User`s guide | Emerson E-DESIGN 150-400A Switch User Manual

7000 Series ACTS
Operator’s Automatic Closed–Transition
Transfer Switches
Manual
E–design 150–400A, F–design 600–800A,
G–design 1000–4000A, F–design 3000–4000A,
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.
CAUTION is used in this manual to warn
of possible equipment damage.
Refer to the outline and wiring drawings provided
with your 7000 Series ACTS 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.
An experienced licensed electrician must install the
ACTS.
Rating Label
Each automatic closed–transition transfer switch contains 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 7000 Series ACTS. Use the switch only within the
limits shown on this nameplate. A typical catalog number
is shown on the next page with its elements explained.
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, 1-3, 1-4, 1-5
TESTING & SERVICE . . . . . . . . . . . . . . . . . .
Transfer Test . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventive Maintenance . . . . . . . . . . . . . . . .
Disconnecting the Controller . . . . . . . . . . . .
Manual Load Transfer . . . . . . . . . . . . . . . . . .
Trouble-Shooting . . . . . . . . . . . . . . . . . . . . . .
2-1
2-1
2-1
2-1
2-2
2-2
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . back cover
150 – 400 ampere sizes
50 Hanover Road, Florham Park, New Jersey 07932–1591 USA
For sales or service call 1 800 800–2726 (ASCO)
www.ascopower.com
381333–128 D
ASCO POWER TECHNOLOGIES CANADA PO Box 1238, 17 Airport Road, Brantford, Ontario, Canada N3T 5T3
Catalog Number Identification
Typical 7000 Series catalog no. for E–design switched neutral, 3 pole, 400 amp, 480 V, ACTS in Type 1 enclosure:
E
design
prefix
letter
7ACTS
Neutral
A – solid
B – switched
C – overlapping
blank – none
C
Phase Poles
2 – single Ø
3 – three Ø
3
400
Amperes
150
260
400
600
800
1000
1200
1600
2000
3000
4000
power
connections
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
L – type 12
blank – open type
field connections
terminal block TB
Transfer
Control
& lights
Dual
Transfer
Switch
Group 5
Controller
power
connections
150–400 amp. sizes in typical enclosure with location of customer connections
SECTION 1
INSTALLATION
ASCO Series 7000 Automatic Closed–Transition Transfer
Switches are factory wired and tested. Field installation
simply requires mounting and connection of service
cables, and auxiliary control circuits (if required).
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.
Remove the Shipping Skid
For large switches, open the front door and remove the
four lag screws (2 in front, 2 in rear) securing enclosure
to the wood skid.
Testing Power Conductors
Supporting Foundation
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.
The supporting foundation for the enclosure must level
and straight. Refer to the applicable enclosure outline
drawing included with the ACTS for all mounting
details including door opening space.
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
Mounting
Refer to the outline and mounting diagram provided
with the ACTS; it shows all mounting details and
instructions.
Protect the switch from construction grit
and metal chips to prevent malfunction or
shortened life of the automatic switch switch.
Mount the ACTS vertically to a rigid supporting structure.
Level all mounting points by using flat washers behind the
holes to avoid distortion of the switch.
The controller is mounted on the cabinet door. An
add-on DIN rail is provided for some optional accessories and is mounted below controller on the door.
Auxiliary Cable Boxes
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.
Do not run cables in front of or behind the switch.
Cables can be bundled on the right side of the switch.
Maintain proper electrical clearance between the live
metal parts and grounded metal: ½ inch minimum for
150-400 amps, 1 inch minimum over 400 amps.
It is not necessary to remove the barriers from the
transfer switches to install the cables. If you do remove
them,however, be sure to reinstall the barriers carefully.
For 1000 & 1200 amp. sizes, an auxiliary cable box is
required for all (normal, emergency, & load)bottom or
top entry. Order ASCO part no. 609027 if required.
Bus Connections
For large switches use grade 5 hardware to connect bus
to appropriate terminal plates. Wipe off the bus
surfaces before they are joined. If the bus is very dirty,
gently clean the surfaces with a non---flammable solvent.
Avoid touching the cleaned surfaces.
On 1000 & 1200 amp. be sure to install auxiliary
cable box if both service and load cables are
entering through the top or bottom of enclosure.
Line Connections
A Wiring Diagram is furnished with the ASCO Series
7000 ACTS (separate from this manual). Refer to this
drawing. All wiring must be made in accordance with
the National Electrical Code and local codes.
Do not breathe cleaning solvent vapors.
1---1
INSTALLATION
Tighten bolted joints to the torque specified in Table A.
The engine control contact connections (if used) are
located on the transfer switch. Connect signal wires to
appropriate terminals as specified in Table B and shown
in Figure 1–1.
The reliablility of the connection depends
on how clean and how tight the joint is.
Table B. Engine start connections
Table A. Tightening torque values for bolted joints
(Grade 5 hardware)
Bolt Diameter
in inches
1/4
5/16
3/8
1/2
5/8
3/4
(continued)
Engine Starting Contacts
When normal
source fails
contact closes
contact opens
Tightening Torque
in foot pounds
7
12
20
50
95
155
Terminals on
transfer switch
TB1 and TB2
TB1 and TB3
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.
engine start
connections
on
customer
terminal
block TB
Controller Ground
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.
Harnesses
The transfer switch is connected to the left side of the
control panel by a plug-in harness (two plugs).
Auxiliary Circuits
Connect auxiliary circuit wires to appropriate terminals on
the transfer switch. Note the control features that are
furnished on this switch. Make the necessary auxiliary
connections by referring to the Wiring Diagram.
Figure 1-1. Customer terminal block
on the top right side of enclosure.
Functional Test
Read all instructions on the Wiring Diagram and labels
affixed to the ACTS. 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 ATS.
1---2
INSTALLATION
(continued)
handle
shafts
handle
handle
Figure 1-2.
150 – 400 A (3 pole)
E–design switches
Figure 1-3.
600 & 800 A (& 4 pole 400 A)
F–design switches
1 – Manual Operation
1000 through 4000 amp. G–design See Figure 1-5.
Install the hub (with pin) onto the shaft and insert the
manual firmly into the side hole in the hub. Push in
or pull out hub to engage opposite source contacts.
A detachable manual operator handle is provided on the
Transfer Switches for maintenance purposes only.
Manual operation of both CN and CE transfer switches
must be checked before they are operated electrically.
3000 and 4000 amp. F–design
See Figure 1-4.
Insert the manual handle into the hole in the weight.
Do not manually operate the transfer switch
until both power sources are disconnected:
open both circuit breakers.
1.
Figure 1-4
3000 & 4000 A
F–design transfer switches
Select the appropriate switch amperage size above
and follow the directions for installing the handle:
150 through 400 amp. E–design
See Figure 1-2.
Insert the manual handle into the hole in the shaft,
left side of the operator.
600 and 800 amp. F–design
See Figure 1-3.
Attach the manual handle onto the pivot shaft
extension, left side of the operator.
2.
Move the handle as shown to manually operate the
Transfer Switch. The switch should operate smoothly
without binding. If it does not, check for shipping
damage or construction debris. Repeat the manual
operation check on the other Transfer Switch.
3.
Return the CN Transfer Switch to the C (closed)
position. Return the CE Transfer Switch to the O
(open) position. Remove manual operator handle and
store it on the Transfer Switch in the place provided.
Verify that the maintenance handle has been
removed and stored properly before proceeding!
Now continue to 2 – Voltage Checks on next page.
Emergency
contacts
window
indicators
Grasp handle
firmly with
both hands
Turn counterclockwise
to OPEN contacts.
Turn clockwise to
CLOSE contacts.
Insert handle
into hole
(spring fully
compressed)
Slide the hub onto the
shaft and insert the pin.
OPEN or
CLOSED
Normal
contacts
contact position
indicators (left side)
counterclockwise DOWN
OPENS the contacts
Pull out shaft to open Emergency
source contacts (upper)
Push in shaft to open Normal
source contacts (lower)
clockwise DOWN
OPENS the contacts
Pull out shaft to close Emergency
source contacts (upper)
Push in shaft to close Normal
source contacts (lower)
Figure 1-5. 1000 – 4000 ampere G–design transfer switches.
1---3
INSTALLATION
GREEN
RED
GREEN
RED
(continued)
RED
RED
RED
observe
these lights
Figure 1-6. Standard controls and indicators.
2 --- Voltage Checks
First check nameplate on transfer switch; rated voltage
must be the same as normal and emergency line voltages.
Close the normal source circuit
breaker. The Transfer Switch
1 Connected To Normal and the
Normal Source Accepted lights
should come on.
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.
Before energizing the switch check to be
sure that both normal and emergency
contacts are not left in the closed position.
Use extreme caution when using a meter
to measure voltages. 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---6.
Q Black square means light is on.
Use a phase rotation meter to
check phase rotation of emer5
gency source; it must be the
same as the normal source.
S White square means light is off.
* 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.
First check nameplate on transfer switch; rated voltage
must be the same as normal and emergency line voltages.
1---4
A B C
INSTALLATION
GREEN
(continued)
RED
RED
observe
these lights
RED
operate
this switch
GREEN
RED
Figure 1-7. Standard controls and indicators.
3 --- Electrical Operation
This procedure will check the electrical operation of the
Automatic Closed–Transition Transfer Switch. See
Figure 1---7.
The Transfer Switch Connected
1 To Normal and Normal Source
Accepted lights should be on.
Turn and hold Transfer Control
switch clockwise to Transfer Test
until the engine starts and runs
2 (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 CE closes and
then Transfer Switch CN opens
(closed–transition overlap). The
Transfer Switch Connected To
3 Emergency light should come on
and the Transfer Switch
Connected to Normal light goes
off (you might see and hear the
brief overlap transfer). **
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.
Transfer switch will operate back
to Normal position after Feature
3A time delay. For immediate
retransfer turn Transfer Control
counterclockwise to Retransfer
4
Delay Bypass. The Transfer
Switch Connected To Normal light
should come on; Transfer Switch
Connected to Emergency light
should go off.
Q Black square means light is on.
S White square means light is off.
** If you do not want closed–transition transfer, press
the Closed Transition Bypass pushbutton while the
controller display shows Waiting for In–Sync. This
action causes open–transition (momentary load
interruption) transfer to the opposite source, if
conditions permit. Also refer to the Group 5 Controller
User’s Guide 381333–126.
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 ACTS.
1---5
RED
SECTION 2
TESTING & SERVICE
TRANSFER TEST
DISCONNECTING THE CONTROLLER
Operate the 7000 Series ACTS 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 ACTS.
An annual preventive maintenance program is recommended.
Do not unplug the controller
until steps 1a or 1b 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.
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
Hazardous voltage capable of causing shock,
burns, or death is used in this switch.
Deenergize both Normal – Emergency power
sources before performing inspections!
2. Separate the two quick disconnect plugs by squeezing the latches. Do not pull on the harness wires.
Reconnecting the Plugs
S Clean the ACTS enclosure. Brush and vacuum
away any excessive dust accumulation. Remove any
moisture with a clean cloth.
Do not unplug the controller
until steps 1a or 1b is completed.
S Check the transfer switch contacts. Remove the
transfer switch barriers and check contact condition.
Replace the contacts if they become pitted or worn
excessively. Reinstall the barriers carefully.
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.
S Check all cable connections & retighten them.
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!
REPLACEMENT PARTS
3. Restore the two sources in sequence as follows:
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:
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.
in United States call 1 800 – 800 – ASCO (2726)
b. If the transfer switch is in the Emergency
position, first close the emergency source circuit
breaker. Second close the normal source circuit
breaker.
2---1
TESTING & SERVICE
MANUAL LOAD TRANSFER
(continued)
2. Use the maintenance handle to manually operate the
transfer switch to the opposite source. First open the
closed contacts, then close the other contacts. Do not
leave both closed. 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
(all conductors deenergized).
Verify that the maintenance handle
has been removed before proceeding!
1. Deenergize both the normal and emergency source
conductors (remove fuses or open circuit breakers).
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.
TROUBLE-SHOOTING
Note any optional accessories that may be furnished on
the ACTS and review their operation. Refer to any
separate drawings and/or instructions that may be
packed with the ACTS.
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 normal source fails.
CHECK IN NUMERICAL SEQUENCE
1 OPERATION
2 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.
3 VOLTAGE
---
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
breaker must be closed.
to time out.
Generator frequency must be
at least 95% of nominal (57 Hz
for a 60 Hz system.) *
Voltmeter should read at least
90% of nominal phase to
phase voltage between
terminals EA and EC (or EL1
and EL2 for 2 pole switches)*
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.
Voltmeter should read at least
90% of nominal phase to
phase voltage between
terminals NB and NC, NC and
NA, and NA and NB (or NL1
and NL2 for 2 pole switches).
Gen. does not stop after load
retransfer to normal source.
Failure to Synchronize
light comes on.
Extended Parallel Time
light comes on.
TS Locked Out
light comes on.
Wait for Feature 2E time delay Starting control must be in the
--to time out.
automatic position.
Conditions of Normal or Emergency Sources not suitable for closed transition transfer.
Recheck voltage and frequency of both sources. Press Alarm Reset pushbutton.
CN and CE contacts are closed longer than setting in the Control Panel. Open the disconnected source circuit breaker, then call your nearest ASCO Service Center for assistance.
Transfer lockout operation has occured; transfer switch is disabled from automatic operation.
Open the disconnected source circuit breaker, then call your nearest ASI for assistance.
---
* These are factory settings. Refer to 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. Furnish the Serial No., Catalog No., & BOM
No. from the transfer switch nameplate.
2---2
INDEX
A
I
R
alarm reset, 1–5, 2–2
inspection, 2–1
rating label, cover
auxiliary circuits, 1–2
installation, 1–1
replacement parts, 2–1
C
cable
lugs, 1–2
preparation, 1–2
catalog number, inside cover
cleaning, 2–1
closed transition bypass, 1–5, 2–2
L
labels,
engine start contacts, 1–2
rating, cover
lights, 1–4, 1–5
lubrication, 2–1
M
connections
line, 1–1
maintenance handle, 1–3
controller, 1–1
disconnecting, 2–1
see Controller User’s Guide
manual load transfer, 2–2
warning, 2–2
E
electrical operation, 1–5
emergency source accepted light,
1–4
extended parallel time, 2---2
F
failure to synchronize, 2---2
frequency, generator, 2–2
functional test, 1–2, 1–3, 1–4, 1–5
G
ground, controller, 1–1
H
maintenance, preventive, 2–1
manual operation, 1–3
illustration of, 1–3
warning, 1–3
N
nameplate, cover
normal source accepted light, 1–4
O
operation
electrical, 1–5
manual, 1–3
illustration of, 1–3
warning, 1–3
optional accessories
see Controller User’s Guide
settings
see Controller User’s Guide
T
test, functional, 1–2, 1–3, 1–4, 1–5
time delays, 2–1
see Controller User’s Guide
Transfer Control selector switch
Retransfer Delay Bypass, 1–5
Transfer Test, 1–5
Transfer Switch Connected To
Emergency light, 1–5, 2–1
Transfer Switch Connected To
Normal light, 1–4, 2–1
transfer test, 1–5
transfer to emergency, 1–5
transfer to normal, 1–5, 2–1
trouble–shooting, 2–2
TS locked out, 2---2
V
voltage checks, 1–4
voltage, pickup and dropout settings
see Controller User’s Guide
P
harness, 1–1
disconnect plugs, 2–1
parts, 2–1
HELP
customercare@asco.com
800–800–ASCO
problem, 2–2
Printed in U.S.A.
S
phase rotation check, 1–4
Copyright 2009 ASCO Power Technologies, L.P.
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