Owners manual - Automatic Transfer Switch
Contents
1. To Set Exerciser Press and hold 5 seconds the Set Engine Exerciser button The exercise period occurs immediately and at approximately the same time weekly thereafter The status light below the button blinks during the exercise period including the cooldown The light stays on to indicate that the exerciser has been set If the light is off the exerciser has not been set To Cancel an Active Exercise Period Press the Bypass Time Delay button to stop an exercising generator If exercise with load is set the ATS retransfers the load to the utility then stops the generator after cooldown 381333 319 D Series 185 CONTROLLER continued S1 DIP switch S2 DIP switch on 2345 amp 910 12345678910 HSH 9955886 BABRBABARR amp Figure 6 DIP switches S1 and S2 at the top right The time delay settings are shown in Figures 6 and 7 and in Table C The sensor settings are shown in Figure 6 and in Table D The standard factory settings are shown in Tables C D and H HOC AL 1 22443678910 S3 DIP switch Table C Time Delay Settings Figure 7 DIP switch S3 at the bottom center Time Delay Description Factory Setting Settings DIP Switch DIP Actuator Actuator Position override momentary 1 second S2 1 on up utility outages 3 seconds y Qutag 3 seconds S2 1 off down transfer to generator 10 seconds app2. ASCO Series 185 Operator S Automatic Transfer Switches ache 100 through 400 ampere sizes A DANGER Refer to the outline and wiring drawings provided with your ASCO Series 185 ATS for all installation details DANGER is used in this manual to warn of high voltages capable of causing shock burns or death ASCO Series 185 Automatic Transfer Switches ATSs are Listed under Underwriter s Laboratories Standard for Transfer Switch Equipment UL 1008 They are intended for use only in optional standby systems in accordance with the National Electrical Code NEC NFPA 70 Article 702 This ATS is for use with 2 wire automatic start generators only WARNING is used in this manual to warn of possible personal injury Refer to Application Information 381339 292 to confirm CAUTION is used in this manual to warn that you have selected the appropriate product for the of possible equipment damage intended installation This automatic transfer switch is intended for standby power applications in residential light commercial use only This product is not intended for emergency or life support systems If you have more stringent application requirements contact ASCO Power Technologies for other products suitable for critical applications An experienced licensed electrician must install the ATS ASCO 185 Powe snsfer Switch Rating Label Each automatic transfer switch contains a rating label to define the
3. spacer cable 1 switches DIP 3 5 T TB7 generator start connections 3 terminal block 1 test functional 6 time delay adjustment 3 4 gen set cooldown 4 how to change 3 override momentary outages 4 settings 3 5 transfer to emergency 4 transfer to normal 4 timer gen exerciser how to set 3 transfer switch position lights 2 Transfer Test button 2 6 troubleshooting 8 9 U unloaded running gen cooldown 4 Utility failure 7 frequency 4 settings 4 voltage 4 Utility Acceptable light 2 7 9 V voltage phase 4 voltage pickup amp dropout settings 4 voltage checks 6 381333 319 D Printed in U S A 10 Copyright ASCO Power Technologies L P 2009
4. applied to it Press the Bypass Time Delay button for immediate load transfer to the generator The ATS transfers the load to the generator but the genera tor bogs down struggles or slows down The ATS retran sfers back to the utility The generator may be overloaded Check to see if the generator circuit breaker tripped Check the sum of the loads to be sure it does not exceed the capacity of the generator Some motor loads require three times more power for starting Check for short circuit in a connected load Observe the Load on Utility and Load on Generator lights The generator stops after a running for awhile The ATS retransfers back to the utility if acceptable Verify proper generator operation it may have run out of fuel or shut down because of low oil level see generator manual The generator may be overloaded Check to see if the generator circuit breaker tripped Check the sum of the loads to be sure it does not exceed the capacity of the generator Some motor loads require three times more power for starting Check for short circuit in a connected load Observe the Load on Utility and Load on Generator lights The ATS does not retransfer the load back to the utility Verify that the Utility Acceptable light is on The ATS will not transfer the load to an unacceptable source Wait approximately 5 minutes for the retransfer to utility time delay The utility must be acceptable for 5 minutes
5. gilcnaa table 2 With ALL POWER OFF verify that the generator feed is 220 240 V ac and 60 5 l Hz Check DIP switch S2 actuator 2 and DIP S1 actuator 4 See Table D for voltage and frequency settings 3 With ALL POWER OFF verify that the generator feed is wired to the terminal lugs on the top of the transfer switch marked L2 and L6 See the wiring diagram 4 With ALL POWER OFF verify that the transfer switch harness is connected properly to the controller plug and receptacle tight 5 Verify generator ac output voltage and frequency see generator manual The generator starts and runs 1 Verify that the Generator Acceptable light is on If it is off see previous trouble but the ATS does not transfer shooting problem The ATS will not transfer the load to an unacceptable source the load to the generator l l l 2 With ALL POWER OFF verify that the transfer switch harness is connected properly to the controller plug and receptacle tight 381333 319 D TROUBLESHOOTING continued Series 185 Problem Cause and Solution The ATS does not immediately transfer the load to the generator Verify that the Generator Acceptable light is on If it is off see previous trouble shooting problem The ATS will not transfer the load to an unacceptable source Wait approximately 10 seconds for the transfer to generator time delay This fixed delay allows the generator output to stabilize before a load is
6. loads and fault circuit withstand closing ratings Refer to the label on the transfer switch for specific values APELIGRO A DANGER Do not exceed the values on the rating label Exceeding the rating can cause personal injury or serious equipment damage TABLE OF CONTENTS page INSTALLATION cccccccceeeeeeees 1 CONTROLLER ooon 2 5 w FUNCTIONAL TEST L a 6 SEQUENCE OF OPERATION 7 TROUBLESHOOTING 2000 8 9 ti l 100 230 ampere sizes INDEX g ap E E E T 10 a i ASCO ines RESTEN TE E n 90999 0190 ASCO POWER TECHNOLOGIES CANADA PO Box 1238 17 Airport Road Brantford Ontario Canada NST 5T3 EMERSON Series 185 Nameplate Catalog Number Identification The Transfer Switch nameplate includes data for A typical Catalog Number is shown below with its each specific ASCO Series 185 ATS Use the ATS elements explained The example is for a D design only within the limits shown on this nameplate 2 pole 200 A 220 240 V in Type 1 indoor enclosure D 185 A 2 200 F 4 C Neutral Phase Poles Amperes Voltage Controller Enclosure A standard 2 single 100 F 220 240 4 standard C Type 1 200 4X if M Type 3R 230 accessories 260 ordered 400 clock battery cable spacers load power i emergency see INSTALLATION connections power connections neutral connections terminals for optio
7. slide the DIP switch actuators up or down to match setting shown All power must be off before making any changes The factory default settings are shown in Table G on page 5 cover must be removed to replace 9V battery use alkaline type SCrew Figure 5 Battery replacement 5 Automatic Generator Exerciser The built in automatic generator exerciser can be set to exercise the generator for 20 minutes once every week Clock Battery Be sure a fresh battery is installed and turned on It will maintain the exerciser clock for about 24 hours in case of a power outage Recommended 9 volt alkaline batteries are see Figure 5 Duracell MN 1404 Everready 522 Panasonic 6AM6 Turn on battery by putting S2 DIP switch actuator 10 in the on position up See Table B and Figure 6 Exercise with or without Load The generator should be exercised under load or follow the recommendations of the generator manufacturer Be sure the exerciser is turned on Then select either exercise with or without load The ATS will transfer the load to the generator when the exercise with load is selected See Figure 6 and Table B Table B Generator Exercise Settings Functi Factory DIP DIP Actuator ee Setting Switch Actuator Position clock on up battery off S2 10 off down l on up exerciser off S1 7 off down with load or without S1 g with up without load load without down
8. starting acceptable E utility returns waiting for utility to return load on generator L generator acceptable load on utility utility off e generator acceptable generator acceptable wait 10 sec for generator load on generator to warm up generator acceptable electrical loads switched to generator 7 381333 319 D Series 185 TROUBLESHOOTING This troubleshooting guide describes some of the simple causes of problems with the installation of the automatic transfer switch Troubleshooting beyond the scope of this guide should not be attempted by the installer A licensed electrician must perform all internal troubleshooting ASCO Power Technologies can be contacted at A DANGER ELECTROCUTION FLASH HAZARD Do not work on the transfer switch until both the utility and generator are off Turn OFF both circuit breakers 1 800 800 2726 or customercare asco com Problem Cause and Solution The Utility Acceptable light 1 Verify that the utility feed is connected and that its circuit breaker is ON does not come on when utility 5 With ALL POWER OFF verify that the utility feed is 220 240 V ac and 60 Hz power is connected to the ATS Check DIP switch S2 actuator 2 and DIP S1 actuator 4 See Table D for voltage and frequency settings 3 With ALL POWER OFF verify that the utility feed is wired to the terminal lugs on the bottom of the transf
9. 0 and 400 ampere transfer switches insulator backing piece Figure 1 Insulator for 260 and 400 A 2 Electrical Power Connections Refer to the wiring diagram The ATS must be protected by suitably sized circuit breakers feeding the utility and generator source terminals The rating of the circuit breakers must be based on the requirements of the National Electrical Code for its nameplate ampere and short circuit withstand ratings A DANGER ELECTROCUTION HAZARD Turn off utility power and turn off the generator to prevent electrocution when wiring the transfer switch Cable Spacers for 200 and 230 A Three cable spacers are included with 200 and 230 ampere transfer switches Run the copper power cables through the cable spacers as shown in Figure 2 Position the cable spacers approximately 11 2 inches from the terminal lugs CABLE LOOSENING DUE TO SHORT CIRCUIT Install three cable spacers 1 1 2 inches from the power terminals to prevent the cables from loosening during a short short condition 1 inch approximate use Copper power cables only for 200 and 230A cable spacer Figure 2 Cable spacers for 200 and 230 A 381333 319 D Series 185 CONTROLLER The Group 4 digital Controller is used in ASCO Series 1 Push Buttons 185 automatic transfer switches It provides the sensing timing and control functions for the ATS This micro processor based controller i
10. bled disabled s3 2 on up enabled on off down Bypass load transfer to utility time delay Normally closed input When opened it bypasses or cancels the generator to utility load transfer time delay The load transfers back to the utility Table G Bypass load transfer to utility time S3 OIOI NIOI oO BR OJN O delay Functi Factory DIP DIP Actuator UNGROD Setting Switch Actuator Position disabled disabled S3 j on up enabled on off down 381333 319 D Series 185 FUNCTIONAL TEST After installing the Series 185 automatic transfer switch ATS perform the following three part functional test 1 Manual Operation A handle is provided on the transfer switch for maintenance purposes only Manual operation of the transfer switch should be checked before it 1s energized operated electrically Do not manually operate the transfer switch until both power sources are disconnected open both circuit breakers 1 Turn OFF both the utility and generator circuit breakers feeding the ATS Verify that ALL POWER IS OFF 2 100 230A Grasp the maintenance handle and turn it quickly with your thumb and fingers to manually operate the transfer switch 260 400 A Insert the maintenance handle into the hole in the shaft left side of the operator Move the handle as shown to manually operate the tra
11. ck battery 3 connections electrical power 1 engine control contact 1 contacts engine control 1 control features remote 5 controller 2 5 D DIP switches 3 5 dropout 4 E electrical operation 2 6 electrical power connections 1 engine exerciser 2 3 9 F features see control features frequency pickup and dropout 4 functional test 6 G generator exerciser 2 3 9 frequency 4 settings 4 starting contacts 3 voltage 4 Generator Acceptable light 2 7 9 ground connection inside cover H handle maintenance 6 warning 6 harness inside cover HELP 800 800 2726 ASCO customercare asco com indicator lights 2 installation 1 insulator backing piece 1 illustration of 6 warning 6 L labels operator transfer switch 6 rating cover lights 2 7 Load on Generator light 2 7 Load on Utility light 2 7 M manual operation 6 illustration of 6 warning 6 mounting 1 O operation electrical 6 manual 6 sequence of 7 override momentary outages 4 P pickup 4 problem 8 9 R rating label cover remote control features 5 bypass transfer time delay 5 remote test 5 remote transfer to emergency 5 S service 800 800 2726 ASCO customercare asco com Set Engine Exerciser button 2 3 settings changing 3 5 factory 3 5 frequency 3 4 phase 4 time delay 3 4 voltage 3 4 source acceptable lights 2
12. continuously Press the Bypass Time Delay button for immediate load retransfer to the utility The ATS retransfers the load back to the utility but the generator keeps running Wait approximately 2 minutes for the unloaded running engine cooldown time delay The engine cooldown fixed time delay is important to prevent generator damage The generator exerciser does not seem to work Verify that the Automatic Generator Exerciser status light 1s blinking Light blinks during the exercise period when the generator is running and during cooldown Light stays on when then exerciser has been set When light is off no exercise period is set With ALL POWER OFF verify that the exerciser is turned on Check DIP switch S1 actuator 7 and S2 actuator 10 See Table B for generator exerciser settings With ALL POWER OFF check the 9 volt battery Replace if necessary with a quality alkaline battery Duracell MN1404 Everready 522 Panasonic 6AM6 or equivalent See Figure 5 The generator exerciser does not transfer the load to the generator With ALL POWER OFF verify that exercise with load is turned on Check DIP switch S1 actuator 8 See Table B for generator exerciser settings 9 381333 319 D Series 185 INDEX A Automatic Generator Exerciser 2 3 9 battery clock 3 buttons push 2 Bypass Time Delay button 2 6 C cable spacers 1 catalog number inside cover clo
13. d with the ATS Activate the appropriate DIP switch S3 actuators as shown in Tables E F or G See Figure 7 Remote test Normally closed input When opened it simulates a utility failure The generator is signalled to start immediately and the load transfers to the generator if acceptable If the generator fails the load stays on the generator until the remote test circuit is closed Table E Remote test Table H Factory Settings Summary 7 Factory Settings Summary DIP Switch DIP Actuator Actuator Position S1 1 on up off down on up off down off down on up off down off down O OI NI OO oO BR OIN off down O on up Functi Factory DIP DIP Actuator sale Setting Switch Actuator Position disabled disabled 93 3 on up enabled on off down Remote test with automatic retransfer Normally closed input When opened it simulates a utility failure The generator is signalled to start immediately and the load transfers to the generator if acceptable If the generator fails the load transfers back to the utility if acceptable Table F Remote transfer to generator S2 off down on up off down O OI NI OO oO ATIT OIN O Functi Factory DIP DIP Actuator UGHA Setting Switch Actuator Position disa
14. e is acceptable for connection to the load Load on Generator This light indicates that the generator voltage is acceptable for connection to the load Automatic Generator Exerciser This light indicates the status of the generator exerciser blinks during the exercise period including cooldown stays on when the exerciser has been set 1s off when the exerciser has not been set 381333 319 D 2 CONTROLLER continued Series 185 3 Generator Starting Contacts The generator starting contacts connections are on the controller Refer to the generator manual Disconnect the generator battery and verify that the ignition switch is in the OFF position Connect the generator starting wires to the appropriate terminals on terminal block TB7 as shown on the wiring diagram For wiring convenience terminal block TB7 has a removable plug See Figure 4 and Table A OECO OUL 1224453678910 EEEE TB7 removable terminal block TB7 4 TB7 5 TB7 6 Figure 4 TB7 generator starting contact terminals Table A Generator Start Connections When the Utility fails Terminals on Controller contact closes TB7 4 and TB7 5 contact opens TB7 5 and TB7 6 4 Settings The time delay and sensor setting in the Group 4 controller are accessible on the inside Refer to Tables B and C and to Figures 6 and 7 Use a ball point pen or other pointed tool to
15. er switch marked L1 and L5 See the wiring diagram 4 With ALL POWER OFF verify that the transfer switch harness is connected properly to the controller plug and receptacle tight The generator does not crank 1 Hold the Transfer Test button for at least 15 seconds when the utility source fails or whenthe Tun fer Test buttonis 2 Verify ae generator starting controls are set for automatic operation not in pressed manual mode 3 Verify that the generator battery is connected and that the battery voltage meets the generator manufacturer s recommendation 4 Verify that the correct contact normally open or normally closed is being utilized see the generator manual 5 With ALL POWER OFF verify engine start low voltage wiring between the controller terminal block and the generator See the wiring diagram Check that the plug is properly seated in the receptacle on the controller The generator cranks but does 1 Verify proper generator operation fuel in tank oil level spark plugs see not start and run when the util generator manual ity source fails or when the a my nsfer Test button is pressed 2 With ALL POWER OFF verify engine start low voltage wiring between the controller terminal block and the generator See the wiring diagram Check that the plug is properly seated in the receptacle The generator starts and runs 1 Verify that the generator feed is connected and that its circuit breaker is ON ba ile
16. nal switch position contacts shown d installed a Transfer E Switch EAA D S ground connections g membrane enerator N a i ae controls ntrol Comoe Mh ae i connections harness plug 200 ampere size in typical enclosure with location of customer connections 381333 319 D INSTALLATION Series 185 Installation of the ASCO Series 185 automatic transfer switch ATS must be performed by a licensed electrician It must be installed according to the National Electrical Code NEC and all local electrical code requirements Remove the enclosure cover and inspect the ATS for shipping damage If damage is evident do not install the ATS 1 Mounting Refer to the enclosure outline drawing Mount the ATS according to details and instructions shown on this diagram Mount the ATS vertically to a rigid supporting structure Level all mounting points by using flat washers behind the holes to avoid distortion of the enclosure MALFUNCTION or SHORTENED LIFE Protect the ATS from construction grit and metal chips to prevent malfunction or shortened life Transfer switches rated 260 and 400 amperes are mounted on an insulator backing piece installed behind the transfer switch If the transfer switch is removed from the enclosure and then reinstalled this insulator must be placed behind the transfer switch See Figure 1 FLASH HAZARD DAMAGE Be sure that the insulator piece is installed behind the 26
17. ncludes built in control buttons and status lights for control of the ATS and generator On the front control display are three push buttons that control the operation of the generator and the ATS Before using the transfer test button be sure that clock battery conditions are safe for running the generator and cover for load transfer see page 3 O Transfer Test Use this button to test the system This operation starts the generator and transfers the load Be sure that conditions are safe to do this operation Bypass Time Delay Use this button to cancel the active time delay or exercise period stops the generator after cooldown Utility a Set Engine Exerciser Use this button to set the automatic generator exerciser Load on page 3 Utility light Transfer Test button 2 Indicator Lights Bypass Time Delay button On the front control display are five lights that indicate Set Engine the status of the sources and the ATS Exerciser button Load on Generator light Utility Acceptable Automatic _ Ganoraier This light indicates that the utility voltage is acceptable Generator Acceptable for connection to the load Exerciser light light Generator Acceptable This light indicates that the generator voltage is acceptable for connection to the load Figure 3 Front view of controller _ Load on Utility This light indicates that the generator voltag
18. nsfer switch 3 The switch should operate smoothly without binding If it does not check for shipping damage or construction debris 4 After checking the manual operation use the handle again to return the transfer switch to the utility source position 100 230 A see Figure 8 The letter P utility on the round weight is facing you 260 400 A see Figure 9 The letter N utility on the round weight is facing you Remove the maintenance handle and store it on the transfer switch in the place provided 260 400 A Remove the maintenance handle before proceeding 2 Voltage Checks The ATS is rated for 220 240 V ac 60 or 50 Hz Verify that both the utility and generator sources are 220 240 V ac 60 or 50 Hz maintenance handle With ALL POWER OFF grasp maintenance handle and turn it quickly with your thumb and an weight marked P utility and A generator Figure 8 Maintenance handle for 100 230 A maintenance handle Figure 9 Maintenance handle for 260 400 A 3 Electrical Operation This procedure checks the electrical operation of the ATS 1 Install the enclosure cover and tighten the screws 2 Verify that the generator battery is connected and that the generator s starting controls are set for automatic 3 Turn on both the utility and generator circuit breakers 4 Verify that the Utility Acceptable and Load on Utility lights are on 5 This ste
19. p will start the generator Press and hold the Transfer Test button until the Generator Acceptable light comes on and stays on Then release the button 6 After the Generator Acceptable light comes on the ATS transfers the load from the utility to the generator after approx 10 second delay The Load on Generator light comes on 7 The ATS stays connected to the generator for 5 minutes approx The utility must be acceptable for 5 minutes continuously Then the load is transferred back to the utility To bypass time delay press the Bypass Time Delay button 8 After load retransfer to utility the generator runs 2 minutes without load then shuts down The Generator Acceptable light goes off indicating that the generator is off This completes the Functional Test 381333 319 D Sequence of Operation Utility Failure Series 185 generator stops generator runs unloaded for 2 min electrical loads Switched back utility acceptable to utility Ye load on utility generator W light is on O lightis off Utility power good Electrical loads on utility Utility fails Pe ses longer than E utility acceptable 3 sec load on utility 0 utility off start generator oWo generator off o load off EJ O 0O generator off acceptable observe observe wait 5 min these these for utility power switch 7 as s generator to stabilize utility lights lights O utility off
20. rox override momentary 4 second S3 9 on up 4 seconds generator outages 0 S3 9 off down transfer to utility 5 minutes approx unloaded running 2 minutes S1 10 on up generator cooldown enue g 5 minutes S1 10 off down Table D Voltage and Frequency Settings Setting Description Setting Factory Setting Settings DIP Switch DIP Actuator Actuator Position voltage 220 240 V non adjustable S2 2 on up 50 Hz S1 4 on up frequency nominal 60 Hz 60 Hz S1 4 off down phase single non adjustable S1 6 on up l 198 V S1 3 on up pickup 198 V 209 V S1 3 off down S1 1 off down 198 V S1 2 off down S1 1 on up utility voltage 187 V S1 2 off down dropout 187 V S1 1 off down 176 V S1 2 on up S1 1 on u 154 V up S1 2 on up pickup 198 V l generator voltage non adjustable dropout 165 V 57 Hz nom 60 Hz generator frequency pickup 48 Hz nom 50 Hz non adjustable d t 51 Hz nom 60 Hz FORSS 43 Hz nom 50 Hz If the dropout voltage is set to 198 V the pickup voltage must be set to 209 V 381333 319 D CONTROLLER continued Series 185 6 Remote Control Features These remote control features require a customer supplied normally closed contact suitable for a5 V dc low energy circuit Refer to the wiring diagram provide
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