Emerson ASCO 7000 User's Manual
Contents
1. 1 Manual Operation Test A maintenance handle is provided on the Transfer Switch for maintenance purposes only Manual operation of the transfer switch should be checked before it is energized operated electrically Do not manually operate the transfer switch until both power sources are disconnected open both circuit breakers 1 After deenergizing both power sources open the enclosure door Locate and the maintenance handle on the left side of the transfer switch See Figure 1 3 2 Grasp the attached maintenance handle and turn it with thumb and fingers as shown to manually operate it The maintenance handle turns the opposite direction of the weight Turn it up or down as shown to manually operate the transfer switch It should operate smoothly without any binding If it does not check for shipping damage or construction debris 3 Return the transfer switch to the Normal position Note If Normal and Emergency connections are reversed this operation is also reversed Now continue to 2 Voltage Checks on next page Position of the transfer switch is indicated here weight marked N normal and E emergency maintenance handle floating weight With ALL POWER OFF grasp maintenance handle and turn it quickly with your thumb and fingers Figure 1 3 Maintenance handle and positions INSTALLATION continued ASCO 7000 SERIES Power Transfer Switch EMERSON Netwark Power2. ASCO 7000 Series ATS Operator s Automatic Transfer Switches Manual D design 30 through 230 A A DANGER Refer to the outline and wiring drawings provided a A with your 7000 Series ATS for all installation and DANGER is used in this manual to warn of high connection details and accessories voltages capable of causing shock burns or death A WARNING Refer to Group 5 Controller User s Guide 381333 126 for ATS status display messages time delays pickup WARNING is used in this manual to warn amp dropout settings and adjustments of possible personal injury Rating Label Each Automatic Transfer Switch contains a rating label to define the loads and fault circuit withstand closing ratings Refer to the label on the Transfer Switch for specific values CAUTION is used in this manual to warn of possible equipment damage 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 ATS 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 An experienced licensed electrician must install the ATS a TABLE OF CONTENTS section page INSTALLATION 0 0 eee e eens 1 1 Mounting and Line Connections 1 1 Auxiliar
3. instructions Protect the switch from construction grit and metal chips to prevent malfunction or shortened life of the automatic switch switch Mount the ASCO ATS vertically to a rigid supporting structure Level all mounting points by using flat washers behind the holes to avoid distortion of the switch The controller is mounted on the cabinet door An add on DIN rail is provided for some optional accesso ries and is mounted below the controller on the door Line Connections A Wiring Diagram is furnished with the ASCO 7000 Series ATS separate from this manual Refer to this drawing All wiring must be made in accordance with the National Electrical Code and local codes 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 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 INSTALLATION often requires considerable force The pulling of cables can damage insulation and stretch or break the conductor s strands For this reason after the cables are pulled into position and before they are connected they should be tested to verify that the
4. type 4X secure 200 and 230 amp Q type 12 secure limited to 480 volts H 380 R 600 lank eene Transfer Switch terminals for switch position contacts load power connections transfer control amp lights emergency power connections maintenance handle see WARNING under Manual Operation terminals for Controller engine start contacts normal power connections cable spacers see INSTALLATION 150 amp size in typical enclosure with location of customer connections SECTION 1 The ASCO 7000 Series Automatic Transfer Switch ATS is factory wired and tested Field installation requires mounting connecting service cables and connecting engine start and auxiliary control circuits if required Supporting Foundation The supporting foundation for the enclosure must be level and straight Refer to the applicable enclosure outline drawing included with the switch for all mounting details including door opening space If bottom cable entry is used the foundation must be prepared so that the conduit stubs are located correctly Refer to the enclosure outline drawing for specified area and location Provide cable bending space and 1 2 inch minimum clearance to live metal parts When a concrete floor is poured use interlocking conduit spacer caps or a wood or metal template to maintain proper conduit alignment Mounting Refer to the Outline and Mounting Diagram provided with the ATS it shows all mounting details and
5. Transfer Transfer Switch Transfer Switch Connected Connected To Normal Emergency To iad Normal Source Accepted i Figure 1 4 Standard controls and indicators Retransfer Delay A observe these lights Emergency Source Accepted 2 Voltage Checks First check nameplate on transfer switch rated voltage must be the same as normal and emergency line voltages 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 terminals shock burns or death could result Perform steps 1 through 6 at the right Observe the status lights See Figure 1 4 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 Control Transfer est ID FOR 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 p
6. by following the five step Electrical Operation Transfer Test procedure on page 1 4 PREVENTIVE MAINTENANCE Reasonable care in preventive maintenance will insure high reliability and long life for the 7000 Series ATS An annual preventive maintenance program is recom mended ASCO Services Inc ASI is ASCO Power Technologies s national service organization ASI can be contacted at 1 800 800 2726 for infor mation on preventive maintenance agreements In Canada call 1 888 234 ASCO 2726 Checklist for Yearly Inspection A Hazardous voltage capable of causing shock burns or death is used in this switch Deenergize both Normal Emergency power sources before performing inspections DANGER O Clean the ATS enclosure Brush and vacuum away any excessive dust accumulation Remove any moisture with a clean cloth Check the transfer switch contacts Remove the transfer switch barriers and check con tact condition Replace the contacts if they become pitted or worn excessively Reinstall the barriers carefully Maintain transfer switch lubrication The transfer 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 625550 001 Castrol EndurexR 4000 lubricant 1 Check all cable conn
7. ections amp retighten them REPLACEMENT PARTS Replacement parts are available in kit form When ordering parts provide the Serial No Bill of Material No BOM and Catalog No from the transfer switch nameplate Contact your local ASCO Power Technolo gies sales office or ASI In the 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 Do not unplug the controller until step 1a or 1b is completed 1 Observe the position of the transfer switch a If the 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 Second place the engine starting control in the test or run 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 Do not unplug the controller until step 1a or 1b is completed Observe the position of the transfer switch If the transfer switch is in the Normal position f
8. hase to neutral voltages pres ent at 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 ASCO 7000 SERIES Power Transfer Switch EMERSON Netwark Power Transfer Transfer Switch Transfer Switch Control Connected Connected To elay esi Normal Emergency T To iad Normal A observe these lights Emergency Source Source Accepted Accepted i Figure 1 5 Standard controls and indicators 3 Electrical Operation This procedure will check the electrical operation of the Automatic Transfer Switch See Figure 1 5 Be sure to close the enclosure door before proceeding to prevent personal injury in case of electrical system fault Transfe
9. irst 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 a If the transfer switch is in the Emergency posi tion first be sure that both normal and emer gency source circuit breakers are open The two harness plugs and sockets are keyed Carefully 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 breaker 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 continued MANUAL LOAD TRANSFER This procedure will manually transfer the load if the controller is disconnected 1 Deenergize both the normal and emergency source conductors remove fuses or open circuit break ers 2 Use the maintenance handle to manually operate the transfer switch to the opposite source See Manual Operation on page 1 2 Do not manually operate the transfer switch until both power sources are disconnected 3 Ifthe transfer switch is in the Emergency position all conductors deenergized gency p
10. 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 automatic transfer switch ATS and review their operation Refer to any separate drawings and or instructions that may be packed with the ATS A DANGER Hazardous voltage capable of causing shock 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 the normal source fails Hold Transfer Test switch 15 seconds or the outage must be long enough to allow for Feature 1C time delay plus engine cranking and starting time Starting control must be in the automatic position Batteries must be charged and connected Check wiring to engine starting contacts on customer terminal block TB Verify that the small plug J3 is connected to receptacle P3 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 if used Generator output circuit breaker must be closed Generator frequency must be at least 95 of nominal 57 Hz for a 60 Hz sys
11. ource Accepted light 1 3 1 4 F frequency generator 2 2 functional test 1 2 1 3 1 4 H harness 1 2 disconnect plugs 2 1 HELP customercare asco com 800 800 ASCO inspection 2 1 installation 1 1 Printed in U S A INDEX L labels engine start contacts 1 2 rating cover lights 1 3 1 4 lubrication 2 1 M maintenance preventive 2 1 manual load transfer 2 2 warning 2 2 manual operation 1 2 illustration of 1 2 warning 1 2 N nameplate cover Normal Source Accepted light 1 3 14 O operation electrical 1 4 manual 1 2 illustration of 1 2 warning 1 2 sequence of see Controller User s Guide optional accessories see Controller User s Guide P parts 2 1 phase rotation check 1 3 problem 2 2 R rating label cover replacement parts 2 1 S service 2 2 settings see Controller User s Guide T test functional 1 2 1 3 1 4 time delays 2 2 see Controller User s Guide Transfer Control selector switch Retransfer Delay Bypass 1 4 Transfer Test 14 Transfer Switch Connected to Emergency light 1 3 1 4 Transfer Switch Connected to Normal light 1 3 1 4 transfer test 1 4 transfer to emergency 1 4 transfer to normal 1 4 trouble shooting 2 2 V voltage checks 1 3 voltage pickup and dropout settings see Controller User s Guide Copyright ASCO Power Technologies L P 2007
12. r Test Both normal and emergency sources must be available and the emergency source generator if 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 Retransfer Transfer Di t 7 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 3 Transfer switch will operate to the Emergency position after Feature 2B time delay The Transfer Switch Connected To Emergency light should come on and Load Connected to Nor mal light goes off Transfer switch will operate back to Normal position after Feature 3A time delay For im mediate retransfer turn Transfer Control counterclockwise to Retransfer Delay Bypass The Transfer Switch Connected To Normal light should come on Transfer Switch Connected to Emergency light should go off This completes the Functional Test of the ATS The engine generator will stop after the Feature 2E time delay unloaded running engine cool down The Emergency Source Accepted light should go off SECTION 2 TESTING amp SERVICE TRANSFER TEST Operate the 7000 Series ATS at least once a month
13. rovides proper grounding which does not rely upon the door hinges INSTALLATION continued Harnesses The transfer switch is connected to the left side of the controller by a plug in harness two plugs Engine Starting Contacts The engine control contact connections if used are located on the transfer switch Connect signal wires to appropriate terminals as specified in Table A and shown in Figure 1 2 Table A Engine Start Connections Terminals on transfer switch TB14 and TB15 TB14 and TB16 When normal source fails contact closes contact opens ENGINE STARTING CONTACTS SHOWN DE ENERGIZED al x lt Yr Figure 1 2 Engine starting contact label and location on left side of transfer switch Auxiliary Circuits Connect auxiliary circuit wires to appropriate terminals on the transfer switch Note the control features that are furnished on this switch Make the necessary auxiliary connections by referring to the Wiring Diagram Functional Test The Functional Test consists of three checks 1 1 Manual Operation Test on this page C 2 Voltage Checks page 1 3 1 3 Electrical Operation page 1 4 Do these checks in the order presented to avoid damaging the ATS 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
14. tem 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 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 if used 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 Engine generator set does not stop after load retransfer to the normal source Wait for Feature 2E time delay to time out if used Starting control must be in the automatic position These are factory settings Refer to the 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 Bill of Material BOM No amp Catalog No from transfer switch nameplate A auxiliary circuits 1 2 cable lugs 1 1 preparation 1 1 spacers 1 1 illustration of 1 1 catalog number inside cover cleaning 2 1 connections line 1 1 controller 1 1 1 2 disconnecting 2 1 see Controller User s Guide grounding 1 1 E electrical operation 1 4 Emergency S
15. y Circuits and Harness 1 2 Engine Starting Contacts 1 2 Functional Test 5 1 2 1 3 1 4 TESTING amp SERVICE 005 2 1 Transfer Test 0 cece eee ees 2 1 Preventive Maintenance 2 1 Disconnecting the Controller 2 1 Manual Load Transfer 2 2 Trouble Shooting 0 000ee 2 2 INDEX cite ettact diced sree back cover 30 230 amp size Power 50 Hanover Road Florham Park New Jersey 07932 1591 USA ASCO Technologies For sales or service call 1 800 800 2726 ASCO www ascopower com 381333 a 7 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 Network Power Catalog Number Identification Typical 7000 Series 7ATS catalog no for overlapping neutral 3 pole 150 amp 480 V in Type 1 enclosure D 7ATS C 3 150 N 5 C design lt prefix letter Neutral Phase Poles Amperes Voltage Controller Enclosure A solid 2 single 30 A115 J 400 5 standard C type 1 B switched 3 three 70 B 120 K 415 5X if F type 3R C overlapping 100 C 208 L440 accessories G type 4 ordered L blank none 150 D 220 M 460 npe le 200 E 230 N 480 M type 3R secure 230 F 240 P 550 N type 4 secure G 277 Q 575 P
16. y are not defective or have been damaged during installation Connecting Power Conductors After the power cables have been tested connect them to the appropriate terminal lugs on the transfer switch as shown on the wiring diagram provided with the switch Make sure the lugs provided are suitable for use with the cables being installed Standard terminal lugs are solderless screw type and will accept the wire sizes listed on the drawings provided with the switch 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 Three cable spacers are included with 150 200 amp 230 A transfer switches When installing power cables run the cables through the cable spacers as shown in Figure 1 1 Position the cable spacers within 112 inches from the lugs The cable spacers must be located as shown for 150 200 and 230 ampere transfer switches cable spacers 1 inch approximate cable spacer Figure 1 1 Cable spacer for 150 200 and 230 amp transfer switches 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 p
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