Winco ASCO-300-G User Manual

Page 1
Operator’s
Manual
Series 300
G design, 1000 throug h 3000 amp. sizes
TABLE OF CONTENTS
section
INSTALLATION 1..........................
SEQUENCE OF OPERATION 2.............
TESTING & SERVICE 3....................
ADJUSTMENTS 4.........................
CONTROL FEATURES 5...................
INDEX back cover.........................
An experienced licensed electrician must install the ATS.
DANGER is used in this manual to warn of high
voltages capable of causing shock, burns, or death.
!
WARNINGisusedinthismanualtowarn
of possible personal injury.
!
CAUTIONisusedinthismanualtowarn
of possible equipment damage.
Refer to the outline and wi ring drawings provided with ASCO Series 300 ATS for all installation details.
1000, 1200, 1600 amp. sizes
50 Hanover Road, Florham Park, New Jersey 07932–1591 USA For sales or service call 1 800 800–2726 (ASCO) www.ascopower.com
In Canada: PO Box 1238, 17 Airport Road, Brantford, Ontario, Canada N3T 5L7 telephone 519 758–8450, fax 519 758–0876, for service call 1 888 234–2726 (ASCO) www.asco.ca
2000 amp. size
381333–122 D
Page 2
Nameplate
The Transfer Switch nameplate includes data for each specific ASCO Series 300 ATS. Use the ATS only within the limits shown on this nameplate.
G300 3 2000 N 1 C
Catalog Number Identification
A typical Catalog Number is shown below with its elements explained. The example is for a G–design Series 300 ATS with switched neutral, 3 pole, 2000 amp, 480 V, in a Type 1 enclosure:
B –switched C – overlapping
blank – solid
neutral
connections
power
connections
Neutral
Phase Poles
2 –singleØ 3 –threeØ
Amperes Voltage Controller Enclosure
1000 1200 1600
2000 2600
3000
C 208
D 220 E 230
F 240
H 380
J 400
K 415
L 440
M 460 N 480
P 550
1 –standard
1X –if
accessories
ordered
Q 575
R 600
* type 4 & 12 enclosures are available
only for 1000, 1200, & 1600 amp. sizes
terminal block TB for
engine start and switch
position contacts
C –type1
F –type3R
G –type4 *
L –type12 *
blank – open type
Controller
Transfer
Switch
power
connections
neutral
connections
membrane
controls
2000 amp. size in typical enclosure with location of customer connections
Page 3
SECTION 1 INSTALLATION
ASCO Series 300 A u tom atic T ran sfer Switches (ATSs) are Listed under Underwriters Laboratories UL 1008 Standard for Safety for Automatic Transfer Switches. ASCO Series 300s are also Listed under CSA C22.2 No. 178 Standard for Au tom atic Transfer Switches. All control features are UL Component R ecog niz ed, which assures that AS CO automatic transfer switches meet OSHA Safety Requ irem ents and will be acceptable to electrical inspectors.
ASCOSeries 300 Automatic Transfer Switches are suitable for emergencyand standby system applications.They meet emergency system rating requirements as defined in National Electrical Code (NEC) Article 700 and UL 1008. Also, they are suitable for the requirements of NEC Article 517 – Health Care Facilities, NEC Article 701 – Legally Required Standby Systems, NEC Article 702 – Optional Standby Systems, NFPA 99 Health Care Facilities, and NFPA 110 Emergency and Standby Power Systems.
Rating Label
Each automatic transfer switch contains a rating lab el 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.
Auxiliary Cable Box for 1000–2000 amp
Anauxiliary cablebox is required if the power cablesdo not enter the enclosure directly adjacent to the terminal lugs (for example, if all power cables enter the top or bottom). Order ASCO part no. 609027 if needed.
!
Do not route the power cables along
thesidesoftheTransferSwitch.
Line Connections
Refer to the Wiring Diagram provided with your Series 300 ATS. All wiring must be made in accordance with the National Electrical Code and local codes.
It is unnecessary to remove pole covers from the transfer switch. If you do remove them, reinstall them carefully.
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
Series 300 Automatic Transfer Switches are factory wired and tested. Installation requires skid removal then securing the enclosure to the supporting foundation.
Remove the Shipping Skid
Open the front door and remove the four lagscrews (two in front, two in rear) securing the 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 Series 300 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 cablebendingspace 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 applicable enclosure outline drawing furnished with this switch and mount the Series 300 according to details and instructions shown on diagram.
Do not connect the power conductors to the ASCO Series 300 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.
!
Protect the automatic transfer switch from
construction grit and metal chips to prevent
malfunction or shortened life of the ATS.
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 this Serie s 300. Make sure the lugs provided are suitable f or 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 Series 300. 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 to conductors. Tighten cable lugs to the torque specified on rating label.
1--1
Page 4
Controller Ground
INSTALLATION (continued)
Harnesses
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
Customer connections for engine control contact and TS auxiliary contacts c onnec tion s are located on terminal block TB which is mounted on the front of the transfer switch. Refer to wiring diagram provided with the Series 300 ATS and connect the engine start wires to the appropriate terminals. See Figure 1–1 and T ab l e A.
Table A. Engine start connections.
When normal
source fails
Te r m i n a l s o n
transfer switch
contact closes TB1 and TB2 contact opens TB1 and TB3
Auxiliary Circuits
Connect auxiliary circuit wires to appropriate terminals on transfer switch terminal block TB as shown on the wiring diagram provided with this Series 300 Automatic Transfer Switch. Make the necessary auxiliary connections by referring to Section 5, Control Features.
The transfer switch is connected to the left side of the controller by a plug–in harness (two plugs).
Engine Starting
Signals
5amps,32VDC
5ampsresistive28VDC
or 120 V AC max.
TS Auxiliary Contacts
Feature 14A & 14B
10 amps, 32 V DC
10 amps 250 V AC
general purpose
TB Terminal Block (field connections) accepts wire range 22–12 AWG
FEATURE 7
closes to start
FEATURE 8
opens to start
Figure 1-1. Connections to engine starting contact
terminal block located on the Transfer Switch.
Connections to Controller
for other Control Features
(located on bottom of Controller)
Load Disconnect
Feature
Connections
(see Wiring Diagram
& refer to page 5–4
for DIP switch settings)
Programmable
Engine Exerciser
connection,
if provided
(refer to
page 5–2)
Remote Control Features Connections
(refer to the Wiring Diagram &
page 5–4 for DIP switch settings)
Each control contact must be suitable
for a 5 V DC low energy circuit.
for factory
use only
Figure 1-2. Input / output label on the Controller showing possible connections to the lower terminal block.
1--2
Page 5
INSTALLATION (continued)
Functional Test
The Functional Test consists of three checks: manual operation, voltage checks, and electrical operation.
!
Do these checks in the order presented to
avoid damaging the automatic transfer switch.
Read all instructions on the Wiring Diagram and labels affixed to the automatic transfer switch. Note the control features that are provided and review their operation before proceeding.
1 – Manual Operation Te st
A detachable maintenance handle is provided on the frame of the Transfer Switch for mainte nance purposes only Manual operation of the transfer switchshould 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.
Table B. Maintenance handle positions.
ATS Position Indicators
E
Normal
N
E
Emergency
N
OPEN
upper contacts o pe n
CLOSED
lower contacts closed
CLOSED
upper contacts closed
OPEN
lower contacts open
Turn counterclockwise to Emergency.
Turn clo c kw i s e to Normal.
insert
slide hub onto shaft
Figure 1-3. Maintenance handle.
1. After deenergizing both power sources, open the enclosure door. Locate and remove the maintenance handle and hub stored on the transfer switch frame.
.
Then install the hub onto the center operator shaft and insert the handle firmly into the hole in the side of the hub (spring fully compressed). See Figure 1–3 and 1–4 and Table B.
2. If the transfer switch is closed on Normal (window shows CLOSED), grasp handle firmly and turn it counterclock­wise. The transfer switch should operate smoothly without binding. If it does not, check for shipping damage or construc tion debris.
3. Turn the handle clockwise to return the transfer switch to the Normal position. Observe that the window indicators (left side) show the top shaft OPEN and the bottom shaft CLOSED.
Note: If Normal and Emergency connections are
reversed this operation is also reversed.
4. Remove the maintenance handle and hub and store it on the frame in the place provided.
!
Verify that the maintenance handle and hub
have been removed befo re proceeding!
handle into hole
Grasp handle firmly
Emergency contacts
window
indicators
OPEN or CLOSED
Normal contacts
contact position
indicators (left side)
Figure 1-4. Contact position indicators and maintenance handle operation.
Now continue to 2–VoltageCheckson next page.
counterclockwise DOWN closes the Emergency source contacts (upper) and opens the Normal source contacts (lower)
1--3
clockwise DOWN closes the Normal source contacts (lower) and opens the Emergency source contacts (upper)
Page 6
INSTALLATION (continued)
Florham Park NJ 07932 USA
TRANSFER SWITCH TEST BYPASS TIME DELAY SET ENGINE EXERCISER
observe these lights
Press for 15 Seconds
Figure 1–5. 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.
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 !
Perform steps 1 through 6 at t he right. Observe the status lights. See Figure 1–5.
Black circle means light is on.White circle 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.
Press until light FLASHES
Close the normal source circuit breaker. The Transfer Switch Connected To Normal and the
1
Normal Source Available 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 and the Emergency Source Available 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
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.
Now continue to 3 – Electrical Operation on next page.
1--4
Page 7
INSTALLATION (continued)
Florham Park NJ 07932 USA
observe these lights
pressthisbutton
TRANSFER SWITCH TEST BYPASS TIME DELAY SET ENGINE EXERCISER
Press for 15 Seconds
Figure 1–6. Standard controls and indicators.
3 – Electrical Operation
First check nameplate on transfer switch; rated voltage mustbethesameasnormalandemergencylinevoltages.
!
Verify that the feeders have been
connected to the proper lugs.
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 !
Perform steps 1 through 8 at t he right. Observe the status lights. See Figure 1–6.
Black circle means light is on.White circle means light is off.
NOTE: IfMotorLoadTransferfeatureis activated, then transfer may not occur immediately after the respective time delays. Transfer will only occur when the phase relationship between sources is correct.
This completes the Functional T es t of the ASCO Series 300 Au tom atic Transfer Switch. Leave the engine–generator starting control in the automatic position.
Press until light FLASHES
The normal source must be availableandthegenerator must be ready to start.
1
Check that the Normal Source Available light is on.
Press and hold the Transfer Switch Test button until the
2
engine starts and runs. This should happen within 15 sec.
The Emergency Source
3
Available light should come on.
The transfer switch should transfer to the Emergency position. The Load Connected
4
to Emergency light should come on and the Load Connected to Normal light should go off.
If the transfer to emergency delay is used the transfer should occurs after a time delay
5
(up to 5 minutes). Forimmediatetransferpress the Bypass Time Delay button.
The transfer switch should transfer back to the Normal position. The Load Connected
6
to Normal light should come on and the Load Connected to Emergency light should go off.
If the retransfer to normal delay is used the retransfer should occur after a time delay
7
(up to 30 minutes). Forimmediateretransferpress the Bypass Time Delay button.
TRANSFER SWITCH TEST
BYPAS S TIME D ELAY
BYPAS S TIME D ELAY
1--5
The unloaded running delay keeps the generator running for 5 minutes (cool–down period).
8
Then the generator should stop and the Emergency Source Available light should go off.
Page 8
SECTION 2 SEQUENCE OF OPERATION
lights show position of transfer switch
Transfer To Emergency
Thesequenceforloadtransferto emergency source begins automati­cally when normal source voltage falls below the preset dropout point or when Transfer Switch Test button is pressed. An under voltage condi­tion on any phase of the normal source is detected by the sensor.
When the normal source voltage fails or the Transfer Switch Test button is pressed, the SE relay de-energizes and relay NR begins its timin g cycle (1 or 3 seconds, moment ar y
Hold 15 sec.to start the engine generator and to transfer the load to emergency.
normal source outage delay). The NR relay is provided with a time delay on
dropout to override momentary outages and prevent nuisance starting of the engine-driven generator. If the normal source voltage returns above the sensor dropout setting before the time delay expires, the NR relay timing cycle is reset to zero and relay SE energizes.
If the normal source voltage does not return above the sensor dropout setting before the time delay expires, the NR relay de-energizes and signals the engine-driven generator to start. At the same time, a voltage and frequency sensor begins monitoring the emergency source. The sensor will accept the emergency source only when
voltage and frequency reach preset pickup points.
both Usually about ten seconds elapse from dropout of the NR relay to acceptance by the sensor. This time span occurs because the engine-driven generator must crank, start, and run up to nominal pickup points. For this reason, if the Transfer Switch Test buttonispresseditmustbeheldfor15 seconds. If the emergency source is available immediately, the sensor may accept it as soon as NR relay drops out.
When the emergency source is accepted by the sensor, relay ER begins its timing cycle (transfer to emergency delay). ER relay is provided with an adjustable (0 to 5 minutes) time delay on pickup to delay transfer of the load to the emergency source. For immediate transfer press Bypass Time Delay button.
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.
The t ransfer switch wi ll remain in the Emergency position until t he normal source is restored. If the Transfer Switch Terst button is used, the transfer switch will remain on emergency until the retransfer to normal delay times out.
TRANSFER SWITCH TEST BYPASS TIME DELAY SET ENGINE EXERCISER
Press for 15 Seconds
Press to cancel the active exercise period (stops engine now or after cooldown) See page 5–1.
lights show the sources available
light for built–in
engine exercise timer
Florham Park NJ 07932 USA
Press until light FLASHES
Hold 5 sec 20 min. engine exercise period immediately (engine starts) and weekly thereafter.
.toset
· blinks rapidly when button is held 5 sec.
while being set
· blinks slowly when button is released (set)
and during 20 min. exercise period.
· stays on after engine stops (exerciser is
enabled for weekly
operation)
Seepage5–1
for complete
instructions
Figure 2–1. Membrane controls and indicator lights.
Retransfer to Normal
The sequence for load retransfer to the normal source automatically begins when the voltage sensor detects restoration of the normal source. The voltage level must rise above the preset pickup point on all phases before the sensor will accept the normal source.
Whenthenormalsourceisacceptedbythesensor,relay SE begins its timing cycle (adjustable 1 sec. to 30 min., retransfer to normal delay). For immediate retransfer press Bypass Time Delay button. SE relay is provided with a time delay on pickup to prevent immediate load retransfer to the normal source. The delay insures that the normal source has stabilized before reconnection of vital loads. If the normal source voltage falls below the present dropout point before the time delay expires, the timing cycle is reset to zero. If the emergency source fails for more than 4 seconds during the timing cycle, ER relay drops out and the load is immediately retransferred to the normal source, if that source is acceptable.
SE relay energizes and ER relay is droppe d out. 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 a gai n.
Upon retransfer to the normal source,NR relay beginsits timing cycle (unloaded running delay [engine cooldown] ). NRrelay is provided with a 5 minute timedelay on pickup to keep the engine running for a cool-down period.
NR relay energizes after the time delay and signals the engine-driven generator to shut down. All circuits are reset for any future normal source failure.
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 9
SECTION 3 TESTING & SERVICE
PREVENTIVE MAINTENANCE
Reasonable care in preventive maintenance will insure high reliability and long life for the automatic transfer switch.
Operate the switch at least once a month.Performthis four step Electrical Operation Test. This is a test with load transfer.
TRANSFER SWITCH TEST BYPASS TIME DELAY SET ENGINE EXERCISER
Press for 15 Seconds
Transfer Switch Test
1. Press and hold the door-mounted TRANSFER SWITCH TEST button until the engine starts a nd
runs. This should happen within 15 seconds.
2. The transfer switch will operate to the Emergency position. If the Transfer To E mer gency Delay is used, the transfer w ill occur after a time delay (up to 5 minutes). For immediate transfer press BYPASS TIME DELAY button.
3. The Transfer Switch will operate back to the Normal position after the R etrans fer To Normal Delay (up t o 30 minutes). For immediate retransfer press BYPASS TIME DELAY button.
4. Unloaded Running (Engine Cooldown) Delay allows engine to run unloaded for 5 minutes.
Clean and inspect the switch once a year. De-energize all sources, then brush and vacuum away any excessive dust accumulation. Remove the transfer switch barriers and check contact condition. Replace contacts when pitted or worn excessively. Reinstall the barriers carefully.
Maintain transfer switch lubrication.Thetransfer 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 kit 75-100.
Replacement parts. Replacement parts are available in kit form. When ordering parts provide the Serial No. and Catalog No. from the transfer switch nameplate. Contact your local ASCO P ower Technologies sales office.
Press until light FLASHES
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 carefully.
Disconnecting the Plugs
!
Do not unplug the controller until step
1a. or 1b. below 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 quick disconnect plugs by squeezing the
latches. Do not pull on the harness wires.
3. Label, remove, and tape the signal wires connected
to the engine start terminals on the transfer switch: TB1 and TB3, or TB1 and TB2.
Reconnecting the Plugs
!
Do not reconnect the controller until step
1a. or 1b. and 2 below are 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 breaker still should be open.
b. If the transfer switch is in the Emergency position,
normal source circuit breaker still should be open.
2. Reconnect the signal wires connected to the
appropriate engine start terminals on the transfer switch. See Section 1, Engine Starting Contacts.
3. The harness plugs and sockets are keyed. Carefully
align the plugs with the sockets and press straight in until both latches click.
4. 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. The load will be automatically retransferred to the normal source after the Retransf e r to Normal Delay. For immediate retransfer, press BYPASS TIME DELAY button. Place the engine starting control in the automatic position.
3--1
Page 10
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 control features that are activated or furnished on the switch and reviewtheir operation. Refer to Section 5, Control Features.
Table 3-1. Trouble-Shooting Checks.
CHECK IN NUMERICAL SEQUENCE
1OPERATION 2 GEN-SET 3VOLTAGE
Gen-Set does not start when the TRANSFER SWITCH TEST button is pressed and held for 15 seconds or when the normal source fails.
T ransfer switch does not transfer the load to emergency source after the gen-set starts.
T ransfer switch does not transfer the load to normal source when normal returns or when TRANSFER SWITCH TEST button is released.
Gen-Set does not stop after load retransfer to the normal source.
Hold the TRANSFER SWITCH TEST button 15 sec. or the outage must be long enough to allow for the 1 or 3 sec.
Momentary Normal Source Outage Delay plus engine
cranking and starting time.
Wait for Transfer to Emergency Delay (0 to 5 min.) to time out. For immediate transfer, press the BYPASS TIME DELAY button. If Motor Load Transfer is active, wait for inphase condition (see below).
Wait for Retransfer to Normal Delay (1 sec. to 30 min.) to time out. For immediate re–transfer, press BYPASS TIME DELAY button. If Motor Load Transfer is active, wait for inphase condition (see below).
Wait for the 5 minute Unloaded Running Delay to time out.
1. Open normal and emergency source circuit breakers.
2. Use the maintenance handle to manually operate
transfer swit ch to the opposite source. See page 1–3, Manual Operation Test.
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 automatic transfer switch is energized.
Starting control must be in 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 57 Hz.
Starting control must be in automatic position.
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). *
* 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 the Motor Load Transfer Feature (refer to page 5–5)
3. Press and hold load should transfer to emergency source when
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 !
meter needle is near 0 volts. If transfer does not occur, Motor Load Transfer feature is not operating.
4. Release the Transfer Switch Test button. The load should retransfer back to the normal source after the
1. Connect a voltmeter (set for twice the system phase–to–phase voltage) between Transfer Switch terminals NA and EA.
2. Manually start the generator. The voltmeter needle should sweep back and forth at a regular rate between 0 and about twice the system voltage.
Retransfer to Normal Delay,ifused. Theretransfer should occur when the needle is near 0 volts. If retransfer does not occur after the time delay, the Motor L oad Tra nsfer feature is not operating.
5. For immediate retransfer, press the Bypass Time Delay button. Then disconnect the voltmeter.
Ifthe problemis isolated to circuits on the controlleror t he transferswitch, call your local ASCO Power Technologies sales office. Furnish Serial No., Bill of Material (BOM) No., & Catalog No. from the transfer switch nameplate.
3--2
the Transfer Switch Test button. The
Page 11
SECTION 4 ADJUSTMENTS
y
OverrideMomentary
TIMER
0minute
s
0to
5
TIMER
30minutes
1secondto
S1DIP
EmergencySource
qy60/50
V
/
V
LOW
/
Time Delay Adjustment
Standard time delays are set to customer specifications (if none specified, standard factory settings are used).
Table4-1.TimeDelaySettings
DESCRIPTION LABELS
Override Momentar
Normal Source Outages
T ransfer to Emergency
Override Momentary
Emergency S. Outages
Retransfer to Normal
Unloaded Running (Engine Cooldown)
FACTORY
SETTING
TD ES 3seconds
TIMER 0 minutes 0to5
N/E
4seconds non-adjustable
TIMER 30 minutes 1secondto
E/N
5 minutes non-adjustable
(full ccw)
(full cw)
ADJUSTMENT
RANGE
1second Actuator 1 on
3seconds Actuator 1 off
minutes
30 minutes
Sensor Adjustments
Voltage and frequency sensor pickup and dropout points are set to customer specifications (if none specified, standard factory settings are used). To change a setting, follow procedure on page 4–2. Use Tables 4-2 and 4–3 for settings and corresponding DIP switch actuators.
To change a setting, follow procedure on pa ge 4-2. Use Table 4-1 as a guide to time delay values and their corre­sponding adjustment DIP switch or potentiometer.
S3 DIP
SWITCH
1
1
!
ADJUSTMENT
POTENTIOMETER
P2
P1
Any change in these settings may affect the normal operation of the automatic transfer switch. This change could allow the load circuits to remain connected to a low voltage source.
Table 4-2. Voltage and Frequency Settings. ( Shaded DIP switches are standard factory settings).
DESCRIPTION LABELS SETTING
PU/N Pickup 90 %
Normal Source Voltage
DO/N Dropout
EmergencySource
Voltage
Emergency Source
Frequency
oltage Phases 3 4 ,14 3 4/1 4 3 4
–– Pickup 90 % non-adjustable
–– Dropout 75 % non-adjustable
–– Pickup 95 % non-adjustable
–– Dropout 85 % non-adjustable
60/50
Hz
60/50 Hz 60 Hz
%ofnominal
FACT. S ET ADJ RANGE
95 % * Actuator 3 off
90 % Actuator 3 on
90 % *
85 %
85 %
80 %
70 %
60 Hz Actuator 4 off
50 Hz Actuator 4 on
3phase Actuator 6 off
1phase Actuator 6 on
Actuator 1 off Actuator 2 off
Actuator 1 on Actuator 2 off
Actuator 1 off Actuator 2 on
Actuator 1 on Actuator 2 on
––
––
S1 DIP
SWITCH
* If dropout voltage is set to 90%, the pickup voltage must be set to 95%.
Table 4-3. Transformer Voltage Adjust.
(Low setting shifts all voltage settings down 4.2%; for example, 240 V to 230 V, or 480 V to 460 V)
DESCRIPTION LABELS FACTORY SETTING ADJUSTMENT S3 DIP SWITCH
LOW Actuator 2 off
HI Actuator 2 on
oltageAdjust (4.2%)
LOW
HI
HI
3
3
21
21
21
21
4
4
6
6
2
2
4--1
Page 12
ADJUSTMENTS
(continued)
!
Do not make any setting changes
while the controller is energized.
How to Change a Setting
1. Prevent the transfer switch from operating bydiscon­necting one source first, then the other, as follows:
a. If the transfer switch is in the Normal position,
open the emergency source circuit breaker. Turn the engine starting control to off. Then open the normal source circuit breaker.
b. If the transfer switch is in the Emergency
position, open the normal source circuit breaker. Turn engine starting control to test or run.Then open the emergency source circuit breaker.
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 appropriateadjustment potentiometeror DIP switch for the setting that you want to change. Refer to Table 4-1 and Table 4–2 on page 4-1 and Figure 4-2, Figure 4–3, Figure 4–4 on page 4–2.
5. Use a small screwdriver to turn the potentiometer clockwise to increase the time delay or counterclock­wise to decrease it. See Figure 4-3.
6. 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 4-4.
cover
hook on left side
Figure 4-1. Controller cover latch.
harness
plugs
S3 DIP
switch
S1 DIP
switch
S2 DIP
switch
Figure 4-2. Location of potentiometers, DIP
switches, battery, and battery jumper.
thumb latch
J5
retransfer to normal
time delay
transfer to
emergency
time delay
9volt
alkaline
battery
battery on/off jumper
P1
P2
7. Install the cover on the controller by hooking it on the left side and latching the right side.
8. Reconnect both harness plugs to the controller by aligning and pressing straight in until lat ches click.
!
Close the enclosure door.
9. Close the enclosure door, then restore both sources:
a. If the transfer switch is in the Normal position
first close the normal source circuit breaker, then close the emergency source circuit breaker.
b. If the transfer switch is in the Emergency
position, close the normalsource circuit breaker. The load will be automatically retransferred to the normal source. Then close the emergency source circuit breaker.
10. Turn the engine starting control to automatic.
clockwise to
increase
P1 or P2
potentiometer
counterclockwise
to decrease
Figure 4-3. Changing time delay potentiometers.
DIP
switches
SW1 SW2 SW3
actuator
(8 on each DIP switch)
onoff
Figure 4-4. Setting DIP switch actuators.
4--2
Page 13
SECTION 5 CONTROL F EATURES – ENGINE EXERCISERS
These timers periodically exercise the emergency engine-generator plant. They can be set to exercise with or without loadtransfer, or they can be completelydisabled. Theengine-generator shouldbe exercised under load once a week for a minimum time period of 20 minutes, or follow the recommendations of the engine-generator set manufacturer. Referto page 4–2 for location of DIP switches, battery (provided), and jumper block in the controller.
BUILT–IN ENGINE EXERCISER
The engine exerciser included in ASCO Series 300 Automatic Transfer Switches provides a once a week 20–minute exercise period. It occurs immediately the SET ENGINE EXERCISER push button is pressed (and held
for at least 5 seconds), and then at the sametime
weekly thereafter. A 9 volt alkaline battery (DuracellR MN1604, EverreadyR 522, or PanasonicR 6AM6) is furnished and installed in the controller to maintain the setting. The battery jumper block must be shifted to ON position
. See Figure 4–2 on page 4–2.
Fill in day and time set. Week Day ______ Time _______.
Press to cancel an active exercise period (stops generator).
If Exercise with Load is set, retransfers load to Normal, then stops generator after 5 min. cooldown.
Figure 5-1. Operator panel pushbuttons and light.
when
the
FUNCTION
Std. Timer
Enabled
Std. Timer
Disabled Exercise
without
Load
Exercise
with Load
Shaded DIP switches are standard factory settings.
Press until light FLASHES
DIP Switch Settings
S1 DIP
SWITCH
Actuator
7on
Actuator
7off
Actuator
8off
Actuator
8on
7
7
8
8
status light
Press and hold for 5 sec light blinks rapidly to set exercise period immediately and every week hereafter (generator starts).
If Exerciser with Load is set, transfers load to Emergency.
S2 DIP
SWITCH
Actuator
5on
Actuator
5on
. or until status
5
5
Select below either Exercise without Load or Exercise with Load according to the setting of DIP switch S1, actuator 8. The load transfers from the Normal source to Emergency source (generator) and back again if Exercise with Load is selected.
Exercise without Load, DIP Switch S1, Actuator 8 off
8
How to Set Built–In Timer
Step Function Explanation
Push Button Status Light
SET ENGINE
1
EXERCISER
hold
5sec.
2 release
press BYPASS
3
TIME DELAY
blinks rapidly
FfFfFf
blinks slowly
FffFff
set exercise period
exercise period now active Generator starts and runs.
Exercise the generator now and
every week at this time hereafter.
F stays on cancel active exercise period Generator stops.
4 F stays on generator off Exerciser enabled; repeats every 7 days.
Exercise with Load, DIP Switch S1, Actuator 8 on
8
How to Set Built–In Timer
Step Function Explanation
Push Button Status Light
SET ENGINE
1
EXERCISER
hold
5sec.
2 release
press BYPASS
3
TIME DELAY
blinks rapidly
FfFfFf
blinks slowly
FffFff
blinks slowly
FffFff
set exercise period
exercise period now active
cancel active exercise period
Exercise the generator now and
every week at this time hereafter.
Generator starts and runs;
the load transfers to Emergency.
The load retransfers to Normal; then
generator runs for 5 minute cooldown
( light blinks slowly during cooldown ).
4 F stays on generator off Exerciser enabled; repeats every 7 days.
NOTE:EverytimeSET ENGINE EXERCISER push button is pressed (held 5 seconds) the exercise period is changed.
5--1
Page 14
2–line display
CONTROL FEATURES (continued)
Optional Accessory 11BG – SOURCE AVAILABILITY SIGNAL
& PROGRAMMABLE ENGINE EXERCISER MODULE
located on inside of door behind operator interface on engine exerciser module
connections for power source
3 buttons
availability signal contacts
Figure 5–2. Accessory 11BG module (mounted behind operator
interface and connected to the controller) includes source
availability signal contacts and a programmable engine exerciser.
Source Availability Signal Contacts
ThemoduleprovidesoneFormCcontacteachforthe normal and emergency sources signal the acceptability of
the operator interface. Field wiring terminals are provided as shown in Figure 5–3 and the wiring diagram.
Contact ratings:
the source as sensed by the controller. The signal contacts operate i n conjunction with the Source Available lights on
Programmable Engine–Generator Exerciser
Themoduleincludesaprogrammableengineexerciser that provides for weekly or biweekly operation. This optional exercise timer may have to be turned on (enabled) by setting the S1 DIP switch actuator 7 to OFF (left position), and S2 DIP switch actuator 5 to OFF (left position).
A backup battery
in the controller (see page 4–2 and page 5–3) must be turned on to maintain the settings and to allow programming with the normal and emergency power turned off (page 5–1).
Theprogrammableengineexerciserincorporatesa7–day or 14–day time base. Proper controller settings must be made to determine whether or not the test will be done with or without load transfer (S1 DIP switch actuator 8).
Seenextpageforinstructionsonsettingthetimer.
Programmable
Programmable
Source Availability Contacts 2 amps @ 30 VDC, resistive
0.5 amp @ 125 VAC, resistive contacts shown de–energized
Figure 5–3. Source availability
signal contacts.
2 amps @ 30 Vdc, 0.5 amp. @ 125 Vac resistive
S1 DIP Switch Settings
in Group 1 Controller
Exerciser
Function
Enabled &
Exercise
without Load
Enabled &
Exercise
with Load
Actuator 7 OFF Actuator 8 OFF
Actuator 7 OFF
Actuator 8 ON
ACTUATORS 7 & 8
OFF ON
7
8
7 8
EXER ACTV
LOAD
EXER ACTV
LOAD
S2 DIP Switch Settings
in Group 1 Controller
Exerciser
Function
Enabled Actuator 5 OFF
Disabled Actuator 5 ON
ACTUATOR 5
OFF ON
5
5
EXT EXER
EXT EXER
5--2
Shaded DIP switches are standard factory settings.
Page 15
CONTROL FEATURES (continued)
How to Set Optional Programmable Engine Exerciser (part of Acc. 11BG module)
Start Time Display
Hazardous voltage capable of causing shock, burns, or death is used in this transfer switch.
Deenergize both Normal & Emergency power
sources before programming the exerciser.
Navigating the M enu
Use the UP and DOWN arrow keys to move through the displays.
Fast/Slow Ad ju st
Daylight Saving
Time Adjust
Date
The Start Time Display shows the engine exerciser start time. There are four parameters that determine the start time:
weekly (”Every”) or bi–weekly (”Alt”) operation
day of week (”Sun” through “Sat”)
start hour (0 through 23)
start minutes (0 through 59)
For example, if the user wants the exerciser to run every other Saturday a t 3 PM, the proper configuration would be:
“Alt Sat @ 15:00”
NOTE: When choosing bi–weekly operation, the exerciser will always run on the week designated “(1)” on thedatedisplay.
Run Time Display
The Run Time Display shows the run time for the engine exerciser. The default setting from the factory is 30 minutes.
Time
Run TIme
Start TIme
Engine Exerciser
Changing the Parameters
Use the UP and DOWN arrow keys to move though the displaystotheparametertobechanged. Pushthe ENTERkey tostarttheeditingprocess.Thefirstparameterwillflash.Use the UPand DOWN arrowkeys to adjust the parameter to the desiredvalue andpresstheENTER keytosavethevalue.The next parameter will now flash.Repeat the process untileach parameter is properly configured.
Engine Exerciser Display
TheEngineExerciserDisplayshowsthestatusofthe engine exerciser. When the unit is shipped from the factory the programmable engine exerciser is “Disabled” and must be set to “Enabled” by the customer. When the engine exerciser is running, t his display will count down the remaining time until the end of the exercise period.
Time Display
The Time Display shows the present system time. The format is “hours:minutes:seconds”.
NOTE: During total power outages, power to the accessory is maintained by a battery in the Controller (see page 4–2). Be sure that the 9–volt alkaline battery is fresh and enabled (jumper in ON position) so that the time and date settings are not lost.
Date Display
The Date Display shows the present system date. The format is “day of week (week) month/day of month/year”.
NOTE: Week is either week 1 or week 2. This is used in conjunction with the bi–weekly timer.
Daylight Savings Time Adjust Display
This display shows whether the automatic daylight saving time adjustment is active. The factory default is “NO”. If enabled,theunitwillautomaticallyadjustfordaylightsaving timeat 2AMon t he first Sundayof April and the last Sunday of October.
Fast / Slow Adjust Display
This display shows the automatic fast/slow adjustment value.Thefactorydefaultis0.Thisfeaturecanbeusedto trim a clock that runs fast or slow. For example, if your clock runs 10 seconds slow per week, change the fast/slow adjust value to “+10” and the unit will automatically add 10 seconds to the clock every week.
NOTE: Adjustments are made Sunday morning at 2 AM. If you want your exerciser period to start at 2 AM on Sunday, you cannot use this feature and the adjustment must be set to 0.
5--3
Page 16
CONTROL FEATURES (continued)
Programmable Engine Exerciser Settings
Fill in your settings for future reference
Weekly or Bi–weekly Day of Week Start Time Run Time
0–23hour
Every = weekly
Sun through Sat
Alt = bi–weekly
0–23hour
0–59minute
0–59minute
30 minutesisthe
default setting
Date exerciser was set ______________________________________
5--4
Page 17
CONTROL FEATURES (continued)
INPHASE MONITOR
FOR MOTOR LOAD TRANSFER
Inphase monit oring 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.
FUNCTION S1 DIP SWITCH
enable Actuator 5 on
disable Actuator 5 off
Shaded DIP switches are standard factory settings.
Note
If the Motor Load Transfer feature is enabled, it will be activated following
the Load Disconnect Feature Delay Before Transfer delay.
5
5
LOAD DISCONNECT FEATURE
Connect external circuits to the terminalsindicated on the Wiring Diagram provided with the ATS.
The double throw (Form C) contact i s rated for 28 VDC or 120 VAC (5 amps resistive). The contact operates prior to a selectable 0, 3, 10, or 20 second delay before transfer of the Automatic Transfer Switch. The contact resets either immediately following transfer or after the same
delay as
set for pre–signal before transfer.
Time delay bet wee n 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 TDBT S2 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 TDAT S2 DIP SWITCH
enable Actuator 6 on
disable Actuator 6 off
6
6
*Enabling the Delay After Transfer will cause the control signal to reset after the same delay
as set for the Delay
Before Transfer.
REMOTE CONTROL FEATURES
These remote control features require a customer–supplied normally closed contact suitable for a 5 V dc low energy circuit. Refer to the Wiring Diagram provided with the ATS. Activate appropriate DIP switch S2 actuators below.
Remote Test (terminals CP6–7)
RTSW S2 DIP SWITCH
disable Actuator 3 on
enable Actuator 3 off
3
3
Remote Transfer to Emergency (CP8–9)
RT /E S2 DIP SWITCH
disable Actuator 2 on
enable Actuator 2 off
2
2
Bypass Transfer Time Delay (CP12–13)
TD E/N BYP. S2 DIP SWITCH
disable Actuator 1 on
enable Actuator 1 off
1
1
Inhibit Transfer to Emergency (CP10–11)
N/E INHIB. S2 DIP SWITCH
disable Actuator 4 on
enable Actuator 4 off
5--5
4
4
Page 18
CONTROL FEATURES (continued)
OPTIONAL STRIP HEATER (Accessory 44)
Accessory 44 Strip Heater is designed to keep ambient temperatures within the Automatic Transfer Switch enclosure at acceptable levels. This accessory consists of a mounting bracket with strip heater, thermostat, and terminal block. A transformer with fuses is included when the power for the assembly is derived from voltages above 120 V ac. The 120 V ac customer powered assembly does not include a transformer. This optional accessory is available factory installed or in kit form.
Turn the thermostat’s dial to required setting as shown.
thermostat
dial
turn counterclockwise
to lower temperature
turn clockwise
to raise temperature
AVAILABLE KITS FROM ASCO
Controls
Description Accessory Kit
ProgrammableEngineExerciser
& Source Availability Contacts
Serial Communication Module 72A K601110
11BG K629830
Figure 5–4. Thermostat.
Strip Heater – Accessory 44
Description Accessory Kit
120 volt
customer supplied voltage
(without transformer)
208 – 480 volt
ATS derived voltage
(with transformer)
380 volt
ATS derived voltage
(with transformer)
550 – 600 volt
ATS derived voltage
(with transformer)
44A K613127–001
44G K613127–002
44G K613127
44G K613127–003
5--6
Page 19
INDEX
A
accessories, 5–2, 5–3, 5–4, 5–5
auxiliary circuits, 1–2
B
barriers, 1–3
battery, 4–2, 5–1
buttons, push, 3–1
bypass time delay, 1–4, 2–1, 3–1
C
cable
lugs, 1–1 preparation, 1–1 spacers, 1–1
illustration of, 1–1
catalog number, inside cover
cleaning, 3–1
connections
engine control contact, 1–2 line, 1–1
contact position indicators, 1–3
contacts
auxiliary, 1–2 engine control, 1–2 main, 3–1 source availability, 5–2
control features, 5–1
load disconnect, 5–5 motor load transfer, 5–5 plant exerciser, 5–1, 5–2, 5–3, 5–4
controller (control panel), 4–1, 4–2
codes, cover cover removal, 4–2 disconnecting, 3–1 time delay potentiometers, 4–2
D
DIP Switches, 4–1, 4–2, 5–1, 5–2, 5–5
E
electrical operation, 1–4
engine exerciser, 5–1, 5–2, 5–3, 5–4
engine starting contacts, 1–2
F
features, see control features
frequency, pi ckup and dropout
settings, 4–1
functiona testl, 1–3, 1–4, 1–5
H
harness, 1–2
disconnect plugs, 3–1
help, service 3–2
I
inphase monitor, 5–5
inspection, 3–1
installation, 1–1
insulator backing piece, 1–1
illustration of, 1–1 warning, 1–1
L
labels,
engine starting contacts, 1–2 inputs / outputs, 1–2 rating, cover
lights, 1–4, 1–5, 5–1
load disconnect feature, 5–4
lubrication, 3–1
M
maintenance, preventive, 3–1
manual load transfer, 3–2
warning, 3–2
manual operation, 1–3
illustration & warning, 1–3
motorloadtransferfeature,5–5
N
nameplate, cover
O
operation
electrical, 1–4 manual, 1–3
illustration & warning, 1–3
sequence of, 2–1
P
parts, 3–1
problem, 3–2
programmable engine exerciser, 5–2,
5–3, 5–4
R
rating label, inside cover
remote control features, 5–5
bypass transfer time delay, 5–5 inhibit transfer to emergency, 5–5 remote test, 5–5 remote transfer to emergency, 5–5
replacement parts, 3–1
S
service, call 800–800–2726 (ASCO)
set engine exerciser, 5–1, 5–2, 5–3,
5–4
settings
changing, 4–1 factory, 4–1 frequency, 4–1 phase, 4–1 time delay, 4–1 voltage, 4–1
T
terminal block, 1–2
test, functional, 1–3, 1–4, 1–5
time delay
adjustment, 4–1 gen–set cooldown, 4–1 how to change, 4–2 override momentary outages, 4–1 settings, 4–1 transfer to emergency, 4–1 transfer to normal, 4–1
timer (plant exerciser), how t o set,
5–1, 5–2, 5–3, 5–4
transfer switch test, 1–4, 3–1
trouble–shooting, 3–2
inphase monitor, 5–4
V
voltage, phase, 4–1
voltage, pickup and dropout settings,
4–1
Printed in U.S.A.
E 2005 ASCO Power Technologies, L.P.
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