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Operator’s

Manual

4000 Series ADTS

Automatic Delayed–TransitionTransfer Switches

J–design150–600A,H–design800–1200A,

G–design1600–3000A,F–design4000A

DANGER is used in this manual to warn of high voltages capable of causing shock, burns, or death.

WARNING is used in this manual to warn of possible personal injury.

Refer to the outline and wiring drawings provided with your 4000 Series ADTS for all installation and connection details and accessories.

Refer to Group 5 Controller User’s Guide381333–126 for ATS status display messages, time delays, pickup & dropout settings, and adjustments.

An experienced licensed electrician must install the ACTS.

CAUTION is used in this manual to warn of possible equipment damage.

Rating Label

Each automatic closed–transitiontransfer 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.

Nameplate

The Transfer Switch nameplate includes data for each specific 4000 Series ADTS. Use the switch only within the limits shown on this nameplate. A typical Catalog Number is shown on the next page with its elements explained.

TABLE OF CONTENTS section-page

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 1-1Mounting and Line Connections . . . . . . . . .1-1Auxiliary Circuits and Harness . . . . . . . . . . .1-2Engine Starting Contacts . . . . . . . . . . . . . . .1-2Functional Test . . . . . . . . . . . . . .1-3through1-8

TESTING & SERVICE . . . . . . . . . . . . . . . . . . 2-1Transfer Test . . . . . . . . . . . . . . . . . . . . . . . . . .2-1Preventive Maintenance . . . . . . . . . . . . . . . .2-1Disconnecting the Controller . . . . . . . . . . . .2-1Manual Load Transfer . . . . . . . . . . . . . . . . . .2-2Trouble-Shooting . . . . . . . . . . . . . . . . . . . . . .2-2

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

50 Hanover Road, Florham Park, New Jersey 07932–1591USA

381333–272B

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 519758–0876,for service call 1 888234–2726(ASCO) www.asco.ca

Catalog Number Identification

Typical 4000 Series catalog no. for J–design,2 pole, 260 amp, 240 V, ADTS in Type 1 enclosure:

design

J

4ADTS

A

2

260

 

F

5

 

 

 

 

 

 

 

 

 

 

 

 

 

prefix

 

 

 

 

 

 

 

 

 

 

 

letter

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Neutral

 

 

 

Phase Poles

 

Amperes

 

Voltage

 

A – solid

 

 

 

2 – single Ø

 

150

1200

 

A 115

J 400

 

B – switched

 

 

 

3 – three Ø

 

260

1600

 

B 120

K 415

 

C – overlapping

 

 

 

 

400

2000

 

C 208

L 440

 

blank – none

 

 

 

 

 

 

600

2600

 

D 220

M 460

 

 

 

 

 

 

 

 

 

 

800

3000

 

E 230

N 480

 

 

 

 

 

 

 

 

 

 

1000

4000

 

F 240

P 550

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

G 277

Q 575

 

 

 

 

 

 

 

 

 

 

 

 

 

H 380

R 600

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

field connections terminal block TB

power connections

Transfer

Switch

C

Controller

5 – standard

5X – if accessories ordered

Enclosure

C – type 1

F – type 3R

G – type 4

H – type 4X

L – type 12 blank – open type

transfer control & lights

Group 5

Controller

power connections

J–design260 ampere size in typical enclosure with location of customer connections

SECTION 1 INSTALLATION

ASCO 4000 Series Automatic Delayed–TransitionTransfer Switches are factory wired and tested. Field installation simply requires mounting and connection of service cables, and auxiliary control circuits (if required).

Remove the Shipping Skid

For large switches, 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 level and straight. Refer to the applicable enclosure outline drawing included with the 4ADTS 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 outline and mounting diagram provided with the ATS; it shows all mounting details and instructions.

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

Mount the ATS vertically to a rigid supporting structure. Level all mounting points by using flat washers behind the holes to avoid distortion of the switch.

The controller is mounted on the cabinet door. An addon DIN rail is provided for some optional accessories and is mounted below controller on the door.

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.

should be tested to verify that they are not defective or have been damaged during installation.

Connecting Power Conductors

A Wiring Diagram is furnished with the ASCO 4000 Series 4ADTS (separate from this manual). Refer to this drawing. All wiring must be made in accordance with the National Electrical Code and local codes.

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. 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 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.

Do not run cables in front of or behind the switch. Cables can be bundled on the right side of the switch. Maintain proper electrical clearance between the live metal parts and grounded metal: ½ inch minimum for 150-400amps, 1 inch minimum over 400 amps.

It is not necessary to remove the barriers from the transfer switches to install the cables. If you do remove them,however, be sure to reinstall the barriers carefully.

Bus Connections

For large switches use grade 5 hardware to connect bus to appropriate terminal plates. Wipe off the bus surfaces before they are joined. If the bus is very dirty, gently clean the surfaces with a non---flammablesolvent. Avoid touching the cleaned surfaces.

Tighten bolted joints to the torque specified in Table A.

The reliability of the connection depends on how clean and how tight the joint is.

Table A. Tightening torque values for bolted joints (Grade 5 hardware)

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-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

1---1

Bolt Diameter

Tightening Torque

in inches

in foot pounds

1/4

7

5/16

12

3/8

20

1/2

50

5/8

95

3/4

155

INSTALLATION (continued)

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 control panel by a plug-inharness (two plugs).

Auxiliary Circuits

Connect auxiliary circuit wires to appropriate terminals on the transfer switch. Note the control features that are furnished on this switch. Make the necessary auxiliary connections by referring to the Wiring Diagram.

Engine Starting Contacts

The engine control contact connections (if used) are located on the transfer switch. Connect signal wires to appropriate terminals as specified in Table B and shown in Figures 1–1and1–2.See the wiring diagram too.

Table B. Engine start connections

When normal

 

Terminals on

source fails

 

 

transfer switch

contact closes

 

TB1 and TB2

contact opens

 

TB1 and TB3

 

left side of transfer switch

 

COMMON

 

Engine Starting

FEATURE 7

 

Signals

 

5 amps, 32 V DC

closes to start

 

5 amps resistive 28 V DC

FEATURE 8

 

or 120 V AC max.

opens to start

 

 

 

 

COMMON

 

TS Auxiliary Contacts

 

 

FEATURE 14B

 

Feature 14A & 14B

 

10 amps, 32 V DC

closed on emergency

 

 

10 amps 250 V AC

FEATURE 14A

 

 

general purpose

closed on normal

 

 

 

 

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

Figure 1-1.Connections to engine starting contact terminal block for 150 through 1200 amp.

J & H–designtransfer switches.

Engine Starting

TS Auxiliary Contacts

 

 

Signals

Feature 14A & 14B

 

 

5 amps, 32 V DC

10 amps, 32 V DC

 

 

5 amps resistive 28 V DC

10 amps 250 V AC

TB Terminal Block

 

or 120 V AC max.

general purpose

 

 

 

(field connections)

 

 

 

accepts wire range

 

FEATURE 7 closes to start FEATURE 8 opens to start

 

22–12AWG

 

 

 

 

 

 

 

 

Figure 1-2.Connections to engine starting contact terminal block located on 1600 through 3000 amp.

G–designtransfer switches.

1---2

INSTALLATION (continued)

Functional Test

The Functional Test consists of three checks:

1 — Manual Operation Test, pages 1–3through1–6

2 — Voltage Checks, page 1–7

3 — Electrical Operation, page 1–8

Do these checks in the order presented to avoid damaging the ATS.

Read all instructions on the Wiring Diagram and labels affixed to the ATS. Note the control features that are provided and review their operation before proceeding.

Continue to 1 – Manual Operation Test starting below.

1 – Manual Operation Test

A detachable operator handle is provided on the transfer switch for maintenance purposes only. Manual operation of the transfer switch must be checked before it is operated electrically.

Do not manually operate the transfer switch until both power sources are disconnected: open both circuit breakers.

1.Select the appropriate switch design / amp. size and follow directions for installing and using the handle:

150–1200 amp J, H–designs Fig.1-3,-4,-6thru-11.Attach the manual handle onto the shaft hub, left side of the operator.

1600 – 3000 amp. G–designSee Figures 1-5, 1-12. Install the hub (with pin) onto the shaft and insert the manual firmly into the side hole in the hub. Push in or pull out hub to engage opposite source contacts.

4000 amp. F–designSee Figure 1-13.

Insert the manual handle into the hole in the weight.

2.Move the handle as shown to manually operate the Transfer Switch. The switch should operate smoothly without binding. If it does not, check for shipping damage or construction debris. Repeat the manual operation check on the other Transfer Switch.

3.Return the transfer switch to the N (closed on normal) position. If removable, remove the maintenance handle and store it on the transfer switch in the place provided.

Emergency contacts (upper shaft)

window indicators

contact

position

O is open

indicators

C is closed

(right side)

 

Normal contacts

 

(lower shaft)

 

Figure 1-3.Contact position indicators on150–600amp.J–designtransfer switches .

Shown with Emergency open and Normal closed.

Emergency contacts (upper shaft)

window indicators

contact

position

O is open

indicators

C is closed

(right side)

 

Normal contacts

 

(lower shaft)

 

Figure 1-4.Contact position indicators on800–1200amp.H–designtransfer switches . Shown with Emergency open and Normal closed.

Emergency contacts

window

contact

indicators

position

OPEN or

indicators

CLOSED

(left side)

Normal

 

contacts

 

Figure 1-5.Contact position indicators on1600–3000amp.G–designtransfer switches . Shown with Emergency closed and Normal open.

1---3

INSTALLATION (continued)

J–design150–600amp

left side of transfer switch

maintenance handle

Emergency source contact shaft hub

clip

Normal source contact shaft hub

H–design800–1200amp

left side of transfer switch

lobes on weights prevent both N & E contacts

from being closed at the same time

Emergency source contact shaft hub

maintenance handle

clips

Normal source contact shaft hub

Figure 1-6.Maintenance handle on150–600amp.J–designtransfer switches. Hubs shown with Normal contacts closed & Emergency open.

Figure 1-9.Maintenance handle on800–1200amp.H–designtransfer switches. Hubs shown with Normal contacts closed & Emergency open.

UP opens the

handle Emergency source contacts

hub

UPPER SHAFT

DOWN closes the

 

 

Emergency source

frame

contacts

 

Figure 1-7.Emergency (upper shaft) operation on150–600amp.J–designtransfer switches.

handle

UP opens the

 

Emergency source

 

contacts

hub

UPPER SHAFT

DOWN closes the

 

 

Emergency source

frame

contacts

 

Figure 1-10.Emergency (upper shaft) operation on800–1200amp.H–designtransfer switches.

 

UP closes the

handle

UP closes the

handle

Normal source

 

Normal source

contacts

 

contacts

 

 

hub

LOWER SHAFT

hub

LOWER SHAFT

 

 

DOWN opens the

 

DOWN opens the

 

 

 

Normal source

 

Normal source

frame

contacts

frame

contacts

 

 

Figure 1-8.

Normal (lower shaft) operation

Figure 1-11.

Normal (lower shaft) operation

on 150–600amp.J–designtransfer switches..

on 800–1200amp.H–designtransfer switches..

 

 

1---4

 

INSTALLATION (continued)

Do not manually operate the transfer switch until both power sources are disconnected: open both circuit breakers.

Table C. Maintenance handle positions on 150–1200amp. transfer switches. .

 

J–design150---600A

H–design800---1200A

 

 

Transfer Switch

Interlocked Shafts 1

Interlocked Weights 2

Maintenance

Shaft Indicators

Position

Link between contact

Lobes prevent

 

Handle

 

 

 

shafts prevents closing

closing both N & E

 

 

 

both N & E contacts

contacts

 

 

 

 

hub

weight

hub

up

 

E

 

 

 

 

E = O

 

 

 

 

upper contacts open

 

 

 

 

 

Normal

contact shafts

lobe

lobe

up

 

N

link

 

 

N = C

 

 

 

hub

 

hub

 

lower contacts closed

 

 

 

 

 

 

 

 

 

weight

 

 

 

 

 

 

 

up

 

E

 

 

 

 

E = O

 

 

 

 

upper contacts open

Load

 

 

 

 

 

 

 

 

 

Disconnected

 

 

 

 

N = O

N

 

 

 

 

 

 

 

 

lower contacts open

 

 

 

 

 

 

 

 

 

down

 

E

 

 

 

 

E = C

 

 

 

down

upper contacts closed

 

 

 

 

Emergency

 

 

 

 

 

 

 

 

 

N

 

 

 

 

N = O

 

 

 

 

lower contacts open

 

 

 

 

 

 

 

 

 

down

 

Note 1: The hub and contact shaft turn in opposite directions through a cam follower mechanism.

Note 2: The hub and contact shaft turn in the same directions.

Note: If Normal and Emergency connections are reversed this operation is also reversed.

1---5

INSTALLATION (continued)

Emergency contacts

window indicators

OPEN or

CLOSED

Normal contacts

contact position indicators (left side)

Grasp handle firmly with both hands

Slide the hub onto the shaft and insert the pin.

Turn counterclockwise

Insert handle

into hole

to OPEN contacts.

(spring fully

Turn clockwise

compressed)

CLOSE

 

counterclockwise DOWN

clockwise DOWN

OPENS the contacts

OPENS the contacts

Pull out shaft to open Emergency

Pull out shaft to close Emergency

source contacts (upper)

source contacts (upper)

Push in shaft to open Normal

Push in shaft to close Normal

source contacts (lower)

source contacts (lower)

Figure 1-12.Removable maintenance handle and positions on 1600 – 3000 amp.G–designtransfer switches.

weight

hole

maintenance handle

Figure 1-13.Removable maintenance handle on 4000 amp.F–designtransfer switch.

Verify that the maintenance handle has been removed and stored properly before proceeding!

Now continue to 2 – Voltage Checks on page1–7.

1---6

INSTALLATION (continued)

Press for 15 Sec.

observe these lights

Figure 1-14.Standard controls and indicators.

2 ---Voltage Checks

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

Verify that the feeders have been connected to the proper terminal lugs.

Use extreme caution when using a meter to measure voltages. 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 1–14.

Black circle means light is on.

White circle means light is off.

*If necessary, adjust the 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.

Note: Refer to Section 3 of the Group 5 ControllerUser’s Guide 381333–126for how to display the status of the ATS and the voltage and frequency of each source.

Note: Press theLamp Test button to verify that all five lights work.

Now continue to 3 --- Electrical Operation on next page.

1---7

Close the normal source (utility) circuit breaker. Two two left lights should come on. The

1normal source Accepted (upper left) and theTransfer Switch Position connected to normal (lower left) lights should be on.

Carefully use an accurate voltmeter to check the phase to

2phase and phase to neutral voltages present at the transfer switch normal source terminals.

Close the emergency source (generator) circuit breaker. (Start generator, if necessary.)

3Another light should come on. The emergency source Accepted light (upper right) should be on.

Carefully use an accurate voltmeter to check the phase to

4phase and phase to neutral voltages present at the transfer switch emergency source terminals.*

 

Carefully use a phase rotation

A B C

 

meter to check the phase

 

5

rotation of the emergency

 

source; it must be the same as

 

 

the phase rotation of the normal

 

 

source (refer to wiring diagram).

 

Shut down the generator, if applicable. The emergency source Accepted light (upper

6right) should go off. Then set the generator’s starting control switch to automatic. Remove all meters; close enclosure door.

INSTALLATION (continued)

observe these lights

step 2 step 4

Press for 15 Sec.

press

these buttons

If this light is on, the buttons will not work until the controls are unlocked. If this light is blinking, the user controls are unlocked for 5 minutes.

Figure 1-15.User controls and indicators.

3 ---Electrical Operation

This procedure will check the electrical operation of the automatic transfer switch. See Figure 1–15.

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.

Black circle means light is on.

White circle means light is off.

If the User Controls Locked light is on, theTransfer Test andRetransfer to Normal buttons will not work until you unlock them.

How to unlock the User Controls

Press up or down arrow keys on Transfer Control Center (Group 5 Controller), enter the password, and pressEnter key. The user controls are now unlocked for 5 minutes. During that time the light will blink.

To lock or unlock the user controls refer to the Group 5 Controller User’s Guide 381333–126.Password information and time delay settings are also provided there.

This completes the functional test of the ATS.

1---8

The two left lights should be on; the normal source Accepted

1(upper left) and the Transfer Switch Position connected to normal (lower left) should be on.

Press and hold theTransfer Test button until the generator starts

2and runs (this should happen within 15 sec.). The emergency source Accepted light (upper right) should come on.

Then the transfer switch should operate to emergency.

The Transfer Switch Positionconnected to emergency light

3(lower right) should come on and the connected to normal light (lower left) should be off.

If Feature 2B is used, the transfer to emergency will occur after the time delay.

The transfer switch should operate back to normal after Feature 3A time delay.

For immediate retransfer press

4the Retransfer to Normalbutton. The Transfer Switch Position connected to normal light

(lower left) should come on and the connected to emergency (lower right) light should be off.

The generator will stop after Feature 2E time delay (unloaded

5running engine cooldown).

The emergency source Accepted light (upper right) should go off.