Melted Automatic Transfer Switch - PV Tap on Generator Feed

[citrixtrainer]

Hello everyone. I just wanted to share a scenario that I came across yesterday. After a routine failover test of a 22kW Generac generator failed, I popped-off the transfer switch cover and found the recent PV installer tapped the generator feed for the PV system. Unless I'm totally missing something, the tap should be at the utility feed.

Am I missing something here, or is this simply an incorrect install?

Note: I'm the homeowner, but not a novice when it comes to electrical systems. I was a licensed merchant marine engineer, so I'm familiar with systems up to 440V 3-phase.

Image of Melted Transfer Switch

 

[tom baker]

As the poster is only asking for comments, I will allow, if this gets into DIY then the post will be closed.

 

[tom baker]

Question. Was the solar install done with a permit and inspection?

 

[ggunn]

Hello everyone. I just wanted to share a scenario that I came across yesterday. After a routine failover test of a 22kW Generac generator failed, I popped-off the transfer switch cover and found the recent PV installer tapped the generator feed for the PV system. Unless I'm totally missing something, the tap should be at the utility feed.

Am I missing something here, or is this simply an incorrect install?

Note: I'm the homeowner, but not a novice when it comes to electrical systems. I was a licensed merchant marine engineer, so I'm familiar with systems up to 440V 3-phase.

Image of Melted Transfer Switch

Irrespective of the cause of the damage, a line side interconnected grid tied PV system should only ever be connected on the utility side of the ATS, never the generator side.

 

[analog8484]

Definitely tapped the wrong feed. Did the installer test the setup after installation?

 

[citrixtrainer]

Question. Was the solar install done with a permit and inspection?

Yep! The county failed the first inspection due to the plans not matching the layout of the panels "as built". I have no idea if the county inspector even looked at the ATS tap. The permits are now approved. The only thing left is the interconnection with Duke.

 

[citrixtrainer]

Definitely tapped the wrong feed. Did the installer test the setup after installation?

I *think* so, but couldn't attest to it.

 

[citrixtrainer]

**UPDATE** I contacted the solar contractor and sent them the marked-up picture. They agree that the installation is jacked-up. They have promised to fix everything, including the ATS. My guess is they want to get the issue corrected before the utility inspector comes out and finds a fried system.

 

[analog8484]

I wonder what it will cost repair the Generac. One expensive mistake.

 

[citrixtrainer]

I wonder what it will cost repair the Generac. One expensive mistake.

I think MSRP for the 200 amp ATS is about $800.

 

[ggunn]

I think MSRP for the 200 amp ATS is about $800.

You'll need to get the generator checked out, too. If the PV system backfed it, it could be toast as well.

 

[citrixtrainer]

Roger that. With the switch being toast I cannot easily check it under load yet, but I should be able to see if proper voltage is present on the generator feed.

 

[analog8484]

I think MSRP for the 200 amp ATS is about $800.

I was referring to the generator. Although the ATS is not cheap either.

 

[Barbqranch]

My generator (not a Generac) has a 120 volt receptacle on it, if this one does, you could plug in a heater or a hair dryer when you check the voltage output.

 

[ggunn]

I was referring to the generator. Although the ATS is not cheap either.

US$800 for a generator sounds low.

 

[analog8484]

US$800 for a generator sounds low.

That's the ATS price.