I'm just a simple dirt farmer, but - you never did say you flip the main breaker 'off'.
I know you implied it, but you didn't say it.
When power goes out & it is minus 5 & the wife is cold & the kids are crying & you are worried about the water freezing up on the cattle waterer if you don't get power flowing in 10 minutes as you struggle to get the generator fired up because it sat too long.......
Can you say 100% of the time, always, you will never ever ever forget to flip that main breaker off? You are 100% foolproof on this?
That is what the transfer switch is all about. It offers 100% foolproof that no matter who is hooking it up -you, the neighbor, your wife - and no matter how much pressure is on your head to get this thing running now in miserable conditions - that 100% of the time it won't be done without forgetting.
You didn't actually say you flipped the main off _before_ putting the generator on, so - you kinda failed right there in your own description. ;)
To me it sounds like your grounding is not right, but it will provide electricity as you have it set up. That is likely all anyone ever wants, they don't care about safety, just that juice comes out of the wall from 2 slots, so that is how most everyone does it? I'm not good enough to say more on the grounding deal. Seems like most folks who do their own wiring always interchange the ground & neutral wire any time they feel like it anyhow, so it all becomes a moot point - your house wiring probably isn't safe or right to start with so who cares how the grounding is set up? (How it seems to me...)
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