Emerson ASCO 7000 Series Operator`s manual

7000 Series ATS
Automatic Transfer Switches
J–design, 260, 400, & 600 A
Operator’s
Manual
DANGER is used in this manual to warn of high
voltages capable of causing shock, burns, or death.
WARNING is used in this manual to
warn of possible personal injury.
Refer to the outline and wiring drawings provided
with your 7000 Series ATS for all installation and
connection details and accessories.
Refer to Group 5 Controller User’s Guide
381333–126 for ATS status display messages, time
delays, pickup & dropout settings, and adjustments.
Rating Label
CAUTION is used in this manual to
warn of possible equipment damage.
Each automatic transfer switch (ATS) has a rating label to
define the loads and fault circuit withstand/closing ratings.
Refer to the label on the transfer switch for specific values.
Do not exceed the values on the rating label.
Exceeding the rating can cause personal injury
or serious equipment damage.
Nameplate
The Transfer Switch nameplate includes data for each
specific ASCO 7000 Series ATS. Use the ATS only within
the limits shown on this nameplate.
An experienced licensed electrician must install the ATS.
TABLE OF CONTENTS
section-page
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Mounting and Line Connections . . . . . . . . . 1-1
Auxiliary Circuits and Harness . . . . . . . . . . . 1-2
Engine Starting Contacts . . . . . . . . . . . . . . . 1-2
Functional Test . . . . . . . . . . . . . . 1-2 through 1-5
TESTING & SERVICE . . . . . . . . . . . . . . . . . .
Transfer Test . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventive Maintenance . . . . . . . . . . . . . . . .
Disconnecting the Controller . . . . . . . . . . . .
Manual Load Transfer . . . . . . . . . . . . . . . . . .
Trouble-Shooting . . . . . . . . . . . . . . . . . . . . . .
260 amp. size
2-1
2-1
2-1
2-1
2-2
2-2
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . back cover
50 Hanover Road, Florham Park, New Jersey 07932–1591 USA
For sales or service call 1 800 800–2726 (ASCO) www.ascopower.com
381333–283 B
ASCO POWER TECHNOLOGIES CANADA PO Box 1238, 17 Airport Road, Brantford, Ontario, Canada N3T 5T3
telephone 519 758–8450, fax 519 758–0876, for service call 1 888 234–2726 (ASCO) www.asco.ca
Catalog Number Identification
A typical Catalog Number is shown below with its elements explained. The example is for a 7000 Series 7ATS
with overlapping neutral, 3 pole, 600 amp, 480 V, in a Type 1 enclosure:
J
design
prefix
letter
7ATS
Neutral
A – solid
B – switched
C – overlapping
blank – none
C
Phase Poles
2 – single Ø
3 – three Ø
3
600
Amperes
260
400
600
N
5
Voltage
A 115
B 120
C 208
D 220
E 230
F 240
G 277
H 380
J 400
K 415
L 440
M 460
N 480
P 550
Q 575
R 600
C
Controller
5 – standard
5X – if
accessories
ordered
Enclosure
C – type 1
F – type 3R
G – type 4
H – type 4X
L – type 12
blank – open type
customer terminals block
load power
connections
transfer
control
& lights
emergency
power
connections
Transfer
Switch
Controller
normal power
connections
260 amp. size in typical enclosure with location of customer connections
SECTION 1
INSTALLATION
Testing Power Conductors
ASCO 7000 Series Automatic Transfer Switches (ATSs)
are factory wired and tested. Field installation requires
requires mounting and connection of service cables,
and auxiliary control circuits (if required).
Do not connect the power conductors to the transfer
switch until they are tested. Installing power cables in
conduit, cable troughs and ceiling-suspended hangers
often requires considerable force. The pulling of cables
can damage insulation and stretch or break the
conductor’s strands. For this reason, after the cables
are pulled into position, and before they are
connected, they should be tested to verify that they are
not defective or have been damaged during
installation.
Remove the Shipping Skid (large ATSs)
For large ATSs, open the front door and remove the
four lag screws (2 in front, 2 in rear) securing enclosure
to the wood skid.
Supporting Foundation
The supporting foundation for the enclosure must be
level and straight. Refer to the applicable enclosure
outline drawing included with the switch for all
mounting details including door opening space.
Protect the automatic transfer switch from
construction grit and metal chips to prevent
malfunction or shortened life of the ATS.
If bottom cable entry is used, the foundation must be
prepared so that the conduit stubs are located
correctly. Refer to the enclosure outline drawing for
specified area and location. Provide cable bending
space and clearance to live metal parts. When a
concrete floor is poured, use interlocking conduit
spacer caps or a wood or metal template to maintain
proper conduit alignment.
Connecting Power Conductors
After the power cables have been tested, connect them
to the appropriate terminal lugs on the transfer switch
as shown on the wiring diagram provided with the
switch. Make sure the lugs provided are suitable for
use with the cables being installed. Standard terminal
lugs are solderless screw type and will accept the wire
sizes listed on the drawings provided with the switch.
Be careful when stripping insulation from the cables;
avoid nicking or ringing the conductor. Remove
surface oxides from cables by cleaning with a wire
brush. When aluminum cable is used, apply joint
compound to conductors. Tighten cable lugs to the
torque specified on rating label.
Mounting
Refer to the applicable enclosure outline drawing
furnished with this switch and mount the automatic
transfer switch according to details and instructions
shown on diagram.
Controller Ground
Line Connections
A grounding wire must be connected to the controller’s
lower left mounting stud. Because the controller is
mounted on the enclosure door, a conductive strap
must be used between the enclosure and the door. This
connection provides proper grounding which does not
rely upon the door hinges.
Refer to the Wiring Diagram provided with the switch.
All wiring must be made in accordance with the
National Electrical Code and local codes.
It is not necessary to remove pole covers from the
transfer switch for cabling. If you do remove them,
reinstall them carefully.
Harnesses
The transfer switch is connected to the left side of the
controller by a plug–in harness (two plugs).
De–energize the conductors before making
any line or auxiliary circuitry connections.
Be sure that Normal and Emergency line
connections are in proper phase rotation.
Place engine generator starting control in the
OFF position. Make sure engine generator is
not in operation.
1---1
INSTALLATION
(continued)
Engine Starting Contacts
All customer connections, including the engine control
contact connections, are located on terminal block TB
which is mounted on the top right side of the
enclosure. Refer to the wiring diagram provided with
the automatic transfer switch and connect the engine
start wires to the appropriate terminals. See Figure
1–1 and Table A.
Table A. Engine start connections.
When normal source
fails
contact closes
contact opens
Terminals on
Terminal Block TB
TB1 and TB2
TB1 and TB3
engine start
connections
on
customer
terminal
block TB
Note: To temporarily disable engine control from
the automatic transfer switch you can unplug J3
from the small P3 receptacle at the bottom of the
assembly. Be sure to reconnect plug J3 to the P3
receptacle for automatic transfer switch operation.
Auxiliary Circuits
Connect auxiliary circuit wires to appropriate terminals
on transfer switch terminal block TB as shown on the
wiring diagram provided with this automatic transfer
switch.
Figure 1-1. Customer terminal block on the top right
side of the enclosure.
Functional Test
Read all instructions on the Wiring Diagram and labels
affixed to the automatic transfer switch. Note the
control features that are provided and review their
operation before proceeding.
The Functional Test consists of three checks:
S 1 — Manual Operation Test, page 1–3
S 2 — Voltage Checks, page 1–4
Continue to 1 – Manual Operation Test on next page.
S 3 — Electrical Operation, page 1–5
Do these checks in the order presented to
avoid damaging the automatic transfer switch.
1---2
INSTALLATION
(continued)
1 – Manual Operation Test
left side of
transfer switch
A detachable maintenance handle is provided on the
frame of the Transfer Switch for maintenance purposes
only. Manual operation of the transfer switch should be
checked before it is energized (operated electrically).
Do not manually operate the transfer switch
until both power sources are disconnected:
open both circuit breakers.
1.
maintenance
handle
After deenergizing both power sources, open the
enclosure door. Locate and remove the maintenance handle from the clips on the left side of the
transfer switch frame. Insert the handle into the
hole in the molded hub on the left side of the
operator. See Figures 1–2 and 1–3 and Table B.
2.
Move the maintenance handle up or down as shown
to manually operate the transfer switch. It should
operate smoothly without any binding. If it does not,
check for shipping damage or construction debris.
3.
Return the transfer switch to the Normal position.
Observe that the window indicators (right side) show
the top shaft O (open) and the bottom shaft C
(closed).
storage clip
Table B. Maintenance handle positions.
ATS Position
E
Handle
up
Indicators
Figure 1-2. Maintenance handle and its storage clips.
E=O
upper contacts open
Normal
4.
N=C
N
lower contacts closed
E=C
E
Verify that the maintenance handle
has been removed before proceeding!
upper contacts closed
Emergency
N
N=O
down
lower contacts open
Now continue to 2 – Voltage Checks on next page.
Note: If Normal and Emergency connections are
reversed this operation is also reversed.
handle
hub
Remove the maintenance handle and store it on the
frame (left side) in the clips provided.
Emergency
contacts
UP closes the
Normal source
contacts (lower)
window
indicators
O is open
C is closed
DOWN closes the
Emergency source
contacts (upper)
contact position
indicators (right side)
Normal
contacts
frame
Figure 1-3. Maintenance handle operation and contact position indicators.
1---3
INSTALLATION
GREEN
RED
GREEN
RED
(continued)
observe
these lights
Figure 1-4. Standard controls and indicators.
Close the normal source circuit
breaker. The Transfer Switch
1 Connected To Normal and the
Normal Source Accepted lights
should come on.
2 – Voltage Checks
First check nameplate on transfer switch; rated voltage
must be the same as normal and emergency line voltages.
Use an accurate voltmeter to
check phase to phase and
2 phase to neutral voltages present at the transfer switch normal
source terminals.
Verify that the feeders have been
connected to the proper lugs.
Close the emergency source
circuit breaker. (Start generator,
if necessary.) The Transfer
3
Switch Connected To Normal &
Emergency Source Accepted
lights should come on.
Use extreme caution when using a meter
to measure voltages in the following
steps. Do not touch power terminals;
shock, burns, or death could result !
Use an accurate voltmeter to
check phase to phase and
4 phase to neutral voltages present at the transfer switch emergency source terminals.*
Perform steps 1 through 6 at the right. Observe the
status lights. See Figure 1–4.
Q Black square means light is on.
S White square means light is off.
Use a phase rotation meter to
check phase rotation of emer5
gency source; it must be the
same as the normal source.
* If necessary, adjust voltage regulator on the generator
according to the manufacturer’s recommendations. The
Automatic Transfer Switch will respond only to the rated
voltage specified on the Transfer Switch nameplate.
Shut down the engine–generator, if applicable. The Emergency Source Accepted light should
6 go off. Then put the starting
control selector switch (on the
generator set) in the automatic
position. Close enclosure door.
Note
Refer to Section 3 of Group 5 Controller User’s Guide
381333–126 for how to display the Status of the ATS
and the Voltage and Frequency of each source.
Now continue to 3 – Electrical Operation on next page.
1---4
A B C
INSTALLATION
GREEN
RED
GREEN
RED
(continued)
operate
this switch
observe
these lights
Figure 1-5. Standard controls and indicators.
3 – Electrical Operation
The Transfer Switch Connected
1 To Normal and Normal Source
Accepted lights should be on.
This procedure will check the electrical operation of
the Automatic Transfer Switch. See Figure 1–5.
Turn and hold Transfer Control
switch clockwise to Transfer
Test until the engine starts
2
and runs (within 15 sec.).
Emergency Source Accepted
light should come on.
Be sure to close the enclosure door
before proceeding to prevent personal
injury in case of electrical system fault !
Transfer switch will operate to
the Emergency position after
Feature 2B time delay. The
3 Transfer Switch Connected To
Emergency light should come
on and Load Connected to Normal light goes off.
Transfer switch will operate
back to Normal position after
Feature 3A time delay. For immediate retransfer turn Transfer
Control counterclockwise to
4
Retransfer Delay Bypass. The
Transfer Switch Connected To
Normal light should come on;
Transfer Switch Connected to
Emergency light should go off.
Transfer Test
Both normal and emergency sources must be available
and the emergency source generator (if used) must be
capable of being started in this procedure.
Perform steps 1 through 5 at the right. Observe the
status lights.
Q Black square means light is on.
S White square means light is off.
The engine–generator will stop
after the Feature 2E time delay
5 (unloaded running engine cooldown). The Emergency Source
Accepted light should go off.
This completes the Functional Test of the ATS.
1---5
SECTION 2
TESTING & SERVICE
TRANSFER TEST
DISCONNECTING THE CONTROLLER
Operate the 7000 Series ATS at least once a month by
following the five–step Electrical Operation Transfer
Test procedure on page 1–5.
The harness disconnect plugs are furnished for repair
purposes only and should not have to be unplugged. If
the controller must be isolated, follow these steps:
Disconnecting the Plugs
PREVENTIVE MAINTENANCE
Reasonable care in preventive maintenance will insure
high reliability and long life for the 7000 Series ATS.
An annual preventive maintenance program is recommended.
Do not unplug the controller until step
1a. or 1b. below is completed.
1. Observe the position of the transfer switch.
In the United States, ASCO Services, Inc. (ASI) is
ASCO Power Technologies’s national service
organization. ASI can be contacted at
1-800-800-2726 (ASCO) for information on
preventive maintenance agreements.
a. If the transfer switch is in the Normal position,
first place standby engine starting control in the
off position. Second, then open the emergency
source circuit breaker. Third, open the normal
source circuit breaker.
In Canada, for service call 1-800-234-2726 (ASCO).
b. If the transfer switch is in the Emergency position, first open the normal source circuit breaker. Second, place the engine starting control in
the test or run position. Third, open the emergency source circuit breaker.
Checklist for Yearly Inspection
2. Separate the two quick disconnect plugs by squeezing the latches. Do not pull on the harness wires.
Hazardous voltage capable of causing shock,
burns, or death is used in this transfer switch.
Deenergize both Normal – Emergency power
sources before performing inspections!
Reconnecting the Plugs
S Clean the ATS enclosure. Brush and vacuum
away any excessive dust accumulation. Remove any
moisture with a clean cloth.
Do not reconnect the controller until step
1a. or 1b. below is completed.
S Check the transfer switch contacts. Remove
the transfer switch barriers and check contact
condition. Reinstall barriers carefully. The
non–replaceable main contacts are designed to last
the life of the transfer switch.
1. Observe the position of the transfer switch.
a. If the transfer switch is in the Normal position,
first be sure that both normal and emergency
source circuit breakers are open. Second, be
sure that the standby engine starting control is
still in the off position.
S Maintain transfer switch lubrication. If the
transfer switch is subjected to severe dust or
abnormal operating conditions, renew factory
lubrication on all movements and linkages.
Relubricate the solenoid operator if the TS coil is
replaced. Do not use oil; order lubrication kit
75-100.
b. If the transfer switch is in the Emergency position, first be sure that both normal and emergency source circuit breakers are open.
2. The two harness plugs and sockets are keyed.
Carefully align the plugs with the sockets and press
straight in until both latches click. Close the door!
S Check all cable connections & retighten them.
3. Restore the two sources in sequence as follows:
REPLACEMENT PARTS
a. If the transfer switch is in the Normal position,
first close the normal source circuit breaker.
Second, close the emergency source circuit
breaker. Third, place the standby engine
starting control in the automatic position.
Replacement parts are available in kit form. When
ordering parts provide the Serial No., Bill of Material
No. (BOM), and Catalog No. from the transfer switch
nameplate. Contact your local ASCO Power Technologies Sales Office or ASI:
b. If the transfer switch is in the Emergency
position, first close the emergency source circuit
breaker. Second close the normal source circuit
breaker.
in United States call 1 800 – 800 – ASCO (2726)
or in Canada call 1 800 – 234 – ASCO (2726)
2---1
TESTING & SERVICE
MANUAL LOAD TRANSFER
(continued)
2. Use the maintenance handle to manually operate
the transfer switch to the opposite source. See
Manual Operation on page 1–3.
This procedure will manually transfer the load if the
controller is disconnected.
3. Then remove the maintenance handle. See page 1–3.
Do not manually operate the transfer switch
until both power sources are disconnected:
open both circuit breakers.
Verify that the maintenance handle
has been removed before proceeding!
4. If the transfer switch is in the Emergency position
manually start the engine generator and then
install emergency source fuse or close the circuit
breaker.
1. Deenergize both the normal and emergency source
conductors (remove fuses or open circuit
breakers).
TROUBLE-SHOOTING
Note any optional accessories that may be furnished on
the automatic transfer switch (ATS) and review their
operation. Refer to any separate drawings and/or
instructions that may be packed with the ATS.
Hazardous voltage capable of causing shock,
burns, or death is used in this switch.
Do not touch the power or load terminals
of the transfer switch!
Table 2-1. Trouble-Shooting Checks.
PROBLEM
Engine–generator set does
not start when the Transfer
Control switch is turned and
held in Transfer Test position
or when the normal source
fails.
CHECK IN NUMERICAL SEQUENCE
1
2
OPERATION
GEN-SET
Hold Transfer Test switch 15
Starting control must be in the
seconds or the outage must
automatic position. Batteries
be long enough to allow for
must be charged and
Feature 1C time delay plus
connected. Check wiring to
engine cranking and starting
engine starting contacts on
time.
customer terminal block TB.
Verify that the small plug J3 is
connected to receptacle P3.
Transfer switch does not
transfer the load to the
emergency source after the
engine–generator set starts.
Wait for Feature 2B time delay Generator output circuit
to time out (if used).
breaker must be closed.
Generator frequency must be
at least 95% of nominal
(57 Hz for a 60 Hz system.) *
Transfer switch does not
transfer the load to normal
source when normal returns
or when the Transfer Control
switch is released.
Wait for Feature 3A time delay
to time out (if used).
Engine–generator-set does
not stop after load retransfer
to the normal source.
Wait for Feature 2E time delay Starting control must be in the
to time out (if used).
automatic position.
–
3
VOLTAGE
–
Voltmeter should read at least
90% of nominal phase to
phase voltage between
transfer switch terminals EA
and EC (or EL1 and EL2 for 2
pole switches). *
Voltmeter should read at least
90% of nominal phase to
phase voltage between
transfer switch terminals NB
and NC, NC and NA, and NA
and NB (or NL1 and NL2 for 2
pole switches).
–
* These are factory settings. Refer to the Group 5 Controller User’s Guide.
If the problem is isolated to circuits on the controller or the transfer switch, call your local ASCO Power
Technologies sales office or ASI. In the United States, call 1–800–800–2726. In Canada, call 1–800–234–2726.
Furnish the Serial No. and Catalog No. from the transfer switch nameplate.
2---2
INDEX
A
auxiliary circuits, 1–2
C
cable
lugs, 1–1
preparation, 1–1
catalog number, inside cover
cleaning, 2–1
connections
line, 1–1
contact position indicators, 1–3
controller, 1–1
disconnecting, 2–1
see Controller User’s Guide
grounding, 1–1
E
electrical operation, 1–5
Emergency Source Accepted light,
1–4, 1–5
engine starting contacts, 1–2
F
frequency, generator, 2–2
functional test, 1–2, 1–3, 1–4, 1–5
G
ground, controller, 1–1
ground lugs, inside front cover
H
harness, 1–1
disconnect plugs, 2–1
I
P
inspection, 2–1
parts, 2–1
installation, 1–1
phase rotation check, 1–4
indicators, contact position, 1–3
problem, 2–2
L
R
labels,
field terminal block TB, 1–2
rating, inside front cover
rating label, inside cover
replacement parts, 2–1
lights, 1–4, 1–5
S
lubrication, 2–1
settings
see Controller User’s Guide
M
maintenance handle, 1–3
illustration of, 1–3
warning, 1–3
T
test, functional, 1–2, 1–3, 1–4, 1–5
maintenance, preventive, 2–1
time delays, 1–5, 2–2
see Controller User’s Guide
manual load transfer, 2–2
warning, 2–2
Transfer Control selector switch
Retransfer Delay Bypass, 1–5
Transfer Test, 1–5
manual operation, 1–3
illustration of, 1–3
warning, 1–3
Transfer Switch Connected To
Emergency light, 1–4, 1–5
N
nameplate, inside cover
Transfer Switch Connected To
Normal light, 1–4, 1–5
Normal Source Accepted light, 1–4
transfer test, 1–5, 2–1
O
operation
electrical, 1–5
manual, 1–3
illustration of, 1–3
warning, 1–3
optional accessories
see Controller User’s Guide
transfer to emergency, 1–5
transfer to normal, 1–5
trouble–shooting, 2–2
V
voltage checks, 1–4
voltage, pickup and dropout settings
see Controller User’s Guide
HELP
800–800–2726 (ASCO)
customercare@asco.com
Printed in U.S.A.
Copyright --- ASCO Power Technologies, L.P. 2007