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.
H–desi g n, 600 throu gh 1200 A
Series 300
Automatic Transfer Switches
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 1-1........................
Mounting and Line Connections 1-1.........
Engine Starting Contacts 1-2...............
Input / Output Label 1-2....................
Functional Test 1-3, 1-4, 1-5.................
SEQUENCE OF OPERATION 2-1...........
TESTING & SERVICE 3-1..................
Preventive Maintenance 3-1................
Transfer Test 3-1..........................
Disconnecting the Controller 3-1............
Manual Load Transfer 3-2..................
Trouble-Shooting 3-2......................
ADJUSTMENTS 4-1.......................
Time Delay and Sensor Adjustments 4-1.....
How to Change a Setting 4-2...............
CONTROL FEATURES 5-1.................
Engine Exercisers 5-1, 5-2, 5-3..............
Motor Load Transfer 5-4...................
Load Disconnect & Remote Control 5-4......
INDEX back of manual.....................
600, 800, 1000 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
381333–201 G
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.
H 300 B 3 600 N 1 C
Catalog Number Identification
A typical Catalog Number is shown below with its
elements explained. The example is for a Series 300
ATSwithswitchedneutral,3pole,600ampere,
480 V, in a Type 1 enclosure:
B –switched
C – overlapping
blank – solid
neutral
connections
power
connections
Neutral
Phase Poles
2 –singleØ
3 –threeØ
Amperes Voltage Controller Enclosure
600
800
1000
1200
C 208
D 220
E 230
F 240
H 380
J 400
K 415
L 440
M 460
N 480
Q 575
R 600
1 –standard
1X –if
accessories
ordered
* available 600 – 1000 A sizes only
C –type1
F –type3R
G –type4 *
L –type12 *
blank – open type
Controller
membrane
controls
Transfer
Switch
terminal block TB
for engine start
and switch
position contacts
power
connections
neutral
connections
600 ampere size in typical enclosure with location of customer connections
neutral
connections
power
connections
Transfer
Switch
terminal block TB
for engine start
and switch
position contacts
Controller
membrane
controls
power
connections
neutral
connections
800 and 1000 ampere sizes in typical enclosure with location of customer connections
neutral
connections
power
connections
Transfer
Switch
Controller
membrane
controls
terminal block TB
for engine start
and switch
position contacts
power
connections
neutral
connections
1200 ampere size in typical enclosure with location of customer connections
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.
Remove the Shipping Skid
Open the front door and remove the four lag screws (2
in front, 2 in rear) securing enclosure to the wood skid.
Supporting Foundation
The supporting foundation for the enclosure must be
level and straight. Refer to the applicable enclosure
outline drawing included with the Series 300 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
spaceandclearancetolivemetalparts. Whena
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 Series 300
according to details and instructions shown on diagram.
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
verify that they are not defective or have been
damaged during installation.
they are connected, they should be tested to
NOTICE
Protect the automatic transfer switch from
construction grit and metal chips to prevent
malfunction or shortened life of the AT S.
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
thewiresizeslistedonthedrawingsprovidedwiththe
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.
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.
It is unnecessary to remove pole covers from the
transfer switch. If you do remove them, reinstall them
carefully.
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.
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).
1 --- 1
INSTALLATION (continued)
Engine Starting Contacts
Customer connections for engine control contact and
TS auxiliary contacts connec tion s are located on
terminal block TB which is mounted on the front lower
left of the transfer switch. Refer to wiring diagram
provided with the Series 300 A TS and connec t the
engine start wires to the appropr iate terminals. See
Figure 1–1 and Table A.
Table A. Engine s tart connections.
When normal
source fails
Te r m i na l s
on transfer
switch
contact closes TB1 and TB2
contact opens TB1 and TB3
Auxiliary Circuits
Connect auxiliary circuit wires to
appropriate terminals on transfer
switch terminal block TB 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
Fea tures.
COMMON
FEATURE 7
closes to start
FEATURE 8
opens to start
COMMON
FEATURE 14B
closed o n emergency
FEATURE 14A
closed on normal
COMMON
FEATURE 14BA
closed o n emergency
FEATURE 14AA
closed on normal
terminal block for engine start and
auxiliary circuit connections
left side of
transfer switch
Engine Starting
Signals
5amps,32VDC
5ampsresistive28VDC
or 120 V AC max.
TS Auxiliary Contacts
Feature 14A & 14B
10 amps, 32 V DC
10 amps 250 V AC
general purpose
Optional
TS Auxiliary Contacts
Feature 14AA & 14BA
10 amps, 32 V DC
10 amps 250 V AC
general purpose
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 5–3)
Figure 1-1. Engine start and auxiliary circuit
terminal block TB located on the transfer switch.
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 1-2. 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.
NOTICE
Do these checks in the order presented to avoid
damaging the automatic transfer switch.
Read all instructions on the Wiring Diagram and labels
affixed to the automatic transfer switch. Note the
control features that are provi ded and review their
operation before proceeding.
1 – Manual Operation Test
A detachable maintenance handle is provided on the
frame of the T r ans fer Switch for maintenance purpose
. Manual operation of the transfer switch should be
only
checked before it is energized (operated electrically).
s
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
holeinthemoldedhubontheleftsideofthe
operator. See Figures 1–3 and 1–4 and Table B.
2. Move the maintenance handle up or down as shown
to manually operate the transfer switch. It should
operate smoothly without any binding. If it does not,
check for shipping damage or construction debris.
Table B. Maintenance handle positions.
ATS Position Handle Indicators
Normal
Emergency
E
N
E
N
up
down
E=O
upper contacts open
N=C
lower contacts closed
E=C
upper contacts closed
N=O
lower contacts open
maintenance
handle
storage clips
Figure1-3.Maintenancehandle&storagelocation.
3. Return the transfer switch to the Normal position.
Observe that window indicators (right side) show the
top shaft O (open) and the bottom shaft C (closed).
Note: If Normal and Emergency connections are
reversed this operation is also reversed.
4. Remove the maintenance handle and store it on the
frame (left side) in the clips provided.
NOTICE
Verify that the maintenance handle has been
removed before proceeding!
Now continue to 2–VoltageCheckson next page.
handle
hub
frame
UP closes the
contacts
Normal source
Emergency
contacts (lower)
DOWN closes the
Emergency source
contacts (upper)
window
indicators
O is open
C is closed
Normal
contact position
indicators (right side)
contacts
Figure 1-4. Maintenance handle operation and contact position indicators.
1 --- 3
INSTALLATION (continued)
Figure 1–5. St andard controls and indicators.
observe these lights
2–VoltageChecks
First check na meplat e on transfer switch; rated voltage
mustbethesameasnormalandemergencyline
voltages.
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.
O Black circle means light is on.
P 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
respondonlytotheratedvoltagespecifiedonthe
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.
Close the normal source circuit
breaker. The Normal Transfer
Switch Position and the Normal
1
Source Accepted lights should
come on.
Use an accurate voltmeter to
check phase to phase and
phase to neutral voltages pres-
2
entatthetransferswitchnormal
source terminals.
Close the emergency source
circuit breaker. (Start generator,
if necessary.) The Emergency
3
Source Accepted light should
come on.
Use an accurate voltmeter to
check phase to phase and
phase to neutral voltages pres-
4
ent at the transfer switch emergency source terminals.*
Useaphaserotationmeterto
check phase rotation of emer-
5
gency 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
6
control selector switch (on the
generator set) in the automatic
position. Close enclosure door.
Source Accepted
Normal
Emergency
Source Accepted
Normal
Emergency
C
B
A
Source Accepted
Normal
Emergency
1 --- 4
Now continue to 3 – Electrical Operation on next page.
pressthisbutton
INSTALLATION (continued)
observe these lights
Figure 1–6. Standard controls and indicators.
3 – Electrical Operation
This procedure will check the electrical opertion of the
Automatic Transfer Switch. See Figure 1–6.
Close the transfer switch enclosure door and
tighten the screws before you test electrical
operation.
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 8 at the right. Observe the
status lights.
O Black circle means light is on.
P White circle means light is off.
NOTE: If Motor Load Tra nsfer
feature is activated, then transfer may
not occur i mmediately 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 A u tom atic T ran sfer Switch. Leave the
engine–generator starting control in the automatic
position.
The normal source must be
available and the generator
must be ready to start.
1
Check that the Normal Source
Accepted light is on.
Press and hold the Transfer Test
button until the engine starts
2
and runs. This should happen
within 15 sec.
The Emergency Source
3
Accepted light should come on.
The transfer switch should
transfer to the Emergency
position. The Emergency
4
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
5
(up to 5 minutes).
Forimmediatetransferpress
the Bypass Time Delay button.
The transfer switch should
transfer back to the Normal
position. The Normal Transfer
6
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
7
(up to 30 minutes).
Forimmediateretransferpress
the Bypass Time Delay button.
Source Accepted
Normal
Emergency
Trans fer
Tes t
Source Accepted
Normal
Emergency
Trans fer Switch
Position
Normal
Emergency
Bypass
Time Delay
Trans fer Switch
Position
Normal
Emergency
Bypass
Time Delay
1 --- 5
The unloaded running delay
keeps the generator running for
5 minutes (cool–down period).
8
Then the generator should stop
and the Emergency Source
Accepted light should go off.
Source Accepted
Normal
Emergency
SECTION 2 SEQUENCE OF OPERATION
Lights show position of transfer switch.
Transfer To Emergency
Thesequenceforloadtransferto
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.
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
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.
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 emergenc y source is available immed iately,
the sensor may accept it as soon as NR relay drops out.
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.
ER relay energizes , the TS coil is energiz ed , the transfer
switch operates, and all switch contacts (mains, controls,
auxiliaries) reverse position. The transf er switch is now
supplying the load from the emergency source.
ThetransferswitchwillremainintheEmergency
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.
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.
Lights show the sources accepted.
Light for built–in
engine exercise timer:
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)
Seepage5–1
Hold 5 sec
20 min. engine exercise
period immediately (engine
starts) and weekly thereafter.
.toset
Figure 2–1. Membrane controls and indicator lights.
Retransfer to Normal
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.
Whenthenormalsourceisacceptedbythesensor,
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.
SE relay energi zes 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 a gai n.
Upon retransfer to the normal source, NR relay begins
its timing cyc le (unloaded running delay , engine cooldown).
NR relay is provided with a 5 min. time delay on picku p
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.
Activationof standard control features shown in Section 5 will
alter the sequence of operation and introduce additional time
delays during transfer operations.
2 --- 1
for complete
instructions
SECTION 3 TESTING & SERVICE
PREVENTIVE MAINTENANCE
For high reliability and long life for the ATS:
Operate the swi tch at least once a month.Performthis
4–step Electrical Operation Test (test with load transfer).
Transfer Switch Test
Press and hold the door-mounted Transfer Test button
1.
until the engine starts and runs. This should happen
within 15 seconds.
The transfer switch will operate to the Emergency
2.
position. If the Transfer To Emer g ency Delay is used,
thetransferwilloccurafteratimedelay(upto5
minutes). For immediate transfer press Bypass
Time Delay button .
The Transfer Switch will operate back to the Norm al
3.
position a f ter the Retransfer To Normal Delay (up to
30 minutes). For immediate retransfer press
Bypass Time Delay button .
Unloaded Running (Engine Cooldown) Delay allows
4.
engine to run unloaded for 5 minutes.
Checklist for Y early Inspection
Hazardous voltage capable of causing shock,
burns, or death is used in this switch.
Deenergize both Normal & Emergency power
sources before performing inspections!
S Check all cable connections & retighten them.
Torquetovaluesshownontransferswitchlabel.
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.
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.
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.
S Clean the enclosur e. De–energize all sources,
then brush and vacuum away any excessive dust
accumulation. Remove moisture with a clean cloth.
S Check the transfer switch contacts. De-energize
all sources, then remov e the transfer switch barriers
and check contact condition. Replace the contacts if
they become pitted or worn excessively. R eins tal l the
barriers carefully.
S Maintain transfer switch lubrication.Under
normal operating conditions no further lubricating
is required. Renew factory lubrication if the switch
is subjected t o severe dust or abnormal operating
conditions or if TS coil is replaced. Order lubricant
kit 75–100.
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 Retran sf er to Norma l Delay.For
immediate retransfer, press Bypass Time Delay
button. Place the engine starting control in the
automati c position.
3 --- 1
TESTING & SERVICE
PROBLEM
MANUAL LOAD TRANSFER
This procedure will manually transfer the load if the
controller is disconnected.
(continued)
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.
TROUBLE-SHOOTING
Note the control features that are activated or
furnished on the switch and review their operation.
Refer to Section 5, Control Features.
Table 3-1. Trouble-Shooting Checks.
1OPERATION 2 GEN-SET 3VOLTAGE
Gen-Set does not start when
the Transfer Test button is
pressed and held for 15
seconds or when the normal
source fails.
T ransfer switch does not
transfer the load to
emergency source after the
gen-set starts.
T ransfer 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.
Hold the Transfe r Test button
15sec.ortheoutagemustbe
long enough to allow for the 1
or 3 sec. Momentary Normal
Source Outage Delay plus
engine cranking and starting
time.
Wait for T ransfer 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).
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.
3. If the transfer switch is in the Emergency position
manually start the engine generator and then close
the emergency source circuit breaker.
Proceed with care! The automatic transfer switch
is energized.
CHECK IN NUMERICAL SEQUENCE
Starting control must be in
automatic position. Batteries
must be charged and
connected. Check wiring to
engine starting contacts.
Generator output circuit
breaker must be closed.
Generator frequency must be
at least 57 Hz.
—
Starting control must be in
automatic position.
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.
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).
—
—
Trouble-Shooting the Motor Load Transfer Feature (refer to page 5–4)
3. Press and hold
should transfer to emergency source when meter
Use extreme caution when using a meter to
measure voltages in the following steps. Do not
touch powe r terminals; shock, burns, or death
could result !
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.
needle is near 0 volts. If transfer does not occur,
Motor L oad Transfer feature is not opera ting.
4. Release the Transfer Test button. The load should
retransfer back to the normal source after the
Retransfer to Normal Delay,ifused. Theretransfer
should occur when the needle is near 0 volts. If
retransfer does not occur after the time delay, the
Motor L oad Transfer feature is not opera ting.
5. For immediate retransfer, press the Bypass Time
Delay button. Then disconnect the voltmeter.
If the problem is isolated to circuits on the controlle r or the transfer switch, c all your local ASCO Power Technolog ies
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 N o. from transfer switch nameplate.
3 --- 2
Transfer Test button. The load
SECTION 4 ADJUSTMENTS
y
OverrideMomentary
TDE
S
—
T
TIMER
0minute
s
0to
5
——P
R
lTIME
R
30minutes
1secondto
——P
DESCRIPTIONLABELSSETTIN
G
S1DIP
PU/NP
ick
EmergencySource
equecy60/50
Vol
P
h
LOW/
Vol
Adj
)
LOW
/
H
I
Time Delay Adjustment
Standard time delays are set to customer specifications
(if none specified, standard factory settings are used).
Table4-1.TimeDelaySettings
DESCRIPTION LABELS
Override Momentar
Normal Source Outages
ransfer toEmergency
Override Momentary
Emergency S. Outages
etransfer toNorma
Unloaded Running
(Engine Cooldown)
FACTORY
SETTING
3seconds
TIMER 0 minutes 0to5
N/E
— 4seconds non-adjustable — — —
TIMER 30 minutes 1secondto
E/N
— 5 minutes non-adjustable — — —
(full ccw)
(full cw)
ADJUSTMENT
RANGE
1second Actuator 1 on
3seconds Actuator 1 off
minutes
30 minutes
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.
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.
S3 DIP
SWITCH
1
1
ADJUSTMENT
POTENTIOMETER
2
1
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).
Normal Source Voltage
EmergencySource
Voltage
Emergency Source
Frequency
tage
ases 3, 1 3/1 3
%ofnominal
FACT. S ET ADJ RANGE
up 90 %
DO/N Dropout
–– Pickup 90 % non-adjustable
–– Dropout 75 % non-adjustable
–– Pickup 95 % non-adjustable
–– Dropout 85 % non-adjustable
60/50
Hz
60/50Hz 60Hz
85 %
95 % * Actuator 3 off
90 % Actuator 3 on
90 % *
85 %
80 %
70 %
60 Hz Actuator 4 off
50 Hz Actuator 4 on
3phase Actuator 6 off
1phase Actuator 6 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
––
––
S1 DIP
SWITCH
* If dropout voltage is set to 90%, the pickup voltage must be set to 95%.
3
3
21
21
21
21
4
4
6
6
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 FACT ORY SET T ING ADJUSTMENT S3 DIP SWITCH
tage
ust(4.2%
HI
LOW Actuator 2 off
HI Actuator 2 on
4 --- 1
2
2
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.
b. 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.
4. Locate the appropriate adjustment potentiometer or
DIP switch for the setting that you want to change.
Refer to T able 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 counterclockwisetodecreaseit. SeeFigure4-3.
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 lat ches click.
cover
hook on
left side
Figure 4-1. Controller cover latch.
harness
plugs
S3 DIP
switch
S1 DIP
switch
Figure 4-2. Location of potentiometers.
clockwise to
increase
P1 or P2
potentiometer
counterclockwise
to decrease
S2 DIP
switch
thumb
latch
9volt
alkaline
battery
J5
battery
on/off
jumper
P1
retransfer
to normal
time delay
P2
transfer to
emergency
time delay
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 circu it breaker.
b. If the transfer switch is in the Emergency
position, close the normal source circuit
breaker. Theloadwillbeautomatically
retransferred to the normal source. Then close
the emergency source circuit breaker.
10. Turn the engine starting control to automatic.
Figure 4-3. Changing time delay potentiometers.
DIP
switches
SW1
SW2
SW3
actuator
(8 on each DIP switch)
onoff
Figure 4-4. Setting DIP switch actuators.
4 --- 2
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 compl etely 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
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
ON position
. See Figure 4–2 on page 4–2.
when
the
FUNCTION
Std. Timer
Enabled
Std. Timer
Disabled
Exercise
without
Load
Exercise
with Load
Shaded DIP switches are standard factory settings.
DIP Switch Settings
S1 DIP
SWITCH
Actuator
7on
Actuator
7off
Actuator
8off
Actuator
8on
7
7
8
8
Actuator
5on
Actuator
5on
S2 DIP
SWITCH
5
5
Fill in day and t ime set. Week Day ______ Time _______.
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.
status light
Press and hold for 5 sec
blinks rapidly to set exercise period immediately
and every week hereafter (generator starts).
. or until status light
If Exerciser with Load is set,
transfers load to Emergency.
Figure 5-1. Operator panel pushbuttons and light.
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
8
How to Set Built–In Timer
Step Function Explanation
Push Button Status Light
Set Engine
1
Exercise r
hold
5sec.
2 release
press Bypass
3
Time Delay
blinks rapidly
OPOPOP
blinks slowly
OPPOPP
set exercise period
exercise period now active Generator starts and runs.
Exercise the generator now and
every week at this time hereafter.
O stays on cancel active exercise period Generator stops.
4 — O stays on generator off Exerciser enabled; repeats every 7 days.
Exercise with Load, DIP Switch S1, Actuator 8 on
8
How to Set Built–In Timer
Step Function Explanation
Push Button Status Light
Set Engine
1
Exercise r
hold
5sec.
2 release
press Bypass
3
Time Delay
blinks rapidly
OPOPOP
blinks slowly
OPPOPP
blinks slowly
OPPOPP
set exercise period
exercise period now active
cancel active exercise period
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 ).
4 — O stays on generator off Exerciser enabled; repeats every 7 days.
NOTE:EverytimeSET 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
ThemoduleprovidesoneFormCcontacteachforthe
normal and emergency sources signal the acceptability
of the source as sensed by the controller. The signal
contacts operate i n conjunction with the Source
Accepted lights on the operator i nterface. Field wiring
terminals are provided as shown i n Figure 5–3 and the
SOURCE
AVAILABILITY SIGNALS
2 AMPS @ 30 VDC , resisti ve
0.5 AMP @ 125 VAC, resistive
contacts shown de–energized
wiring diagram.
Contact ratings:
2 amps @ 30 Vdc, 0.5 amp. @ 125 Vac resistive
Figure 5–3. Source availability signal contacts.
ProgrammableEngineExerciser
Themoduleincludesaprogrammableengineexerciser
that provides for weekly or biweekl y 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).
Theprogrammableengineexerciserincorporatesa7
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).
Seenextpageforinstructionsonsettingthetimer.
5 --- 2
DIP Switch Settings in the Controller
(see page 4–2)
FUNCTION
Opt. Timer
Enabled
Opt. Timer
Disabled
Exercise
without
Load
Exercise
with
Load
SWITCH
Actuator
7off
Actuator
7off
Actuator
8off
Actuator
8on
S1 DIP
7
7
8
8
Shaded DIP switches are standard factory settings.
S2 DIP
SWITCH
Actuator
5off
Actuator
5on
5
5
CONTROL FEATURES (continued)
How to Set Optional Programmable Engine Exerciser (part of Acc. 11BG module)
NOTE: When choosing bi–weekly operation, the
exerciser will always run on the week designated “(1)”
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 param eter
is properly configured.
Fast/Slow Ad ju st
Daylight Saving
Time Adjust
Date
Time
Run TIme
Start TIme
Engine Exerciser
Engine Exerciser Display
TheEngineExerciserDisplayshowsthestatusofthe
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 ti me until the
end of the exercise period.
Start Time Display
TheStartTimeDisplayshowstheengineexerciserstart
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 a t 3 PM, the proper configuration would
be: “Alt Sat @ 15:00”
Fill in your settings for future reference
Weekly or Bi–weekly Day of Week Start Time Run Time
Every = weekly
Alt = bi–weekly
Sun through Sat
onthedatedisplay.
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 i s used
in conjunction with the bi–weekly timer.
Daylight Savings Time Adjust Display
This display shows whet her 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.
Start 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.
629857–001* 629857–002*
Fast / Slow Adjust Display
This display shows the automatic fast/slow adjustment
value. Thefactorydefaultis0. Thisfeaturecanbe
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 ___________________________
0–23hour
0–59minute
0–23hour
0–59minute
30 min. is default setting
5 --- 3
CONTROL FEATURES (continued)
INPHASE MONITOR
FOR MOTOR LOAD TRANSFER
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.
FUNCTION S1 DIP SWITCH
enable Actuator 5 on
disable Actuator 5 off
Shaded DIP switches are standard factory settings.
Note
If the Motor L oad Transfer feature is enabled, it
will be activated following
the Load Disconnect
Feature Delay Before Transfer delay.
5
5
LOAD DISCONNECT FEATURE
Connect external circuits to the terminals indicated on
the Wiring Diagram provided with the ATS.
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.
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:
Delay Before Transfer
LD TDBT S2 DIP SWITCH
0 (disable)
3seconds
10 seconds
20 seconds
Actuator 7 on
Actuator 8 on
Actuator 7 on
Actuator 8 off
Actuator 7 off
Actuator 8 on
Actuator 7 off
Actuator 8 off
87
87
87
87
Shaded DIP switches are standard factory settings.
Delay After Transfer*
LD TDAT S2 DIP SWITCH
enable Actuator 6 on
disable Actuator 6 off
6
6
*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 S2 DIP SWITCH
disable Actuator 3 on
enable Actuator 3 off
3
3
Remote Transfer to Emergency (CP8–9)
RT /E S2 DIP SWITCH
disable Actuator 2 on
enable Actuator 2 off
2
2
Bypass Transfer Time Delay (CP12–13)
TD E/N BYP. S2 DIP SWITCH
disable Actuator 1 on
enable Actuator 1 off
1
1
Inhibit Transfer to Emergency (CP10–11)
N/E INHIB. S2 DIP SWITCH
disable Actuator 4 on
enable Actuator 4 off
5 --- 4
4
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
AVAILABLE KITS
Controls
Description Accessory Kit
ProgrammableEngineExerciser
& Source Availability Contacts
Serial Communication Module 72A K601110
11BG K629830
Figure 5–4. Thermostat.
Strip Heater – Accessory 44
Description Accessory Kit
120 volt
customer supplied voltage
(without transformer)
208 – 480 volt
ATS derived voltage
(with transformer)
380 volt
ATS derived voltage
(with transformer)
44A K613127–001
44G K613127–002
44G K613127
5 --- 5
550 – 600 volt
ATS derived voltage
(with transformer)
44G K613127–003
A
G
INDEX
strip heater, 5–5
accessories, 5–2, 5–5
auxiliary circuits, 1–2
B
battery, 4–2, 5–1
buttons, push, 3–1
bypass time delay, 1–5, 2–1, 3–1
C
cable
lugs, 1–1
preparation, 1–1
catalog number, inside cover
cleaning, 3–1
connections
engine control contact, 1–2
line, 1–1
contact position indicators, 1–3
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
D
DIP Switches, 4–1, 4–2, 5–1, 5–2, 5–4
E
electrical operation, 1–5
engine exerciser, 5–1, 5–2, 5–3
engine starting contacts, 1–2
F
features, see control features
frequency, pi ckup and dropout
settings, 4–1
functional test, 1–3, 1–4, 1–5
ground, controller, 1–1
H
handle, maintenance, 1–3
warning, 1–3
harness, 1–2
disconnect plugs, 3–1
HELP
800–800–2726 (ASCO)
customercare@asco.com
I
inphase monitor, 5–4
inspection, 3–1
installation, 1–1
L
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
M
maintenance, preventive, 3–1
manual load transfer, 3–2
warning, 3–2
manual operation, 1–3
warning, 1–3
motorloadtransferfeature,5–4
N
nameplate, cover
O
operation
electrical, 1–5
manual, 1–3
illustration of, 1–3
warning, 1–3
sequence of, 2–1
optional accessories
programmableengineexerciser
& source availability signal
contacts, 5–2, 5–3
serial communication module, 5–5
P
parts, 3–1
problem, 3–2
programmable engine exerciser, 5–2,
5–3
R
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
S
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
T
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
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
V
voltage, phase, 4–1
voltage, pickup and dropout settings,
4–1
Printed in U.S.A.
Copyright --- ASCO Power Technologies, L.P. 2011
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