Emerson 7000 ATB User Manual

Operator’s

Manual

Bypass–Isolation Switches

F–design, 3000 and 4000 amp. sizes

TABLE OF CONTENTS

section-page

INSTALLATION 1-1........................

Mounting 1-1.............................

Power Connections 1-2....................

Engine Starting & Auxiliary Circuits 1-2......

Functional Test 1-5, 1-6, 1–7................

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

BYPASSING & ISOLATING 3-1..............

Bypassing the ATS 3-1....................

Isolating the ATS 3-1......................

Return to Service 3-3......................

INDEX back cover.........................

AnexperiencedlicensedelectricianmustinstallATB

7000 Series A T B

Automatic Transfer &

Refer to the outline and wiring drawings provided
with your 7000 Series ATB for all installation and
connection details and accessories.

Refer t o Group 5 Controller User’s Guide 381333–126
for ATS status display messages, time delays, pickup
& dropout settings, and adjustments.

Rating Label

Each 7000 Series ATB contains a rating label to define the
loads and fault circuit withstand/cl o sin g ratings. Refer to the
label on the T ransfer Switch for specific values.

!

Do not exceed the values on the rating label.

Exceeding the rating can cause personal injury

or serious equipment damage.

Nameplate

The Transfer Switch nameplate includes data for each
specific 7000 Series ATB. Use the switch only within the
limits shown on this nameplate. A typical Catalog Number
is shown below with its elements explained:

Catalog Number Identification

Typical 7000 Series ATB catalog no. for overlapping neutral, 3 pole, 4000 amp, 480 V, in Type 1 enclosure:

7ATB C 3 4000 N 5 C

Neutral

A –solid

C – overlapping

blank --- none

ASCO POWER TECHNOLOGIES CANADA PO Box 1238, 17 Airport Road, Brantford, Ontario, Canada N3T 5T3
telephone [phone], fax [phone], for service call 1 888 234–2726 (ASCO) www.asco.ca

Phase Poles

2 –singleØ
3 –threeØ

50 Hanover Road, Florham Park, New Jersey 07932–1591 USA
1 800 937–2726 (ASCO), for service call 1 800 800–2726 (ASCO) www.asco.com

Amperes Voltage Controller Enclosure

3000
4000

A 115

B 120

C 208

D 220
E 230

F 240
G 277

H 380

J 400

K 415

L 440

M 460
N 480

P 550

Q 575

R 600

5 –standard
5X – if accesso-

ries ordered

C –type1

F –type3R

G –type4

L –type12

blank – open type

381333–133 A

SECTION 1 INSTALLATION

The ASCO 7000 Series Automatic Transfer & Bypass–
Isolation Switch (ATB) consists of an upper bypass–isola­tion switch, a transfer switch, a monitoring and transfer
controller, and door–mounted controls. The ATB is
factory wired and tested. Installation requires removal of
the shipping skid then securing the enclosure to the
supporting foundation.

Remove the Transfer Switch

The Transfer Switch is shi pped inside the enclosure (ATS
side) in the fully engaged position. Before installing the
enclosure remove the Transfer Switch as follows:

1. Open the enclosure doors and install the two ramps
(stored on right side).

2. Remove the Isolation Handle which is stored on the
lower right front of the Transfer Switch carriage
frame. Install the Isolation Handle onto the
protruding shaft and turn it counterclockwise
(approximately 10 turns) until it stops

3. Unplug J2 and J5 harness plugs, and roll out the
Transfer Switch. Cover i t to keep it clean.

.

Supporting Foundation

The supporting foundation and adjacent area must be
level and straight, otherwise the Transfer Switch and
enclosure may not align causing door problems. The
floor under the enclosure must be flat and level. This is
very important! The structure of the enclosure must be
straightand square. Allowat least 36 inches for roll out of
Transfer Switch. Refer to the enclosure drawing for
required door opening space.

Mounting

Refer to the enclosure outline drawing furnished with
this switch and mount the 7000 Series ATB according to
the details and instructions shown on the drawing.

Bolt the cubiclesections together so that they are linedup
on the f ront faces. See Figure 1–1.

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.

Testing Power Conductors

Do not connect the power conductors to the ATB 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 rea son, after the cables are pulled into position,
and before they are connected they should be tested to
verify that they are not defective or have been damaged
during installation.

!

Protect the switch from construction grit

and metal chips to prevent malfunction or

shortened life for the ATB switch.

If bottom cable entry is used, the foundation must be pre­pared so that conduit stubs are located correctly. Refer to
appropriate enclosure outline drawing for specified cable
entrance 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.

1--1

INSTALLATION (continued)

Connecting Power Conductors

A Wiring Diagram is furnished with the ATB. All wiring
must be made in accordance with the local codes. After
the power cables have been tested, connect them to the
appropriate terminal lugs on the Bypass Switch as shown
on the wiring diagram provided with this ATB. Make
sure that 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 ATB. Be careful when
stripping insulation from conductors; avoid nicking or
ringing the conductor. Remove surface oxides from
conductors by cleaning with a wire brush. Follow
conductor manufacturer’s instructions when aluminum
conductor is used. Apply joint compound to conductor,
then carefully wipe away excess compound. Tighten the
cable lugs to the torque specified on the rating label.

!

Be sure that the Normal and Emergency power

connections are in proper phase rotation.

Bus Connections

If bus connection is used, use SAE grade 5 hardware to
connect bus to appropriate terminal plates on bypass
switching device. Wipe off bus surfaces before they are
joined. If bus is dirty, gently clean surfaces with a
non-flammablesolvent. Avoidtouching cleaned surfaces.

!

Do not breathe cleaning solvent vapors.

UseSAEgrade5hardwareandtightentheboltedjoints
tothetorquespecifiedinTable2-1.

!

The reliability of the connection depends

on how clean and how tight the joint is.

Table 2-1. Tightening torque values for bolted joints.

Bolt Diameter

(Grade 5 hardware)

in inches

5/16 12

3/8 20
1/2 50
5/8 95
3/4 155

Recommended

Tightening Torque

in foot pounds

Figure 1–1. Bus tie plates (top view).

!

See job specific drawings supplied with ATB.

Harnesses

All internal connections are made at the factory. The
bypass switch, transfer switch, and control panel are
joined together by an interconnecting wire harness. The
disconnect plugs are already engaged on enclosed
switches. For open–type switches, the plugs must be
engaged after installation is completed. Align harness
plugs with sockets in the control and push them together
until they are secure.

Engine Starting Contacts

and Auxiliary Circuits

The engine control contact signal connections and
auxiliary circuits are located on terminal block TB as
shownontheWiring Diagram provided with the ATB.
Connect the signal wires to the appropriate terminals.

1--2

INSTALLATION (continued)

Install the Transfer Switch

After the enclosure is installed and power cables or bus
connected to the Bypass Switch, the Transfer Switch
carriagecanberolledin. Thefloorofthecabinetmustbe
free of debris and clean. If necessary, use a vacuumcleaner.
Make a thorough inspection to be sure no tools are left
inside. The Bypass Handle must be in the BYPASS POS
position (closed on normal). The Isolation Handle (draw­outcrank)mustbefullycounterclockwiseagainststop.

Do not apply any electrical power to the ATB yet.

It is not necessary to remove the barriers from the bypass
switch and transfer switch. If you do remove them,
however, reinstall them carefully.

NOTE: Be sure to roll the correct Transfer
Switch into the enclosure. If more than one is
supplied, each will be labeled above the
solenoid operator.

The Transfer Switch NORMAL contacts must be closed.
If not, use the manual operator handle (maintenance
handle stored on lower carriage) to manually operate the
switch. See Figure 1–10. Check that all arc chutes and
interphase barriers are in place on the Transfer Switch.
Then grasp the Transfer Switch carriage frame and roll it
into the cabinet (isolation contacts facing inward). Align
the rollersbetween the floor guides and push the carriage
in until its crank pins engage the latch plates on both
sides. Then follow the procedure below:

Remove interference tag

after making inspection

on page 1-4.

SL1

solenoid

lock

handle

carriage

frame

Figure1–2. Solenoid latch interference tag.

Isolation
Handle shaft

Turn the draw-out
crank while checking
alignment of the
isolation contacts.

Figure 1–3. Isolation Handle.

NOTE: Solenoid lock SL1 on the Isolation
shaft inhibits operation of the drawout(Isola­tion contacts) unless the Transfer Switch and
Bypass Switch are in compatible positions.
This solenoid must energize to unlock. Be­cause all power sources are de-energized, the
interference tag defeats the solenoid in the
following inspections.

Do the three inspections on page 1-4 without any
electrical power connected. The inspections will verify
that the isolation contacts are in proper alignment. If
necessary, add shims under the floor. It may be helpful to
remove the the right side of the enclosure to expose the
isolation contacts during the inspections.

!

Do not apply any power to the Bypass Switch.

Be sure that the Normal and Emergency source

circuit breakers are OPEN before proceeding.

Tran s f e r S w itch

NOMINAL CONTACT GAP 1/8” WHEN OPEN.

Figure 1–4. Switched neutral interlock.

1--3

INSTALLATION (continued)

Inspection 1

!

Do not force the Isolation Handle. Be sure that

the sensing lead isolation contacts do not hit the

male stabs head on, but rather slide on them.

IS

stab

Figure 1–5. Isolation contacts in TEST position.

sensing lead contact

isolation contacts

Move ATS from DISCONNECTED To TEST Position

(without electrical power)

Action T urn the Isolation Handle (Figure 1–3) clockwise approximately 7 or 8 turns.

Observe

The Transfer Switch should be pulled inward; the sensing lead isolation
contacts should make with the male stabs as shown in Figure 1–5.

Inspection 2

!

Do not force the Isolation Handle. Be sure that

the isolation contact fingers make with the male

stabs on both sides

in the CONNECTED position.

IS TS

Figure 1–6. Isolation contacts CONNECTED

(CLO SED).

TS

Move ATS From TEST To CONNECTED Position

(without electrical power)

With solenoid latch interference tag in place (Figure 1–2), continue slowly

Action

turning the Isolation Handle clockwise until it stops (approximately 6 or 7
turns). Now remove the interference tag from the solenoid latch.

The Transfer Switch should be pulled inward; the isolation contact fingers

Observe

should make with the male stabs as shown in Figure 1–6. Also check that
the Bypass Switch switched neutral contacts have opened (Figure 1–4).

Inspection 3

!

Be sure that the isolation contacts disconnect

in the TEST position; the sensing lead contacts

should still touch the male stabs.

Move ATS From CONNECTED Back To TEST Position

(without electrical power)

Action

Observe

Turn the Isolation Handle (Figure 1–3) back counterclockwise until the
isolation contacts separate (approximately 6 or 7 turns).

The Transfer Switch should be pushed outward; the isolation contacts
should disconnect, but the sensing lead contacts should remain touching
asshowninFigure1–7.

IS TS

Figure 1–7. Isolation contacts back in TEST position.

If all inspections are satisfactory connect harness plugs J2 and J5. Proceed to the Function Test.

1--4