Emerson ASCO 7000 User Manual

Operator’s
7000 Series A T S
Manual
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.
D design, 30 throug h 230 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 stat us display messages, t ime delays, pickup & dropout settings, and adjustments.
Rating Label
Each Automatic Tran sfer Switch contains a rating label to define the loads and fault circuit withstand/closing ratings. Refer to the label on the Tr ansfer 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 Tran sfer Switch nameplate incl udes 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 1-1........................
Mounting and Line Connections 1-1.........
Auxiliary Circuits and Harness 1-2...........
Engine Starting Contacts 1-2...............
Functional Test 1-2, 1-3, 1-4.................
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.........................
30--- 230 amp. size
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
381333–229 D
design prefix letter
Catalog Number Identification
Typical 7000 Series 7ATS catalog no. for overlapping neutral, 3 pole, 150 amp, 480 V, in Type 1 enclosure:
D
Neutral
7ATS C 3 150 N 5 C
Phase Poles
Amperes Voltage Controller
Enclosure
A –solid
B –switched
C – overlapping
blank – none
load power connections
2 –singleØ 3 –threeØ
Transfer Switch
30 70
100
150
200 **
230 **
** 200 and 230 amp.
limited to 480 volts
terminals for switch
position contacts
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
accessories
ordered
C –type1
F –type3R
G –type4
L –type12
M –type 3R secure
N –type 4 secure P –type 4X secure
Q –type 12 secure
blank – open type
transfer control &lights
emergency power connections
maintenance
handle
(see WARNING
under Manual
Operation)
terminals for
engine start
contacts
normal power connections
cable spacers (see INSTALLATION)
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 Diagram provided with the A TS; 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.
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 defectiveorhavebeendamagedduringinstallation.
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. Makesurethelugsprovidedaresuitableforuse 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 t o 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.
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-on DIN 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.
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 transfer switch until they are tested. Installing power cables in conduit, cable troughs and ceiling-suspended hangers
The cable spacers must be located as shown for 150, 200, and 230 ampere transfer switches.
cable spacers
1 ½ inch approximate
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-in harness (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
source fails
Te r m in a l s o n
transfer switch
contact closes TB14 and TB15 contact opens TB14 and TB16
Functional Test
The Functional Test consists of three checks:
S 1 — Manual Operation Test, on this page
S 2—VoltageChecks,page1–3
S 3 — Electrical Operation, page 1–4
ENGINE STARTING CONTACTS
(SHOWNDE–ENERGIZED)
TOP
STUD
MIDDL E
STUD
BOTTOM
STUD
14
TS
15
NR
16
NR
TB 14
TB 16
TB 15
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 connec tion s by referring to the Wiring Diagram.
directionoftheweight.Turnitupordownasshown to manu ally operate the transfer switc h. 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.
Do these checks in the order presented to avoid damaging the ATS.
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.
1 – Manual Operation Test
A maintenance handle is provided on the Transfer Switch for maintenance purposes only 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
. Manual operation of the
Now continue to 2–VoltageCheckson next page.
Position of the transfer switch is indicated here
weight marked N (normal) and E (emergency)
maintenance handle
weight
floating weight
With ALL POWER OFF grasp
maintenance handle and turn it
quickly with your thumb and fingers.
Figure 1–3. Maintenance handle and positions.
1 --- 2
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. 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.
S White 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.
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.
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.
C
B
A
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 --- 3
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.
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 and h old Tra ns f er Co ntr o l 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 ns f 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 --- 4
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.
SECTION 2 TESTING & SERVICE
TRANSFER TEST
Operate the 7000 Series ATS at least once a month by following the five–step Electrical Operation Transfer Tes t procedure on page 1–4.
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.
ASCO Services, Inc. (ASI) is ASCO Power Technologies’s national service organization. ASI can be contacted at 1-800-800-2726 for infor­mation on preventive maintenance agreements. In Canada call 1–888–234–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!
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 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
position, fi rst open the normal source circuit breaker. Second, place the 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.
S Clean the A TS 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. Replace the contacts if they become pitted or worn excessively. Reinstall the barriers carefully.
S Maintain 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 (Castrol EndurexR 4000 lubricant).
S Check all cable 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 the United States call 1–800–800–ASCO (2726), or in Canada call 1–888–234–ASCO (2726).
Reconnecting the Plugs
Do not unplug the controller until step 1a or 1b is completed.
1. Observe the position of the t ransfer 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 in 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
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).
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.
Table 2-1. Trouble-Shooting Checks.
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.
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.
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).
2
GEN-SET
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.
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 NB (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 controlle r 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 1–888–234–2726. Furnish the Serial No., Bill of Material (BOM) No., & Catalog No. from transfer switch nameplate.
2 --- 2
INDEX
A
auxiliary circuits, 1–2
C
cable
lugs, 1–1 preparation, 1–1 spacers, 1–1
illustration of, 1–1
catalog number, inside cover
cleaning, 2–1
connections
line, 1–1
controller, 1–1, 1–2
disconnecting, 2–1 see Controller User’s Guide grounding, 1–1
E
electrical operation, 1–4
Emergency Source Accepted light,
1–3, 1–4
F
frequency, generator, 2–2
functional test, 1–2, 1–3, 1–4
H
harness, 1–2
disconnect plugs, 2–1
HELP
customercare@asco.com 800–800–ASCO
I
L
labels,
engine start contacts, 1–2 rating, cover
lights, 1–3, 1–4
lubrication, 2–1
M
maintenance, preventive, 2–1
manual load transfer, 2–2
warning, 2–2
manual operation, 1–2
illustration of, 1–2 warning, 1–2
N
nameplate, cover
Normal Source Accepted light, 1–3,
1–4
O
operation
electrical, 1–4 manual, 1–2
illustration of, 1–2 warning, 1–2
sequence of
see Controller User’s Guide
optional accessories
see Controller User’s Guide
P
parts, 2–1
phase rotation check, 1–3
problem, 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, 1–4 Transfer 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, 1–4
transfer to normal, 1–4
trouble–shooting, 2–2
V
voltage checks, 1–3
voltage, pickup and dropout settings
see Controller User’s Guide
inspection, 2–1
installation, 1–1
Printed in U.S.A.
Copyright ASCO Power Technologies, L.P. 2007
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