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
INSTALLATION1-1........................
Mounting and Line Connections1-1.........
Auxiliary Circuits and Harness1-2...........
Engine Starting Contacts1-2...............
Functional Test1-2, 1-3, 1-4.................
TESTING & SERVICE2-1..................
Transfer Test2-1..........................
Preventive Maintenance2-1................
Disconnecting the Controller2-1............
Manual Load Transfer2-2..................
Trouble-Shooting2-2......................
INDEXback 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
7ATSC3150N5C
Phase Poles
AmperesVoltageController
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 1INSTALLATION
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 closesTB14 and TB15
contact opensTB14 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 SwitchConnected 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 TransferTest 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 erControl 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 SourceAccepted light should go off.
SECTION 2TESTING & SERVICE
TRANSFER TEST
Operate the 7000 Series ATS at least once a month by
following the five–step Electrical Operation TransferTes 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 lubrication625550–001 (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 nsferControl 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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