DANGER is used in this manual to warn of a
hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING is used in this manual to warn of a
hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION is used in this manual to warn of a
hazardous situation which, if not avoided, could
result in minor or moderate injury.
Series 386
Refer to the outline and wiring drawings provided with
the ASCO Series 386 N–ATS for all installation details.
Rating Label
Each non–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.
Identification Label
The identification label on the Transfer Switch includes
data for each specific ASCO Series 386. Use the switch only
within the limits shown on identification label.
An experienced licensed electrician must install the
Non–Automatic Transfer Switch (N–ATS).
TABLE OF CONTENTS
section-page
INSTALLATION1-1........................
Mounting and Line Connections1-1.........
Functional Test1-2, 1-3.....................
SEQUENCE OF OPERATION2-1...........
TESTING & SERVICE3-1..................
Preventive Maintenance3-1................
Transfer Test3-1..........................
Trouble-Shooting3-2......................
ADJUSTMENTS4-1.......................
Sensor Adjustments4-1...................
How to Change a Setting4-1...............
OPTIONAL FEATURES5-1.................
Motor Load Transfer5-1...................
Load Disconnect5-1......................
INDEXback of manual.....................
G–design 1000–1200 A 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
381333–086 D
Page 2
Page 3
SECTION 1INSTALLATION
ASCO 386 Non–Automatic Transfer Switches (N–ATSs)
are factory wired and tested. Field installation simply
requires mounting and connection of service cables, and
auxiliary control circuit s (if required).
Remove the Shipping Skid (large N–ATSs)
For large N–ATSs, 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 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 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 N–ATS; it shows all mounting details and
instructions.
NOTICE
Protect the non–automatic transfer switch from
construction grit and metal chips to prevent
malfunction or shortened life of the N–ATS.
Mount the ASCO 386 vertically to a rigid supporting
structure. Level all mounting points by using flat washers
behind the holes to avoid distortion of the switch.
Auxiliary Cable Boxes for 1000 and 1200 A
For G–design 1000 and 1200 ampere sizes, auxiliary
cable boxes are required for all (normal, emergency, &
load) bottom or top entry. Be sure to install auxiliary
cable boxes if both service and load cables are entering
through the top or bottom of enclosure. Consult ASCO
Power Technologies.
Be sure that the insulator piece is behind the 260
and 400 ampere transfer switches.
insulator
backing
piece
Figure 1-1. Insulator for E–design 260 and 400 ampere
Controller Ground
The controller is mounted on the cabinet door. The
transfer switch is connected to the left side of the
controller by a plug–in harness (two plugs). An add-on
DIN rail is provided for some optional accessories and is
mounted below the controller on the door.
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.
Auxiliary Circuits
Connect auxiliary circuit wires to appropriate terminals
on transfer switch terminal block TB as shown on the
wiring diagram provi ded with this Non–Automatic
Tra ns f e r Swi tc h.
Read all instructions on the Wiring Diagram and labels
affixed to the non–automatic transfer swi tch. Note the
control features that are provi ded and review their
operation before proceeding.
Insulator Backing Piece for 260 and 400 A
E–design transfer switches rated 260 and 400 ampere are
mounted on an insulator backing piece (installed behind
the transfer switch). If the transfer switch is removed
from the cabinet and then reinstalled, this insulator
piece must be placed behind the transfer switch. See
Figure 1-1.
1 --- 1
Page 4
INSTALLATION(continued)
Line Connections
A Wiring Diagram is furnished with the ASCO 386
(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
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
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.
Bus Connections
If bus connection is used, use SAE grade 5 hardware to
connect bus to appropriate terminal p lates on the
transfer switch. Wipe off bus surfaces before they are
joined. If bus is very dirty, gently clean surfaces with a
non–flammable solvent. Avoid touching cleaned
surfaces.
The reliability of the connection depends on how
clean and how tight the joint is.
Table A. Tightening torque values for bolted joints.
Bolt Diameter
(Grade 5 hardware)
in inches
5/1612
3/820
1/250
5/895
3/4155
Continue to 1–ManualOperationTest on next page.
Recommended
Tightening Torque
in foot pounds
Do not run cables behi nd the switch. Cables can be
bundled on the right side of the switch. Maintain proper
electrical clearance between the live metal parts and
grounded metal: ½inch minimum for 260-400
amperes, 1 inch minimum over 400 amperes.
1 --- 2
Page 5
INSTALLATION(continued)
Functional Test
The Functional Test consists of three checks: manual
operation, voltage checks, and electrical operation.
NOTICE
Do these checks in the order presented to avoid
damaging the non–automatic transfer switch.
1 – Manual Operation Test
A detachable maintenance handle is provided on the
transfer switch for maintenance purpose s only.Manual
operation of the 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. Selecttheappropriateswitchamperagesize/design
and follow the directions for installing the handle:
260 and 400 amp. E–designSeeFigure1-2.
Insert the manual handle into the hole in the shaft, left
side of the operator.
1000 – 3000 ampere. G–designSeeFigure1-3.
Install the hub onto the center operator shaft and
insert the manual firmly into the hole in the side of
the hub (spring fully compressed).
handle
Figure 1-2. Maintenance handle for E–design 260 and
400 ampere
2. Movethehandleasshowntomanuallyoperatethe
Transfer Switch. The switch should operate
smoothly without binding. If it does not, check for
shipping damage or construction debris.
3.Return the transfer switch to the N (normal) position.
Remove manual operator handle (if detachable) and
store it on the transfer switch in the place provided.
NOTICE
Verify that the maintenance handle has been
removed before proceeding!
Now continue to 2–VoltageCheckson next page.
Emergency
contacts
window
indicators
OPEN or
CLOSED
Normal
contacts
contact position
indicators (left side)
Figure 1-3. Maintenance handle on 1000 – 3000 ampere G design transfer switches.
Grasp handle firmly
with both hands
Insert handle into hole
(spring fully compressed)
counterclockwise DOWN
closes the Emergency
source contacts (upper)
and opens the Normal
source contacts (lower)
1 --- 3
Turn counterclockwise
to Emergency.
Turn clock w ise
to Normal.
Slide hub
onto shaft
clockwise DOWN closes
the Normal source contacts
(lower) and opens the
Emergency source
contacts (upper)
Page 6
INSTALLATION(continued)
Functional Test (continued)
2–VoltageChecks
First check nameplate on the transfer switch for rated
voltage. It should be the same as the normal and
emergency line voltages.
Use extreme caution when using a meter to
measure voltages in the following steps.
Do not touch power terminals; shock, burns, or
death could result !
1.Close the normal source circuit breaker. The Load
Connected To Normal lamp should come on.
2.Use an accurate voltmeter to check phase to phase
and phase to neutral voltages present at the Transfer
Switch normal source terminals.
3.Close the emergency source circuit breaker. (Start
the generator, if necessary.)
4.Use an accurate voltmeter to check phase to phase
and phase to neutral voltages present at the Transfer
Switch emergency source terminals.
If necessary, adjust the voltage regulator on the
generator according to the manufacturer’s recommendations. The ASCO 386 will respond only to the rated
voltage specified on the Transfer Switch nameplate.
5.Check phase rotation; it must be the same as the
normal source.
6.Shut down engine-driven generator, if applicable.
7.Close the cabinet door and tighten the screws.
3 – Electrical Operation
This procedure will check the electrical operation of the
Non-Automatic Transfer Switch. See Figure 1–4.
Close the transfer switch enclosure door and
tighten the screws before you test electrical
operation.
Transfer Test
Both normal and emergency sources must be available
and above 90% of nominal voltage specified on
nameplate.
1.Turn the door-mounted Tr an sfe r Co n tr ol switch
clockwise to Tr ans fer To E mer g en c y.
2.The transfer switch will operate to the Emergency
position. The Load Connected To Emergency light
should come on and the Load Connected To Normal
light should go off.
3.Turn the door-mounted Tr an sfe r Co n tr ol switch
counterclockwise to Transfer To Normal.
4.The transfer switch will operate back to the Normal
position. The Load Connected to Normal light
should come on and the Load Connected ToEmergency light should go off.
This completes the Functional Test of the ASCO 386
non-automatic transfer switch.
Figure 1–4. Operating Controls.
1 --- 4
Page 7
SECTION 2
SEQUENCE OF OPERATION
Controller Code 1
Refer to Section 5, Optional Accessories for additional control functions.
Refer to Wiring Diagram furnish e d with the ASCO 386. Note Control Features furnished on this switch, and review operation.
Trans fer
Control
Trans fer
To
Normal
Trans fer
To
Emergency
Transfer To Emergency
The sequence for load transfer to the emergency
source begins when you turn the door-mounted
Transfer Control switch clockwise to the Tr a n sfer To
Emergency position.
When the T ran sfer Control switch is operated to
Transfer T o Emergency, the voltage and frequency
sensor begins monitoring the emergency source.
The sensor will accept the emergency source only
when both
pickup points. If the emergency source is available
immediately, the sensor may accept it as soon as
the Tr ans fer Cont rol switch is operated.
When the emergency source is accepted by the
sensor, relay ER picks up to transfer the load to
the emergency source.
ER relay energizes, the TS coil is energized, the
transfer switch operates, and all switch contacts
(mains, controls, auxiliaries) reverse position.
The transfer switch is now supplying the load from
the emergency source.
voltage and frequency reach preset
Trans fer
Control
Trans fer
To
Normal
Trans fer
To
Emergency
Retransfer to Normal
The sequence for load retransfer to the normal
source begins when you turn the door-mounted
Transfer Control switch counterclockwise to the
T ransfer To Normal position.
When the Transfer Control switch is operated to
T ransfer To Normal, the voltage sensor begins
monitoring the normal source.
The SE relay energizes when the sensor accepts
the normal source voltage.
SE relay energizes. The TS coil is energized, the
transfer switch operates, and all switch contacts
(mains, controls, auxiliaries) reverse position.
The transfer switch is now supplying the load from
the normal source again.
The SE relay de–energizes when the Tra n sfe rControl switch is released.
ThetransferswitchwillremainintheNormal
position until the Transfer Control switch is
operated to the Transfer To Emergency position.
ThetransferswitchwillremainintheEmergency
position until the Transfer Control switc h is
operated to the Transfer To Normal position.
Note
Activation of standard control features
shown in Section 5 will alter the sequence of
operation and introduce additional time
delays during transfer operations.
2 --- 1
Page 8
SECTION 3
TESTING & SERVICE
PREVENTIVE MAINTENANCE
Reasonable care in preventive maintenance will insure
high reliability and long life for the switch. 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.
TESTING
Operate the switch at least once a month by following
this four-step Electrical Operation Test.
Transfer Switch Test
A. Turn the door-mounted Tra ns f er C on t ro l switch
clockwise to Transfer to Emergency.
B. The transfer switch will operate to the Emergency
position. The Load Connected To Emergency light
should come on and the Load Connected to Normal
light should go off.
C. Turn the door-mounted Tr a n s fe r Con t ro l switch
counterclockwise to Transfer to Normal.
D. The transfer switch will operate to the Normal
position. The Load Connected to Normal light
should come on and the Load Connected to Emergen-cy light should go off.
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).
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
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 posi-
tion, ope n the normal source circuit breaker.
Place the engine starting control in the test or
run position.
2. Separate the quick disconnect plugs by squeezing the
latches. Do not pull on the harness wires.
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!
S Clean the switch enclosure. Brush and vacuum
away any excessive dust accumulation. Remove
anymoisturewithacleancloth.
S Check the Switch Contacts
switch barriers and check the condition of the
contacts. Replace the contacts if they become pitted
or worn excessively. Reinstall barriers carefully.
S 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 replaced. F or 260–400 A order lubri-cation 625550–001 (Castrol EndurexR 4000 lubri-
cant). For 1000–3000 A order lubricant kit 75–100.
S Check all cable connections and retighten them.
.Removetransfer
Reconnecting the Plugs
1. Observe the position of the t ransfer 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 transfer switch is in the Emergency position,
normal source circuit breaker still should be open.
2. The 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.
3 --- 1
Page 9
TESTING & SERVICE
PROBLEM
(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:
open both circuit breakers.
TROUBLE-SHOOTING
Note the ControlFeaturesthat are activated or furnished
on the switch and review their operation. Refer to
Section 5, Optional Features.
Table 3-1. Trouble-Shooting Checks.
1OPERATION2VOLTAGE
T ransfer switch does not
transfer the load to the
emergency source.
T ransfer switch does not
transfer the load to the normal
source.
Tur n Transfer Control switch clockwise to
Transfer to Emergency position.
Tur n Transfer Control switch counterclockwise to Transfer to Normal position.
1. Open normal and emergency source circuit breakers.
2. Use manual handle to manually operate transfer
switch to the opposite source. Remove the handle.
See Section 1, Manual Operation.
3. If the transfer switch is in the Emergency position
manually start the engine generator and then close
the emergency source circuit breaker.
Proceed with care! The ASCO 386 is energized.
CHECK IN NUMERICAL SEQUENCE
Generator ouput circuit breaker must be
closed. 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). *
Generator frequency must be at least 57 Hz. *
* These are factory settings.
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).
Trouble-Shooting Motor Load Transfer (Optional Feature 27) (refer to page 5-1)
3. Turn the TRANSFER TO EMERGENCY control
switch clockwise. The load should transfer to
Use extreme caution when using a meter to
measure voltages in the following steps. Do not
touch powe r terminals; shock, burns, or death
could result !
1. Connect a voltmeter (set for twice system
phase-to-phase voltage) between Transfer Switch
terminals NA and EA.
2. Manually start generator. Voltmeter needle should
sweep back and forth at a regular rate between 0
and about twice system voltage.
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 t he United States, call 1–800–800–2726. Furnish the Serial No., B ill of
Material (BOM ) No., & Catalog No. from transfer switch nameplate .
emergency source when meter needle is near 0
volts. If t ransfer does not occur, the Motor Load
Transfer accessory is not operating.
4. Turn the TRANSFER TO NORMAL control
switch counterclockwise. The load should
retransfer back to the normal source when the
needle is near 0 volts. If retransfer does not occur
after the time delay, the Motor L oad Transfer
accessory is not operating.
5. Disconnect the voltmeter.
3 --- 2
Page 10
SECTION 4ADJUSTMENTS
F
Sensor Adjustments
Voltage and frequency sensor pickup and dropout
points are factory set as specified on the Wiring
Diagram. The frequency setting can be set for 50 or 60
Hz.. To change this setting, follow the procedure
below. Use Table 4-1 for the setting and corresponding
DIP switch actuator.
Table 4-1. Frequency Settings. (Shaded DIP switch i s standard factory setting).
DESCRIPTIONLABEL
requency60/50Hz60Hz
cover
hook on
left side
FACTORY
SETTING
thumb
latch
ADJUSTMENT
NOTICE
Do not change any other factory settings. Any
change in these settings may affect the normal
operation of the ASCO 386. This change could
allow the load circuits to remain connected to a
low voltage source.
RANGE
60 HzActuator 4 off
50 HzActuator 4 on
S1 DIP SWITCH
4
4
Figure 4-1. Controller cover latch.
How to Change a Setting
NOTICE
Do not make any setting changes while the
controller is energized.
1. Deenergize all power, then open the enclosure door.
2. Disconnect both harness plugs from controller by
squeezing the latches. Do not pull on the wires.
3. Remove cover from the controller by releasing latch
on right side with your thumb. See Figure 4-1.
4. Locate the appropriate adjustment DIP switch for
the setting that you want to change. Refer to Table
4-1 above and Figure 4-2 and Figure 4-3.
5. Use a ball-point pen (or similar pointed tool) to slide
the switch actuators left or right so they match the
illustrationnext to the setting (left = off, right = on).
Recheck the setting. See Figure 4-3.
6. Install the cover o n the controller by hooking it on
the left side and latching the right side.
harness
plugs
S1 DIP
switch
Figure 4-2. Location of DIP switch.
DIP
switch
S1
actuator
(8 on each DIP switch)
S2 DIP
switch
(load disconnect feature)
seepage5---1
onoff
7. Reconnect both harness plugs to the controller by
aligning and pressing straight in until lat ches click.
8. Close the enclosure door, then restore both sources.
Figure 4-3. Setting DIP switch actuator.
4 --- 1
Page 11
SECTION 5OPTIONAL FEATURES
MOTOR LOAD TRANSFER
Inphase monitoring logic controls transfer and
retransfer of motor loads, so that inrush currents do
not exceed normal starting currents. It avoids nuisance
tripping of circuit breakers and mechanical damage to
motor couplings.
The Motor Load Transfer feature is built into the
controller. DIP switch S1 (actuator 5) activates this
feature: right = ON, left = OFF.
FUNCTIONS1 DIP SWITCH
enableActuator 5 on
disableActuator 5 off
Shaded DIP switches are standard factory settings.
Note
If the Motor L oad Transfer feature is enabled,
it will be activated following
the Load
Disconnect Feature Delay Before Transfer
delay. Also, the transfer switch may not
operate immediately after the transfer control
switch is operated, even if both sources are
available. This delay is intentional introduced
if the two power sources are not inphase.
Depending on the frequency difference, it
may take a few seconds for the sources to
reach synchronism.
5
5
LOAD DISCONNECT FEATURE
Connect external circuits to the terminals indicated on
the Wiring Diagram in the back of this manual.
The double throw (Form C) contact is rated for 28
VDCor120VAC(6ampsresistive). Thecontact
operates prior to a selectable 0, 3, 10, or 20 second
delay before transfer of the Non-Automatic Transfer
Switch. The contact resets either immediately
following transfer or after the same
delay as set for
pre–signal before transfer.
Time delay between the load disconnect control signal
and initiation of transfer is set on the controller with
DIP switch S2 (actuators 6, 7, 8) as shown below:
Delay Before Transfer
LD TDBTS2 DIP SWITCH
0 (disable)
3seconds
10 seconds
20 seconds
Actuator 7 on
Actuator 8 on
Actuator 7 on
Actuator 8 off
Actuator 7 off
Actuator 8 on
Actuator 7 off
Actuator 8 off
87
87
87
87
Shaded DIP switches are standard factory settings.
Delay After Transfer*
LD TDATS2 DIP SWITCH
enableActuator 6 on
disableActuator 6 off
*Enabling the Delay After Transfer will cause the
control signal to reset after the same delay
the Delay Before Transfer.