Size:
1.08 Mb
Download

Operator’s

Manual

7000 Series ATS Automatic Transfer Switches D design, 30 through 230 A

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 7000 Series ATS 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.

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

30---230amp. size

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.

Nameplate

The Transfer Switch nameplate includes data for each specific 7000 Series ATS. 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.

An experienced licensed electrician must install the ATS.

TABLE OF CONTENTS section-page

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 1-1Mounting and Line Connections . . . . . . . . .1-1Auxiliary Circuits and Harness . . . . . . . . . . .1-2Engine Starting Contacts . . . . . . . . . . . . . . .1-2Functional Test . . . . . . . . . . . . . . . . .1-2,1-3,1-4

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

381333–229D

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 7000 Series 7ATS catalog no. for overlapping neutral, 3 pole, 150 amp, 480 V, in Type 1 enclosure:

D

7ATS

C

3

150

design prefix letter

Neutral

Phase Poles

 

Amperes

 

 

 

 

 

 

 

A – solid

2

– single Ø

30

 

B – switched

3

– three Ø

70

 

C – overlapping

 

 

100

 

blank – none

 

 

150

 

 

 

 

 

200

**

 

 

 

 

230 **

 

 

 

 

 

 

 

 

 

 

** 200 and 230 amp.

 

 

 

 

limited to 480 volts

N 5 C

Voltage

A 115

J 400

B 120

K 415

C 208

L 440

D 220

M 460

E 230

N 480

F 240

P 550

G 277

Q 575

H 380

R 600

 

 

Controller

5 – standard

5X – if accessories ordered

Enclosure

C – type 1

F – type 3R

G – type 4

L – type 12

M –type3R secure

N –type4 secure

P –type4X secure

Q –type12 secure blank – open type

Transfer Switch

terminals for switch

position contacts

 

load power connections

emergency power connections

maintenance handle

(see WARNINGunder Manual Operation)

terminals for engine start contacts

normal power connections

cable spacers

(see INSTALLATION)

transfer control & lights

Controller

150 amp. size in typical enclosure with location of customer connections

SECTION 1 INSTALLATION

The ASCO 7000 Series Automatic Transfer Switch (ATS) is factory wired and tested. Field installation requires mounting, connecting service cables, and connecting engine start and auxiliary control circuits (if required).

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 space and ½ inch minimum 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 Diagramprovided 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 ASCO 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 add-onDIN rail is provided for some optional accessories and is mounted below the controller on the door.

Line Connections

A Wiring Diagram is furnished with the ASCO 7000 Series ATS (separate from this manual). Refer to this drawing. All wiring must be made in accordance with the National Electrical Code and local codes.

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

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. 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.

Three cable spacers are included with 150, 200, & 230 A transfer switches. When installing power cables, run the cables through the cable spacers as shown in Figure 1-1.

Position the cable spacers within 1½ inches from the lugs.

The cable spacers must be located as shown for 150, 200, and 230 ampere transfer switches.

cable spacers

1 ½ inch approximate

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.

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

cable spacer

Figure 1-1.Cable spacer for 150, 200, and 230 amp. transfer switches.

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.

1---1

INSTALLATION (continued)

Harnesses

The transfer switch is connected to the left side of the controller by a plug-inharness (two plugs).

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 A and shown in Figure 1-2.

Table A. Engine Start Connections

When normal

Terminals on

source fails

transfer switch

contact closes

TB14 and TB15

contact opens

TB14 and TB16

ENGINE STARTING CONTACTS ( SHOWN DE–ENERGIZED)

TOP

14

 

 

STUD

 

 

 

 

 

MIDDLE

TS

TB 14

 

NR

 

STUD

15

 

 

 

 

 

BOTTOM

16

TB 16

TB 15

STUD

NR

 

 

 

 

 

Figure 1-2.Engine starting contact label and location on left side of transfer switch.

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.

Functional Test

The Functional Test consists of three checks:

S1 — Manual Operation Test, on this page

S2 — Voltage Checks, page 1–3

S3 — Electrical Operation, page 1–4

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

direction of the weight. Turn it 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 Normal position.

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

Now continue to 2 – Voltage Checks on next page.

Position of the transfer switch is indicated here

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 maintenance handle is provided on 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 the maintenance handle on the left side of the transfer switch. See Figure 1–3.

2.Grasp the attached maintenance handle and turn it with thumb and fingers as shown to manually operate it. The maintenance handle turns the opposite

1---2

weight marked N (normal) andE (emergency)

maintenance handle

weight

floating weight

With ALL POWER OFFgrasp maintenance handle and turn it quickly with your thumb and fingers.

Figure 1–3.Maintenance handle and positions.

INSTALLATION (continued)

observe these lights

Figure 1-4.Standard controls and indicators.

2 – Voltage Checks

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

Verify that the feeders have been connected to the proper 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 1–4.

Q Black square means light is on.

SWhite square 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.

Note

Refer to Section 3 of Group 5 Controller User’s Guide

381333–126for 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---3

Close the normal source circuit breaker. The Transfer Switch

1Connected To Normal and the Normal Source Acceptedlights should come on.

Use an accurate voltmeter to check phase to phase and

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

Close the emergency source circuit breaker. (Start generator,

3if necessary.) The Transfer Switch Connected To Normal &Emergency Source Accepted lights should come on.

Use an accurate voltmeter to check phase to phase and

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

A B C

Use a phase rotation meter to 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. TheEmergency Source Accepted light should

6go off. Then put the starting control selector switch (on the generator set) in the automatic position. Close enclosure door.

INSTALLATION (continued)

observe these lights

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.

This completes the Functional Test of the ATS.

operate this switch

The Transfer Switch Connected

1To Normal and Normal Source Acceptedlights should be on.

Turn and hold Transfer Controlswitch clockwise to Transfer

2Test until the engine starts and runs (within 15 sec.).

Emergency Source Accepted light should come on.

Transfer switch will operate to the Emergency position after Feature 2B time delay. The

3Transfer Switch Connected To Emergency light should come on and Load Connected to Normallight goes off.

Transfer switch will operate back to Normal position after Feature 3A time delay. For immediate retransfer turn Transfer

4Control counterclockwise to

Retransfer Delay Bypass. The Transfer Switch Connected To Normallight should come on;

Transfer Switch Connected to Emergency light should go off.

The engine–generatorwill stop after the Feature 2E time delay

5(unloaded running engine cooldown). The Emergency Source Accepted light should go off.

1---4

SECTION 2 TESTING & SERVICE

TRANSFER TEST

Operate the 7000 Series ATS at least once a month by following the five–stepElectrical Operation Transfer Test procedure on page1–4.

PREVENTIVE MAINTENANCE

Reasonable care in preventive maintenance will insure high reliability and long life for the 7000 Series ATS. An annual preventive maintenance program is recommended.

ASCO Services, Inc. (ASI) is ASCO Power Technologies’s national service organization. ASI can be contacted at 1-800-800-2726for information on preventive maintenance agreements. In Canada call1–888–234–ASCO(2726).

Checklist for Yearly Inspection

Hazardous voltage capable of causing shock, burns, or death is used in this switch. Deenergize both Normal – Emergency power sources before performing inspections!

SClean the ATS enclosure.

Brush and vacuum away any excessive dust accumulation. Remove any moisture with a clean cloth.

SCheck the transfer switch contacts.

Remove the transfer switch barriers and check contact condition. Replace the contacts if they become pitted or worn excessively. Reinstall the barriers carefully.

SMaintain transfer switch lubrication.

The transfer switch has been properly lubricated, and under normal operating conditions no further lubricating is required. Renew factory lubrication if the switch is subjected to severe dust or abnormal operating conditions. Relubricate the operator if TS coil is replaced. Order lubrication 625550–001 (CastrolEndurexR 4000 lubricant).

SCheck all cable connections & retighten them.

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 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 theoff 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 position, first open the normal source circuit breaker. Second, place the engine starting control in thetest orrun 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

Do not unplug the controller until step 1a or 1b is completed.

1.Observe the position of the transfer switch.

a.If the transfer switch is in the Normal position, first be sure thatboth normal and emergency source circuit breakers are open. Second, be sure that the standby engine starting control is still in theoff position.

b.If the transfer switch is in the Emergency position, first be sure thatboth normal and emergency source circuit breakers are open.

2.The two harness plugs and sockets are keyed. Carefully align the plugs with the sockets and press straight in until both latches click. Close the door!

3.Restore the two sources in sequence as follows:

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 the United States call 1–800–800–ASCO(2726), or in Canada call1–888–234–ASCO(2726).

2---1

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 theautomatic 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.

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 (all conductors deenergized).

1.Deenergize both the normal and emergency source conductors (remove fuses or open circuit breakers).

2.Use the maintenance handle to manually operate the transfer switch to the opposite source. See

Manual Operation on page 1–2.

3.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.

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.

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!

Table 2-1.Trouble-ShootingChecks.

PROBLEM

CHECK IN NUMERICAL SEQUENCE

1

2

3

 

OPERATION

GEN-SET

VOLTAGE

Engine–generatorset does

Hold Transfer Test switch 15

Starting control must be in the

 

not start when the Transfer

seconds or the outage must

automatic position. Batteries

 

Control switch is turned and

be long enough to allow for

must be charged and

 

held in Transfer Testposition

Feature 1C time delay plus

connected. Check wiring to

or when the normal source

engine cranking and starting

engine starting contacts on

 

fails.

time.

customer terminal block TB.

 

 

 

Verify that the small plug J3 is

 

 

 

connected to receptacle P3.

 

 

 

 

 

Transfer switch does not

Wait for Feature 2B time delay

Generator output circuit

Voltmeter should read at least

transfer the load to the

to time out (if used).

breaker must be closed.

90% of nominal phase to

emergency source after the

 

Generator frequency must be

phase voltage between

engine–generatorset starts.

 

at least 95% of nominal

transfer switch terminals EA

 

 

(57 Hz for a 60 Hz system.) *

and EC (or EL1 and EL2 for 2

 

 

 

pole switches). *

 

 

 

 

Transfer switch does not

Wait for Feature 3A time delay

 

Voltmeter should read at least

transfer the load to normal

to time out (if used).

 

90% of nominal phase to

source when normal returns

 

 

phase voltage between

or when the Transfer Control

 

transfer switch terminals NB

switch is released.

 

 

and NC, NC and NA, and NA

 

 

 

and NB (or NL1 and NL2 for 2

 

 

 

pole switches).

 

 

 

 

Engine–generator-setdoes

Wait for Feature 2E time delay

Starting control must be in the

 

not stop after load retransfer

to time out (if used).

automatic position.

to the normal source.

 

 

 

 

 

 

 

* 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, call1–888–234–2726.Furnish the Serial No., Bill of Material (BOM) No., & Catalog No. from transfer switch nameplate.

2---2

A

auxiliary circuits, 1–2

C

cable lugs, 1–1

preparation, 1–1spacers,1–1

illustration of, 1–1catalog number, inside cover cleaning,2–1

connections line, 1–1

controller, 1–1,1–2disconnecting,2–1

see Controller User’s Guidegrounding, 1–1

E

electrical operation, 1–4

Emergency Source Accepted light, 1–3, 1–4

F

frequency, generator, 2–2functional test,1–2,1–3,1–4

H

harness, 1–2disconnect plugs,2–1

HELP customercare@asco.com 800–800–ASCO

I

inspection, 2–1installation,1–1

INDEX

L

labels,

engine start contacts, 1–2rating, cover

lights, 1–3,1–4lubrication,2–1

M

maintenance, preventive, 2–1

manual load transfer, 2–2warning,2–2

manual operation, 1–2illustration of,1–2warning,1–2

N

nameplate, cover

Normal Source Accepted light, 1–3, 1–4

O

operation electrical, 1–4manual,1–2

illustration of, 1–2warning,1–2

sequence of

see Controller User’s Guide

optional accessories

see Controller User’s Guide

P

parts, 2–1

phase rotation check, 1–3problem,2–2

R

rating label, cover replacement parts, 2–1

S

service, 2–2

settings

see Controller User’s Guide

T

test, functional, 1–2,1–3,1–4

time delays, 2–2

see Controller User’s Guide

Transfer Control selector switch Retransfer Delay Bypass, 1–4Transfer Test,1–4

Transfer Switch Connected to Emergency light, 1–3, 1–4

Transfer Switch Connected to Normal light, 1–3, 1–4

transfer test, 1–4

transfer to emergency, 1–4transfer to normal,1–4trouble–shooting,2–2

V

voltage checks, 1–3

voltage, pickup and dropout settings see Controller User’s Guide

Printed in U.S.A.

Copyright ASCO Power Technologies, L.P. 2007