ASCO 7000 Series ACTS Automatic Transfer Switch Operator's Manual

Operator’s

Manual

7000 Series, Automatic

Closed–Transition Transfer Switches

J–design 150, 260, 400, & 600 amp

DANGER is used in this manual to warn of high voltages capable of causing shock, burns, or death.

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.

WARNING is used in this manual to warn of possible personal injury.

CAUTION is used in this manual to warn of possible equipment damage.

Rating Label

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.

TABLE OF CONTENTS

section-page

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

Mounting and Line Connections

Auxiliary Circuits and Harness

. . . . . . . . .

. . . . . . . . . . .

1-1

1-1

1-2

Engine Starting Contacts

Functional Test

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

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

1-2

1-2 through 1-5

TESTING & SERVICE

Transfer Test

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

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

Preventive Maintenance . . . . . . . . . . . . . . . .

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

Manual Load Transfer

Trouble-Shooting

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

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

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

2-1

2-1

2-1

2-1

2-2

2-2 back cover

Nameplate

The Transfer Switch nameplate includes data for each specific ASCO 7000 Series ACTS. Use the ACTS only within the limits shown on this nameplate.

An experienced licensed electrician must install the ATS.

J

Catalog Number Identification

A typical Catalog Number is shown below with its elements explained. The example is for a 7000 Series 7ACTS with switched neutral, 3 pole, 600 amp, 480 V, in a Type 1 enclosure:

7ACTS C 3 600 N 5 C

design prefix letter

Neutral Phase Poles Amperes Voltage Controller Enclosure

A

– solid

B

– switched blank – none

2

3

– single Ø

– three Ø

150

260

400

600

A

115

B

120

C

208

D

220

E

230

F

240

G

277

H

380

J

K

L

R

400

415

440

M

460

N

480

P

550

Q

575

600

5

– standard

5X

– if accessories ordered

C

F

G

H

– type 1

– type 3R

– type 4

– type 4X

L

– type 12 blank – open type

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 telephone 519 758–8450, fax 519 758–0876, for service call 1 888 234–2726 (ASCO) www.asco.ca

381333–284 A

SECTION 1 INSTALLATION

ASCO 7000 Series Automatic Closed–Transition

Transfer Switches (ACTSs) are factory wired and tested. Field installation requires mounting and connection of service cables, and auxiliary control circuits (if required).

Remove the Shipping Skid (large ACTSs)

For large ACTSs, 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

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.

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

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.

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.

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.

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.

Line Connections

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

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 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

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.

engine start connections on customer terminal block TB

Figure 1-1. Customer terminal block on the top right side of the enclosure.

The Functional Test consists of three checks:

S 1 — Manual Operation Test, page 1–3

S 2 — Voltage Checks, page 1–4

S 3 — Electrical Operation, page 1–5

Functional Test

Do these checks in the order presented to avoid damaging the ACTS.

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.

Note the position of the contact shafts as shown below.

Emergency contacts

(upper shaft) window indicators

O is open

C is closed contact position indicators

(right side)

Normal contacts

(lower shaft)

Figure 1-2. Contact position indicators.

Shown with Emergency open and Normal closed.

Continue to 1 – Manual Operation Test on next page.

1---2

INSTALLATION

(continued)

1 – Manual Operation Test

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).

left side of transfer switch

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 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 1–3 through 1–5 and Table B.

2. Move the maintenance handle up or down as shown to manually operate the transfer switch.

The transfer switch should operate smoothly without binding. If it does not, check for shipping damage or construction debris. Operate both upper and lower contact shafts.

maintenance handle

Emergency source contact shaft hub clip

Normal source contact shaft hub

3. Return the transfer switch to the Normal position.

Observe that the window indicators (right side) show the upper shaft O (Emergency open) and the lower shaft C (Normal closed). Remove the maintenance handle and store it on the frame in the clips provided.

Figure 1-3. Maintenance handle storage location.

Hubs shown with Normal closed & Emergency open.

Table B. Maintenance handle positions.

ATS Position Handle up

Indicators

E

N up

E = O upper contacts open

N = C lower contacts closed

handle

UP opens the

Emergency source contacts

UPPER SHAFT hub

DOWN closes the

Emergency source contacts frame

Figure 1-4. Emergency (upper shaft) operation.

E

E = C upper contacts closed

N down

N = O lower contacts open down

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

Now continue to 2 – Voltage Checks on the next page.

handle

UP closes the

Normal source contacts

LOWER SHAFT hub

DOWN opens the

Normal source contacts frame

Figure 1-5. Normal (lower shaft) operation.

1---3

INSTALLATION

(continued)

GREEN RED RED RED RED observe these lights

GREEN RED

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.

Before energizing the switch check to be sure that both normal and emergency contacts are not left in the closed position.

Verify that the feeders have been connected to the proper lugs.

Use extreme caution when using a meter to measure voltages. 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---6.

Q Black square means light is on.

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.

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

1

Close the normal source circuit breaker. The Transfer Switch

Connected To Normal and the

Normal Source Accepted lights should come on.

2

3

4

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 Transfer

Switch Connected To Normal &

Emergency Source Accepted lights should come on.

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

5

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

6

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.

A B C

INSTALLATION

(continued)

GREEN RED RED RED RED observe these lights 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.

Close the enclosure door first !

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.

** 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.

This completes the Functional Test of the ACTS.

1

The Transfer Switch Connected

To Normal and Normal Source

Accepted lights should be on.

2

3

4

Turn and hold Transfer Control switch clockwise to Transfer Test until the engine starts and runs

(within 15 sec.). Emergency

Source Accepted light should come on.

Transfer switch CE closes and then Transfer Switch CN opens

(closed–transition overlap). The

Transfer Switch Connected To

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 switch will operate back to Normal position after Feature

3A time delay. For immediate retransfer turn Transfer Control counterclockwise to Retransfer

Delay Bypass. The Transfer

Switch Connected To Normal light should come on; Transfer Switch

Connected to Emergency light should go off.

5

The engine–generator will stop after the Feature 2E time delay

(unloaded running engine cooldown). The Emergency Source

Accepted light should go off.

1---5

SECTION 2 TESTING & SERVICE

TRANSFER TEST

Operate the 7000 Series ACTS at least once a month by following the five–step Electrical Operation

Transfer Test procedure on page 1–5.

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:

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.

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.

In Canada, for service call 1-888-234-2726 (ASCO).

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!

Do not unplug the controller until step

1a. or 1b. below is completed.

1. Observe the position of the transfer switch.

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.

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.

S Check the transfer switch contacts. Remove transfer switch barriers and check the condition of the contacts. Reinstall barriers carefully. The non–replaceable main contacts are designed to last the life of the transfer switch.

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.

S Check all cable connections & retighten them.

REPLACEMENT PARTS

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:

in United States call 1 800 – 800 – ASCO (2726) or in Canada call 1 888 – 234 – ASCO (2726)

Do not reconnect the controller until step 1a. or 1b. below is completed.

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.

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!

3. Restore the two sources in sequence as follows: 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.

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

(continued)

MANUAL LOAD TRANSFER

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

Do not manually operate the transfer switch until both power sources are disconnected

(all conductors deenergized).

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.

3. Then remove the maintenance handle. See page 1–3.

1. Deenergize both the normal and emergency source conductors (remove fuses or open 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.

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.

Engine–generator set does not start when the Transfer

Control switch is turned and held in Transfer Test position or when normal source fails.

Transfer switch does not transfer the load to the emergency source after the engine–generator set starts.

Transfer switch does not transfer the load to normal source when normal returns or when the Transfer Control switch is released.

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.

CHECK IN NUMERICAL SEQUENCE

1 OPERATION

Hold Transfer Test switch 15 seconds or the outage must be long enough to allow for

Feature 1C time delay plus engine cranking and starting.

2 GEN-SET

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

Wait for Feature 2B time delay to time out.

Generator output circuit breaker must be closed.

Generator frequency must be at least 95% of nominal (57 Hz for a 60 Hz system.) *

3 VOLTAGE

---

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)*

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).

Wait for Feature 2E time delay to time out.

Starting control must be in the 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. In Canada, call 1–888–234–2726. Furnish the

Serial No. and Catalog No. from the transfer switch nameplate.

2---2

INDEX

A alarm reset, 1–5, 2–2 auxiliary circuits, 1–2

C cable lugs, 1–2 preparation, 1–2 catalog number, inside cover cleaning, 2–1 closed transition bypass, 1–5, 2–2 connections line, 1–1 contact position indicators, 1–2, 1–3 controller, 1–1 disconnecting, 2–1 see Controller User’s Guide

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 harness, 1–1 disconnect plugs, 2–1

HELP

800–800–2726 (ASCO) [email protected]

I inspection, 2–1 installation, 1–1 indicators, contact position, 1–3

L labels, engine start contacts, 1–2 rating, cover lights, 1–4, 1–5 lubrication, 2–1

M maintenance handle, 1–3 maintenance, preventive, 2–1 manual load transfer, 2–2 warning, 2–2 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 parts, 2–1

P phase rotation check, 1–4 problem, 2–2

R rating label, cover replacement parts, 2–1

S 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

Printed in U.S.A.

Copyright --- ASCO Power Technologies 2007