DANGER is used in this manual to warn of high
voltages capable of causin g shock, burns, or death.
WARNINGisusedinthismanualtowarn
of possible personal injury.
CAUTIONisusedinthismanualtowarn
of possible equipment damage.
An experienced licensed electrician must install the A TS.
100 throu gh 400 ampe re sizes
Series 185
Refer to the outline and wiring drawings provided with
your ASCO Series 185 ATS for all installation details.
ASCO Series 185 Automatic Transfer Switches (ATSs) are
Listed under Underwriter’s Laboratories Standard for
Transfer Switch Equipment, UL–1008. They are intended
for use only in optional standby system s in accordanc e with
the National Electrical Code, NEC/NFPA 70, Article 702.
This ATS is for use with 2–wire automatic start generators
only.
Refer to Application Informaton 381339–292 to confirm
that you have selected tha appropriate product for the
intended installatio n .
This automatic transfer switch is intended for standby
power applicato n s in residential / lig h t commercial use only.
This product is not intended for emergency
or life–support systems.
If you have more stringen t applicatio n requirements contact
ASCO Pow er Technolog ies for other produc ts suitable for
critical applications.
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.
TABLE OF CONTENTS
page
INSTALLATION1..........................
CONTROLLER2–5........................
FUNCTIONAL TEST6......................
SEQUENCE OF OPERATION7.............
TROUBLESHOOTING8–9..................
100–230 ampere sizes
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
INDEX10.................................
381333–319 A
Series 185
Nameplate
The Transfer Switch nameplate includes data for each
specific ASCO Series 185 ATS. Use the ATS only
within the limits shown on this nameplate.
D 185A2200F4C
Neutral
A –standard
Phase Poles
2 –singleØ
AmperesVoltageControllerEnclosure
100
200
230
260
400
clock battery
cable spacers
(see INSTALLATION)
Catalog Number Identification
A typical Catalog Number is shown below with its
elements explained. The example is for a D–design,
2 pole, 200 A, 220–240 V, in a Type 1 indoor enclosure:
F 220--- 240
4 –standard
4X
–if
accessories
ordered
load power
connections
C –Type1
M –Type3R
emergency
power
connections
neutral
connections
terminals
for optional
switch
position
contacts
(shown
installed)
Transfer
Switch
ground
connections
200 ampere size in typical enclosure with location of customer connections
381333–319 A
membrane
controls
generator
control
connections
Controller
harness plug
utility power
connections
INSTALLATION
Series 185
Installation of the ASCO Series 185 automatic transfer
switch (ATS) must be performed by a licensed electrician.
It must be installed according to the National Electrical
Code (NEC) and all local electrical code requirements.
Remove the enclosure cover and inspect the ATS for
shipping damage. If damage is evident do not install the
ATS .
1 --- M o u n t i n g
Refer to the enclosure outline drawing. Mount the ATS
according to details and instructions shown on this
diagram. 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 enclosure.
MALFUNCTION or SHORTENED LIFE
Protect the ATS from construction grit and metal
chips to prevent malfunction or shortened life.
Transfer switches rated 260 and 400 amperes are
mounted on an insulator backing piece (installed behind
the transfer switch). If the transfer switch is removed
from the enclosure and then reinstalled, this insulator
must be placed behind the transfer switch. See Figure 1.
2 --- Electrical Power Connections
Refer to the wiring diagram. The ATS must be protected
by suitably sized circuit breakers feeding the utility and
generator source terminals. The rating of the circuit
breakers must be based on the requirements of the
National Electrical Code for its nameplate ampere and
short circuit withstand ratings.
ELECTROCUTION HAZARD Turn off utility
power and turn off the generator to prevent
electrocution when wiring the transfer switch.
Cable Spacers for 200 and 230 A
Three cable spacers are included with 200 and 230
ampere transfer switches. Run the copper power cables
throughthecablespacersasshowninFigure2. Position
the cable spacers approximately 1½ inches from the
terminal lugs.
CABLE LOOSENING DUE TO SHORT CIRCUIT
Install three cable spacers 1 1/2 inches from
the power terminals to prevent the cables from
loosening during a short–short condition.
FLASH HAZARD – DAMAGE
Be sure that the insulator piece is installed behind
the 260 and 400 ampere transfer switches.
insulator
backing
piece
Figure 1. Insulator for 260 and 400 A.
cable spacers
1 ½ inch approximate
use copper power
cables only for
200 and 230 A
cable spacer
Figure 2. Cable spacers for 200 and 230 A.
1
381333–319 A
CONTROLLERSeries 185
The Group 4 digital Controller is used in ASCO Series
185 automatic transfer switches. It provides the sensing,
timing, and control functions for the ATS. This micro–
processor–based controller includes built–in control
buttons and st atus lights for control of the ATS and
generator.
clock
battery
cover
seepage3
Utility
Acceptable
light
Trans fer
Tes t
button
Load on
Utility light
1 --- P u s h B u t t o n s
On the front control display are three push buttons that
control the operation of the generator and the ATS .
Before using the transfer test button, be sure that
conditions are safe for running the generator and
for load transfer.
Transfer Test
Use this button to test the system. This operation starts
the generator and transfers the load. Be sure that
conditions are safe to do this operation.
Bypass Time Delay
Use this button to cancel the active time delay or exercise
period (stops the generator after cooldown).
Set Engine Exerciser
Use this button to set the automatic generator exerciser
(page 3).
2 --- I n d i c a t o r L i g h t s
Bypass
Time Delay
button
Set
Exerciser
button
Automatic
Generator
Exerciser
light
Load on
Generator
light
Generator
Acceptable
light
Figure 3. Front view of controller.
On the f ront control display are five lights that indicate
the status of the sources and the ATS.
Utility Acceptable
This light i ndicates that the utility voltage is acceptable
for connection to the load.
Generator Acceptable
This light indicates that the generator voltage is
acceptable for connection to the load.
Load on Utility
This light indicates that the generator voltage is
acceptable for connection to the load.
Load on Generator
This light indicates that the generator voltage is
acceptable for connection to the load.
Automatic Generator Exerciser
When the utility is acceptable and the load is on the
utility, this light flashes the number of days until the next
exercise period. When i t is off, no exerciser period is set.
The light is also off when the generator is running.
381333–319 A
2
CONTROLLER
Series 185(continued)
3 --- Generator Starting Contacts
The generator starting contacts connections are on the
controller. Refer to the generator manual. Disconnect
the generator battery and verify that the ignition switch is
in the OFF position. Connect the generator starting
wires to the appropriate terminals on terminal block TB7
as shown on the wiring diagram. For wiring convenience
terminalblockTB7hasaremovableplug. SeeFigure4
and Table A.
Turn on battery by putting S2 DIP switch actuator 10 in
the on position (up). See Table B and Figure 6.
Exercise with or without Load
The generator should be exercised under load or follow
the recommendations of the generator manufacturer. Be
sure the exerciser is turned on. Then select either
exercise with or without load. The ATS will transfer the
load to the generator when the exercise with load is
selected. See Figure 6 and Table B.
Table A. Generator Start Connections
When the Utility failsTerminals on Controller
contact closesTB7–4 and TB7–5
contact opensTB7–5 and TB7–6
4 --- S e t t i n g s
ThetimedelayandsensorsettingintheGroup4
controller are accessible on the inside. Refer to Tables B
and C and to Figures 6 and 7. Use a ball–point pen or
other pointed tool to slide the DIP switch actuators up or
down to match setting shown.
All power must be off before making any changes.
The factory default settings are shown in Table G on
page 5.
cover must be removed
to replace 9V battery
(use alkaline type)
screw
Table B. Generator Exercise Settings
Function
clock
battery
exerciseroffS17
with load or
without load
Factory
Setting
offS210
without
load
DIP
Switch
S18
DIP
Actuator
Actuator
Position
on (up)
off (down)
on (up)
off (down)
without (up)
with (down)
To S e t E x e rci s e r
Press and hold (5 seconds) the Set Engine Exerciser
button. The exercise period occurs immediately
and at
the same time weekly thereafter. The status light below
the button blinks rapidly to indicate that the exerciser
has been set. The number of flashes indicates the
number of days until the next exercise period (at
approximately
thesametimethebuttonwaspressed).
To Cancel an Active Exercise Period
Press the Set Engine Exerciser button t o stop a n
exercising generator. If exercise with load is set, the ATS
retransfers the load to the utility, then stops the
generator after cooldown.
Figure 5. Battery replacement.
3
381333–319 A
Series 185
overridemomentary
3
overridemomentary
unloadedrunning
f
l60
H
198
V
198V*
ili
1
87V
d
1
87V
176
V
154V
d
j
b
le–––
d
j
b
le–––
CONTROLLER
(continued)
S1 DIP switch
S2 DIP switch
S3 DIP switch
Figure 6. DIP switches S1 and S2 at the top right.
The time delay settings are shown in Figures 6 and 7 and
in Table C. The sensor settings are shown in Figure 6
and in Table D. The standard (factory) settings are
showninTablesC,D,andH.
Figure 7. DIP switch S3 at the bottom center.
TableC. TimeDelaySettings
Time Delay DescriptionFactory SettingSettingsDIP SwitchDIP ActuatorActuator Position
override momentary
utility outages
transfer to generator10 seconds (approx.)––––
override momentary
generator outages
transfer to utility15 minutes (approx.)––––
unloaded running
(generator cooldown)
seconds
4seconds
5minutes
1secondS21on (up)
3secondsS21off (down)
4secondS39on (up)
0S39off (down)
5 minutesS110on (up)
0S110off (down)
Table D. Voltage and Frequency Settings
Setting DescriptionSettingFactory SettingSettingsDIP SwitchDIP ActuatorActuator Position
voltage–220 – 240 Vnon–adjustableS22on (up)
requencynomina
phase–singlenon–adjustableS12off (down)
pickup
ut
ty voltage
ropout
generator voltage
generator frequencypickup
pickup198 V
dropout165 V
57 Hz (nom 60 Hz)
48 Hz (nom 50 Hz)
dropout
51 Hz (nom 60 Hz)
43 Hz (nom 50 Hz)
z
50 HzS14on (up)
60 HzS14off (down)
198 VS13on (up)
209 V *S13off (down)
S11off (down)
S12off (down)
S11on (up)
S12off (down)
S11off (down)
S12on (up)
S11on (up)
S12on (up)
non–a
non–a
*
usta
usta
* If the dropout voltage is set to 198 V, the pickup voltage must be set to 209 V.
381333–319 A
4
CONTROLLER
disable
d
disable
d
disable
d
S
1
S
2
S
3
Series 185(continued)
6 --- Remote Control Features
These remote control features require a customer–
supplied normally–closed contact suitable for a 5 V dc
low energy circuit. Refer to the wiring diagram provided
withtheATS. ActivatetheappropriateDIPswitchS3
actuators as shown in Tables E, F, or G. See Figure 7.
Remote test
Normally–closed input. When opened, it simulates a
utility failure. The generator is signalled to start
immediately and the load transfers to the generator (if
acceptable). If the generator fails, the load stays on the
generator until the remote test circuit is closed.
TableE. Remotetest
Function
disabled
enabled
Factory
Setting
disabled
(on)
DIP
Switch
S33
DIP
Actuator
Actuator
Position
on (up)
off (down)
Remote test (with automatic retransfer)
Normally–closed input. When opened, it simulates a
utility failure. The generator is signalled to start
immediately and the load transfers to the generator (if
acceptable). If the generator fails, the load transfers
back to the utility (if acceptable).
Table F. Remote transfer to generator
Function
disabled
enabled
Factory
Setting
disabled
(on)
DIP
Switch
S32
DIP
Actuator
Actuator
Position
on (up)
off (down)
Bypass load transfer to utility time delay
Normally–closed input. When opened, it bypasses or
cancels the generator to utility load transfer time delay.
The load transfers back to the utility.
Table G. Bypass load transfer to utility time
delay
Function
disabled
enabled
Factory
Setting
disabled
(on)
DIP
Switch
S31
DIP
Actuator
Actuator
Position
on (up)
off (down)
7 --- F a c t o r y S e t t i n g s --- S u m m a r y
Table H. Factory Settings – Summary
DIP SwitchDIP ActuatorActuator Position
1on (up)
2off (down)
3on (up)
4off (down)
5off (down)
6on (up)
7off (down)
8off (down)
9off (down)
10on (up)
1off (down)
2on (up)
3off (down)
4on (up)
5on (up)
6on (up)
7on (up)
8on (up)
9off (down)
10off (down)
1on (up)
2on (up)
3on (up)
4on (up)
5on (up)
6off (down)
7on (up)
8on (up)
9on (up)
10on (up)
5
381333–319 A
FUNCTIONAL TESTSeries 185
After installing the Series 185 automatic transfer switch
(ATS) perform the following three–part functional test.
1 --- M a n u a l O p e r a t i o n
A 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. Turn OFF both the utility and generator circuit
breakers feeding the ATS. Verify that ALL POWER
IS OFF!
2. 100–230 A
Grasp the maintenance handle and turn it quickly
with your thumb and fingers to manually operate the
transfer switch.
260–400 A
Insert the maintenance handle into the hole in the
shaft, left side of the operator. Move the handle as
shown to manually operate the transfer switch.
3. The switch should operate smoothly without binding.
If it does not, check for shipping damage or
construction debris.
4. Aft er checking the manual operation, use the handle
again to return the transfer switch to the utility
source position.
100–230 AseeFigure8.
The letter P (utility) on the round weight is facing
you.
260–400 AseeFigure9.
The letter N (utility) on the round weight is facing
you.
Remove the maintenance handle and store it on the
transfer switch in the place provided.
260–400 A Remove the maintenance handle
before proceeding!
2 --- V o l t a g e C h e c k s
The ATS is rated for 220–240 V ac 60 or 50 Hz. Verify that
both the utility and generator sources are 220–240 V ac 60
or 50 Hz.
maintenance handle
With ALL POWER OFF
grasp maintenance
handle and turn it
quickly with your
thumb and fingers.
weight marked P (utility) and A (generator)
Figure 8. Maintenance handle for 100–230 A.
hole
maintenance
handle
shaft
Figure 9. Maintenance handle for 260–400 A.
3 --- Electrical Operation
This procedur e checks the elec tr ic al operation of the ATS.
1. Install the enclosure cover and tighten the screws.
2. Verify that the generator battery is connected and
that the generator’s starting controls are set for
automatic.
3.Turn on both the utility and generator circuit breakers.
4. Verify that the Utility Acceptable and Load on Utility
lights are on.
5. This step will start the gene rator. Press and hold the
Tra ns f er Te st button until the Generator Acceptable
light comes on and stays on. Then release the button.
6. Aft er the Generator Acceptable light comes on, the
ATS transfers the load from the uti lity to the
generator (after approx. 10 second delay). The Loadon Generator light comes on.
7. The ATS stays connected to the generator for 15
minutes (approx.). The utility must be acceptable for
15 minutes continuously. Then the load i s transferred back to the utility. To bypass time delay, press
the Bypass Time Delay button.
8. After load retransfer to utility, the generator runs 5
minutes (without load), then shuts down. The
Generator Acceptable light goes off indicating that
the generator is off.
This troubleshooting guide describes some of the simple
causes of problems with the installation of the automatic
transfer switch. Troubleshooting beyond the scope of this
guide should not be attempted by the installer. A licensed
electrician must perform all internal troubleshooting.
ASCO Power Technologies can be contacted at:
1–800–800–2726 or customercare@asco.com
ELECTROCUTION FLASH HAZARD Do not work
on the transfer switch until both the utility and
generator are off. Turn OFF both circuit breakers.
Problem
The Utility Acceptable light
does not come on when utility
power i s connected to the ATS.
The generator does not crank
when the utility source fails or
when the Transfer Test button is
pressed.
The generator cranks but does
not start and run when the utility source fails or when the
Transfer Test button is pressed.
The generator starts and runs
but the Generator Acceptable
light does not come on.
The generator starts and runs
but the ATS does not transfer
the load to the generator.
Cause and Solution
1. Verify that the utility feed is connected and that its circuit breaker is ON.
2. With ALL POWER OFF, verify that the utility feed is 220–240 V ac and 60 Hz.
Check DIP switch S2 actuator 2, and DIP S1 actuator 4. See Table D for voltage
and frequency settings.
3. With ALL POWER OFF, verify that the utility feed is wired to the terminal lugs
on the bottom of the transfer switch marked L1 and L5. See the wiring diagram.
4. With ALL POWER OFF, verify that the transfer switch harness is connected
properly to the controller (plug and receptacle tight).
1. Hold the Transfer Test button for at least 15 seconds.
2. Verify that the generator starting controls are set for automatic operation (not in
manual mode).
3. Verify that the generator battery is connected and that the battery voltage meets
the generator manufacturer’s recommendation.
4. Verify that the correct contact (normally open or normally closed) is being
utilized (see the generator manual).
5. With ALL POWER OFF, verify engine start low voltage wiring between the
controller terminal block and the generator. See the wiring diagram. Check that
the plug is properly seated in the receptacle on the controller.
1. Verify proper generator o peration (fuel in tank, oil level, spark plugs --- see
generator manual).
2. With ALL POWER OFF, verify engine start low voltage wiring between the
controller terminal block and the generator. See the wiring diagram. Check that
the plug is properly seated in the receptacle.
1. Verify that the generator feed i s connected and that its circuit breaker is ON.
2. With ALL POWER OFF, verify that the generator feed is 220–240 V ac and 60
Hz. Check DIP switch S2 actuator 2, and DIP S1 actuator 4. See Table D for
voltage and frequency settings.
3. With ALL POWER OFF, verify that the generator feed is wired to the terminal
lugs on the top of the transfer switch marked L2 and L6. See the wiring diagram.
4. With ALL POWER OFF, verify that the transfer switch harness is connected
properly to the controller (plug and receptacle tight).
5. Verify generator ac output (voltage and frequency --- see generator manual).
1. Verify that the Generator Accepted light is on. If it is off, see previous troubleshooting problem. The AT S will not transfer the load to an unacceptable source.
2. With ALL POWER OFF, verify that the transfer switch harness is connected
properly to the controller (plug and receptacle tight).
381333–319 A
8
ProblemCause and Solution
The ATS does not i mmediately
transfer the load to the
generator.
The ATS transfers the load to
the generator, but the generator bogs down (struggles or
slows down). The ATS retransfers back to the utility.
The generator stops after a
running for awhile. The ATS
retransfers back to the utility
(if acceptable).
The ATS does not retransfer
the load back to the utility.
The ATS retransfers the load
back to the utility but the
generator keeps running.
The generator exerciser does
not seem to work.
The generator exerciser does
not transfer the load to the
generator.
TROUBLESHOOTING
1. Verify that the Generator Accepted light is on. If it is off, see previous trouble-
shooting problem. The AT S will not transfer the load to an unacceptable source.
2. Wait approximately 10 seconds for the transfer to generator time delay. This
fixed delay allows the generator output to stabilize before a load is applied to i t.
3. Press the Bypass Time Delay butto n for immediate load transfer to the generator.
1. The generator may be overloaded. Check to see if the generator circuit breaker
tripped. Check the sum of the loads to be sure it does not exceed the capacity of
the generator. Some motor loads require three times more power for starting.
2. Check for short circuit in a connected load.
3. Observe the Load on Utility and Load on Generator lights.
1. Verify proper generator operation; it may have run o ut of fuel or shut down
because of low oil level (see generator manual).
2. The generator may be overloaded. Check to see if the generator circuit breaker
tripped. Check the sum of the loads to be sure it does not exceed the capacity of
the generator. Some motor loads require three times more power for starting.
3. Check for short circuit in a connected load.
4. Observe the Load on Utility and Load on Generator lights.
1. Verify that the Utility Accepted light is on. The ATS will not transfer the load to
an unacceptable source.
2. Wait approximately 15 minutes for the retransfer to utility time delay. The utility
must be acceptable for 15 minutes continuously.
3. Press the Bypass Time Delay button for immediate load retransfer to the utility.
1. Wait approximately 5 minutes for the unloaded running (engine cooldown) time
delay.
2. The engine cooldown fixed time delay is important to prevent generator damage.
1. Verify that the Automatic Generator Exerciser light is blinking. When the utility is
acceptable and the load is on t he utility, this light flashes the number of days until
the next exercise period. When the light is off, no exercise period is set. The
light is also off when the generator is running.
2. With ALL POWER OFF, verify that the exerciser is turned on. Check DIP switch
S1 actuator 7, and S2 actuator 10. See Table B for generator exerciser settings.
3. With ALL POWER OFF,checkthe9voltbattery. Replace,ifnecessary,witha
quality alkaline battery: Duracell MN1404, Everready 522, Panasonic 6AM6, or
equivalent. See Figure 5.
1. With ALL POWER OFF, verify that exercise with load is turned on. Check DIP
switch S1 actuator 8. See Table B for generator exerciser settings.