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Operator’s

Manual

Series 300 Automatic Transfer Switches

H–design,600 through 1200 A

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.

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 . . . . . . . . . . . . . . . . . . . . . . . . 1-1Mounting and Line Connections . . . . . . . . .1-1Engine Starting Contacts . . . . . . . . . . . . . . .1-2Input / Output Label . . . . . . . . . . . . . . . . . . . .1-2Functional 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 07932–1591USA

381333–201G

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

Nameplate

Catalog Number Identification

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

A typical Catalog Number is shown below with its elements explained. The example is for a Series 300 ATS with switched neutral, 3 pole, 600 ampere,

480 V, in a Type 1 enclosure:

H 300

 

B

 

3

 

600

 

N

 

1

 

C

Neutral

 

Phase Poles

 

Amperes

 

Voltage

 

Controller

 

Enclosure

B – switched

 

2

– single Ø

 

600

 

C 208

K 415

 

1 – standard

 

C – type 1

C – overlapping

 

3

– three Ø

 

800

 

D 220

L 440

 

1X – if

 

F – type 3R

blank – solid

 

 

 

 

1000

 

E 230

M 460

 

accessories

 

G – type 4 *

 

 

 

 

 

1200

 

F 240

N 480

 

ordered

 

L – type 12 *

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

H 380

Q 575

 

 

 

blank – open type

 

 

 

 

 

 

 

J 400

R 600

 

 

 

 

 

 

 

 

 

 

 

 

* available 600 – 1000 A sizes only

 

 

 

 

 

 

 

 

 

 

neutral

Controller

 

connections

 

power connections

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

Controller

 

power connections

membrane controls

Transfer

Switch

terminal block TB for engine start and switch position contacts

power connections

neutral connections

800 and 1000 ampere sizes in typical enclosure with location of customer connections

Controller

neutral connections

power connections

Transfer

Switch

terminal block TB for engine start and switch position contacts

power connections

neutral connections

membrane controls

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 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 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-suspendedhangers 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, andbefore they are connected, they should be tested to verify that they are not defective or have been damaged during installation.

NOTICE

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

Connecting Power Conductors

After the power cables have been tested, connect them to the appropriate terminal lugs on the transfer switch as shown on the wiring diagram provided with this Series 300. Make sure the lugs provided are suitable for use with the cables being installed. Standard terminal lugs are solderless screw type and will accept the wire sizes listed on the drawings provided with the Series 300. Be careful when stripping insulation from the cables; avoid nicking or ringing the conductor. Remove surface oxides from cables by cleaning with a wire brush. When aluminum cable is used, apply joint compound to conductors. Tighten cable lugs to the torque specified on rating label.

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–energizethe 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–inharness (two plugs).

1---1

INSTALLATION (continued)

Engine Starting Contacts

Customer connections for engine control contact and TS auxiliary contacts connections 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 ATS and connect the

engine start wires to the appropriate terminals. See

Figure 1–1and Table A.

COMMON

 

 

 

Table A. Engine start connections.

FEATURE 7

 

 

 

closes to start

When normal

Terminals

 

FEATURE 8

on transfer

 

opens to start

source fails

 

COMMON

switch

 

 

 

 

contact closes

TB1 and TB2

 

FEATURE 14B

contact opens

TB1 and TB3

 

closed on emergency

 

FEATURE 14A

 

 

 

 

 

 

closed on normal

Auxiliary Circuits

left side of transfer switch

Engine Starting

Signals

5 amps, 32 V DC

5 amps resistive 28 V DC or 120 V AC max.

TS Auxiliary Contacts Feature 14A & 14B

10 amps, 32 V DC

10 amps 250 V AC general purpose

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 Features.

COMMON

Optional

TS Auxiliary Contacts

 

FEATURE 14BA

Feature 14AA & 14BA

10 amps, 32 V DC

closed on emergency

10 amps 250 V AC

FEATURE 14AA

general purpose

closed on normal

 

terminal block for engine start and auxiliary circuit connections

Connections to Controller

Figure 1-1.Engine start and auxiliary circuit

for other Control Features

terminal block TB located on the transfer switch.

(located on bottom of Controller)

 

Load Disconnect

Programmable

Feature

Engine Exerciser

Connections

connection,

(see Wiring Diagram

if provided

& refer to page 5–4

(refer to

for DIP switch settings) page 5–3)

Remote Control Features Connections

 

(refer to the Wiring Diagram &

 

page 5–4for DIP switch settings)

 

Each control contact must be suitable

for factory

for a 5 V DC low energy circuit.

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 provided and review their operation before proceeding.

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).

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 1–3and1–4and 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

 

E

up

E = O

Normal

 

 

upper contacts open

 

 

N = C

 

N

 

 

 

lower contacts closed

 

 

 

 

 

E

 

E = C

Emergency

 

 

upper contacts closed

 

 

N = O

 

N

 

 

down

lower contacts open

 

 

 

 

 

 

 

left side of transfer switch

maintenance handle

storage clips

Figure 1-3.Maintenance handle & storage location.

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 – Voltage Checks on next page.

handle

hub

frame

UP closes the Normal source contacts (lower)

DOWN closes the Emergency source contacts (upper)

Emergency contacts

window

 

indicators

contact position

O is open

indicators (right side)

C is closed

 

Normal

 

contacts

 

Figure 1-4.Maintenance handle operation and contact position indicators.1---3

INSTALLATION (continued)

observe these lights

Figure 1–5.St andard controls and indicators.

2 – Voltage Checks

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

PWhite circle means light is off.

*If necessary, adjust voltage regulator on the generator according to the manufacturer’s recommendations. The Automatic Transfer Switch will respond only to the rated voltage specified on the Transfer Switch nameplate.

Also see page 4–1for theHI–LOWvoltage 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

Source Accepted

1

Switch Position and the Normal

Normal

 

Source Accepted lights should

 

Emergency

 

come on.

 

 

 

Use an accurate voltmeter to

 

 

check phase to phase and

 

2 phase to neutral voltages pres-

 

 

ent at the transfer switch normal

 

 

source terminals.

 

 

Close the emergency source

Source Accepted

 

circuit breaker. (Start generator,

3

if necessary.) The Emergency

Normal

 

Source Accepted light should

Emergency

 

come on.

 

 

Use an accurate voltmeter to

 

 

check phase to phase and

 

4 phase to neutral voltages pres-

 

 

ent at the transfer switch emer-

 

 

gency source terminals.*

 

 

Use a phase rotation meter to

A B C

 

 

5

check phase rotation of emer-

 

gency source; it must be the

 

 

same as the normal source.

 

 

Shut down the engine–genera-

 

 

tor, if applicable. The Emergen-

Source Accepted

 

cy Source Accepted light should

6 go off. Then put the starting

Normal

 

control selector switch (on the

Emergency

 

generator set) in the automatic

 

 

position. Close enclosure door.

 

Now continue to 3 – Electrical Operation on next page.

1---4

INSTALLATION (continued)

observe these lights

press this button

Figure 1–6.Standard controls and indicators.

3 – Electrical Operation

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

This completes the Functional Test of the ASCO Series 300 Automatic Transfer Switch. Leave the engine–generatorstarting control in theautomatic position.

 

The normal source must be

 

 

available and the generator

Source Accepted

1 must be ready to start.

Normal

 

Check that the Normal Source

 

Emergency

 

Accepted light is on.

 

 

 

Press and hold theTransfer Test

 

2

button until the engine starts

Transfer

and runs. This should happen

Test

 

within 15 sec.

 

3

The Emergency Source

Source Accepted

 

 

Accepted light should come on.

Normal

 

 

Emergency

 

The transfer switch should

 

 

transfer to the Emergency

Transfer Switch

4

position. The Emergency

Position

Transfer Switch Position light

Normal

 

should come on and the Normal

Emergency

 

light should go off.

 

 

If the transfer to emergency

 

 

delay is used the transfer

 

5

should occurs after a time delay

Bypass

(up to 5 minutes).

Time Delay

 

For immediate transfer press

 

 

the Bypass Time Delaybutton.

 

 

The transfer switch should

 

 

transfer back to the Normal

Transfer Switch

6

position. The Normal Transfer

Position

Switch Position light should

Normal

 

come on and the Emergency

Emergency

 

light should go off.

 

 

If the retransfer to normal delay

 

 

is used the retransfer should

 

7

occur after a time delay

Bypass

(up to 30 minutes).

Time Delay

 

For immediate retransfer press

 

 

the Bypass Time Delaybutton.

 

 

The unloaded running delay

 

 

keeps the generator running for

Source Accepted

8

5 minutes (cool–downperiod).

Normal

Then the generator should stop

 

and the Emergency Source

Emergency

 

 

 

Accepted light should go off.

 

1---5

SECTION 2 SEQUENCE OF OPERATION

 

Lights show position of transfer switch.

Lights show the sources accepted.

Transfer To Emergency

 

 

 

 

Light for built–in

The sequence for load transfer to

 

 

 

 

engine exercise timer:

 

 

 

 

³ blinks rapidly when

emergency source begins automatical-

 

 

 

 

 

 

 

 

button is held 5 sec.

ly when normal source voltage falls

 

 

 

 

while being set

below the preset dropout point or

 

 

 

 

³ blinks slowly when

when Transfer Test button is pressed.

 

 

 

 

button is released (set)

An under voltage condition on any

 

 

 

 

and during 20 min.

phase of the normal source is de-

 

 

 

 

exercise period.

 

 

 

 

³ stays on after engine

tected by the sensor.

 

 

 

 

 

When the normal

 

 

 

 

 

stops (exerciser is

 

 

 

 

 

enabled for weekly

source voltage fails or

 

 

 

 

 

operation)

the Transfer Test

 

 

 

 

 

See page 5–1

button is pressed, the

Hold 15 sec. to

Press to cancel the

 

Hold 5 sec. to set

for complete

SE relay de-energizes

 

instructions

start the engine

active exercise period

20 min. engine exercise

 

and relay NR begins

 

generator and to

(stops engine now or

period immediately (engine

 

its timing cycle (1 or 3

transfer the load

after cooldown) See

 

starts) and weekly thereafter.

 

seconds, momentary

to emergency.

page 5–1.

Figure 2–1.Membrane controls and indicator lights.

normal source outage

 

 

 

 

Retransfer to Normal

delay). The NR relay is provided with a time delay on

 

 

dropout to override momentary outages and prevent

The sequence for load retransfer to the normal source

nuisance starting of the engine-drivengenerator. If the

automatically begins when the voltage sensor detects

normal source voltage returns above the sensor dropout

restoration of the normal source. The voltage level

setting before the time delay expires, the NR relay timing

must rise above the preset pickup point on all phases

cycle is reset to zero and relay SE energizes.

 

before the sensor will accept the normal source.

If the normal source voltage does not return above the sensor dropout setting before the time delay expires, the NR relay de-energizesand signals theengine-drivengenerator to start. At the same time, a voltage and frequency sensor begins monitoring the emergency source. The sensor will accept the emergency source only whenboth 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 theengine-drivengenerator must crank, start, and run up to nominal pickup points. For this reason, if theTransfer Test button is pressed it must be held for 15 seconds. If the emergency source is available immediately, the sensor may accept it as soon as NR relay drops out.

When the 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 pressBypass Time Delay button.

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

The transfer switch will remain in the Emergency position until the normal source is restored. If the Transfer Test button is used, the transfer switch will remain on emergency until theretransfer to normal delay times out.

When the normal source is accepted by the sensor, relay SE begins its timing cycle (adjustable 1 sec. to 30 min., retransfer to normal delay). For immediate retransfer pressBypass 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 energizes and ER relay is dropped out. The TS coil is energized, the transfer switch operates, and all switch contacts (mains, controls, auxiliaries) reverse position. The transfer switch is now supplying the load from the normal source again.

Upon retransfer to the normal source, NR relay begins its timing cycle (unloaded running delay, engine cooldown). NR relay is provided with a 5 min. time delay on pickup to keep the engine running for acool-downperiod.

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

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

2---1