ASCO Series 300 D-design Automatic Transfer Switch Operator's Manual

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Document

Advertentie

Operator’s

Manual

DANGER is used in this manual to warn of a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING is used in this manual to warn of a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION is used in this manual to warn of a hazardous situation which, if not avoided, could result in minor or moderate injury.

Series 300

Automatic Transfer Switches

D–design, 30 through 230 A

Refer to the outline and wiring drawings provided with your ASCO Series 300 ATS for all installation details.

Rating Label

Each automatic 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.

An experienced licensed electrician must install the

Automatic Transfer Switch (ATS).

TABLE OF CONTENTS

section-page

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .

Mounting and Line Connections

Engine Starting Contacts

. . . . . . . . .

. . . . . . . . . . . . . . .

1-1

1-2

Input / Output Label

Functional Test

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . .

1-2

1-3, 1-4, 1-5

SEQUENCE OF OPERATION . . . . . . . . . . .

2-1

TESTING & SERVICE . . . . . . . . . . . . . . . . . .

Preventive Maintenance

Transfer Test

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

Disconnecting the Controller . . . . . . . . . . . .

Manual Load Transfer

Trouble-Shooting

. . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

3-1

3-2

ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . .

Time Delay and Sensor Adjustments . . . . .

How to Change a Setting . . . . . . . . . . . . . . .

4-1

4-2

CONTROL FEATURES . . . . . . . . . . . . . . . . .

. . . . . .

5-1

Engine Exercisers

Motor Load Transfer

. . . . . . . . . . . . . .

5-1, 5-2, 5-3

. . . . . . . . . . . . . . . . . . .

5-4

Load Disconnect & Remote Control 5-4

INDEX . . . . . . . . . . . . . . . . . . . . .

back of manual

30–200 A sizes

50 Hanover Road, Florham Park, New Jersey 07932–1591 USA

For sales or service call 1 800 800–2726 (ASCO) www.ascopower.com

ASCO POWER TECHNOLOGIES CANADA PO Box 1238, 17 Airport Road, Brantford, Ontario, Canada N3T 5T3

381333–228 H

Nameplate

The Transfer Switch nameplate includes data for each specific ASCO Series 300 ATS. Use the ATS only within the limits shown on this nameplate.

D 300 B 3 200

Catalog Number Identification

A typical Catalog Number is shown below with its elements explained. The example is for a Series 300

ATS with switched neutral, 3 pole, 200 amp, 480 V, in a Type 1 enclosure:

N 1 C

Neutral

– switched

– overlapping blank – solid

Phase Poles

– single Ø

– three Ø

Amperes

104

150

200

* 200 ampere is limited to 480 volts

Voltage

115

120

208

220

230

240

380

400

415

440

460

480

575

600 terminals for switch position contacts membrane controls

Controller

– standard

– if accessories ordered load power connections

Enclosure

– type 1

– type 3R

– type 4

– type 12 blank – open type

Controller emergency power connections

Transfer

Switch maintenance handle

(see

WARNING

under

Manual

Operation) terminals for engine start contacts normal power connections cable spacers

(see INSTALLATION)

200 ampere size in typical enclosure with location of customer connections

Catalog Number Identification

A typical Catalog Number is shown below with its elements explained. The example is for a Series 300 ATS with switched neutral, 3 pole, 230 ampere, 480 V, in a Type 1 enclosure:

D 300 B 3 230 N 1 C

Neutral

– switched

– overlapping blank – solid

Phase Poles

– single Ø

– three Ø

Amperes

230

** 230 ampere is limited to 480 volts terminals for switch position contacts

Voltage

115

120

208

220

230

240

380

400

415

440

460

480

Controller

– standard

– if accessories ordered membrane controls load power connections

Enclosure

– type 1

– type 3R

– type 4

– type 12 blank – open type emergency power connections

Transfer Switch maintenance handle

(see WARNING under

Manual Operation) terminals for engine start contacts normal power connections cable spacers

(see INSTALLATION)

230 ampere size in typical enclosure with location of customer connections

Controller

Refer to the applicable enclosure outline drawing furnished with this switch and mount the Series 300 according to details and instructions shown on diagram.

NOTICE

Mounting

SECTION 1 INSTALLATION

Series 300 Automatic Transfer Switches are factory wired and tested. Installation requires skid removal then securing the enclosure to the supporting foundation.

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 this

Series 300. 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

Series 300. 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.

Protect the automatic transfer switch from construction grit and metal chips to prevent malfunction or shortened life of the ATS.

Mount the ASCO ATS vertically to a rigid supporting structure. Level all mounting points by using flat washers behind the holes to avoid distortion of the switch.

Three cable spacers are included with 150, 200, and 230 ampere transfer switches. When installing power cables, run the cables through the cable spacers as shown in Figure 1–1. Position cable spacers within 1½ inches from lugs.

NOTICE

Line Connections

Refer to the Wiring Diagram provided with your Series

300 ATS. All wiring must be made in accordance with the National Electrical Code and local codes.

The cable spacers must be located as shown for

150, 200, and 230 ampere transfer switches.

cable spacers

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.

It is unnecessary to remove pole covers from the transfer switch. If you do remove them, reinstall them carefully.

Testing Power Conductors

Do not connect the power conductors to the ASCO

Series 300 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.

1 ½ inch approximate cable spacer

Figure 1–1. Cable spacers for 150, 200, and 230 ampere transfer switches.

1---1

INSTALLATION

(continued)

Engine Starting Contacts Controller Ground

Customer connections for engine control contact connections are located on the transfer switch. Refer to wiring diagram provided with the Series 300 ATS and connect the engine start wires to the appropriate terminals. See Figure 1–2 and Table A.

Table A. Engine start 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.

When normal source fails

contact closes contact opens

Terminals on transfer switch

TB14 and TB15

TB14 and TB16

Harnesses

The transfer switch is connected to the left side of the controller by a plug–in harness (two plugs).

ENGINE STARTING CONTACTS

( SHOWN DE–ENERGIZED ) left side of switch

TOP

STUD

MIDDLE

STUD

BOTTOM

STUD

TB 14

TB 16

TB 15

Figure 1–2. Engine starting contact label and terminals located on the transfer switch.

Auxiliary Circuits

Connect auxiliary circuit wires to appropriate terminals on transfer switch as shown on the wiring diagram provided with this Series 300 Automatic Transfer

Switch. Make the necessary auxiliary connections by referring to Section 5, Control Features.

Connections to Controller for other Control Features

(located on bottom of Controller)

Load Disconnect

Feature

Connections

(see Wiring Diagram

& refer to page 5–4 for DIP switch settings)

Programmable

Engine Exerciser connection, if provided

(refer to page 5–2)

Remote Control Features Connections

(refer to the Wiring Diagram & page 5–4 for DIP switch settings)

Each control contact must be suitable for a 5 V DC low energy circuit.

for factory use only

Figure 1–3. Input / output label on the Controller showing possible connections to the lower terminal block.

1---2

INSTALLATION

(continued)

Functional Test

The Functional Test consists of three checks: manual operation, voltage checks, and electrical operation.

Position of the transfer switch is indicated here weight marked

N (normal) and E (emergency)

NOTICE

Do these checks in the order presented to avoid damaging the automatic transfer switch.

maintenance handle

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.

1 – Manual Operation Test

A maintenance handle is provided on the Transfer Switch for maintenance purposes only. Manual operation of the transfer switch should be checked before it is energized (operated electrically).

floating weight weight

With ALL POWER OFF grasp maintenance handle and turn it quickly with your thumb and fingers.

Figure 1–4. Maintenance handle and positions.

Do not manually operate the transfer switch until both power sources are disconnected: open both circuit breakers.

1. After deenergizing both power sources, open the enclosure door. Locate and the maintenance handle on the left side of the transfer switch frame.

See Figure 1–4.

2. Grasp the attached maintenance handle and turn it with thumb and fingers as shown to manually operate it. The maintenance handle turns the opposite direction of the weight. Move it 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.

Note: If Normal and Emergency connections are reversed this operation is also reversed.

Now continue to 2 – Voltage Checks on next page.

1---3

INSTALLATION

(continued)

observe these lights

Figure 1–5. 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

Normal Transfer

Switch Position and the Normal

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 !

Perform steps 1 through 6 at the right. Observe the status lights. See Figure 1–5.

Black circle means light is on.

White circle 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.

Also see page 4–1 for the HI–LOW voltage adjust setting in the controller. The LOW setting shifts all voltage settings down 4.2%; for example, 240 V to

230V.

Source Accepted

Normal

Emergency

Use an accurate voltmeter to check phase to phase and phase to neutral voltages present at the transfer switch normal source terminals.

Close the emergency source circuit breaker. (Start generator, if necessary.) The

Emergency

Source Accepted light should come on.

Source Accepted

Normal

Emergency

Use an accurate voltmeter to check phase to phase and phase to neutral voltages present at the transfer switch emergency source terminals.*

A B C

Use a phase rotation meter to check phase rotation of emergency source; it must be the same as the normal source.

Shut down the engine–generator, if applicable. The

Emergen-

cy Source Accepted light should go off. Then put the starting control selector switch (on the generator set) in the

automatic

position. Close enclosure door.

Source Accepted

Normal

Emergency

Now continue to 3 – Electrical Operation on next page.

1---4

INSTALLATION

(continued)

observe these lights press this button

Figure 1–6. Standard controls and indicators.

3 – Electrical Operation

First check nameplate on transfer switch; rated voltage must be the same as normal and emergency line voltages.

Close the transfer switch enclosure door and tighten the screws before you test electrical operation.

The normal source must be available and the generator must be ready to start.

Check that the

Normal Source

Accepted light is on.

Press and hold the

Transfer Test

button until the engine starts and runs. This should happen within 15 sec.

Perform steps 1 through 8 at the right. Observe the status lights. See Figure 1–6.

Black circle means light is on.

White circle means light is off.

NOTE: If Motor Load Transfer feature is activated, then transfer may not occur immediately after the respective time delays. Transfer will only occur when the phase relationship between sources is correct.

This completes the Functional Test of the ASCO

Series 300 Automatic Transfer Switch. Leave the engine–generator starting control in the automatic position.

The transfer switch should transfer to the Emergency position. The

Emergency

Transfer Switch Position light should come on and the

Normal

light should go off.

If the

transfer to emergency

delay is used the transfer should occurs after a time delay

(up to 5 minutes).

For immediate transfer press the

Bypass Time Delay button.

The transfer switch should transfer back to the Normal position. The

Normal Transfer

Switch Position light should come on and the

Emergency

light should go off.

If the

retransfer to normal delay

is used the retransfer should occur after a time delay

(up to 30 minutes).

For immediate retransfer press the

Bypass Time Delay button.

The

unloaded running delay

keeps the generator running for

5 minutes (cool–down period).

Then the generator should stop and the

Emergency Source

Accepted light should go off.

Source Accepted

Normal

Emergency

Transfer

Test

Source Accepted

Normal

Emergency

Transfer Switch

Position

Normal

Emergency

Bypass

Time Delay

Transfer Switch

Position

Normal

Emergency

Bypass

Time Delay

Source Accepted

Normal

Emergency

1---5

SECTION 2 SEQUENCE OF OPERATION

Transfer To Emergency

When the normal source voltage fails or the Transfer Test button is pressed, the

SE relay de-energizes and relay NR begins its timing cycle (1 or 3 seconds, momentary

normal source outage

Lights show position of transfer switch.

The sequence for load transfer to emergency source begins automatically when normal source voltage falls below the preset dropout point or when Transfer Test button is pressed.

An under voltage condition on any phase of the normal source is detected by the sensor.

Hold 15 sec. to start the engine generator and to transfer the load to emergency.

Press to cancel the active exercise period

(stops engine now or after cooldown) See page 5–1.

delay

). The NR relay is provided with a time delay on dropout to override momentary outages and prevent nuisance starting of the engine-driven generator. If the normal source voltage returns above the sensor dropout setting before the time delay expires, the NR relay timing cycle is reset to zero and relay SE energizes.

Lights show the sources accepted.

Light for built–in engine exercise timer:

Hold 5 sec. to set

20 min. engine exercise period immediately (engine starts) and weekly thereafter.

³ blinks rapidly when button is held 5 sec.

while being set

³ blinks slowly when button is released (set) and during 20 min.

exercise period.

³ stays on after engine stops (exerciser is enabled for weekly operation)

Retransfer to Normal

See page 5–1 for complete instructions

Figure 2–1. Membrane controls and indicator lights.

The sequence for load retransfer to the normal source automatically begins when the voltage sensor detects restoration of the normal source. The voltage level must rise above the preset pickup point on all phases before the sensor will accept the normal source.

If the normal source voltage does not return above the sensor dropout setting before the time delay expires, the

NR relay de-energizes and signals the engine-driven generator to start. At the same time, a voltage and frequency sensor begins monitoring the emergency source. The sensor will accept the emergency source only when both voltage and frequency reach preset pickup points. Usually about ten seconds elapse from dropout of the NR relay to acceptance by the sensor. This time span occurs because the engine-driven generator must crank, start, and run up to nominal pickup points. For this reason, if the

Transfer Test

button is pressed it must be held for 15 seconds. If the emergency source is available immediately, the sensor may accept it as soon as NR relay drops out.

When the normal source is accepted by the sensor, relay SE begins its timing cycle (adjustable 1 sec. to 30 min., retransfer to normal delay). For immediate retransfer press Bypass Time Delay button. SE relay is provided with a time delay on pickup to prevent immediate load retransfer to the normal source. The delay insures that the normal source has stabilized before reconnection of vital loads. If the normal source voltage falls below the present dropout point before the time delay expires, the timing cycle is reset to zero. If the emergency source fails for more than 4 seconds during the timing cycle, ER relay drops out and the load is immediately retransferred to the normal source, if that source is acceptable.

When the emergency source is accepted by the sensor, relay ER begins its timing cycle (transfer to emergency

delay

). ER relay is provided with an adjustable (0 to 5 minutes) time delay on pickup to delay transfer of the load to the emergency source. For immediate transfer press Bypass Time Delay button.

SE relay energizes and ER relay is dropped out. The

TS coil is energized, the transfer switch operates, and all switch contacts (mains, controls, auxiliaries) reverse position. The transfer switch is now supplying the load from the normal source again.

ER relay energizes, the TS coil is energized, the transfer switch operates, and all switch contacts (mains, controls, auxiliaries) reverse position. The transfer switch is now supplying the load from the emergency source.

The transfer switch will remain in the Emergency position until the normal source is restored. If the

Transfer Test

button is used, the transfer switch will remain on emergency until the retransfer to normal

delay

times out.

Upon retransfer to the normal source, NR relay begins its timing cycle (unloaded running delay, engine cooldown).

NR relay is provided with a 5 min. time delay on pickup to keep the engine running for a cool-down period.

NR relay energizes after the time delay and signals the engine-driven generator to shut down. All circuits are reset for any future normal source failure.

Activation of standard control features shown in Section 5 will alter the sequence of operation and introduce additional time delays during transfer operations.

2---1

SECTION 3 TESTING & SERVICE

PREVENTIVE MAINTENANCE

Check all cable connections & retighten them.

Torque to values shown on transfer switch label.

For high reliability and long life for the ATS:

Operate the switch at least once a month. Perform this

4–step Electrical Operation Test (test with load transfer).

Replacement parts. When ordering parts provide the

Serial and Catalog Nos. from the transfer switch nameplate. Contact ASI. In the US call

1–800–800–ASCO (2726)).

DISCONNECTING THE CONTROLLER

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 carefully.

Transfer Switch Test

Press and hold the door-mounted

Transfer Test button until the engine starts and runs. This should happen within 15 seconds.

The transfer switch will operate to the Emergency position. If the Transfer To Emergency Delay is used, the transfer will occur after a time delay (up to 5 minutes). For immediate transfer press

Bypass

Time Delay button.

The Transfer Switch will operate back to the Normal position after the Retransfer To Normal Delay (up to

30 minutes). For immediate retransfer press

Bypass Time Delay button.

Unloaded Running (Engine Cooldown) Delay allows engine to run unloaded for 5 minutes.

Disconnecting the Plugs

1. Observe the position of the transfer switch.

a. If the transfer switch is in the Normal position, place standby engine starting control in the off position. Then open the emergency source circuit breaker.

b. If the transfer switch is in the Emergency position, open the normal source circuit breaker. Place the engine starting control in the test or run position.

2. Separate the quick disconnect plugs by squeezing the latches. Do not pull on the harness wires.

3. Label, remove, and tape the signal wires connected to the engine start terminals on the transfer switch:

TB1 and TB3, or TB1 and TB2.

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!

Clean the enclosure. De–energize all sources, then brush and vacuum away any excessive dust accumulation. Remove moisture with a clean cloth.

Check the transfer switch contacts. De-energize all sources, then remove the transfer switch barriers and check contact condition. The non–replaceable main contacts are designed to last the life of the transfer switch. Reinstall the barriers carefully.

Maintain transfer switch lubrication. Under normal operating conditions no further lubricating is required. Renew factory lubrication if the switch is subjected to severe dust or abnormal operating conditions or if TS coil is replaced. Order lubricant

625550–001 (Castrol EndurexR 4000 lubricant).

3---1

Reconnecting the Plugs

1. Observe the position of the transfer switch.

a. If the transfer switch is in the Normal position, be sure that the standby engine starting control is still in the off position. The emergency source circuit breaker still should be open.

b. If the transfer switch is in the Emergency position, normal source circuit breaker still should be open.

2. Reconnect the signal wires connected to the appropriate engine start terminals on the transfer switch. See Section 1, Engine Starting Contacts.

3. The harness plugs and sockets are keyed.

Carefully align the plugs with the sockets and press straight in until both latches click.

4. Restore the opposite source as follows: a. If the transfer switch is in the Normal position, place the standby engine starting control in the

automatic

position. Then close the emergency source circuit breaker.

b. If the transfer switch is in the Emergency position, close the normal source circuit breaker. The load will be automatically retransferred to the normal source after the Retransfer to Normal Delay. For immediate retransfer, press Bypass Time Delay button. Place the engine starting control in the

automatic

position.

TESTING & SERVICE

(continued)

MANUAL LOAD TRANSFER

This procedure will manually transfer the load if the controller is disconnected.

1. Open normal and emergency source circuit breakers.

2. Use the maintenance handle to manually operate transfer switch to the opposite source. See page

1–3, Manual Operation Test.

Do not manually operate the transfer switch until both power sources are disconnected: open both circuit breakers.

3. If the transfer switch is in the Emergency position manually start the engine generator and then close the emergency source circuit breaker.

TROUBLE-SHOOTING

Note the control features that are activated or furnished on the switch and review their operation.

Refer to Section 5, Control Features.

Gen-Set does not start when the

Transfer Test button is pressed and held for 15 seconds or when the normal source fails.

Transfer switch does not transfer the load to emergency source after the gen-set starts.

Transfer switch does not transfer the load to normal source when normal returns or when

Transfer Test button is released.

Gen-Set does not stop after load retransfer to the normal source.

Proceed with care! The automatic transfer switch is energized.

Table 3-1. Trouble-Shooting Checks.

CHECK IN NUMERICAL SEQUENCE

1 OPERATION

Hold the

Transfer Test button

15 sec. or the outage must be long enough to allow for the 1 or 3 sec.

Momentary Normal

Source Outage Delay plus engine cranking and starting time.

2 GEN-SET

Starting control must be in automatic position. Batteries must be charged and connected. Check wiring to engine starting contacts.

Wait for

Transfer to Emergen-

cy Delay (0 to 5 min.) to time out. For immediate transfer, press the

Bypass Time Delay

button. If Motor Load Transfer is active, wait for inphase condition (see below).

Generator output circuit breaker must be closed.

Generator frequency must be at least 57 Hz.

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). *

* These are factory settings.

Wait for

Retransfer to Normal

Delay (1 sec. to 30 min.) to time out. For immediate re– transfer, press

Bypass Time

Delay button. If Motor Load

Transfer is active, wait for inphase condition (see below).

Wait for the 5 minute

Unloaded Running Delay to time out.

—

Starting control must be in automatic position.

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).

— could result !

Trouble-Shooting the Motor Load Transfer Feature (refer to page 5–4)

Use extreme caution when using a meter to measure voltages in the following steps. Do not touch power terminals; shock, burns, or death

1. Connect a voltmeter (set for twice system phase–to–phase voltage) between Transfer Switch terminals NA and EA.

2. Manually start generator. Voltmeter needle should sweep back and forth at a regular rate between 0 and about twice system voltage.

3. Press and hold Transfer Test button. The load should transfer to emergency source when meter needle is near 0 volts. If transfer does not occur,

Motor Load Transfer feature is not operating.

4. Release the Transfer Test button. The load should retransfer back to the normal source after the

Retransfer to Normal Delay

, if used. The retransfer should occur when the needle is near 0 volts. If retransfer does not occur after the time delay, the

Motor Load Transfer feature is not operating.

5. For immediate retransfer, press the Bypass Time

Delay

button. Then disconnect the voltmeter.

If the problem is isolated to circuits on the controller or the transfer switch, call your local ASCO Power Technologies sales office, representative, or ASI. In the United States, call 1–800–800–2726. Furnish the Serial No., Bill of

Material (BOM) No., and Catalog No. from transfer switch nameplate.

3---2

SECTION 4 ADJUSTMENTS

Time Delay Adjustment

Standard time delays are set to customer specifications

(if none specified, standard factory settings are used).

To change a setting, follow procedure on page 4-2. Use

Table 4-1 as a guide to time delay values and their corresponding adjustment DIP switch or potentiometer.

Table 4-1. Time Delay Settings

DESCRIPTION

Override Momentary

Normal Source Outages

LABELS

TIMER

N/E

FACTORY

SETTING

0 minutes

(full ccw)

ADJUSTMENT

RANGE

1 second

3 seconds

0 to 5 minutes

S3 DIP

SWITCH

Actuator 1 on

Actuator 1 off

— —

ADJUSTMENT

POTENTIOMETER

—

Override Momentary

Emergency S. Outages

— 4 seconds non-adjustable — — —

Unloaded Running

(Engine Cooldown)

TIMER 30 minutes

E/N (full cw)

— 5 minutes

1 second to

30 minutes non-adjustable

—

— —

Sensor Adjustments

Voltage and frequency sensor pickup and dropout points are set to customer specifications (if none specified, standard factory settings are used). To change a setting, follow procedure on page 4–2. Use Tables 4-2 and 4–3 for settings and corresponding DIP switch actuators.

NOTICE

Any change in these settings may affect the normal operation of the automatic transfer switch. This change could allow the load circuits to remain connected to a low voltage source.

Table 4-2. Voltage and Frequency Settings. (

Shaded DIP switches are standard factory settings).

LABELS SETTING

% of nominal

FACT. SET ADJ RANGE

S1 DIP

SWITCH

95 % * Actuator 3 off

90 %

Normal Source Voltage

Emergency Source

Voltage

Emergency Source eque cy

– –

60 / 50

Pickup

Dropout

Pickup

Dropout

90 %

75 %

95 %

85 %

90 % *

85 %

80 %

70 % non-adjustable non-adjustable non-adjustable non-adjustable

60 Hz

50 Hz

3 phase

Actuator 3 on

Actuator 1 off

Actuator 2 off

Actuator 1 on

Actuator 2 off

Actuator 1 off

Actuator 2 on

Actuator 1 on

Actuator 2 on

– –

Actuator 4 off

Actuator 4 on

Actuator 6 off

1 phase Actuator 6 on

* If dropout voltage is set to 90%, the pickup voltage must be set to 95%.

Table 4-3. Transformer Voltage Adjust.

(Low setting shifts all voltage settings down 4.2%; for example, 240 V to 230 V, or 480 V to 460 V)

DESCRIPTION LABELS

LOW /

FACTORY SETTING ADJUSTMENT

LOW

S3 DIP SWITCH

Actuator 2 off

Actuator 2 on

4---1

ADJUSTMENTS

(continued)

NOTICE

Do not make any setting changes while the controller is energized.

How to Change a Setting

1. Prevent the transfer switch from operating by disconnecting one source first, then the other, as follows: a.

If the transfer switch is in the Normal position, open the emergency source circuit breaker.

Turn the engine starting control to off. Then open the normal source circuit breaker.

If the transfer switch is in the Emergency position, open the normal source circuit breaker.

Turn engine starting control to test or run. Then open the emergency source circuit breaker.

2. Disconnect both harness plugs from controller by squeezing the latches. Do not pull on the wires.

3. Remove cover from the controller by releasing latch on right side with your thumb. See Figure 4-1.

cover hook on left side

Figure 4-1. Controller cover latch.

thumb latch

9 volt alkaline battery

4. Locate the appropriate adjustment potentiometer or

DIP switch for the setting that you want to change.

Refer to Table 4-1 and Table 4–2 on page 4-1 and

Figure 4-2, Figure 4–3, Figure 4–4 on page 4–2.

5. Use a small screwdriver to turn the potentiometer clockwise to increase the time delay or counterclockwise to decrease it. See Figure 4-3.

6. Use a ball-point pen (or similar pointed tool) to slide the switch actuators left or right so they match the illustration next to the setting (left = off, right = on). Recheck the setting. See Figure 4-4.

7. Install the cover on the controller by hooking it on the left side and latching the right side.

8. Reconnect both harness plugs to the controller by aligning and pressing straight in until latches click.

harness plugs

S3 DIP switch

S1 DIP switch

S2 DIP switch

J5 battery on/off jumper

P1 to normal time delay

P2 emergency time delay

Figure 4-2. Location of potentiometers.

Close the transfer switch enclosure door.

9. Close the enclosure door, then restore both sources: a.

If the transfer switch is in the Normal position first close the normal source circuit breaker, then close the emergency source circuit breaker.

If the transfer switch is in the Emergency position, close the normal source circuit breaker. The load will be automatically retransferred to the normal source. Then close the emergency source circuit breaker.

10. Turn the engine starting control to automatic.

4---2 clockwise to increase

P1 or P2 potentiometer counterclockwise to decrease

Figure 4-3. Changing time delay potentiometers.

DIP switches

SW1

SW2

SW3 actuator

(8 on each DIP switch) off on

Figure 4-4. Setting DIP switch actuators.

SECTION 5 CONTROL FEATURES – ENGINE EXERCISERS

These timers periodically exercise the emergency engine-generator plant. They can be set to exercise with or without load transfer, or they can be completely disabled. The engine-generator should be exercised under load once a week for a minimum time period of 20 minutes, or follow the recommendations of the engine-generator set manufacturer. Refer to page 4–2 for location of DIP switches, battery (provided), and jumper block in the controller.

BUILT–IN ENGINE EXERCISER

The engine exerciser included in ASCO Series 300

Automatic Transfer Switches provides a once a week

20–minute exercise period. It occurs immediately when the

Set Engine Exerciser push button is pressed (and held for at least 5 seconds), and then at the same time weekly thereafter. A 9 volt alkaline battery (Duracell

MN1604, Everready 522, or Panasonic 6AM6) is furnished and installed in the controller to maintain the setting. The battery jumper block must be shifted to the

ON position. See Figure 4–2 on page 4–2.

Fill in day and time set. Week Day ______ Time _______.

FUNCTION

Std. Timer

Enabled

Std. Timer

Disabled

Exercise without

Load

Exercise with Load

DIP Switch Settings

S1 DIP

SWITCH

Actuator

7 on

Actuator

7 off

Actuator

8 off

Actuator

8 on

S2 DIP

SWITCH

Actuator

5 on

Actuator

5 on

Shaded DIP switches are standard factory settings.

status light

Press to cancel an active exercise period (stops generator).

If Exercise with Load is set, retransfers load to

Normal, then stops generator after min. cooldown.

Press and hold for 5 sec. or until status light blinks rapidly to set exercise period immediately and every week hereafter (generator starts).

Figure 5-1. Operator panel pushbuttons and light.

Exerciser with Load is set, transfers load to Emergency.

Select below either Exercise without Load or Exercise with Load according to the setting of DIP switch S1, actuator 8. The load transfers from the Normal source to Emergency source (generator) and back again if Exercise with Load is selected.

Exercise without Load, DIP Switch S1, Actuator 8 off

How to Set Built–In Timer

Step

Push Button

Set Engine

Exerciser

hold 5 sec.

release press

Bypass

Time Delay

—

Function

Status Light

blinks rapidly

OPOPOP set exercise period blinks slowly

OPPOPP exercise period now active

O stays on cancel active exercise period

O stays on generator off

Explanation

Exercise the generator now and every week at this time hereafter.

Generator starts and runs.

Generator stops.

Exerciser enabled; repeats every 7 days.

Exercise with Load, DIP Switch S1, Actuator 8 on

How to Set Built–In Timer

Step Function Explanation

Push Button

Set Engine

Exerciser

hold 5 sec.

release press

Bypass

Time Delay

—

Status Light

blinks rapidly

OPOPOP blinks slowly

OPPOPP blinks slowly

OPPOPP

O stays on set exercise period exercise period now active cancel active exercise period generator off

Exercise the generator now and every week at this time hereafter.

Generator starts and runs; the load transfers to Emergency.

The load retransfers to Normal; then generator runs for 5 minute cooldown

( light blinks slowly during cooldown ).

Exerciser enabled; repeats every 7 days.

NOTE: Every time SET ENGINE EXERCISER push button is pressed (held 5 seconds) the exercise period is changed.

5---1

2–line display

3 buttons

CONTROL FEATURES (continued)

Optional Accessory 11BG – SOURCE AVAILABILITY SIGNAL

& PROGRAMMABLE ENGINE EXERCISER MODULE

connections for source availability signal contacts

Figure 5–2. Accessory 11BG module (mounted behind operator interface and connected to the controller) includes source availability signal contacts and a programmable engine exerciser.

Source Availability Signal Contacts

The module provides one Form C contact each for the normal and emergency sources signal the acceptability of the source as sensed by the controller. The signal contacts operate in conjunction with the Source

Accepted

lights on the operator interface. Field wiring terminals are provided as shown in Figure 5–3 and the wiring diagram.

Contact ratings:

2 amps @ 30 Vdc, 0.5 amp. @ 125 Vac resistive

SOURCE

AVAILABILITY SIGNALS

2 AMPS @ 30 VDC, resistive

0.5 AMP @ 125 VAC, resistive contacts shown de–energized

Figure 5–3. Source availability signal contacts.

Programmable Engine Exerciser

The module includes a programmable engine exerciser that provides for weekly or biweekly operation. This optional exercise timer may have to be turned on

(enabled) by setting the S1 DIP switch actuator 7 to off, and S2 DIP switch actuator 5 to off. A backup battery in the controller (see page 4–2 and page 5–3) must be turned on to maintain the settings and to allow programming with the normal and emergency power turned off (page 5–1).

The programmable engine exerciser incorporates a 7 day or 14 day time base. Proper controller settings must be made to determine whether or not the test will be done with or without load transfer (S1 DIP switch actuator 8).

See next page for instructions on setting the timer.

5---2

DIP Switch Settings in the Controller

FUNCTION

Opt. Timer

Enabled

Opt. Timer

Disabled

Exercise without

Load

Exercise with

Load

(see page 4–2)

S1 DIP

SWITCH

Actuator

7 off

Actuator

7 off

Actuator

8 off

Actuator

8 on

S2 DIP

SWITCH

Actuator

5 off

Actuator

5 on

Shaded DIP switches are standard factory settings.

CONTROL FEATURES (continued)

How to Set Optional Programmable Engine Exerciser

(part of Acc. 11BG module)

Hazardous voltage capable of causing shock, burns, or death is used in this transfer switch.

Deenergize both Normal and Emergency power sources before programming the exerciser.

Navigating the Menu

Use the UP and DOWN arrow keys to move through the displays.

Changing the Parameters

Use the UP and DOWN arrow keys to move though the displays to the parameter to be changed.

Push the ENTER key to start the editing process. The first parameter will flash. Use the UP and DOWN arrow keys to adjust the parameter to the desired value and press the ENTER key to save the value. The next parameter will now flash. Repeat the process until each parameter is properly configured.

Fast/Slow Adjust

Daylight Saving

Time Adjust

Date

Time

Run TIme

Start TIme

Engine Exerciser

NOTE: When choosing bi–weekly operation, the exerciser will always run on the week designated “(1)” on the date display.

Run Time Display

The Run Time Display shows the run time for the engine exerciser. The default setting from the factory is 30 min.

Time Display

The Time Display shows the present system time. The format is “hours:minutes:seconds”.

NOTE: During total power outages, power to the accessory is maintained by a battery in the Controller

(see page 4–2). Be sure that the 9–volt alkaline battery is fresh and enabled (jumper in ON position) so that the time and date settings are not lost.

Date Display

The Date Display shows the present system date. The format is “day of week (week) month/day of month/year”.

NOTE: Week is either week 1 or week 2. This is used in conjunction with the bi–weekly timer.

Daylight Savings Time Adjust Display

This display shows whether the automatic daylight saving time adjustment is active. The factory default is

“NO”. If enabled, the unit will automatically adjust for daylight saving time at 2 AM on Sunday as follows:

Part No. 629857–001*

Start

629857–002* first Sunday in April 2nd Sunday in March

Stop last Sunday in Oct first Sunday in Nov

* Part no. on back of circuit board. New DST starts in 2007.

Engine Exerciser Display

The Engine Exerciser Display shows the status of the engine exerciser. When the unit is shipped from the factory the programmable engine exerciser is

“Disabled” and must be set to “Enabled” by the customer. When the engine exerciser is running, this display will count down the remaining time until the end of the exercise period.

Start Time Display

The Start Time Display shows the engine exerciser start time. There are four parameters that determine the start time: weekly (”Every”) or bi–weekly (”Alt”) operation day of week (”Sun” through “Sat”) start hour (0 through 23) start minutes (0 through 59)

For example, if the user wants the exerciser to run every other Saturday at 3 PM, the proper configuration would be:

“Alt Sat @ 15:00”

Fast / Slow Adjust Display

This display shows the automatic fast/slow adjustment value. The factory default is 0. This feature can be used to trim a clock that runs fast or slow. For example, if your clock runs 10 seconds slow per week, change the fast/slow adjust value to “+10” and the unit will automatically add 10 seconds to the clock every week.

NOTE: Adjustments are made Sunday morning at 2

AM. If you want your exerciser period to start at 2 AM on Sunday, you cannot use this feature and the adjustment must be set to 0.

Date exerciser was set ___________________________

Fill in your settings for future reference

Weekly or Bi–weekly Day of Week

Every = weekly

Alt = bi–weekly

Sun through Sat

Start Time

0 – 23 hour

0 – 59 minute

Run Time

0 – 23 hour

0 – 59 minute

30 min. is default setting

5---3

CONTROL FEATURES (continued)

INPHASE MONITOR

FOR MOTOR LOAD TRANSFER

LOAD DISCONNECT FEATURE

Connect external circuits to the terminals indicated on the Wiring Diagram provided with the ATS.

Inphase monitoring logic controls transfer and retransfer of motor loads, so that inrush currents do not exceed normal starting currents. It avoids nuisance tripping of circuit breakers and mechanical damage to motor couplings.

The Motor Load Transfer feature is built into the controller. DIP switch S1 (actuator 5) activates this feature: right = ON, left = OFF.

The double throw (Form C) contact is rated for

28 VDC or 120 VAC (5 amperes resistive). The contact operates prior to a selectable 0, 3, 10, or 20 second delay before transfer of the Automatic Transfer Switch.

The contact resets either immediately following transfer or after the same delay as set for pre–signal before transfer.

FUNCTION

enable disable

S1 DIP SWITCH

Actuator 5 on

Actuator 5 off

Time delay between the load disconnect control signal and initiation of transfer is set on the controller with

DIP switch S2 (actuators 6, 7, 8) as shown below:

Shaded DIP switches are standard factory settings.

Note

If the Motor Load Transfer feature is enabled, it will be activated following the Load Disconnect

Feature Delay Before Transfer delay.

LD TDBT

0 (disable)

3 seconds

10 seconds

20 seconds

Delay Before Transfer

S2 DIP SWITCH

Actuator 7 on

Actuator 8 on

Actuator 7 on

Actuator 8 off

Actuator 7 off

Actuator 8 on

Actuator 7 off

Actuator 8 off

Shaded DIP switches are standard factory settings.

LD TDAT

enable

Delay After Transfer*

S2 DIP SWITCH

Actuator 6 on disable Actuator 6 off

*Enabling the Delay After Transfer will cause the control signal to reset after the same delay as set for the

Delay Before Transfer.

REMOTE CONTROL FEATURES

These remote control features require a customer–supplied normally closed contact suitable for a 5 V dc low energy circuit. Refer to the Wiring Diagram provided with the ATS. Activate appropriate DIP switch S2 actuators below.

Remote Test (terminals CP6–7)

RTSW

disable

S2 DIP SWITCH

Actuator 3 on enable Actuator 3 off

Remote Transfer to Emergency (CP8–9)

RT /E

disable

S2 DIP SWITCH

Actuator 2 on enable Actuator 2 off

Bypass Transfer Time Delay (CP12–13)

TD E/N BYP.

disable

S2 DIP SWITCH

Actuator 1 on enable Actuator 1 off

Inhibit Transfer to Emergency (CP10–11)

N/E INHIB.

disable

S2 DIP SWITCH

Actuator 4 on enable Actuator 4 off

5---4

CONTROL FEATURES (continued)

OPTIONAL STRIP HEATER (Accessory 44)

Accessory 44 Strip Heater is designed to keep ambient temperatures within the Automatic Transfer Switch enclosure at acceptable levels. This accessory consists of a mounting bracket with strip heater, thermostat, and terminal block. A transformer with fuses is included when the power for the assembly is derived from voltages above 120 V ac. The 120 V ac customer powered assembly does not include a transformer. This optional accessory is available factory installed or in kit form.

Turn the thermostat’s dial to required setting as shown.

thermostat dial turn counterclockwise to lower temperature turn clockwise to raise temperature

Figure 5–4. Thermostat.

Controls

Description

Programmable Engine Exerciser

& Source Availability Contacts

Serial Communication Module

Accessory

AVAILABLE KITS

Strip Heater – Accessory 44

Kit Description Accessory

11BG

72A

K629830

K601110

120 volt customer supplied voltage

(without transformer)

208 – 480 volt

ATS derived voltage

(with transformer)

380 volt

ATS derived voltage

(with transformer)

550 – 600 volt

ATS derived voltage

(with transformer)

44A

44G

Kit

K613127–001

K613127–002

K613127

K613127–003

5---5

accessories, 5–2, 5–5 auxiliary circuits, 1–2

battery, 4–2, 5–1 buttons, push, 3–1 bypass time delay, 1–5, 2–1, 3–1

cable lugs, preparation, 1–1 catalog number, cover cleaning, 3–1 connections engine control contact, 1–2 line, 1–1 contacts auxiliary, 1–2 engine control, 1–2 main, 1–3, 3–1 source availability signal, 5–2 control features, 5–1 load disconnect, 5–4 motor load transfer, 5–4 plant exerciser, 5–1, 5–2, 5–3 controller, 4–1, 4–2 codes, cover cover removal, 4–2 disconnecting, 3–1 time delay potentiometers, 4–2

DIP Switches, 4–1, 4–2, 5–1, 5–2, 5–4

electrical operation, 1–5 engine exerciser, 5–1, 5–2, 5–3 engine starting contacts, 1–2

features, see control features frequency, pickup and dropout, 4–1 functional test, 1–3, 1–4, 1–5

ground, controller, 1–1

Printed in U.S.A.

INDEX

handle, maintenance, 1–3 warning, 1–3 harness, 1–2 disconnect plugs, 3–1

HELP

800–800–2726 (ASCO) [email protected]

parts, 3–1

problem, 3–2 programmable engine exerciser, 5–2,

5–3

inphase monitor, 5–4 inspection, 3–1 installation, 1–1

labels, engine starting contacts, 1–2 inputs / outputs, 1–2 rating, cover lights, 1–4, 5–1 load disconnect feature, 5–4 lubrication, 3–1

maintenance, preventive, 3–1 manual load transfer, 3–2 warning, 3–2 manual operation, 1–3 illustration of, 1–3 warning, 1–3 motor load transfer feature, 5–4

rating label, cover remote control features, 5–4 bypass transfer time delay, 5–4 inhibit transfer to emergency, 5–4 remote test, 5–4 remote transfer to emergency, 5–4 replacement parts, 3–1

service, call 800–800–2726 (ASCO) set engine exerciser, 5–1, 5–2, 5–3 settings changing, 4–1 factory, 4–1 frequency, 4–1 phase, 4–1 time delay, 4–1 voltage, 4–1 source accepted lights, 1–4, 1–5

nameplate, cover

operation electrical, 1–5 manual, 1–3 illustration of, 1–3 warning, 1–3 sequence of, 2–1 optional accessories programmable engine exerciser

& source availability signal contacts, 5–2, 5–3 serial communication module, 5–5 strip heater, 5–5

terminal block, 1–2 test, functional, 1–3, 1–4, 1–5 time delay adjustment, 4–1 gen–set cooldown, 4–1 how to change, 4–2 override momentary outages, 4–1 settings, 4–1 transfer to emergency, 4–1 transfer to normal, 4–1 timer (plant exerciser), how to set,

5–1, 5–2, 5–3 transfer switch position lights, 1–4,

1–5 transfer test, 1–5, 3–1 trouble–shooting, 3–2

voltage, phase, 4–1 voltage, pickup and dropout settings,

4–1

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