ASCO 300 Installation Manual

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SERIES 300 Dual Purpose Quick Connect Power Panels 800 – 4000 amp Pad Mount
Installation Manual
381333-488 2/2021
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SERIES 300 Quick Connect Power Panel Installation Manual
Table of Contents
Limited Warranty ...................................................................................................................................................... 3
Maintenance ............................................................................................................................................................. 3
Technical Support ..................................................................................................................................................... 3
Prior to Installation ................................................................................................................................................... 4
Shipment: Unpacking and Inspection ................................................................................................................ 4
Initial Installation ....................................................................................................................................................... 5
Step 1: Fasten ASCO SERIES 300 Dual Purpose Quick Connect Power Panel to secure base ............................ 5
Step 2: Installing the Conduit .................................................................................................................................... 5
Installation .................................................................................................................................................................. 6
Step 3: Wiring the Lug Terminals (ATS only) ........................................................................................................... 6
Step 4: Wiring the Lug Terminals (ATS & Permanent Generator) ........................................................................... 6
Step 5: Configuring the Phase Rotation Monitor ...................................................................................................... 7
Step 6: Determine Phase Rotation ........................................................................................................................... 7
Set-up -Portable Generator Connection (Lower Section) ............................................................................ 8
Step 7: Determining phase rotation of generator ..................................................................................................... 8
Step 8: Conduct a safety test to ensure proper installation ...................................................................................... 8
Step 9: Making Cam Connections ............................................................................................................................ 8
Step 10: Connect two wire auto start circuit ............................................................................................................. 9
Step 11: Close and lock lower chamber door, allowing cables to exit through smaller cable door ........................ 9
Step 12: Powering Up ............................................................................................................................................... 9
Step 13: Disconnection .......................................................................................................................................... 10
Step 14: Secure front door to complete .................................................................................................................. 10
Set-up Load Bank Connection Section (Upper Section) ............................................................................ 11
Step 15: Making Cam Connections ........................................................................................................................ 11
Step 16: Connecting Load Dump Circuit ............................................................................................................... 11
Step 17: Powering Up ............................................................................................................................................. 11
Step 18: Disconnection .......................................................................................................................................... 11
Trap Key Interlocks ................................................................................................................................................ 12
Standard Accessories ........................................................................................................................................... 13
Load Dump Receptacle .......................................................................................................................................... 13
Auto Start Terminals & Auto Start Destination Switch ........................................................................................... 13
Standard Accessory Wiring Diagram ..................................................................................................................... 13
Appendix A ............................................................................................................................................................... 14
Pre-Operation and Maintenance Checklist ............................................................................................................. 14
Index .......................................................................................................................................................................... 15
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Installation SERIES 300 Quick Connect Power Panel
Limited Warranty
DANGER is used in this manual to warn of a hazard 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.
When this ASCO SERIES 300 Dual Purpose Quick Connect Power Panel is installed and operated, according to the manual instructions, ASCO Power Technologies will repair or replace any of its mechanical or electrical parts if they are found to be defective in material or workmanship within two years of the purchase date.
Maintenance
The ASCO SERIES 300 Dual Purpose Quick Connect Power Panels will require maintenance. ASCO Power Technologies recommends annual inspections to keep the panel in safe operating condition. ASCO Power Technologies recommends that the Pre-Operation and Maintenance Checklist under Appendix A serve a basis for annual inspection
Important
This manual contains information critical to proper installation and operation of the ASCO SERIES 300 Dual Purpose Quick Connect Power Panels. Be certain to read and understand all instructions prior to installation and operation.
The ASCO SERIES 300 Dual Purpose Quick Connect 800-4000A Pad Mount Power Panels are not designed for simultaneous operation of both input and output connections when the Power Panels are connected to a permanent generator and ATS via mechanical lugs. Castell or Kirby Key locks must be installed on generation connection door and permanent generator breaker which serves as an interlock between permanent generator and portable generator.
ASCO SERIES 300 Dual Purpose Quick Connect Power Panels are ETL listed to UL891 Standards.
Technical Support
ASCO Power Services are available to assist in resolving issues by calling 1-800-800-2726 (ASCO) or by emailing powerwarranty@ascopower.com. For any additional information, please refer to ascopower.com.
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SERIES 300 Quick Connect Power Panel Installation Manual
Prior to Installation: Site Preparation
Prepare the installation site according to local codes
The ASCO SERIES 300 Dual Purpose Quick Connect Power Panels are to be set on an exterior pad and secured to a building or to the pad using 3/8” fasteners (Figure 1).
The surface where the ASCO SERIES 300 Dual Purpose Quick Connect Power Panel is to be secured must be capable of supporting the weight of the cabinet as well as the cable attached to it.
The following should be taken into consideration when locating the ASCO SERIES 300 Dual Purpose Quick Connect Power Panel:
The ASCO SERIES 300 Dual Purpose Quick
Connect Power Panel is designed for exterior operation ONLY.
Identify and meet local codes and local Authority
Having Jurisdiction (AHJ)
To prevent carbon monoxide poisoning from
improperly ventilated generator emissions, the Power Panel must be mounted outdoors only. The mounting location is to be carefully selected to allow convenient connection to a generator and located a suitable distance away from any building openings or HVAC inlets.
Shipment: Unpacking and Inspection
Be careful in the use of sharp objects when cutting packaging as damage to the outer enclosure may result.
Perform a visual inspection to ensure the door and all hasps are in functioning condition and that the panel integrity is intact.
Proper clearance must be allowed in front of the
ASCO SERIES 300 Dual Purpose Quick Connect Power Panel to allow for opening of access doors and attachment of externally connected cables. This distance should be no less than six(6) feet from the face of the panel.
While lock protection is provided, access by
unauthorized personnel and vandals should be taken into consideration when locating this device.
Secure with 3/8” fasteners
Figure 1. Bottom View
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Installation SERIES 300 Quick Connect Power Panel
Initial Installation
The installation of the ASCO SERIES 300 Dual Purpose Quick Connect Power Panel must be done by qualified personnel in accordance with local electrical codes.
ASCO SERIES 300 Dual Purpose Quick Connect Power Panels are front heavy. Care must be taken to secure the device when its lifted and moved. Lifting eyes are provided on the enclosure to assist with proper lifting and movement of enclosures (Figure 2).
Step 1: Fasten the ASCO SERIES 300 Dual Purpose Quick Connect Power Panel to secure base.
1. Base must be level and plumb to allow for proper
drainage from the ASCO SERIES 300 Dual Purpose Quick Connect Power Panel weep holes.
2. Fastening onto an external wall using 3/8” fasteners must be completed prior to proceeding with any terminations (see Figure 1 for hole spacing).
Step 2: Installing the Conduit
Conduit to enter through the bottom, rear and sides unit (Figure 3).
To maintain TYPE 3R Rating compliance for the enclosure, proper sealing procedures must be followed. This is to include, but not limited to, the use of proper gaskets.
1. Remove rear and side panels to expose termination chamber.
Figure 2
2. Conduit to be sized according to cable rating.
3. It is recommended that a knockout punch be used to cut hole for conduit.
4. Place the punch on the panel that was removed from the enclosure and draw the punch through to the die on the outside.
Figure 3
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SERIES 300 Quick Connect Power Panel Installation Manual
Installation
Connecting to ATS ONLY
Step 3: Wiring the Lug Terminals
Ensure circuit breakers are OFF and the transfer switch is locked out from utility power prior to connection.
Failure to install transfer switch will create the potential for the generator to energize utility lines and endanger utility personnel. Conversely, utility lines may energize the ASCO SERIES 300 Dual Purpose Quick Connect Power Panel and endanger generator personnel.
The ASCO SERIES 300 Dual Purpose Quick Connect Power Panels consist of both recessed male 16 series single pole connectors (inlets) and female single pole connectors (outlets).
The ASCO SERIES 300 Dual Purpose Quick Connect Power Panel inlet portion is for use only for connection of a generator to the source terminals of a transfer switch, such that the inlets are only energized from the generator.
The ASCO SERIES 300 Dual Purpose Quick Connect Power Panel outlet portion is used only for connection of a load bank to the portable generator such that the outlets are only energized from the portable generator.
1. Pull the cables from the transfer switch to the ASCO SERIES 300 Quick Connect Power Panel
2. Beginning with the ground, strip and install the cables in the appropriate mechanical lugs.
The mechanical lugs can accommodate 500 to 800 MCM, Copper or Aluminum wire.
3. Tighten mechanical lugs to 375 lb.-in torque each
4. If metallic conduit is used, connect ground wire from ground bushing on conduit to the ground connection point in the upper right quadrant of the panel
5. Ground conductor must be a minimum of #2 AWG
Connection to ATS & Permanent Generator via mechanical lugs
Step 4: Wiring the Lug Terminals
The ASCO SERIES 300 Dual Purpose Quick Connect Power Panels 800 – 4000A Pad Mount Power Panels are not designed for simultaneous operation of both input and output connections when the Power Panel is connected to both a permanent generator and ATS via mechanical lugs. Castell or Kirk Key locks must be installed on generator breaker which serves as an interlock between permanent generator and portable generator.
Ensure circuit breakers on the permanent generator are OFF and the transfer switch is locked out from utility power prior to connection.
Failure to install transfer switch will create the potential for the generator to energize utility lines and endanger utility personnel. Conversely, utility lines may energize the ASCO SERIES 300 Dual Purpose Quick Connect Power Panel and endanger generator personnel.
The ASCO SERIES 300 Dual Purpose Quick Connect Power Panels consist of both recessed male 16 series single pole connectors (inlets) and female single pole connectors (outlets).
1. Pull the cables for the transfer switch to the ASCO SERIES 300 Quick Connect Power Panel
2. Beginning with the ground, strip and install the cables in the appropriate mechanical lugs.
The mechanical lugs can accommodate 500 to 800 MCM, Copper or Aluminum wire.
3. Tighten mechanical lugs to 375 lb.-in torque each
4. If metallic conduit is used, connect ground wire from ground bushing on conduit to the ground connection point in the upper right quadrant of the panel
5. Ground conductor must be a minimum of #2 AWG
Conduit shall NOT be relied upon to provide grounding protection to tap box
6. Continue to connect the neutral and then the phases. (continue to page 6).
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Conduit shall NOT be relied upon to provide grounding protection to tap box
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Installation SERIES 300 Quick Connect Power Panel
6. Continue to connect the neutral and then the phases
7. Repeat steps 1-6 for cable connection from permanent generator to mechanical lugs of ASCO SERIES 300 Quick Connect Power Panel
8. Ensure that Castell K-lock (provided with unit) is installed on the permanent generator breaker.
Three phase power systems consist of three phase or hot conductors that are shifted by 120 degrees. Three phase loads such as motors may only work properly if the phases are connected in the correct order. Some motors may work when connected improperly but will operator backwards. Utility power and electrical generators may be wired either in a clockwise or counterclockwise order. It is important that any generator connected to the ASCO SERIES 300 Dual Purpose Quick Connect Power Panel is connected in the same rotation (clockwise or counterclockwise) as the utility power
Step 6: Determine Phase Rotation
This information will be needed when connecting a generator.
1. Determine phase rotation of the utility power.
2. Connect a phase rotation meter to a three phase power source in the building and record whether the building is wired clockwise or counterclockwise
3. Apply the provided label to the inside of the ASCO SERIES 300 Dual Purpose Quick Connect Power Panel on the inside of the cam connection chamber box door (Figure 6).
4. Should the phase rotation monitor configuration and utility power (label found on the inside of the door for the Cam connection chamber) match, proceed to Step 7.
5. Should the phase rotation monitor configuration and the utility power (label found on the inside of the door for the Cam connection chamber) differ, swap the A and B phase rotation connection wires at the camlock connection so it matches utility power and is consistent with the label found inside the door.
Step 5: Configuring the Phase Rotation Monitor
A phase rotation monitor comes standard on all ASCO SERIES 300 Dual Purpose Quick Connect Power Panels (Figure 4). The Phase Rotation Monitor is prewired from the factory for ABC rotation (Figure 5)
Figure 4
Place rotation label here
Figure 6
Figure 5
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SERIES 300 Quick Connect Power Panel Installation Manual
Set-up – Portable Generator Connection (Lower Section)
The ASCO SERIES 300 Dual Purpose Quick Connect Power Panels consist of both recessed male 16 series single pole connectors (inlets) and female single pole connectors (outlets). The portable generator connectors are in the lower compartment of the enclosure.
DO NOT ATTEMPT CONNECTION WHILE CIRCUITS ARE LIVE
Do not use cables if they appear frayed
Do not use cable if connectors or plug do not seat
properly
Do not use cables if any copper cabling is exposed
To limit risk of shock, disable generator automatic
start to prevent unintended starting
Step 7: Determining Phase Rotation of generator
1. Disconnect generator from all loads if needed
2. Connect a phase rotation meter to the output phases of the generator
3. Record generator phase rotation (clockwise or counterclockwise)
Proper Connection (Figure 7)
A. Grasp connection jacket and firmly insert cam
connector into cam plug
B. Push on cam connector jacket until connector fully
seats in the cam plug
C. Rotate cam connector jacket counterclockwise until
it stops
Figure 7
Step 9: Making Cam Connections
1. Open main chamber door.
2. Continue with connections, beginning with the rear of the cabinet and working forward.
3. Complete ALL Ground connections working from back to front prior to proceeding
4. Complete the Neutral (white) connections, beginning with the furthest from the front door
Step 8: Conduct a safety test to ensure proper installation
1. Do not attempt to use the ASCO SERIES 300 Dual Purpose Quick Connect Power Panel prior to installation and completing the Pre-Operation and Maintenance Checklist under Appendix A.
2. Open lower chamber door.
3. Complete the Ground (green) connections, beginning with the furthest from the front door to the left
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Installation SERIES 300 Quick Connect Power Panel
Proper Connection (Figure 7)
A. Grasp connection jacket and firmly insert cam
connector into cam plug
B. Push on cam connector jacket until connector fully
seats in the cam plug
C. Rotate cam connector jacket counterclockwise until
it stops
D. Continue with connections, beginning with the rear
of the cabinet and working forward.
E. Complete the Phase (hot) connections
i. Should the phase rotation of the generator (as
determined in Step 5 above) and utility power (label found on the inside of the door for the Cam connection chamber) match, connect the Hots as follows:
Generator Hot ASCO SERIES 300 Quick
Connect Power Panel Hot
A A
B B
C C
Step 10: Connect Two wire auto start circuit
1. Connect 2 wire auto start circuit from transfer switch to terminal post located in the upper right corner of the Quick Connect Panel (Figure 8).
2. Connect the 2 wire auto start circuit from the generator to terminal post.
Figure 8
Step 11: Close and lock lower chamber door, allowing cables to exit through smaller cable door
Step 12: Powering Up
ii. Should the phase rotation of the generator (as
determined in Step 7.3 above) and utility power (label found on the inside of the door for the Cam connection chamber) NOT match, connect the Hots as follows:
Generator Hot ASCO SERIES 300 Quick
Connect Power Panel Hot
A B
B A
C C
Proper Connection (Figure 7)
A. Grasp connection jacket and firmly insert cam
connector into cam plug
B. Push on cam connector jacket until connector fully
seats in the cam plug
C. Rotate cam connector jacket counterclockwise until
it stops
5. Continue with connections, beginning with the rear of the cabinet and working forward.
6. Complete ALL Phase connections working back to front prior to proceeding
Power MUST BE supplied from single generator
1. Start generator per manufacturer instructions.
7. Make sure all connections are right and secure
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SERIES 300 Quick Connect Power Panel Installation Manual
Step 13: Disconnection
DO NOT ATTEMPT CONNECTION WHILE CIRCUITS ARE LIVE
1. To limit risk of shock, disable generator automatic start to prevent unintended starting:
Open lower chamber door
Order of disconnect
2. Disconnect the Phase (hot) connections, beginning with close to the front door to the right.
Proper Connection (Figure 9)
A. Grasp connector jacket firmly and rotate cam
connector clockwise until it stops
B. Firmly pull on connector until it separates from the
plug
C. Set aside
3. Continue with ALL Phase (hot) connections, beginning with the front of the cabinet and working from front to back.
7. Complete disconnect of ALL Neutral connections prior to proceeding. Disconnect the Ground (green) connections, beginning with the closest to front door.
Proper Disconnection (Figure 9)
A. Grasp connector jacket firmly and rotate cam
connector clockwise until it stops
B. Firmly pull on connector until it separates from the
plug
C. Set aside
8. Continue with ALL Ground (green) connections, beginning with the front of the cabinet and working rearward.
9. Complete disconnect of ALL Neutral connections prior to proceeding
Step 14: Secure front door to complete.
Set-up – Load Bank Connection (Upper Section)
The ASCO SERIES 300 Dual Purpose Quick Connect Power Panels consist of both recessed male 16 series single pole connectors (inlets) and female single pole connectors (outlets). The load bank connectors are in the upper compartment of the enclosure.
Figure 9
4. Complete disconnect of ALL hot connections prior to proceeding.
5. Disconnect the Neutral (white) connection, beginning with closest to the front door.
Proper Disconnection (Figure 9)
A. Grasp connector jacket firmly and rotate cam
connector clockwise until it stops
B. Firmly pull on connector until it separates from the
plug
C. Set aside
6. Continue with ALL Neutral (white) connections, beginning with the front of the cabinet and working from front to back.
Dual Purpose Quick Connect Panel Enclosure door must remain open while load bank is connected.
DO NOT ATTEMPT CONNECTION WHILE CIRCUITS ARE LIVE
Do not use cables if they appear frayed
Do not use cable if connectors or plug do not seat
properly
Do not use cables if any copper cabling is exposed
To limit risk of shock, disable generator automatic
start to prevent unintended starting
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Installation SERIES 300 Quick Connect Power Panel
Step 15: Making Cam Connections
1. Open upper chamber door.
2. Complete the Ground (green) connections, beginning with the furthest from the front door to the left.
Proper Connection (Figure 10)
A. Grasp connection jacket and firmly insert cam
connector into cam plug
B. Push on cam connector jacket until connector fully
seats in the cam plug
C. Rotate cam connector jacket counterclockwise until
it stops.
Step 16: Connecting Load Dump Circuit
1. Connect Load Dump cable to L1-15 receptable if required.
Step 17: Powering Up
Power MUST BE supplied from a source wired to a Transfer Switch
1. Toggle the transfer switch, diverting power from building loads to load bank.
Figure 10
3. Continue with connections, beginning with the rear of the cabinet and working forward
4. Complete ALL Ground connections working from back to front prior to proceeding
5. Continue with connections, beginning with the rear of the cabinet and working forward.
6. Complete the Phase (hot) connections.
Proper Disconnection (Figure 10)
A. Grasp connection jacket and firmly insert cam
connector into cam plug
B. Push on cam connector jacket until connector fully
seats in the cam plug
C. Rotate cam connector jacket counterclockwise until
it stops.
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SERIES 300 Quick Connect Power Panel Installation Manual
Trap Key Interlocks
The ASCO SERIES 300 Dual Purpose Quick Connect Power Panels come with a Castell Type D lock with a flip cap mounted to the trap door of the lower compartment housing the portable generator connections. This is shown in Figures 12 and 13. This lock is required for applications where the Power Panel is connected to both a permanent generator and automatic transfer switch via mechanical lugs
Figure 12
The ASCO SERIES 300 Dual Purpose Quick Connect Power Panels come with a Castell K Bolt interlock inside of the enclosure to be mounted at the breaker of the permanent generator. To install this lock, mount the lock at the breaker so that the bolt is fully extended and prohibits the breaker from operation.
Castell Type K Bolt interlock Operation
1. While the bolt is extended, the key is free and mechanism is locked.
2. By inserting and turning the key, you can retract the bolt. This will trap the key into the lock.
Figure 13
Castell Type D lock Operation
1. While the catch is trapped, the key is free. The mechanism is locked keeping the door lock closed.
2. By inserting and turning the key in the D lock, you can release the catch. This will trap the key in the lock.
3. The Key remains trapped while the catch is released and the door is open.
3. The key stays trapped while the bolt is retracted.
K-Lok Bolt Installation
While the bolt is completely retracted, cut of the excess portion of the bolt that would prevent the breaker from operating while the key is captive.
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Installation SERIES 300 Quick Connect Power Panel
Standard Accessories
Load Dump Receptacle
The ASCO SERIES 300 Dual Purpose Quick Connect Power Panels come with an L1-15 Twist Lock Receptacle standard to be used to connect a Load Bank Load Dump circuit (Figure 14). This receptacle is rated for 15A 125V and is prewired to the load dump terminal block located inside of the enclosure.
Figure 14-Load Dump Receptable
Auto Start Terminals & Auto Start Destination Switch
Standard Accessory Wiring Diagram
The Load Dump receptacle and Auto Start Destination switch is prewired to two separate terminal blocks as shown in Figure 16. Permanent Generator auto start wiring, and ATS engine start wiring are landed at the terminal block in the enclosure. Portable generator auto start wiring is landed at the banana terminal post located at the front of the enclosure. Figure 17 shows the terminal block mounted inside of the enclosure.
The ASCO SERIES 300 Dual Purpose Quick Connect Power Panels come with red & black banana binding terminal post standard for easy connection of a two-wire engine start circuit from the generator (Figure 15). These binding posts are prewired internally to an Auto Start Destination toggle switch (Figure 15) which allows the user to select which generator the ATS will start when the engine start signal is sent from the ATS.
Figure 16
Figure 15- Portable Gen Auto Start Terminals &
Auto Start Destination Switch
Figure 17
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SERIES 300 Quick Connect Power Panel Installation Manual
Appendix A
Pre-Operation Checklist
1. Visual inspection of the enclosure:
Ensure the ASCO SERIES 300 Dual Purpose Quick
Connect Power Panel is firmly secured to its base and/or building
Review conduit connection for signs of leakage
Ensure pain is intact with no signs of rust or
corrosion
2. Open main chamber door and remove side panels:
Ensure unit is dry and free of debris
Ensure that gaskets are pliable and no cracking
exists
Ensure that door hinges are secure and lubricated
Ensure that keylocks are intact and operational
Ensure that all load terminals are securely fastened
and that the bolts are set at 98 foot pounds of torque
Ensure paint is intact with no signs of rusting or
corrosion
Ensure electrical connections are intact with no
signs of corrosion or cracking
3. Review all safety labels and ensure that they are present and legible:
Replace as needed
4. Inspect all portable cables:
Do not use cables if they appear frayed
Do not use cables if connectors or plugs do not seat
properly
Do not use cables if any copper wiring is exposed
5. ASCO Power Services are available to assist in resolving issues. If you have any questions or need technical advice or suggestions regarding this product, please contact ASCO Power Technologies at 1-800-800-2726(ASCO) or email
powerwarranty@ascopower.com
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Index Operator’s Manual
INDEX
A
annual inspection 3
auto start circuit 9
auto start destination switch 13
auto start terminals 13
C
cam connections 8.10
chamber door 8, 9, 10, 11
circuit breakers 6
conduit 5, 6, 14
installing, 5
copper wiring 14
D
disconnection 9, 11
G
H
Help 3, 14
1-800–800–ASCO (2726)
powerwarranty@ascopower.com
hot conductors 7
I
inspection 3, 4, 14
L
limited warranty 3
load bank 10
load circuit dump 10
load dump receptable 13
lugs 6
M
maintenance 3, 8
S
safety test 8
safety labels 14
secure base 5
site preparation 4
shipment 4
T
technical support 3
terminals 6, 13, 14
torque 6, 14
trap key 12
U
unpacking 4
V
visual inspection 4, 14
gasket 5, 14
generator 8
P
phase rotation 7, 8
monitor, 7
plug 10, 11, 14
portable cables 14
powering up 9, 10
pre-operation checklist 14
W
wiring 6
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Installation Manual SERIES 300 Quick Connect Power Panel
Printed in U.S.A
ASCO Power Technologies 160 Park Avenue Florham Park, NJ 07932-1591 USA Phone: 1 800 800-2726 (ASCO) for sales or service
www.ascopower.com
©2021 ASCO Power Technologies. All Rights Reserved
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