Emerson FDESIGN 30004000A Switch User Manual
Contents
1. between the live metal parts and grounded metal 1 2 inch minimum for 150 400 amps 1 inch minimum over 400 amps It is not necessary to remove the barriers from the transfer switches to install the cables If you do remove them however be sure to reinstall the barriers carefully Bus Connections For large switches use grade 5 hardware to connect bus to appropriate terminal plates Wipe off the bus surfaces before they are joined If the bus is very dirty gently clean the surfaces with a non flammable solvent Avoid touching the cleaned surfaces Do not breathe cleaning solvent vapors INSTALLATION Tighten bolted joints to the torque specified in Table A The reliablility of the connection depends on how clean and how tight the joint is Table A Tightening torque values for bolted joints Grade 5 hardware Bolt Diameter Tightening Torque in inches in foot pounds 1 4 7 5 16 12 3 8 20 1 2 50 5 8 95 3 4 155 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 control panel by a plug in harness two plugs Auxiliary Circuits Connect auxiliary2. 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 continued 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 B and shown in Figure 1 1 Table B Engine start connections When normal source fails Terminals on transfer switch contact closes TB1 and TB2 contact opens TB1 and TB3 engine start connections on customer terminal block TB Figure 1 1 Customer terminal block on the top right side of enclosure Functional Test Read all instructions on the Wiring Diagram and labels affixed to the ADTS Note the control features that are provided and review their operation before proceeding The Functional Test consists of three checks 1 Manual Operation Test page 1 3 2 Voltage Checks page 1 4 3 Electrical Operation page 1 5 Do these checks in the order presented to avoid damaging the ATS 1 2 Continue to 1 Manual Operation Test on next page INSTALLATION handle Figure 1 2 150 400 A 3 pole E design switches Figure 1 3 F design switches 1 Manual Operation A detachable manual operator handle is provided on the Transfe
3. 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 TESTING amp SERVICE continued 2 Use manual handle to manually operate transfer switch to the opposite source First open the closed transfer switch then close the other transfer switch MANUAL LOAD TRANSFER This procedure will manually transfer the load if the control panel is disconnected 3 Thenremove the maintenance handle See page 1 3 Do not manually operate the transfer switch until both power sources are disconnected all conductors deenergized Verify that the maintenance handle has been removed before proceeding 1 Deenergize both the normal and emergency source conductors remove fuses or open circuit breakers 4 Ifthe 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 ADTS and review their operation Refer to any A DANGER separate drawings and or instructions that may be packed with the ADTS Hazardous voltage capable of causing shock burns or death is used in this switch Do not touch the power or load termi
4. J Operator S Automatic Manual ASCO 7000 Series ADTS Delayed Transition Transfer Switches E design 150 4004 F design 600 8004 G design 1000 4000A F design 3000 40004A TABLE OF CONTENTS section page INSTALLATION 000 cece eens 1 1 Mounting and Line Connections 1 1 Auxiliary Circuits and Harness 1 2 Engine Starting Contacts 1 2 Functional Test 1 2 1 3 1 4 1 5 TESTING amp SERVICE 2 1 Transfer Test 0 0 cece eee ees 2 1 Preventive Maintenance 2 1 Disconnecting the Controller 2 1 Manual Load Transfer 2 2 Trouble Shooting sssseues 2 2 INDEX ilex m RR REB RS back cover lr Refer to the outline and wiring drawings provided with your 7000 Series ADTS for all installation and connection details and accessories et G design 2000 A A DANGER DANGER is used in this manual to warn of high voltages capable of causing shock burns or death WARNING is used in this manual to warn of possible personal injury CAUTION is used in this manual to warn of possible equipment damage Refer to Group 5 Controller User s Guide 381333 126 for ATS status display messages time delays pickup amp dropout settings and adjustments An experienced licensed electrician must install the ADTS G design 4000 A 50 Hanover Ro
5. ad Florham Park New Jersey 07932 1591 USA For sales or service call 1 800 800 2726 ASCO 381333 129 C WWW ascopower com ASCO Power Technologies ASCO POWER TECHNOLOGIES CANADA PO Box 1238 17 Airport Road Brantford Ontario Canada N3T 5T3 EMERSON Network Power Catalog Number Identification Typical 7000 Series catalog no for G design switched neutral 3 pole 2000 A 480 V ADTS in Type 1 enclosure ds G 7ADTS B 3 2000 N 5 C esign prefix jet letter Neutral Phase Poles Amperes Voltage Controller Enclosure A solid 2 single 150 1000 A 115 J 400 5 standard C ype 1 B switched 3 three 260 1200 B 120 K 415 5X if F type 3R 400 1600 C 208 L 440 accessories G type 4 blank none 600 2000 D 220 M 460 Sees L type 12 800 3000 E 230 N 480 M type 3R secure 4000 F 240 P 550 N type 4 secure G 277 Q 575 P type 4X secure Q type 12 secure H 380 R 600 blank open type 7 field connections Group 5 1 terminal block TB Controller power connections Transfer Control amp lights FMFRGENCY Transfer Switch power connections G design 2000 ampere size in typical enclosure with location of customer connections Rating Label Each automatic delayed transition transfer switch contains a rating label to define the loads and fault circuit withstand closing ratings Refer to the label on the
6. c Transfer Switch will respond only to the rated voltage specified on the Transfer Switch nameplate Note 6 Refer to Section 3 of Group 5 Controller User s Guide 381333 126 for how to display the Status of the ATS and 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 the Voltage and Frequency of each source Now continue to 3 Electrical Operation on next page 1 4 INSTALLATION ASCO 7000 SERIES continued EMERSON Network Power Power Transfer Switch Transfer Transfer Switch Transfer Switch Connected Connected Control T Retransfer Transfer Del Normal Emergency To Emergency Source Accepted o GREEN A observe these lights Normal Source Accepted Figure 1 7 Standard controls and indicators 3 Electrical Operation This procedure will check the electrical operation of the Automatic Delayed Iransition Transfer Switch See Figure 1 7 Close the enclosure door first Transfer 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 J White square means light i
7. e 2E time delay to time out Starting control must be in the automatic position These are factory settings Refer to 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 at 1 800 800 2726 Furnish the Serial No and Catalog No from the transfer switch nameplate A auxiliary cable box 1 1 auxiliary circuits 1 2 B barriers 1 1 C cable lugs 1 2 preparation 1 2 catalog number cover cleaning 2 1 connections line 1 1 controller 1 1 disconnecting 2 1 see Controller User s Guide E electrical operation 1 5 Emergency Source Accepted light 1 5 F frequency generator 2 2 functional test 1 2 1 3 1 4 1 5 H harness 1 2 disconnect plugs 2 1 HELP customercare asco com 800 800 ASCO Printed in U S A INDEX inspection 3 1 installation 1 1 L labels engine start contacts 1 2 rating cover lights 1 4 1 5 Load Disconnect Active light 1 5 lubrication 2 1 M maintenance preventive 3 1 manual load transfer 3 2 warning 3 2 manual operation 1 3 illustration of 1 3 warning 1 3 N nameplate cover Normal Source Accepted light 1 5 O operation electrical 1 5 manual 1 3 illustration of 1 3 warning 1 3 sequence of 2 1 optional accessories see Controller User s Guide P parts 2 1 phase
8. e in preventive maintenance will insure high reliability and long life for the 7000 Series ADTS An annual preventive maintenance program is recom mended ASCO Services Inc ASI is ASCO Power Technologies national service organization ASI can be contacted at 1 800 800 2726 for information on preventive maintenance agreements Checklist for Yearly Inspection A DANGER Hazardous voltage capable of causing shock burns or death is used in this switch Deenergize both Normal Emergency power sources before performing inspections Clean the ADTS enclosure Brush and vacuum away any excessive dust accumulation Remove any moisture with a clean cloth Check the transfer switch contacts Remove transfer switch barriers and check the condition of the contacts Replace contacts when pitted or worn excessively Reinstall the barriers carefully Maintain transfer switch lubrication If switch is subjected to severe dust or abnormal operating conditions renew factory lubrication on all move ments and linkages Relubricate solenoid operator if TS coil is replaced Don t use oil order lubrica tion kit 75 100 Check all cable connections 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 Po
9. 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 ADTS it shows all mounting details and instructions Protect the switch from construction grit and metal chips to prevent malfunction or shortened life of the automatic switch switch Mount the ADTS 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 controller on the door Auxiliary Cable Boxes For 1000 amp 1200 amp sizes an auxiliary cable box is required for all normal emergency amp load bottom or top entry Order ASCO part no 609027 if required On 1000 amp 1200 amp be sure to install auxiliary cable box if both service and load cables are en tering through the top or bottom of enclosure Line Connections A Wiring Diagram is furnished with the ASCO Series 7000 ADTS separate from this manual Refer to this drawing All wiring must be made in accordance with the National Electrical Code and local codes INSTALLATION 1 1 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 rotati
10. nals of the transfer switch Table 2 1 Trouble Shooting Checks CHECK IN NUMERICAL SEQUENCE PROBLEM 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 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 9096 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 9096 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 Featur
11. on 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 often requires considerable force The pulling of cables can damage insulation and stretch or break the conductor s strands For this reason after the cables are pulled into position and before they are connected they should be tested to verify that they are not defective or have been damaged during installation 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 Do not run cables in front of or behind the switch Cables can be bundled on the right side of the switch Maintain proper electrical clearance
12. r Switches for maintenance purposes only Manual operation of both CN and CE transfer switches must be checked before they are operated electrically Do not manually operate the transfer switch until both power sources are disconnected open both circuit breakers 1 Selectthe appropriate switch amperage size above and follow the directions for installing the handle 3 150 through 400 A E design See Figure 1 2 Insert the manual handle into the hole in the shaft left side of the operator 600 and 800 A F design See Figure 1 3 Attach the manual handle onto the pivot shaft extension left side of the operator 600 amp 800 A amp 4 pole 400 A continued handle Figure 1 4 3000 amp 4000 A F design transfer switches 1000 through 4000 A G design See Figure 1 5 Install the hub with pin onto the shaft and insert the manual firmly into the side hole in the hub Push in or pull out hub to engage opposite source contacts 3000 and 4000 A F design See Figure 1 4 Insert the manual handle into the hole in the weight Move the handle as shown to manually operate the Transfer Switch The switch should operate smoothly without binding If it does not check for shipping damage or construction debris Repeat the manual operation check on the other Transfer Switch Return the CN Transfer Switch to the C closed position Return the CE Transfer Switch to the O open position Remove manual operator handle and sto
13. re it on the Transfer Switch in the place provided Verify that the maintenance handle has been removed and stored properly before proceeding Now continue to 2 Voltage Checks on next page Turn counterclockwise Insert handle Emergency Grasp handle to OPEN contacts ae ul RODIBEIS firmly with Turn clockwise to compressed both hands CLOSE contacts LP Slide the hub onto the window shaft and insert the pin indicators OPEN or CLOSED o Normal contacts counterclockwise DOWN clockwise DOWN P OPENS the contacts OPENS the contacts Pull out shaft to open Emergency Pull out shaft to close Emergency ti source contacts upper source contacts upper d yeu Push in shaft to open Normal Push in shaft to close Normal indicators left side source contacts lower source contacts lower Figure 1 5 1000 4000 ampere G design transfer switches 1 3 INSTALLATION ASCO 7000 SERIES Power Transfer Switch continued EMERSON Network Power Transfer Transfer Switch Transfer Switch Control Connected Connected T Normal Retransfer Transfer Delay a oLpFte Bypass Des To Emergency Emergency Source Source Disconnect Accepted Accepted Active a bili o GREEN A Normal Load observe these lights Figure 1 6 Standard controls and indicators 2 Voltage Checks First check nameplate on transfer switch rated voltage must be the same as normal and emergenc
14. 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 Transfer Switch Connected to Normal light 1 4 1 5 transfer test 1 5 transfer to emergency 1 5 transfer to normal 1 5 2 1 trouble shooting 2 2 V voltage checks 1 4 voltage pickup and dropout settings see Controller User s Guide ASCO Power Technologies L P 2009
15. s off This completes the Functional Test of the ADTS elay Tesi FOLD FOR Bypass Dues Load Disconnect Active a bl 1 5 E operate this switch Turn and hold Transfer Control switch clockwise to Transfer Test until the engine starts and runs within 15 sec The Emergency Source Accepted light should come on Transfer switch CN opens and the Transfer Switch Connected to Normal light should go off and the Load Disconnect Active light should come on Both CN amp CE contacts are now open After the delay transition time delay the CE Transfer switch will operate to the Emergency position The Transfer Switch Connected To Emergency light should come on and Load Dis connect Active 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 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 ADTS at least once a month by following the five step Electrical Operation Transfer Test procedure on page 1 5 PREVENTIVE MAINTENANCE Reasonable car
16. 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 Nameplate The Transfer Switch nameplate includes data for each specific 7000 Series ADTS Use the switch only within the limits shown on this nameplate A typical Catalog Number is shown on the previous page with its elements explained Transfer Switch field connections terminal block TB Group 5 Controller G design 4000 ampere size in typical enclosure with location of customer connections SECTION 1 ASCO Series 7000 Automatic Delayed Transition Transfer Switches are factory wired and tested Field installation simply requires mounting and connection of service cables and auxiliary control circuits if required Remove the Shipping Skid For large switches 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 level and straight Refer to the applicable enclosure outline drawing included with the ADTS 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 clearance to live metal parts When a concrete floor
17. wer Technolo gies Sales Office or ASI call 1 800 800 ASCO 2726 DISCONNECTING THE CONTROLLER The harness disconnect plugs are furnished for repair purposes only and should not have to be unplugged If the control panel must be isolated follow these steps Disconnecting the Plugs Do not unplug the controller until steps 1a or 1b 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 Ifthe 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 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 steps 1a or 1b is 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 The two harness plugs and sockets are keyed Carefully align the plugs with the sockets and press straight in until both latches click 3 Restore the opposite
18. y line voltages Close the normal source circuit breaker The Transfer Switch Connected To Normal and the Normal Source Accepted lights should come on Before energizing the switch check to be sure that both normal and emergency contacts are not left in the closed position Use an accurate voltmeter to check phase to phase and phase to neutral voltages pres ent at the transfer switch normal source terminals Verify that the feeders have been A DANGER connected to the proper lugs 3 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 extreme caution when using a meter to measure voltages Do not touch power terminals shock burns or death could result 4 Perform steps 1 through 6 at the right Observe the status lights See Figure 1 6 Use an accurate voltmeter to check phase to phase and phase to neutral voltages pres ent at the transfer switch emer gency source terminals E Black square means light is on J White square means light is off 5 If necessary adjust voltage regulator on the generator Use a phase rotation meter to check phase rotation of emer gency source it must be the same as the normal source ABC according to the manufacturer s recommendations The Automati
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