU) ~ ~ ~(400W) 3.4A@120V
Radio ~ ~ ~ ~ ~ ~ ~ ~ ~ ~(50 to 200W) 0.5 to 1.7A@120V
*Refrigerator ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~(600W) 5A@120V
*Submersible Well Pump (1 HP) ~ ~(2000W) 8.4A@240V
Sump Pump ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~(600W) 5A@120V
PLAN THE INSTALLATION
The installer and the homeowner decide which circuits
are to be powered by the generator during a utility
power outage:
• The plan should ensure that no single circuit load
exceeds 15 Amps.
• The plan should also identify circuits that exceed the
15 Amp maximum.
• During generator operation, the homeowner should
use only necessary household items and to alternate
use of larger loads, such as water pump or electric
skillet. The installer will instruct the homeowner in
appropriate load management techniques.
Three methods of determining loads are given here:
Measure Actual Loads
Television ~ ~ ~ ~ ~ ~ ~ ~(200 to 500W) 1.7 to 4.2A@120V
* Allow 3 times the listed watts for starting these devices.
WATTS = AMPS x VOLTS
The installer uses a clamp-on ammeter to measure
each of the actual desired loads to ensure each total
circuit draws less than 15 Amps.
3
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hole, as shown in Figure 3. Secure the conduit
connector to the load center with the supplied lock
nut.
INSTALLATION
PROCEDURE
Load Manager™ Switch
Figure 3 — Wire Loom from Switch
Before removing the load center cover, plan mounting
location for both Load Manager™ switches. To do so,
hold a Load Manager™ switch about 18 inches from
the center of the load center, as shown in Figure 2.
Figure 2 — Planning Switch Location
NOTE: The following procedure describes the
installation of one Load Manager™ switch. Use
identical instructions to install and test the second
Load Manager™ switch.
5. Anchor the Load Manager™ switch to the wall at
the selected position, as shown in Figure 4.
1. Ensure there is enough room to mount both Load
Manager™ switches so their flex conduit attaches
directly to the load center.
Figure 4 — Anchoring Load Manager™ Switch
2. Identify appropriate vacant load center 3/4”
knockouts.
DANGER: Contact with wires and terminals
inside the load center must be avoided as
contact may result in dangerous electrical
shock. Before removing the load center cover,
switch OFF the main circuit breaker serving the
load center. Remember that wires on the line
side of the main circuit breaker are electrically
dangerous.
3. Turn OFF the load center’s main circuit breaker,
then remove the load center cover.
4. Remove the predetermined knockouts. Route all
wires extending from the flexible conduit attached
to a Load Manager™ switch through the empty
4
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6. From the load management plan, determine the
IMPORTANT:The installer should never cross the
black and red leads from the Load Manager™ switch.
Doing so will void the warranty and could cause
significant damage to Load Manager™ components
and the generator.
load that is to be connected to Load Manager™
switch circuit “A”. Turn that load center circuit
breaker to its “OFF” position. Loosen the screw
that retains the wire to this breaker, then detach
the wire. Figure 5 shows the selected load wire
detached from the circuit breaker.
Make Sure:
• The RED wire from the Load Manager™ switch is
always connected to the circuit breaker.
Figure 5 — Wire Detached From Breaker
• The BLACK wire from the Load Manager™ switch is
always connected to the wire going to the load.
DANGER! You must connect the Load
Manager™ switch wires as described or serious
damage to the equipment or yourself may result.
9. Select the load center circuit that will become load
management circuit “B”. Repeat Steps 6 through 8
for the red and black wires marked “B” coming
from the Load Manager™ switch.
Wire removed
10. If you wish to connect a 240 Volt AC two-pole
circuit, such as a well pump, proceed as follows:
a. Turn off the two-pole circuit breaker used for
the pump circuit and detach the load wires
from that breaker.
7. Find the black and red wires marked “A” that come
from the Load Manager™ switch. Using good
workmanship, route both of these wires near the
selected circuit breaker. Trim and strip the red “A”
wire and install it properly into the circuit breaker.
b. Select the four wires marked “C” and “D”
coming from the Load Manager™ switch
conduit and route them close to the selected
circuit breaker(s).
8. Trim and strip the black “A” wire to mate with the
wire previously detached from the breaker. Secure
the wire ends with a wire nut. Neatly dress the
wires into the load center, as shown in Figure 6.
c. Repeat Steps 6 through 8 for each pair of red
and black wires “C” and “D”.
d. A typical two-pole circuit connection is shown
in simplified form in Figure 7.
Figure 6 — Single-pole Connection
Figure 7 — Two-pole Connection
5
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11. If a two-pole circuit is not needed, the two-pole
b. Trim and strip the green wire and install it into
coupled switch can be converted into two single-
pole circuits. Simply remove and discard the
handle tie connecting load management circuits
“C” and “D”, as shown on the right in Figure 8.
the GROUND bar.
c. Remove protective backing from the “Attention
Decal”. Per National Electric Code, affix decal
to load center surface closest to the green wire
installed in (b.) above.
Figure 8 — Convert Two Pole to Single Pole
d. If no ground bar exists, install the GREEN wire
into an unused hole in the neutral bar. Affix
label as described in (c.).
e. Figure 10 shows a properly-connected GREEN
lead.
Figure 10 — GREEN Lead Installation
Handle Tie Installed
Handle Tie Removed
12. When steps 6 through 8 have been completed for
all desired circuits, install the WHITE (neutral) lead
coming from the Load Manager™ switch, as
follows:
a. Find an unused hole in the load center neutral
bar.
b. Trim and strip the white wire and install it into
the neutral bar.
c. Figure 9 shows a properly-connected WHITE
lead.
Figure 9 — WHITE Lead Installation
14. Install the second Load Manager™ switch,
repeating the instructions given in Steps 4 through
13 above.
15. After both Load Manager™ switches have been
installed, install the load center cover. Set all
switches on both Load Manager™ switches to the
“LINE” position. Turn ON the load center MAIN
breaker. All breakers in the load center connected
to Load Manager™ circuits should be switched on.
Load Manager™ switch installation is now
complete.
(Neutral)
13. Install the GREEN lead coming from the Load
Manager™ switch, as follows:
a. Find an unused hole in the load center
GROUND bar.
6
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Figure 11 — Typical Completed Power Transfer System Installation
Connection Box
Figure 12 — Junction Box Installation
The installer should use local codes and the following
procedure to install the generator connection box
provided with this system.
16. Locate and mount the connection box on an
outside wall as close as possible to the load
center. However, consider household air intake
ducting when when locating generator and
connection box. A typical power transfer system
complete installation is depicted in Figure 11.
17. As shown in Figure 12, mount a junction box at the
appropriate distance from the Load Manager™
switches so that both 1/2” flexible conduits can be
connected to it.
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18. Referring to Figure 13, remove the connection box
20. Pull four properly-sized insulated wires through the
conduit joining the junction box and the connection
box. Trim and strip each wire in the junction box.
Make secure connections using wire nuts.
Figure 14 shows wires from one of the two Load
Manager™ switches installed. When both switches
have been connected, install the junction box
cover.
inner panel. Mount the connection box at its
planned location on an outside wall.
Figure 13 — Connection Box Installation
Figure 14 — Junction Box Connections
19. Run appropriately sized conduit from the junction
box to the connection box. Anchor all boxes,
conduit, and fittings.
8
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21. As shown in Figure 15, trim, strip, and connect
Figure 16 — 50 Amp Cord Set Connector
each wire to the appropriate terminal on the
locking receptacle on the connection box inner
panel. Use the schematic affixed to the inside of
the connection box to make proper wire
connections. When all connections have been
made, install the connection box inner panel.
Figure 15 — Connection Box Connections
Identifying Circuits
A label, similar to that depicted in Figure 17, is
provided on each Load Manager™ switch cover. The
installer should fill in this information, describing the
appliance and the related circuit numbers in the load
control center.
Connecting Cord Set
22. Referring to the schematic in Figure 16 and the
markings on the connector itself, properly attach
the plug to the pigtail end of the connecting cord
set.
This completes the installation of the Generac Portable
Products Power Transfer System. The installer should
test the system, as described in the TESTING section,
and instruct the homeowner in proper routine testing
techniques.
Figure 17 — Circuit Identification Label
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INSTALLATION AND LOAD MANAGEMENT NOTES
10
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LOAD MANAGER™ SCHEMATIC DIAGRAM
11
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EXPLODED VIEW & PARTS LIST
Item Part No. Qty. Description
Item Part No. Qty. Description
1
20030
1
COMPLETE ENCLOSURE,
Front & Back
4
99151
1
ASSY., Circuit Breaker, 15
Amp
2
39271
1
5
6
B4603
B56832
2
METER, 30 Amp, 3600 Watt
398927
1
ASSY.,
BUSHING,
Anti
Short
Item Part No. Qty. Description
Item Part No. Qty. Description
1
2
B4608
97774
1
2
CORD SET, Connecting
SWITCH, Load Manager™
Connecting
4
5
B4626
B4612
1
1
DECAL, Attention
PLUG, Connecting
3B4609
1
BOX,
12
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Figure 19 — Connection Box Connection
OPERATING PROCEDURE
This manual section describes the routine procedures
used by the owner to operate the Power Transfer
system.
Each Load Manager™ switch is equipped with six
three-position switches. The switch positions labeled
“LINE” are used for connecting the desired devices to
the utility power source. The switch positions labeled
“OFF” are used for load management. The switch
positions labeled “GEN” are used for connecting
desired circuits to the generator power source.
Switch To Generator Power
To switch to generator power after a utility power
failure:
1. Ensure all Load Manager™ switches are in “LINE”
position, as shown in Figure 18.
Figure 18 — Switches in LINE Position
Figure 20 — Align Connector at Generator
2. Align the female socket of the connecting cord set
with the connection box receptacle’s mating male
prongs, as shown in Figure 19. Push cord set
connector in and twist clockwise to lock.
3. Align the male prongs on the other end of the cord
set with the mating female terminals of the
generator’s 50 Amp 240V receptacle, as shown in
Figure 20. Push connector fully into receptacle.
4. Ensure generator is outdoors and fuel is adequate.
5. Start the generator using instructions given in the
generator owner’s manual.
13
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6. At the Load Manager™ switches, move desired
1. Ensure that all Load Manager™ switches are at
“LINE” position (see Figure 18).
circuit switches from “LINE” position to “GEN”
position (as shown in Figure 21).
2. Connect the connection cord set to the house
connector box (see Figure 19).
Figure 21 — All Switches in GEN Position
3. Connect the other end of the connection cord set
to the generator (see Figure 20).
4. Start the generator.
5. At one of the Load Manager™ switches, set the
“A” switch to the “GEN” position, as shown in
Figure 22. Verify that the load attached to the “A”
circuit is operating properly. Return “A” switch to
“LINE” position.
Figure 22 — “A” Switch in GEN Position
Load Management
The number of circuits that can be operated
simultaneously during a utility failure will depend on the
wattage capacity of your generator. Most portable
generators do not have the capacity to handle loads on
all Load Manager™ switch circuits at the same time.
Review the load management plan developed with the
installer (see “Plan the Installation”). It may be
necessary to selectively turn on and off certain loads
while using generator power so that necessary
appliances can be operated safely.
6. Repeat Step 5, above, for each remaining load
management circuit on both switches.
The watt meters provided on the Load Manager™
monitor the current draw through each set of three
circuits (i.e.: circuits “A”, “B”, and “C” are monitored by
the lower left meter; circuits “D”, “E”, and “F” are
monitored by the lower right meter.) When switching
loads to the GEN position, watch the watt meter to
ensure that maximum current levels are not exceeded.
Circuit Breakers in Load Manager™
Switch
Individual Load Manager™ switch circuits “A” through
“F” are each protected by a 15 Amp circuit breaker.
These breakers are labeled “A, “B”, “C”, and so forth,
as seen in Figure 22, for example. If an electrical load
on one of these circuits exceeds 15 Amps, the Load
Manager™ switch circuit breaker will open.
Switch To Utility Power
To revert from generator power to utility power after
utility power is restored:
To reset a Load Manager™ switch breaker:
1, Eliminate the overload condition.
2. Place the switch with the tripped circuit breaker in
the “OFF” or middle position.
1. At the Load Manager™ switches, place all
switches in “LINE” position, as shown in Figure 18.
3. Press in the circuit breaker button and observe that
the button remains in.
2. Shut off the generator.
3. Disconnect the connecting cord set from the
generator and the connection box.
4. Place the switch that was in the OFF position back
to GEN (or LINE, if that is what is desired).
Testing
The load controlled by that Load Manager™ switch
circuit should now be operating properly.
Following installation and periodically thereafter, test
the power transfer system as follows:
If the circuit breaker does not reset, contact a licensed
electrician to repair the problem.
14
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TROUBLESHOOTING
Problem
Cause
1. Generator circuit breaker is
open.
Solution
1. Reset circuit breaker.
2. Poor connection or defective
cord set.
3. Connected device is bad.
2. Check and repair.
Generator is running, but no
AC output is available.
3. Select a different appliance or load
that is in good condition.
4. Fault in generator.
1. Short circuit in a connected
load.
2. Generator is overloaded.
1. Load management switches
in OFF or LINE positions.
2. Generator circuit breaker is
open.
4. Contact authorized service center.
1. Disconnect shorted electrical load.
Generator runs good but
bogs down when loads are
connected.
2. See “Load Management” on page 14.
1. Set Load Manager™ switches in GEN
position.
2. Reset circuit breaker.
All Load Manager™ switches
do not work when on
generator power.
3. Poor connection or defective
cord set.
3. Check and repair.
4. Connected device is bad.
4. Select a different appliance or load
that is in good condition.
5. Fault in generator.
5. Contact authorized service center.
1. Load management switch in
OFF or GEN position.
2. Load management switch
circuit breaker(s) is open.
1. Set switch to LINE position.
Appliances don’t work after
utility power comes back on.
2. Reset circuit breaker. See “Circuit
Breakers in Load Manager™ Switch”
section, page 14.
Load management switch circuit
breaker is open.
Reset circuit breaker. See “Circuit
Breakers in Load Manager™ Switch”
section, page 14.
Only some loads work on
generator power.
Connected loads on circuits
exceed 3600 watts.
Reduce loads on circuits.
Wattmeter overloaded.
15
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LIMITED WARRANTY
One Year Limited Warranty
Generac Portable Products (hereafter referred to as the COMPANY), warrants to the original purchaser that this
Power Transfer System will be free from defects in material and or workmanship for a period of one year from
date of original sale. To register Power Transfer System ownership, the Owner’s Registration card must be
completed and returned to the COMPANY by the installer (licensed electrician or qualified professional). Any
equipment that the buyer claims to be defective in material and or workmanship must be examined by a licensed
electrician or qualified professional who is familiar with local electrical codes. The COMPANY will, at its option,
repair and/or replace any part which is found by the COMPANY to be defective under normal use and service. All
transportation costs under this warranty, including return to the factory, are to be borne and prepaid by the
purchaser.
Warranty Schedule
Year One - 100% for all components (as listed in manual)
All warranty expense allowances are subject to the conditions as defined in the published COMPANY Policies
and Procedures Manual.
This Warranty Shall Not Apply To:
1. Power Transfer Systems NOT installed by a licensed electrician or qualified professional.
2. Cost of installation or start-up.
3. Travel expenses of individuals performing repairs.
4. Units used as demonstrators or rentals.
5. Failures due to (a) normal wear and tear, or (b) accident, misuse, abuse, negligence, or improper installation.
Incidental, consequential, or indirect damages caused by defects in material or workmanship, or any costs
associated with the delay in repair or replacement of the defective parts.
THIS WARRANTY REPLACES ALL PREVIOUS POWER TRANSFER SYSTEM WARRANTIES,
EXPRESS OR IMPLIED. SPECIFICALLY, THE COMPANY MAKES NO OTHER WARRANTIES AS TO
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. THE COMPANY’S ONLY
LIABILITY SHALL BE THE REPAIR AND/OR REPLACEMENT OF PARTS AS STATED ABOVE. IN NO
EVENT SHALL THE COMPANY BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL
DAMAGES.
Generac Portable Products
Jefferson, Wisconsin U.S. A.
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