Emerson THROUGH 1200 User's Manual
Contents
1. Feature 1C time delay plus engine cranking and starting Starting control must be in the automatic position Batteries must be charged and connected Check wiring to engine starting contacts Transfer switch does not transfer the load to the emergency source after the engine generator set starts Wait for Feature 2B time delay to time out Generator output circuit breaker must be closed Generator frequency must be at least 95 of nominal 57 Hz for a 60 Hz system Voltmeter should read at least 90 of nominal phase to phase voltage between terminals EA and EC or EL1 and EL2 for 2 pole switches Transfer switch does not transfer the load to normal source when normal returns or when the Transfer Control switch is released Wait for Feature 3A time delay to time out Voltmeter should read at least 90 of nominal phase to phase voltage between terminals NB and NC NC and NA and NA and NB or NL1 and NL2 for 2 pole switches Gen does not stop after load retransfer to normal source Wait for Feature 2E time delay to time out Starting control must be in the automatic position Failure to Synchronize light comes on Conditions of Normal or Emergency Sources not suitable for closed transition transfer Recheck voltage and frequency of both sources Press Alarm Reset pushbutton Extended Parallel Time light comes on CN and CE contacts are closed longer than setting in the C2. in the test orrun position Third open the emergency source circuit breaker 2 Separate the two quick disconnect plugs by squeez ing the latches Do not pull on the harness wires Reconnecting the Plugs A WARNING Do not reconnect the controller until steps 1a or 1b is completed Observe the position of the transfer switch a Ifthe transfer switch is in the Normal position first be sure that both normal and emergency source circuit breakers are open Second be sure that the standby engine starting control is still in the off position If the transfer switch is in the Emergency position first be sure that both normal and emergency source circuit breakers are open The two harness plugs and sockets are keyed Care fully align the plugs with the sockets and press straight in until both latches click Close the door Restore the two sources in sequence as follows a If the transfer switch is in the Normal position first close the normal source circuit breaker Second close the emergency source circuit break er Third place the standby engine starting control in the automatic position If the transfer switch is in the Emergency position first close the emergency source circuit breaker Second close the normal source circuit breaker TESTING amp SERVICE MANUAL LOAD TRANSFER This procedure will manually transfer the load if the controller is disconnected ZN WARNING Do not manually ope
3. 50 Hanover Road Florham Park New Jersey 07932 1591 USA 1 2 ASCO Technologies For sales or service call 1 800 800 2726 ASCO www ascopower com 381333 03 C ASCO POWER TECHNOLOGIES CANADA PO Box 1238 17 Airport Road Brantford Ontario Canada N3T 5T3 EMERSON telephone 519 758 8450 fax 519 758 0876 for service call 1 888 234 2726 ASCO www asco ca i Rating Label Each Automatic Closed Transition 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 A WARNING Do not exceed the values on the rating label Exceeding the rating can cause personal injury or serious equipment damage Nameplate The Transfer Switch nameplate includes data for each specific 7000 Series ACTS Use the switch only within the limits shown on this nameplate A typical Catalog Number is shown on the next page with its elements explained Catalog Number Identification Typical 7000 Series ACTS catalog no for switched neutral 3 pole 800 amp 480 V ATS in Type 1 enclosure H7ACTS B 3 800 N 5 C Neutral Phase Poles Amperes Voltage Controller Enclosure A solid 2 single 600 C 208 K 415 5 standard C type 1 B switched 3 three 800 D 220 L 440 5X if F type 3R 1000 E 230 M 460 accessories G type 4 blank none 1200 F 240 N 480 SE L type 12 G 277 P 550 b
4. Operator s ASCO 7000 Series ACTS Manual Automatic Closed Transition Transfer Switches H design 600 through 1200 amps TABLE OF CONTENTS A DANGER aoe DANGER is used in this manual to warn of high Secton Page voltages capable of causing shock burns or death INSTALLATION 0000 cece 1 1 Mounting and Line Connections 1 1 A WARNING Auxiliary Circuits and Harness 1 2 WARNING is used in this manual to warn Engine Starting Contacts 1 2 of possible personal injury Functional Test 1 2 1 3 1 4 1 5 TESTING amp SERVICE 2 1 A CAUTION i en Enon Promise by CAUTION is used in this manual to warn rans er es Dieter eee ee eee of possible equipment damage Preventive Maintenance 2 1 Disconnecting the Controller 2 1 Refer to Group 5 Controller User s Guide 381333 126 Manual Load Transfer 0 2 2 for ATS status display messages time delays pickup Trouble Shooting 000ee 2 2 amp dropout settings and adjustments INDEX inni pec ane ea back cover Note Refer to the outline and wiring drawings provided with your 7000 Series ACTS for all installation and connection details and accessories LL LT An experienced licensed electrician must install the ACTS LLL LLLI in Fa 6 ol lt 1200 amp size 600 1000 amp size Power
5. b to avoid damaging the ACTS lower shaft VW Figure 1 2 Contact position indicators Read all instructions on the Wiring Diagram and labels Shown with Emergency open and Normal closed affixed to the automatic transfer switch Note the control features that are provided and review their operation before proceeding Continue to 1 Manual Operation Test on next page INSTALLATION continued 1 Manual Operation Test A detachable maintenance handle is provided on the frame of the Transfer Switch for maintenance purposes only Manual operation of the transfer switch should be checked before it is energized operated electrically A WARNING Do not manually operate the transfer switch until both power sources are disconnected open both circuit breakers After deenergizing both power sources open the enclosure door Locate and remove the maintenance handle from the clips on the left side of the transfer switch frame Insert the handle into the hole in the molded hub on the left side of the operator See Figures 1 3 through 1 5 and Table B Move the maintenance handle up or down as shown to manually operate the transfer switch The transfer switch should operate smoothly without binding If it does not check for shipping damage or construction debris Operate both upper and lower contact shafts Return the transfer switch to the Normal position Observe that the window indicators right side show the upper shaft O Eme
6. cified 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 applicable enclosure outline drawing fur nished with this switch and mount the automatic transfer switch according to details and instructions shown on diagram Line Connections Refer to the Wiring Diagram provided with the switch 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 A DANGER 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 gen erator starting control in the OFF position Make sure engine generator is not in operation INSTALLATION 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 conduc tor 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 no
7. f used must be capable of being started in this procedure Perform steps 1 through 5 at the right Observe the status lights E Black square means light is on O White square means light is off Tf you do not want closed transition transfer press the Closed Transition Bypass pushbutton while the controller display shows Waiting for In Sync This action causes Open transition momentary load interruption transfer to the opposite source if conditions permit Also refer to the Group 5 Controller User s Guide 381333 126 This completes the Functional Test of the ACTS Automatic Closed Transition Transfer Switch Extended Failure Parallel To Time WW operate this switch The Transfer Switch Connected To Normal and Normal Source Accepted lights should be on Turn and hold Transfer Control switch clockwise to Transfer Test until the engine starts and runs within 15 sec Emergency Source Accepted light should come on Transfer switch CE closes and then Transfer Switch CN opens closed transition overlap The Transfer Switch Connected To Emergency light should come on and the Transfer Switch Connected to Normal light goes off you might see and hear the brief overlap transfer Transfer switch will operate back to Normal position after Feature 3A time delay For immediate retransfer turn Transfer Control counterclockwise to Retransfer Delay Bypass The Transfer Switch Connected To Norma
8. ghts 1 4 1 5 lubrication 2 1 M maintenance handle 1 3 maintenance preventive 2 1 manual load transfer 2 2 warning 2 2 manual operation 1 3 illustration of 1 3 warning 1 3 N nameplate cover normal source accepted light 1 4 O operation electrical 1 5 manual 1 3 illustration of 1 3 warning 1 3 optional accessories see Controller User s Guide P parts 2 1 phase rotation check 1 4 problem 2 2 R rating label cover replacement parts 2 1 S settings see Controller User s Guide T test functional 1 2 1 3 1 4 1 5 time delays 2 1 see Controller User s Guide Transfer Control selector switch Retransfer Delay Bypass 1 5 Transfer Test 1 5 Transfer Switch Connected To Emergency light 1 5 2 1 Transfer Switch Connected To Normal light 1 4 2 1 transfer test 1 5 transfer to emergency 1 5 transfer to normal 1 5 2 1 trouble shooting 2 2 TS locked out 2 2 V voltage checks 1 4 voltage pickup and dropout settings see Controller User s Guide Copyright ASCO Power Technologies 2006
9. ively Reinstall the barriers carefully Maintain transfer switch lubrication If the transfer switch is subjected to severe dust or abnormal operating conditions renew factory lubrication on all movements and linkages Relubricate the solenoid operator if the TS coil is replaced Do not use oil order lubrication kit 75 100 C Check all cable connections amp retighten them REPLACEMENT PARTS Replacement parts are available in kit form When or dering parts provide the Serial No Bill of Material No BOM and Catalog No from the transfer switch name plate Contact your local ASCO Power Technologies Sales Office or ASI in United States call 1 800 800 ASCO 2726 or in Canada call 1 888 234 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 AN WARNING Do not unplug the controller until steps 1a or 1b is completed 1 Observe the position of the transfer switch a Ifthe transfer switch is in the Normal position first place standby engine starting control in the off position Second then open the emergency source circuit breaker Third open the normal source circuit breaker If the transfer switch is in the Emergency position first open the normal source circuit breaker Sec ond place the engine starting control
10. l light should come on Transfer Switch Connected to Emergency light should go off The engine generator will stop after the Feature 2E time delay unloaded running engine cool down The Emergency Source Accepted light should go off Synchronize SECTION 2 TESTING amp SERVICE TRANSFER TEST Operate the 7000 Series ACTS at least once a month by following the five step Electrical Operation Transfer Test procedure on page 1 5 PREVENTIVE MAINTENANCE Reasonable care in preventive maintenance will insure high reliability and long life for the 7000 Series ACTS An annual preventive maintenance program is recom mended In the United States ASCO Services Inc ASI is ASCO Power Technologies s national service organization ASI can be contacted at 1 800 800 2726 ASCO for information on preventive maintenance agreements In Canada for service call 1 888 234 2726 ASCO Checklist for Yearly Inspection A DANGER Hazardous voltage capable of causing shock burns or death is used in this transfer switch Deenergize both Normal Emergency power sources before performing inspections C Clean the ACTS enclosure Brush and vacuum away any excessive dust accumulation Remove any moisture with a clean cloth O Check the transfer switch contacts Remove the transfer switch barriers and check contact condition Replace the contacts if they become pitted or worn excess
11. lank open type H 380 Q 575 J 400 R 600 available 600 1000 amp sizes only field connections terminal block TB power C Sa de connections MW ground lug ae ua 4 Transfer Switch ground lug power connections Transfer Control amp lights Group 5 Controller 800 1000 amp sizes in typical enclosure with location of customer connections field connections terminal block TB ground lug Transfer Control amp lights power connections Group 5 Controller Se eee A a Transfer Switch power connections PSST SS 1200 amp size in typical enclosure with location of customer connections SECTION 1 ASCO 7000 Series Automatic Closed Transition Trans fer Switches ACTSs are factory wired and tested Field installation requires mounting and connection of service cables and auxiliary control circuits if required Remove the Shipping Skid large ACTSs For large ACTSs 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 spe
12. ontrol Panel Open the discon nected source circuit breaker then call your nearest ASCO Service Center for assistance TS Locked Out light comes on Transfer lockout operation has occured transfer switch is disabled from automatic operation Open the disconnected source circuit breaker then call your nearest ASI for assistance These are factory settings Refer to Group 5 Controller User s Guide 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 the United States call 1 800 800 2726 In Canada call 1 888 234 2726 Furnish the Serial No and Catalog No from the transfer switch nameplate A alarm reset 1 5 2 2 auxiliary circuits 1 2 cable lugs 1 2 preparation 1 2 catalog number inside cover cleaning 2 1 closed transition bypass 1 5 2 2 connections line 1 1 contact position indicators 1 3 controller 1 1 disconnecting 2 1 see Controller User s Guide E electrical operation 1 5 emergency source accepted light 14 extended parallel time 2 2 F failure to synchronize 2 2 frequency generator 2 2 functional test 1 2 1 3 1 4 1 5 G ground controller 1 1 H harness 1 1 disconnect plugs 2 1 Printed in U S A INDEX inspection 2 1 installation 1 1 indicators contact position 1 3 L labels engine start contacts 1 2 rating cover li
13. rate the transfer switch until both power sources are disconnected all conductors deenergized 1 Deenergize both the normal and emergency source conductors remove fuses or open circuit breakers continued 2 Use the maintenance handle to manually operate the transfer switch to the opposite source First open the closed contacts then close the other contacts Do not leave both closed See Manual Operation on page 1 3 3 Thenremove the maintenance handle See page 1 3 A WARNING Verify that the maintenance handle has been removed before proceeding 4 If the transfer switch is in the Emergency position manually start the engine generator and then install emergency source fuse or close the circuit breaker TROUBLE SHOOTING Note any optional accessories that may be furnished on the ACTS and review their operation Refer to any separate drawings and or instructions that may be packed A DANGER Hazardous voltage capable of causing shock with the ACTS burns or death is used in this switch Do not touch the power or load terminals of the transfer switch Table 2 1 Trouble Shooting Checks PROBLEM CHECK IN NUMERICAL SEQUENCE 1 OPERATION 2 GEN SET 3 VOLTAGE Engine generator set does not start when the Transfer Control switch is turned and held in Transfer Test position or when normal source fails Hold Transfer Test switch 15 seconds or the outage must be long enough to allow for
14. rgency open and the lower shaft C Normal closed Remove the maintenance handle and store it on the frame in the clips provided Table B Maintenance handle positions ATS Position Handle up o Indicators Pe E 0 upper contacts open ff Normal N C lower contacts closed E C upper contacts closed Emergency N 0 lower contacts open eo down Note If Normal and Emergency connections are reversed this operation is also reversed Now continue to 2 Voltage Checks on the next page left side of transfer switch Emergency source contact shaft hub maintenance handle clip Normal source contact shaft hub Figure 1 3 Maintenance handle storage location Hubs shown with Normal closed amp Emergency open UP opens the Emergency source contacts UPPER SHAFT DOWN closes the Emergency source contacts UP closes the a handle Normal source contacts LOWER SHAFT DOWN opens th Normal source contacts INSTALLATION continued ASCA 7000 SERIES Transfer Transfer Switch Transfer Switch Connected petra D Connected ster ela T Normal Emergency o o H Normal T A observe these lights Emergency Source Source Accepted Accepted aie Figure 1 6 Standard controls and indicators 2 Voltage Checks First check nameplate on transfer switch rated voltage must be the same as no
15. rmal and emergency line voltages A WARNING Before energizing the switch check to be sure that both normal and emergency contacts are not left in the closed position A CAUTION Verify that the feeders have been connected to the proper lugs A DANGER Use extreme caution when using a meter to measure voltages Do not touch power termi nals shock burns or death could result Perform steps 1 through 6 at the right Observe the status lights See Figure 1 6 E Black square means light is on O White square means light is off If necessary adjust voltage regulator on the generator according to the manufacturer s recommendations The Automatic Transfer Switch will respond only to the rated voltage specified on the Transfer Switch nameplate Note Refer to Section 3 of Group 5 Controller User s Guide 381333 126 for how to display the Status of the ATS and the Voltage and Frequency of each source Now continue to 3 Electrical Operation on next page Y HOU Bypass SSE Control Transfer Test 1 4 CONDS Automatic Closed Transition Transfer Switch Extended Failure Parallel Te o Time Synchroniz Closed Transition Bypass Close the normal source circuit breaker The Transfer Switch Connected To Normal and the Normal Source Accepted lights should come on Use an accurate voltmeter to check phase to phase and phase to neutral voltages pres ent at
16. t defective or have been damaged during installation A CAUTION Protect the automatic transfer switch from construction grit and metal chips to prevent malfunction or shortened life of the ATS 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 solder less screw type and will accept the wire sizes listed on the drawings provided with the switch 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 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 Harnesses The transfer switch is connected to the left side of the controller by a plug in harness two plugs INSTALLATION continued Engine Starting Contacts All customer connections including the engine control contact connections are loca
17. ted on terminal block TB which is mounted on the top right side of the enclosure Refer to the wiring diagram provided with the automatic transfer switch and connect the engine start wires to the appropriate terminals See Figure 1 1 and Table A Table A Engine start connections When normal source Terminals on fails Terminal Block TB contact closes TB1 and TB2 contact opens TB1 and TB3 engine start AN connections Note To temporarily disable engine control from on the automatic transfer switch you can unplug J3 customer from the small P3 receptacle at the bottom of the hairs assembly Be sure to reconnect plug J3 to the P3 receptacle for automatic transfer switch operation Auxiliary Circuits Connect auxiliary circuit wires to appropriate terminals on transfer switch terminal block TB as shown on the wiring diagram provided with this automatic transfer switch Figure 1 1 Customer terminal block on the top right side of the enclosure Functional Test The Functional Test consists of three checks Note the position of the contact shafts as shown below ate 1 1 Manual Operation Test page 1 3 Emergency contacts r ee upper shaft ae T 2 Voltage Checks page 1 4 a mg EAEE window indicators hie 3 Electrical Operation page 1 5 O is open Po indicators C is closed ight sid A CAUTION Corse C Do these checks in the order presented Normal contacts W
18. the transfer switch normal source terminals Close the emergency source circuit breaker Start generator if necessary The Transfer Switch Connected To Normal amp Emergency Source Accepted lights should come on Use an accurate voltmeter to check phase to phase and phase to neutral voltages pres ent at the transfer switch emer gency source terminals Use a phase rotation meter to check phase rotation of emer gency source it must be the same as the normal source ABC Shut down the engine genera tor if applicable The Emergen cy Source Accepted light should go off Then put the starting control selector switch on the generator set in the automatic position Close enclosure door INSTALLATION continued ASCA 7000 SERIES Transfer Transfer Switch Transfer Switch Connected Connected Retransfer To To Delay Normal Emergency observe Normal Emergency these lights Source Source Accepted Accepted aie Figure 1 7 Standard controls and indicators 3 Electrical Operation This procedure will check the electrical operation of the Automatic Closed Transition Transfer Switch See Figure 1 7 A WARNING Control Transfer Test HOLD FOR Bypass 8 SECONDS Close the enclosure door first Transfer Test Both normal and emergency sources must be available and the emergency source generator i
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