Page 1
Operator’s
7000 Series A T S
Automatic T ransfer Switches
Manual
DANGER is used in this manual to warn of high
voltages capable of causin g shock, burns, or death.
WARNINGisusedinthismanualto
warn of possible personal injury.
CAUTIONisusedinthismanualto
warn of possible equipment damage.
J–desi gn , 260, 400, & 600 A
Refer to the outline and wiring drawings provided
with your 7000 Series ATS for all installation and
connection details and accessories.
Refer to Group 5 Controller User’s Guide
381333–126 for ATS status display messages, time
delays, pickup & dropout settings, and adjustments.
Rating Label
Each automatic transfer switch (ATS) has a rating label to
define the loads and fault circuit withstand/closing ratings.
Refer to the label on the transfer switch for specific values.
Do not exceed the values on the rating label.
Exceeding the rating can cause personal injury
or serious equipment damage.
260 amp. size
Nameplate
The Transfer Switch nameplate includes data for each
specific ASCO 7000 Series ATS. Use the ATS only within
the limits shown on this nameplate.
An experienced licensed electrician must install the ATS.
TABLE OF CONTENTS
section-page
INSTALLATION 1-1........................
Mounting and Line Connections 1-1.........
Auxiliary Circuits and Harness 1-2...........
Engine Starting Contacts 1-2...............
Functional Test 1-2 through 1-5..............
TESTING & SERVICE 2-1..................
Transfer Test 2-1..........................
Preventive Maintenance 2-1................
Disconnecting the Controller 2-1............
Manual Load Transfer 2-2..................
Trouble-Shooting 2-2......................
INDEX back cover.........................
50 Hanover Road, Florham Park, New Jersey 07932–1591 USA
For sales or service call 1 800 800–2726 (ASCO) www.ascopower.com
ASCO POWER TECHNOLOGIES CANADA PO Box 1238, 17 Airport Road, Brantford, Ontario, Canada N3T 5T3
telephone 519 758–8450, fax 519 758–0876, for service call 1 888 234–2726 (ASCO) www.asco.ca
381333–283 B
Page 2
Catalog Number Identification
A typical Catalog Number is shown below with its elements explained. The example is for a 7000 Series 7ATS
with overlapping neutral, 3 pole, 600 amp, 480 V, in a Type 1 enclosure:
design
prefix
letter
A –solid
B –switched
C – overlapping
blank – none
load power
connections
J
Neutral
7ATS C 3 600 N 5 C
Phase Poles
2 –singleØ
3 –threeØ
Amperes Voltage Controller Enclosure
260
400
600
A 115
B 120
C 208
D 220
E 230
F 240
G 277
H 380
customer terminals block
J 400
K 415
L 440
M 460
N 480
P 550
Q 575
R 600
5 –standard
5X –if
accessories
ordered
C –type1
F –type3R
G –type4
H –type4X
L –type12
blank – open type
emergency
power
connections
Transfer
Switch
normal power
connections
transfer
control
&lights
Controller
260 amp. size in typical enclosure with location of customer connections
Page 3
SECTION 1 INSTALLATION
ASCO 7000 Series Automatic Transfer Switches (ATSs)
are factory wired and tested. Field installation requires
requires mounting and connection of service cables,
and auxiliary control circuits (if required).
Remove the Shipping Skid (large ATSs)
For large ATSs, 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 switch for all
mounting details including door opening space.
If bottom cable entry is used, the foundation must be
prepared so that the conduit stubs are located
correctly. Refer to the enclosure outline drawing for
specified area and location. Provide cable bending
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 a pplicable enclosure outline drawing
furnished with this switch and mount the automatic
transfer switch according to details and instructions
shownondiagram.
Testing Power Conductors
Do not connect the power conductors to the transfer
switch until they are tested. Installing power cables in
conduit, cable troughs and ceiling-suspended hangers
often requires considerable force. The pulling of cables
can damage i nsulation and stretch or break the
conductor’s strands. For this reason, after the cables
are pulled into position, and before
connected, they should be tested to verify that they are
not defective or have been damaged during
installation.
Protect the automatic transfer switch from
construction grit and metal chips to prevent
malfunction or shortened life of the ATS.
they are
Connecting Power Conductors
After the power cables have been tested, connect them
to the appropriate terminal lugs on the transfer switch
as shown on the wiring diagram provided with the
switch. Makesurethelugsprovidedaresuitablefor
use with the cables being installed. Standard terminal
lugs are solderless screw type and will accept the wire
sizes listed on the drawings provided with the switch.
Be careful when stripping insulation from the cables;
avoid nicking or ringing the conductor. Remove
surface oxides from cables by cleaning with a wire
brush. When aluminum cable is used, apply joint
compound to conductors. Tighten cable lugs to the
torque specified on rating label.
Line Connections
Refer to the Wiring Diagram provided with the switch.
All wiring must be made in accordance with the
National Electrical Code and local codes.
It is not necessary to remove pole covers from the
transfer switch for cabling. 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
Page 4
INSTALLATION (continued)
Engine Starting Contacts
All customer connections, including the engine control
contact connections, are located on terminal block TB
which is mounted on the top right side of the
enclosure. Refer to the wi ring diagram provided with
the automatic transfer switch and connect the engine
start wires to the appropriate terminals. See Figure
1–1 and Table A.
Table A . Engine start connections.
When normal source
fails
contact closes TB1 and TB2
contact opens TB1 and TB3
Te r m i n a l s o n
Te r m i n a l B l o c k T B
Note: To temporarily disable engine control from
the automatic transfer switch you can unplug J3
from the small P3 receptacle at the bottom of the
assembly. BesuretoreconnectplugJ3totheP3
receptacle for automatic transfer switch operation.
Auxiliary Circuits
Connect auxiliary circuit wires to appropriate terminals
on transfer switch terminal block TB as shown on the
wiring diagram provided with this automatic transfer
switch.
engine start
connections
on
customer
terminal
block TB
Figure 1-1. Customer terminal block on the top right
side of the enclosure.
Functional Test
The Functional Test consists of three checks:
S 1 — Manual Operation Test, page 1–3
S 2—VoltageChecks,page1–4
S 3 — Electrical Operation, page 1–5
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.
Continue to 1–ManualOperationTest on next page.
1 --- 2
Page 5
INSTALLATION (continued)
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).
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 1–2 and 1–3 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.
3. Return the transfer switch to the Norm al position.
Observe that the window indicators (right side) show
the top shaft O (open) and the bottom shaft C
(closed).
left side of
s
transfer switch
maintenance
handle
storage clip
Table B. Maintenance handle positions.
ATS Position Handle Indicators
E
Normal
N
E
Emergency
N
Note: If Normal and Emergency connections are
reversed this operation is also reversed.
handle
up
down
UP closes the
Normal source
E=O
upper contacts o pen
N=C
lower contacts closed
E=C
upper contacts closed
N=O
lower contacts open
contacts (lower)
hub
DOWN closes the
Emergency source
contacts (upper)
frame
Figure 1-2. Maintenance handle and its storage clips.
4. Remove the maintenance handle and store it on the
frame (left side) in the clips provided.
Verify that the maintenance handle
has been removed before proceeding!
Now continue to 2–VoltageCheckson next page.
Emergency
contacts
window
indicators
O is open
contact position
indicators (right side)
C is closed
Normal
contacts
Figure 1-3. Maintenance handle operation and contact position indicators.
1 --- 3
Page 6
INSTALLATION (continued)
GREEN
RED
observe
these lights
GREEN
RED
Figure 1-4. Standard controls and indicators.
2–VoltageChecks
First check nameplate on transfer switch; rated voltage
mustbethesameasnormalandemergencylinevoltages.
Verify that the feeders have been
connected to the proper lugs.
Useextremecautionwhenusingameter
to measure voltages in the following
steps. Do not touch power terminals;
shock, burns, or death could result !
Close the normal source circuit
breaker. The Transfer Switch
Connected To Normal and the
1
Normal 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 Transfer
3
Switch Connected To Normal &
Emergency Source Accepted
lights should come on.
Perform steps 1 through 6 at the right. Observe the
status lights. See Figure 1–4.
Q Black square means light is on.
S White square means light is off.
* If necessary, adjust voltage regulator on the generator
according to the manufacturer’s recommendations. The
Au tom atic Tran sfer Switch wil l respond only to the rated
voltage specified on the Transfer Switch nameplate.
Note
Refer to Section 3 of Group 5 Controller User’s Guide
381333–126 for how to display the Status of the ATS
and the Voltage and Frequency of each source.
Now continue to 3 – Electrical Operation on next page.
1 --- 4
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.
C
B
A
Page 7
INSTALLATION (continued)
GREEN
RED
observe
these lights
GREEN
RED
Figure 1-5. Standard controls and indicators.
3 – Electrical Operation
This procedure will check the electrical operation of
the Automatic Transfer Switch. See Figure 1–5.
Be sure to close the enclosure door
before proceeding to prevent personal
injury in case of electrical system fault !
Transfer Test
Both normal and emergency sources must be available
and the emergency source generator (if used) must be
capable of being started in this procedure.
Perform steps 1 through 5 at the right. Observe the
status lights.
Q Black square means light is on.
S White square means light is off.
operate
this switch
The Transfer Switch Connected
1
To No r mal and Normal Source
Accepted lights should be on.
Turn an d h o l d Tr a nsf er C ont r ol
switch clockwise to Transfer
Test until the engine starts
2
and runs (within 15 sec.).
Emergency Source Accepted
light should come on.
Transfer switch will operate to
the Emergency position after
Feature2Btimedelay.The
Transfer Switch Connected To
3
Emergency light should come
on and Load Connected to Nor-
mal light goes off.
Transfer switch will operate
back to Normal position after
Feature3Atimedelay.Forimmediate retransfer turn Tr a nsf er
Control counterclockwise to
4
Retransfer Delay Bypass.The
Transfer Switch Connected To
Normal light should come on;
Transfer Switch Connected to
Emergency light should go off.
This completes the Functional Test of the ATS.
1 --- 5
The engine–generator will stop
after the Feature 2E time delay
(unloaded running engine cool-
5
down). The Emergency Source
Accepted light should go off.
Page 8
SECTION 2 TESTING & SERVICE
TRANSFER TEST
Operate the 7000 Series ATS at least once a month by
following the fi ve–step Electrical Operation Transfer
Tes t procedure on page 1–5.
PREVENTIVE MAINTENANCE
Reasonable care in preventive maintenance will insure
high reliability and long life f or the 7000 Series ATS.
An annual preventive maintenance program is recommended.
In the United States, ASCO Services, Inc. (ASI) is
ASCO Power Technologies’s national service
organization. ASI can be contacted at
1-800-800-2726 (ASCO) for information on
preventive maintenance agreements.
In Canada, for service call 1-800-234-2726 (ASCO).
Checklist for Yearly Inspection
Hazardous voltage capable of causing shock,
burns, or death is used in this transfer switch.
Deenergize both Normal – Emergency power
sources before performing inspections!
DISCONNECTING THE CONTROLLER
The harness disconnect plugs are furnished for repair
purposes only and should not have to be unplugged. If
the controller must be isolated, follow these steps:
Disconnecting the Plugs
Do not unplug the controller until step
1a. or 1b. below is completed.
1. Observe the position of the transfer switch.
a. If the transfer switch is in the Normal position,
first place standby engine starting control in the
off position. Second, then open the emergency
source circuit breaker. Third, open the normal
source circuit breaker.
b. If the transfer switch is in the Emergency posi-
tion, first open the normal source circuit breaker. Second, place t he engine starting control in
the test or run position. Third, open the emergency source circuit breaker.
2. Separate the two quick disconnect plugs by squeezing the latches. Do not pull on the harness wires.
Reconnecting the Plugs
S Clean the ATS enclosure. Brush and vacuum
away any excessive dust accumulation. Remove any
moisture with a clean cloth.
S Check the transfer switch contacts.Remove
the transfer switch barriers and check contact
condition. Reinstall barriers carefully. The
non–replaceable main contacts are designed to last
thelifeofthetransferswitch.
S Maintain transfer switch lubrication.Ifthe
transfer switch is subjected to severe dust or
abnormal operating conditions, renew factory
lubrication on all movements and linkages.
Re l u b r ic ate the solenoid operator if the TS coil is
replaced. Do not use oil; order lubrication kit
75-100.
S Check all cabl e connections & retighten them.
REPLACEMENT PARTS
Replacement parts are available in kit form. When
ordering parts provide the Serial No., Bill of Material
No. (BOM), and Catalog No. from the transfer switch
nameplate. Contact your local ASCO Power Technologies Sales Office or ASI:
in United States call 1 800 – 800 – ASCO (2726)
or in Canada call 1 800 – 234 – ASCO (2726)
Do not reconnect the controller until step
1a. or 1b. below is completed.
1. Observe the position of the transfer switch.
a. If the transfer switch is in the Normal position,
firstbesurethatboth
source circuit breakers are open. Second, be
sure that the standby engine starting control is
still in the off position.
b. If the transfer switch is in the Emergency posi-
tion, first be sure that both
gency source circuit breakers are open.
2. The two harness plugs and sockets are keyed.
Carefully align t he plugs with the sockets and press
straight in until both latches click. Close the door
3. Restore the two sources i n sequence as follows:
a. If the transfer switch is in the Normal position,
first close the normal source circuit breaker.
Second, close the emergency source circuit
breaker. Third, place the standby engine
starting control in the automatic position.
b. If the transfer switch is in the Emergency
position, first close the emergency source circuit
breaker. Second close the normal source circuit
breaker.
normal and emergency
normal and emer-
!
2 --- 1
Page 9
TESTING & SERVICE
(continued)
MANUAL LOAD TRANSFER
This procedure will manually transfer the load if the
controller is disconnected.
Do not manually operate the transfer switch
until both power sources are disconnected:
open both circuit breakers.
1. Deenergize both the normal and emergency source
conductors (remove fuses or open circuit
breakers).
TROUBLE-SHOOTING
Note any optional accessories that may be furnished on
the automatic transfer switch (ATS) and review their
operation. Refer to any separate drawings and/or
instructions that may be packed with the ATS.
2. Use the maintenance handle to manually operate
the transfer switch to the opposite source. See
Manual Operation on page 1–3.
3. Then remove
the maintenance handle. See page 1–3.
Verify that the maintenance handle
has been removed before proceeding!
4. If the transfer switch is in the Emergency position
manually start the engine generator and then
install emergency source fuse or close the circuit
breaker.
Hazardous voltage capable of causing shock,
burns, or death is used in this switch.
Do not touch the power or load terminals
of the transfer switch!
PROBLEM
Engine–generator set does
not start when the Tra nsfer
Control switch is turned and
held
in Transfer Test position
or when the normal source
fails.
T ransfer switch does not
transfer the load to the
emergency source after the
engine–generator set starts.
T ransfer switch does not
transfer the load to normal
source when normal returns
or when the Transfer Control
switch is released.
Engine–generator-set does
not stop after load retransfer
to the normal source.
Table 2-1. Trouble-Shooting Checks.
CHECK IN NUMERICAL SEQUENCE
1
OPERATION
Hold Transfer Test switch 15
seconds or the outage must
be long enough to allow for
Feature1Ctimedelayplus
engine cranking and starting
time.
Wait for Feature 2B time delay
to time out (if used).
Wait for Feature 3A time delay
to time out (if used).
Wait for Feature 2E time delay
to time out (if used).
Starting control must be in the
automatic position. Batteries
must be charged and
connected. Check wiring to
engine starting contacts on
customer terminal block TB.
Verify that the small plug J3 is
connected to receptacle P3.
Generator output circuit
breaker must be closed.
Generator frequency must be
at least 95% of nominal
(57Hzfora60Hzsystem.)*
Starting control must be in the
automatic position.
2
GEN-SET
–
3
VOLTAGE
–
Voltmeter should read at least
90% of nominal phase to
phase voltage between
transfer switch terminals EA
and EC (or EL1 and EL2 for 2
pole switches). *
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 N B (or NL1 and NL2 for 2
pole switches).
–
* These are factory settings. Refer to the Group 5 Controller User’s Guide.
If the problem is isolated to circuits on the controller or the transfer switch, call your local ASCO Power
Technologies sales office or ASI. In the United States, call 1–800–800–2726. In Canada, call 1–800–234–2726.
Furnish the Serial No. and Catalog No. from the transfer switch nameplate.
2 --- 2
Page 10
INDEX
A
auxiliary circuits, 1–2
C
cable
lugs, 1–1
preparation, 1–1
catalog number, inside cover
cleaning, 2–1
connections
line, 1–1
contact position indicators, 1–3
controller, 1–1
disconnecting, 2–1
see Controller User’s Guide
grounding, 1–1
E
electrical operation, 1–5
Emergency Source Accepted light,
1–4, 1–5
engine starting contacts, 1–2
F
frequency, generator, 2–2
functional test, 1–2, 1–3, 1–4, 1–5
G
ground, controller, 1–1
ground lugs, inside front cover
H
harness, 1–1
disconnect plugs, 2–1
HELP
800–800–2726 (ASCO)
customercare@asco.com
I
inspection, 2–1
installation, 1–1
indicators, contact position, 1–3
L
labels,
field terminal block TB, 1–2
rating, inside front cover
lights, 1–4, 1–5
lubrication, 2–1
M
maintenance handle, 1–3
illustration of, 1–3
warning, 1–3
maintenance, preventive, 2–1
manual load transfer, 2–2
warning, 2–2
manual operation, 1–3
illustration of, 1–3
warning, 1–3
N
nameplate, inside cover
Normal Source Accepted light, 1–4
O
operation
electrical, 1–5
manual, 1–3
illustration of, 1–3
warning, 1–3
optional accessories
see Controller User’s Guide
P
parts, 2–1
phase rotation check, 1–4
problem, 2–2
R
rating label, inside cover
replacement parts, 2–1
S
settings
see Controller User’s Guide
T
test, functional, 1–2, 1–3, 1–4, 1–5
time delays, 1–5, 2–2
see Controller User’s Guide
Transfer Control selector switch
Retransfer Delay Bypass, 1–5
Transfer Test, 1–5
Transfer Switch Connected To
Emergency light, 1–4, 1–5
Transfer Switch Connected To
Normal light, 1–4, 1–5
transfer test, 1–5, 2–1
transfer to emergency, 1–5
transfer to normal, 1–5
trouble–shooting, 2–2
V
voltage checks, 1–4
voltage, pickup and dropout settings
see Controller User’s Guide
Printed in U.S.A. Copyright --- ASCO Power Technologies, L.P. 2007
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