Schneider Electric ASCO 7000, ASCO 7ATB, ASCO 7ACTB, ASCO 7ADTB Installation Manual

ASCO 7000 SERIES 7ATB, 7ACTB, 7ADTB Automatic Transfer & Bypass–Isolation Switches G, Q, S, & U design Installation Manual

381333-415 A 9/2016

An experienced licensed electrician must install

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.

the ATB.

The Transfer Switch nameplate includes data for each specific 7000 Series ATB Use the switch only within the limits shown on this nameplate. A typical Catalog Number is shown below with its elements explained:

Nameplate

CAUTION is used in this manual to warn of a hazardous situation which, if not avoided, could result in minor or moderate injury.

Refer to the outline and wiring drawings provided with your 7000 Series ATB for all installation and connection details and accessories.

Refer to Group 5 Controller User’s Guide 381333–126 for ATS status display messages, time delays, pickup & dropout settings, and adjustments.

Rating Label

Each 7000 Series ATB contains a rating label to define the load 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.

typical 4000

Installation Manual 7000 Series ATB, ACTB, ADTB

Table of Contents

Rating Label.............................................................................................................................................................. 1

Nameplate ................................................................................................................................................................ 1

Catalog Number Identification .................................................................................................................................. 3

Installation .............................................................................................................................................................. 4-7

Remove the Shipping Skid ....................................................................................................................................... 4

Supporting Foundation and Mounting ...................................................................................................................... 4

Mounting ................................................................................................................................................................... 4

Remove Shipping Brackets/Angles from the Transfer Switch .................................................................................. 4

Testing Power Conductors ....................................................................................................................................... 5

Connecting Power Conductors ................................................................................................................................. 5

Bus Connections ...................................................................................................................................................... 5

Harnesses ................................................................................................................................................................. 5

Engine Starting & Auxiliary Circuits .......................................................................................................................... 5

Functional Test ......................................................................................................................................................... 6

Functional Test – Voltage Checks ............................................................................................................................ 6

Functional Test - -Electrical Operation .................................................................................................................... 6

Testing & Service ...................................................................................................................................................... 8

Transfer Test ............................................................................................................................................................ 8

Preventive Maintenance ........................................................................................................................................... 8

Replacement Parts ................................................................................................................................................... 8

Manual Load Transfer .............................................................................................................................................. 8

Maintenance Handle ................................................................................................................................................. 8

Trouble-Shooting ...................................................................................................................................................... 9

Bypassing & Isolating ............................................................................................................................................. 10

Bypassing the ATS ................................................................................................................................................. 10

To Bypass Normal Source ...................................................................................................................................... 10

To Bypass Emergency Source ............................................................................................................................... 10

Isolating the ATS .................................................................................................................................................... 11

Return to Service .................................................................................................................................................... 13

Index .......................................................................................................................................................................... 15

2 381333-415 B

7000 Series ATB, ACTB, ADTB Installation Manual

Catalog Number Identification

Typical 7000 Series G7ATB catalog no. for overlapping neutral, 3 pole, 4000 A, 480 V, in a Type 1 enclosure:

G 07A TB C 3 4000 N 5

Design prefix letter

G Q S U

Transition

Type

07A open 7AC closed 7AD delayed

Neutral Phase

A- solid B- switching C- overlapping* blank-none

* Overlapping neutral

not available for Q, S, & U-designs

Poles

single

2 3 three

Amperes

600

800 1000 1200 1600 2000 2600 3000

Voltage Controller

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

4000

Status Lights

Engine

Control

Bypass Handle

Transfer Control

5 standard

accessories ordered

& Lights

Enclosure

C type 1 F type 3R G type 4 L type 12

blanc – open type

Isolation

Handle

Group 5 Controller

Transfer Switch

Typical G7ATB with lower doors open (transfer switch shown)

381333-415 B 3

Installation Manual Installation

INSTALLATION

The ASCO 7000 Series Automatic Transfer & Bypass–Isolation Switch (ATB) consists of an upper bypass–isolation switch, a lower transfer switch, a monitoring and transfer controller, and door–mounted controls. The ATB is factory wired and tested. Installation requires removal of the shipping skid then securing the enclosure to the supporting foundation.

Remove the Shipping Skid

Open the front lower door and remove the two front lag screws securing the enclosure to the wood skid. Next remove the rear lower panel and remove the two rear lag screws securing the enclosure to the wood skid.

Supporting Foundation and Mounting

The supporting foundation for the enclosure must be level and straight. Allow at least 35 inches in front of the enclosure for draw out of the Transfer Switch. Refer to the enclosure outline drawing included with the 7000 Series ATB for all mounting details including door opening space.

To prevent serious damage, remove three or four shipping brackets or L–angles from the Transfer Switch carriage. Do not turn the Isolation Handle until they are removed!

If bottom cable entry is used, the foundation must be prepared so that the conduit stubs are located correctly. Refer to the appropriate enclosure outline drawing for specified cable entrance 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 enclosure outline drawing furnished with this switch and mount the 7000 Series ATB according to the details and instructions shown on the drawing.

Remove Shipping Brackets / Angles

from the Transfer Switch

Open the lower front door(s). The Transfer Switch carriage is secured to the frame for shipment. Remove the three or four shipping brackets or L– angles: (1 upper left, 1 upper right, and 2 lower).

remove 3 or 4 shipping brackets ( L–angles)

Figure 1. 600–3000 A remove shipping brackets.

remove 2 upper shipping brackets

remove 2 lower shipping brackets

Figure 2. 4000 A remove four shipping brackets.

4 381333-415 B

Installation Installation Manual

Bus Connections

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.

If bus connection is used, use SAE grade 5 hardware to connect bus to appropriate terminal plates on bypass switching device. Wipe off bus surfaces before they are joined. If bus is dirty, gently clean surfaces with a non-flammable solvent. Avoid touching cleaned surfaces.

Testing Power Conductors

Do not connect the power conductors to the ATB 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 they are connected they should be tested to verify that they are not defective or have been damaged during installation.

Protect the switch from construction grit and metal chips to prevent malfunction or shortened life of the ATB switch.

Connecting Power Conductors

A Wiring Diagram is furnished with the ATB. All wiring must be made in accordance with the local codes. After the power cables have been tested, connect them to the appropriate terminal lugs on the Bypass Switch as shown on the wiring diagram provided with this ATB. Make sure that 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 ATB. Be careful when stripping insulation from conductors; avoid nicking or ringing the conductor. Remove surface oxides from conductors by cleaning with a wire brush. Follow conductor manufacturer’s instructions when aluminum conductor is used. Apply joint compound to conductor, then carefully wipe away excess compound. Tighten the cable lugs to the torque specified on the rating label.

Do not breathe cleaning solvent vapors.

Use SAE grade 5 hardware and tighten the bolted joints to the torque specified in Table A.

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

5/16 12

3/8 20 1/2 50 5/8 95

Recommended

Tightening Torque

in foot pounds

Harnesses

All internal connections are made at the factory. The bypass switch, transfer switch, and control panel are joined together by an interconnecting wire harness. The disconnect plugs are already engaged on enclosed switches. For open–type switches, the plugs must be engaged after installation is completed. Align harness plugs with sockets in the control and push them together until they are secure.

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.

Engine Starting Contacts

and Auxiliary Circuits

Be sure that the Normal and Emergency power connections are in proper phase rotation.

381333-415 B 5

The engine control contact signal connections and auxiliary circuits are located on terminal block TB as shown on the Wiring Diagram provided with the ATB. Connect the signal wires to the appropriate terminals.

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