Operator’s
7000 Series ADTS
Automatic Delayed–T ransition T ransfer Switches
Manual
E–design 150–400A, F–design 600–800A,
G–design 1000–4000A, F–design 3000–4000A,
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, 1-5.............
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.........................
Refer to the outline and wiring drawings provided
with your 7000 Series ADTS for all installation and
connection details and accessories.
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.
Refer to Group 5 Controller User’s Guide
381333–126 for ATS status display messages, time
delays, pickup & dropout settings, and adjustments.
An experienced licensed electrician must install the
ADTS.
G design 2000 A
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
Gdesign4000A
381333–129 C
Catalog Number Identification
T ypical 7000 Series catalog no. for G–design switched neutral, 3 pole, 2000 A, 480 V, ADTS in Type 1 enclosure:
design
prefix
letter
G
Neutral
A –solid
B –switched
blank – none
7ADTS B 3 2000 N 5 C
Phase Poles
2 –singleØ
3 –threeØ
Amperes Voltage Controller Enclosure
150
260
400
600
800
1000
1200
1600
2000
3000
4000
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
field connections
terminal block TB
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
Group 5
Controller
power
connections
Transfer
Switch
power
connections
Transfer
Control
&lights
G–design 2000 ampere size in typical enclosure with location of customer connections
Rating Label
Each automatic delayed–transition transfer switch contains a
rating label to define the loads and fault circuit withstand /
closing ratings. R efer 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 ADTS. Use the switch only within the
limits shown on this nameplate. A typical Catalog Number
is shown on the previous page with its elements explained.
Transfer
Switch
field connections
terminal block TB
Group 5
Controller
G–design 4000 ampere size in typical enclosure with location of customer connections
SECTION 1 INSTALLATION
ASCO Series 7000 Automatic Delayed–Transition
Transfer 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 ADTS 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 ADTS; 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 ADTS 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 controller on the door.
Auxiliary Cable Boxes
For 1000 & 1200 amp. sizes, an auxiliary cable box is
required for all (normal, emergency, & load)bottom or
top entry. Order ASCO part no. 609027 if required.
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
often requires considerable force. The pulling of cables
can damage i nsulation and stretch or break the
conductor’s strands. For this reason, after the cables are
pulled into position, and before
should be tested to verify that they are not defective or
have been damaged during installation.
they are connected, they
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. B e 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.
Cablescanbebundledontherightsideoftheswitch.
Maintain proper electrical clearance between the live
metal parts and grounded metal: ½ inch minimum for
150-400 amps, 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
On 1000 & 1200 amp. be sure to install auxiliary
cable box if both service and load cables are entering through the top or bottom of enclosure.
Line Connections
A Wiring Diagram is furnished with the ASCO Series
7000 ADTS (separate from this manual). Refer to this
drawing. All wiring must be made in accordance with
the National Electrical Code and local codes.
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--- flammable solvent. Avoid
touching the cleaned surfaces.
Do not breathe cleaning solvent vapors.
1--1
INSTALLATION (continued)
Tighten bolted joints to the torque specified in Table A.
The reliablility of the connection depends
on how clean and how tight the joint is.
Table A . Tightening torque values for bolted j oints
(Grade 5 hardware)
Bolt Diameter
in inches
1/4 7
5/16 12
3/8 20
1/2 50
5/8 95
3/4 155
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 betwee n 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-in harness (two plugs).
Tightening Torque
in foot pounds
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
i n F i g u r e 1 --- 1 .
Table B. Engine start connections
When normal
source fails
contact closes TB1 and TB2
contact opens TB1 and TB3
Te r m i n a l s on
transfer switch
engine start
connections
on
customer
terminal
block TB
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:
V 1 — Manual Operation Test, page 1–3
V 2—VoltageChecks,page1–4
V 3 — Electrical Operation, page 1–5
Do these checks in the order presented
to avoid damaging the ATS.
Figure 1-1. Customer terminal block
on the top right side of enclosure.
Read all instructions on the Wiring Diagram and labels
affixed to the ADTS. Note the control features that are
provided and review their operation before proceeding.
Continue to 1–ManualOperationTest on next page.
1--2
INSTALLATION (continued)
handle
shafts
handle
Figure 1-2. Figure 1-3. Figure 1-4
150 – 400 A (3 pole) 600 & 800 A (& 4 pole 400 A) 3000 & 4000 A
E–design switches F–design switches F–design transfer switches
handle
1 – Manual Operation
A detachable manual operator handle is provided on the
Tra ns fe r S wi tc h e s for maintenance purposes only.Manual
operation of both CN and CE transfer switches must be
checked before they are operated electrically.
Do not manually operate the transfer switch
until both power sources are disconnected:
open both circuit breakers.
1. Select the appropriate switch amperage size aboveand
follow the directions for installing the handle:
150 through 400 A E–design SeeFigure1-2.
Insert the manual handle into the hole in the shaft, left
side of the operator.
600 and 800 A F–design SeeFigure1-3.
Attach the manual handle onto the pivot shaft
extension, left side of the operator.
Emergency
contacts
Grasp handle
firmly with
both hands
1000 through 4000 A G–design SeeFigure1-5.
Install the hub (with pin
manualfirmlyintothesideholeinthehub. Pushinor
pull out hub to engage opposite source contacts.
3000 and 4000 A F–design SeeFigure1-4.
Insert the manual handle into the hole in the weight.
2. Movethehandleasshowntomanuallyoperatethe
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 Tr ansfer Switch.
3. Return the CN Transfer Switch to the C (closed)
position. Return the CE Transfer Switch to the O
(open) position. Rem ove manual operator handle and
store it on the Transfer Switch in the place provided.
Ve r i fy that the maintenance handle has been
removed and stored properly before proceeding!
Now continue to 2–VoltageCheckson next page.
Turn counterclockwise
to OPEN contacts.
Turn cl ock w ise to
CLOSE contacts.
) onto the shaft and insert the
Insert handle
into hole
(spring fully
compressed)
window
indicators
OPEN or
CLOSED
Normal
contacts
contact position
indicators (left side)
Slide the hub onto the
shaft and insert the pin
counterclockwise DOWN
OPENS the contacts
Pull out
source contacts (upper)
Push in
source contacts (lower)
Figure 1-5. 1000 – 4000 ampere G–design transfer switches.
shaft to open Emergency
shaft to open Normal
1--3
.
clockwise DOWN
OPENS the contacts
Pull out
source contacts (upper)
Push in
source contacts (lower)
shaft to close Emergency
shaft to close Normal
INSTALLATION (continued)
GREEN
RED
observe
these lights
GREEN
RED
AMBER
Figure 1-6. Standard controls and indicators.
2–VoltageChecks
First check na meplat e on transfer switch; rated voltage
mustbethesameasnormalandemergencylinevoltages.
Before energizing the switch check to be
sure that both normal and emergency
contacts are not left in the closed position.
Verify that the feeders have been
connected to the proper lugs.
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.
Load
Disconnect
Active
Load
Disconnect
Active
Useextremecautionwhenusingameterto
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 1–6.
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.
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--4
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.
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.
C
B
A
Load
Disconnect
Active
INSTALLATION (continued)
GREEN
RED
observe
these lights
GREEN
RED
AMBER
Figure 1-7. Standard controls and indicators.
3 --- Electrical Operation
This procedure will check the electrical operation of the
Automatic Delayed–Transition Transfer Switch. See
F i g u r e 1 --- 7 .
Close the enclosure door first !
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
Turn and h old Tr an s fe r Co ntr o l
switch clockwise to Transfer
Test until the engine starts
1
and runs (within 15 sec.). The
Emergency Source Accepted
light should come on.
Transfer switch CN opens and
the Transfer Switch Connected
to Normal light should go off
2
and the Load Disconnect Active
light should come on. Both CN
& CE contacts are now open.
After the delay transition time
delay, the CE Transfer switch
will operate to the Emergency
position. The Transfer Switch
3
Connected To Emergency light
should come on and Load Dis-
connect Active light goes off.
Transfer switch will operate
back to Normal position after
Feature3Atimedelay.Forimmediate retransfer turn Tr a nsf 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.
Load
Disconnect
Active
Load
Disconnect
Active
Load
Disconnect
Active
Load
Disconnect
Active
This completes the Functional Test of the ADTS.
1--5
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.
Load
Disconnect
Active
SECTION 2 TESTING & SERVICE
TRANSFER TEST
Operate the 7000 Series ADTS at least once a month
by following the five–step Electrical Operation
Tra ns fe r Test procedure on page 1–5.
PREVENTIVE MAINTENANCE
Reasonable care in preventive maintenance will insure
high reliability and long life for the 7000 Series ADTS.
An annual preventive maintenance program is recommended.
ASCO Services, Inc. (ASI) is ASCO Power
Technologies’ national service organization.
ASI can be contacted at 1-800-800-2726 for
information on preventive maintenance agreements.
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!
j Clean the ADTS enclosure. Brush and vacuum
away any excessive dust accumulation. Remove
anymoisturewithacleancloth.
j Check the transfer switch contacts.Remove
transfer switch barriers and check the condition of
the contacts. Replace contacts when pitted or worn
excessively. Reinstall the barriers carefully.
j Maintain transfer switch lubrication.Ifswitchis
subjected to severe dust or abnormal operating
conditions, renew factory lubrication on all movements and linkages. Relubricate solenoid operator
if TS coil is replac e d. Don’t use oil ; order lubrica-
tion kit 75-100.
j 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:
call 1 – 800 – 800 – ASCO ( 2726 )
DISCONNECTING THE CONTROLLER
The harness disconnect plugs are furnished for repair
purposes only and should not have to be unplugged.
If the control panel must be isolated, follow these
steps:
Disconnecting the Plugs
Do not unplug the controller
until steps 1a or 1b is completed.
1. Observe the position of the transfer switch.
a. If the transfer switch is in the Normal position,
place standby engine starting control in the off
position. Then open the emergency source circuit
breaker.
b. If the transfer switch is in the Emergency
position, open the normal source circuit
breaker. Place the engine starting control in
the test or run position.
2. Separate the two quick disconnect plugs by squeez-
ing the latches. Do not pull o n the harness wires.
Reconnecting the Plugs
Do not unplug the controller
until steps 1a or 1b is completed.
1. Observe the position of the transfer switch.
a. If the transfer switch is in the Normal position,
be sure that the standby engine starting control
is still in the off position. The emergency
source circuit brea ker still should be open.
b. If the transfer switch is in the Emergency
position, normal source circuit breaker still
should be 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.
3. Restore the opposite source as follows:
a. If the transfer switch is in the Normal position,
place the standby engine starting control in the
automatic position. Then close the emergency
source circuit breaker.
b. If the transfer switch is in the Emergency
position, close the normal source circuit
breaker.
2 --- 1
TESTING & SERVICE
MANUAL LOAD TRANSFER
This procedure will manually transfer the load if the
control panel is disconnected.
(continued)
2. Use manual handle to manually operate transfer
switch to the opposite source. First open the
closed transfer switch, then close the other transfer
switch.
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).
TROUBLE-SHOOTING
Note any optional accessories that may be furnished
on the ADTS and review their operation. Refer to any
separate drawings and/or instructions that may be
packed with the ADTS.
Table 2-1. Trouble-Shooting Checks.
PROBLEM
Engine–generator set does
not start when the Tra nsfer
Control switch is turned and
held
in Transfer Test position
or when 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.
Gen. does not stop after load
retransfer to normal source.
Hold Transfer Test switch 15
seconds or the outage must
be long enough to allow for
Feature1Ctimedelayplus
engine cranking and starting.
Wait for Feature 2B time delay
to time out.
Wait for Feature 3A time delay
to time out.
Wait for Feature 2E time delay
to time out.
1
OPERATION
3. Then remove
the maintenance handle. See page 1–3.
Verify that the maintenance handle
has been removed before proceeding!
4. 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!
CHECK IN NUMERICAL SEQUENCE
2
GEN-SET
Starting control must be in the
automatic position. Batteries
must be charged and
connected. Check wiring to
engine starting contacts.
Generator output circuit
breaker must be closed.
Generator frequency must be
at least 95% of nominal (57 Hz
for a 60 Hz system.) *
---
Starting control must be in the
automatic position.
Voltmeter should read at least
90% of nominal phase to
phase voltage between
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
terminals NB and NC, NC and
NA, and NA and NB (or NL1
and NL2 for 2 pole switches).
3
VOLTAGE
---
---
* These are factory settings. Refer t o Controller User’s Guide.
If the probl em is isolated to circuits on the controller or the transfer switch, call your local ASCO Power Technologies
sales office or ASI at 1–800–800–2726. Furnish the Serial No. and Catalog No. from the transfer switch nameplate.
2 --- 2
INDEX
A
auxiliary cable box, 1–1
auxiliary circuits, 1–2
B
barriers, 1–1
C
cable
lugs, 1–2
preparation, 1–2
catalog number, cover
cleaning, 2–1
connections
line, 1–1
controller, 1–1
disconnecting, 2–1
see Controller User’s Guide
E
electrical operation, 1–5
Emergency Source Accepted light, 1–5
F
frequency, generator, 2–2
functional test, 1–2, 1–3, 1–4, 1–5
H
harness, 1–2
disconnect plugs, 2–1
HELP
customercare@asco.com
800–800–ASCO
I
inspection, 3–1
installation, 1–1
L
labels,
engine start contacts, 1–2
rating, cover
lights, 1–4, 1–5
Load Disconnect Active light, 1–5
lubrication, 2–1
M
maintenance, preventive, 3–1
manual load transfer, 3–2
warning, 3–2
manual operation, 1–3
illustration of, 1–3
warning, 1–3
N
nameplate, cover
Normal Source Accepted light, 1–5
O
operation
electrical, 1–5
manual, 1–3
illustration of, 1–3
warning, 1–3
sequence of, 2–1
optional accessories
see Controller User’s Guide
P
parts, 2–1
phase rotation check, 1–4
problem, 2–2
R
rating label, cover
replacement parts, 2–1
S
settings
see Controller User’s Guide
T
test, functional, 1–2, 1–3, 1–4, 1–5
time delays, 2–1
see Controller User’s Guide
Transfer Control selector switch
Retransfer Delay Bypass, 1–5
Transfer Test, 1–5
Transfer Switch Connected to
Emergency light, 1–5
Transfer Switch Connected to Normal
light, 1–4, 1–5
transfer test, 1–5
transfer to emergency, 1–5
transfer to normal, 1–5, 2–1
trouble–shooting, 2–2
V
voltage checks, 1–4
voltage, pickup and dropout settings
see Controller User’s Guide
Printed in U.S.A.
E ASCO Power Technologies, L.P. 2009
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