Emerson Series 300 Users Manual Operator's For ATS H 600 1200 A UL/CSA
300 to the manual 7a1be399-a587-4c57-a65c-76f46d2eb45c
2015-01-05
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Operator’s Manual Series 300 Automatic Transfer Switches H–design, 600 through 1200 A DANGER is used in this manual to warn of a hazardous situation which, if not avoided, will result in death or serious injury. WARNING is used in this manual to warn of a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION is used in this manual to warn of a hazardous situation which, if not avoided, could result in minor or moderate injury. Refer to the outline and wiring drawings provided with your ASCO Series 300 ATS for all installation details. 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. Do not exceed the values on the rating label. Exceeding the rating can cause personal injury or serious equipment damage. An experienced licensed electrician must install the Automatic Transfer Switch (ATS). TABLE OF CONTENTS section-page INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Mounting and Line Connections . . . . . . . . . 1-1 Engine Starting Contacts . . . . . . . . . . . . . . . 1-2 Input / Output Label . . . . . . . . . . . . . . . . . . . . 1-2 Functional Test . . . . . . . . . . . . . . . . . 1-3, 1-4, 1-5 SEQUENCE OF OPERATION . . . . . . . . . . . 2-1 TESTING & SERVICE . . . . . . . . . . . . . . . . . . Preventive Maintenance . . . . . . . . . . . . . . . . Transfer Test . . . . . . . . . . . . . . . . . . . . . . . . . . Disconnecting the Controller . . . . . . . . . . . . Manual Load Transfer . . . . . . . . . . . . . . . . . . Trouble-Shooting . . . . . . . . . . . . . . . . . . . . . . 3-1 3-1 3-1 3-1 3-2 3-2 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . 4-1 Time Delay and Sensor Adjustments . . . . . 4-1 How to Change a Setting . . . . . . . . . . . . . . . 4-2 CONTROL FEATURES . . . . . . . . . . . . . . . . . 5-1 Engine Exercisers . . . . . . . . . . . . . . 5-1, 5-2, 5-3 Motor Load Transfer . . . . . . . . . . . . . . . . . . . 5-4 Load Disconnect & Remote Control . . . . . . 5-4 INDEX . . . . . . . . . . . . . . . . . . . . . back of manual 600, 800, 1000 A sizes 50 Hanover Road, Florham Park, New Jersey 07932–1591 USA For sales or service call 1 800 800–2726 (ASCO) www.ascopower.com 381333–201 G ASCO POWER TECHNOLOGIES CANADA PO Box 1238, 17 Airport Road, Brantford, Ontario, Canada N3T 5T3 Nameplate Catalog Number Identification The Transfer Switch nameplate includes data for each specific ASCO Series 300 ATS. Use the ATS only within the limits shown on this nameplate. H 300 Neutral B – switched C – overlapping blank – solid B Phase Poles 2 – single Ø 3 – three Ø 3 A typical Catalog Number is shown below with its elements explained. The example is for a Series 300 ATS with switched neutral, 3 pole, 600 ampere, 480 V, in a Type 1 enclosure: 600 Amperes 600 800 1000 1200 N 1 Voltage C 208 D 220 E 230 F 240 K 415 L 440 M 460 N 480 H 380 Q 575 J 400 R 600 C Controller Enclosure 1 – standard C – type 1 F – type 3R G – type 4 * L – type 12 * 1X – if accessories ordered blank – open type * available 600 – 1000 A sizes only Controller neutral connections power connections membrane controls Transfer Switch terminal block TB for engine start and switch position contacts power connections neutral connections 600 ampere size in typical enclosure with location of customer connections neutral connections Controller power connections membrane controls Transfer Switch terminal block TB for engine start and switch position contacts power connections neutral connections 800 and 1000 ampere sizes in typical enclosure with location of customer connections Controller membrane controls neutral connections power connections Transfer Switch terminal block TB for engine start and switch position contacts power connections neutral connections 1200 ampere size in typical enclosure with location of customer connections SECTION 1 Series 300 Automatic Transfer Switches are factory wired and tested. Installation requires skid removal then securing the enclosure to the supporting foundation. INSTALLATION Testing Power Conductors Remove the Shipping Skid Open the front door and remove the four lag screws (2 in front, 2 in rear) securing enclosure to the wood skid. Supporting Foundation Do not connect the power conductors to the ASCO Series 300 transfer switch until they are tested. Installing power cables in conduit, cable troughs and ceiling-suspended hangers often requires considerable force. The pulling of cables can damage insulation and stretch or break the conductor’s strands. For this reason, after the cables are pulled into position, and before they are connected, they should be tested to verify that they are not defective or have been damaged during installation. NOTICE The supporting foundation for the enclosure must be level and straight. Refer to the applicable enclosure outline drawing included with the Series 300 for all mounting details including door opening space. Protect the automatic transfer switch from construction grit and metal chips to prevent malfunction or shortened life of the ATS. 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 is poured, use interlocking conduit spacer caps or a wood or metal template to maintain proper conduit alignment. Connecting Power Conductors Mounting Refer to the applicable enclosure outline drawing furnished with this switch and mount the Series 300 according to details and instructions shown on diagram. After the power cables have been tested, connect them to the appropriate terminal lugs on the transfer switch as shown on the wiring diagram provided with this Series 300. 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 Series 300. Be careful when stripping insulation from the cables; avoid nicking or ringing the conductor. Remove surface oxides from cables by cleaning with a wire brush. When aluminum cable is used, apply joint compound to conductors. Tighten cable lugs to the torque specified on rating label. Line Connections Controller Ground Refer to the Wiring Diagram provided with your Series 300 ATS. All wiring must be made in accordance with the National Electrical Code and local codes. 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. It is unnecessary to remove pole covers from the transfer switch. If you do remove them, reinstall them carefully. Harnesses The transfer switch is connected to the left side of the controller by a plug–in harness (two plugs). De–energize the conductors before making any line or auxiliary circuitry connections. Be sure that Normal and Emergency line connections are in proper phase rotation. Place engine generator starting control in the OFF position. Make sure engine generator is not in operation. 1---1 INSTALLATION (continued) Engine Starting Contacts Customer connections for engine control contact and TS auxiliary contacts connections are located on terminal block TB which is mounted on the front lower left of the transfer switch. Refer to wiring diagram provided with the Series 300 ATS and connect the engine start wires to the appropriate terminals. See Figure 1–1 and Table A. COMMON Table A. Engine start connections. When normal source fails contact closes contact opens Terminals on transfer switch TB1 and TB2 TB1 and TB3 FEATURE 7 closes to start FEATURE 8 opens to start COMMON FEATURE 14B closed on emergency FEATURE 14A left side of transfer switch Engine Starting Signals 5 amps, 32 V DC 5 amps resistive 28 V DC or 120 V AC max. TS Auxiliary Contacts Feature 14A & 14B 10 amps, 32 V DC 10 amps 250 V AC general purpose closed on normal Auxiliary Circuits Connect auxiliary circuit wires to appropriate terminals on transfer switch terminal block TB as shown on the wiring diagram provided with this Series 300 Automatic Transfer Switch. Make the necessary auxiliary connections by referring to Section 5, Control Features. COMMON FEATURE 14BA closed on emergency FEATURE 14AA Optional TS Auxiliary Contacts Feature 14AA & 14BA 10 amps, 32 V DC 10 amps 250 V AC general purpose closed on normal terminal block for engine start and auxiliary circuit connections Connections to Controller for other Control Features (located on bottom of Controller) Programmable Load Disconnect Engine Exerciser Feature connection, Connections if provided (see Wiring Diagram (refer to & refer to page 5–4 for DIP switch settings) page 5–3) Figure 1-1. Engine start and auxiliary circuit terminal block TB located on the transfer switch. Remote Control Features Connections (refer to the Wiring Diagram & page 5–4 for DIP switch settings) Each control contact must be suitable for a 5 V DC low energy circuit. for factory use only Figure 1-2. Input / output label on the Controller showing possible connections to the lower terminal block. 1---2 INSTALLATION (continued) Functional Test The Functional Test consists of three checks: manual operation, voltage checks, and electrical operation. NOTICE Do these checks in the order presented to avoid damaging the automatic transfer switch. Read all instructions on the Wiring Diagram and labels affixed to the automatic transfer switch. Note the control features that are provided and review their operation before proceeding. left side of transfer switch 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). maintenance handle 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 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 and 1–4 and Table B. 2. Move the maintenance handle 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. Table B. Maintenance handle positions. ATS Position Handle Indicators E up 3. N=C lower contacts closed E E=C NOTICE Verify that the maintenance handle has been removed before proceeding! upper contacts closed N N=O down Return the transfer switch to the Normal position. Observe that window indicators (right side) show the top shaft O (open) and the bottom shaft C (closed). Note: If Normal and Emergency connections are reversed this operation is also reversed. 4. Remove the maintenance handle and store it on the frame (left side) in the clips provided. E=O N Emergency hub Figure 1-3. Maintenance handle & storage location. upper contacts open Normal handle storage clips Now continue to 2 – Voltage Checks on next page. lower contacts open Emergency contacts UP closes the Normal source contacts (lower) window indicators O is open C is closed DOWN closes the Emergency source contacts (upper) contact position indicators (right side) Normal contacts frame Figure 1-4. Maintenance handle operation and contact position indicators. 1---3 INSTALLATION (continued) observe these lights Figure 1–5. St andard controls and indicators. 2 – Voltage Checks First check nameplate on transfer switch; rated voltage must be the same as normal and emergency line voltages. Close the normal source circuit breaker. The Normal Transfer 1 Switch Position and the Normal Source Accepted lights should come on. Source Accepted Normal Emergency Use an accurate voltmeter to check phase to phase and 2 phase to neutral voltages present at the transfer switch normal source terminals. Use extreme caution when using a meter to measure voltages in the following steps. Do not touch power terminals; shock, burns, or death could result ! Close the emergency source circuit breaker. (Start generator, 3 if necessary.) The Emergency Source Accepted light should come on. Perform steps 1 through 6 at the right. Observe the status lights. See Figure 1–5. O Black circle means light is on. P White circle means light is off. Source Accepted Normal Emergency Use an accurate voltmeter to check phase to phase and 4 phase to neutral voltages present at the transfer switch emergency source terminals.* * 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. Use a phase rotation meter to check phase rotation of emer5 gency source; it must be the same as the normal source. Also see page 4–1 for the HI–LOW voltage adjust setting in the controller. The LOW setting shifts all voltage settings down 4.2%; for example, 240 V to 230V. Shut down the engine–generator, if applicable. The Emergency Source Accepted light should 6 go off. Then put the starting control selector switch (on the generator set) in the automatic position. Close enclosure door. A B C Source Accepted Normal Emergency Now continue to 3 – Electrical Operation on next page. 1---4 INSTALLATION (continued) observe these lights press this button Figure 1–6. Standard controls and indicators. 3 – Electrical Operation This procedure will check the electrical opertion of the Automatic Transfer Switch. See Figure 1–6. The normal source must be available and the generator 1 must be ready to start. Check that the Normal Source Accepted light is on. Press and hold the Transfer Test button until the engine starts 2 and runs. This should happen within 15 sec. Close the transfer switch enclosure door and tighten the screws before you test electrical operation. The Emergency Source 3 Accepted light should come on. 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. 4 Perform steps 1 through 8 at the right. Observe the status lights. O Black circle means light is on. P White circle means light is off. 5 NOTE: If Motor Load Transfer feature is activated, then transfer may not occur immediately after the respective time delays. Transfer will only occur when the phase relationship between sources is correct. 6 This completes the Functional Test of the ASCO Series 300 Automatic Transfer Switch. Leave the engine–generator starting control in the automatic position. 7 The transfer switch should transfer to the Emergency position. The Emergency Transfer Switch Position light should come on and the Normal light should go off. If the transfer to emergency delay is used the transfer should occurs after a time delay (up to 5 minutes). For immediate transfer press the Bypass Time Delay button. The transfer switch should transfer back to the Normal position. The Normal Transfer Switch Position light should come on and the Emergency light should go off. If the retransfer to normal delay is used the retransfer should occur after a time delay (up to 30 minutes). For immediate retransfer press the Bypass Time Delay button. The unloaded running delay keeps the generator running for 5 minutes (cool–down period). 8 Then the generator should stop and the Emergency Source Accepted light should go off. 1---5 Source Accepted Normal Emergency Transfer Test Source Accepted Normal Emergency Transfer Switch Position Normal Emergency Bypass Time Delay Transfer Switch Position Normal Emergency Bypass Time Delay Source Accepted Normal Emergency SECTION 2 SEQUENCE OF OPERATION Transfer To Emergency Lights show position of transfer switch. The sequence for load transfer to emergency source begins automatically when normal source voltage falls below the preset dropout point or when Transfer Test button is pressed. An under voltage condition on any phase of the normal source is detected by the sensor. Lights show the sources accepted. Light for built–in engine exercise timer: ³ blinks rapidly when button is held 5 sec. while being set ³ blinks slowly when button is released (set) and during 20 min. exercise period. ³ stays on after engine stops (exerciser is enabled for weekly operation) When the normal source voltage fails or See page 5–1 the Transfer Test for complete button is pressed, the Hold 15 sec. to Hold 5 sec. to set instructions Press to cancel the SE relay de-energizes start the engine active exercise period 20 min. engine exercise and relay NR begins generator and to (stops engine now or period immediately (engine transfer the load after cooldown) See starts) and weekly thereafter. its timing cycle (1 or 3 to emergency. page 5–1. seconds, momentary Figure 2–1. Membrane controls and indicator lights. normal source outage Retransfer to Normal delay). The NR relay is provided with a time delay on dropout to override momentary outages and prevent The sequence for load retransfer to the normal source nuisance starting of the engine-driven generator. If the automatically begins when the voltage sensor detects normal source voltage returns above the sensor dropout restoration of the normal source. The voltage level setting before the time delay expires, the NR relay timing must rise above the preset pickup point on all phases cycle is reset to zero and relay SE energizes. before the sensor will accept the normal source. If the normal source voltage does not return above the sensor dropout setting before the time delay expires, the NR relay de-energizes and signals the engine-driven generator to start. At the same time, a voltage and frequency sensor begins monitoring the emergency source. The sensor will accept the emergency source only when both voltage and frequency reach preset pickup points. Usually about ten seconds elapse from dropout of the NR relay to acceptance by the sensor. This time span occurs because the engine-driven generator must crank, start, and run up to nominal pickup points. For this reason, if the Transfer Test button is pressed it must be held for 15 seconds. If the emergency source is available immediately, the sensor may accept it as soon as NR relay drops out. When the normal source is accepted by the sensor, relay SE begins its timing cycle (adjustable 1 sec. to 30 min., retransfer to normal delay). For immediate retransfer press Bypass Time Delay button. SE relay is provided with a time delay on pickup to prevent immediate load retransfer to the normal source. The delay insures that the normal source has stabilized before reconnection of vital loads. If the normal source voltage falls below the present dropout point before the time delay expires, the timing cycle is reset to zero. If the emergency source fails for more than 4 seconds during the timing cycle, ER relay drops out and the load is immediately retransferred to the normal source, if that source is acceptable. When the emergency source is accepted by the sensor, relay ER begins its timing cycle (transfer to emergency delay). ER relay is provided with an adjustable (0 to 5 minutes) time delay on pickup to delay transfer of the load to the emergency source. For immediate transfer press Bypass Time Delay button. SE relay energizes and ER relay is dropped out. The TS coil is energized, the transfer switch operates, and all switch contacts (mains, controls, auxiliaries) reverse position. The transfer switch is now supplying the load from the normal source again. Upon retransfer to the normal source, NR relay begins its timing cycle (unloaded running delay, engine cooldown). NR relay is provided with a 5 min. time delay on pickup to keep the engine running for a cool-down period. ER relay energizes, the TS coil is energized, the transfer switch operates, and all switch contacts (mains, controls, auxiliaries) reverse position. The transfer switch is now supplying the load from the emergency source. NR relay energizes after the time delay and signals the engine-driven generator to shut down. All circuits are reset for any future normal source failure. The transfer switch will remain in the Emergency position until the normal source is restored. If the Transfer Test button is used, the transfer switch will remain on emergency until the retransfer to normal delay times out. Activation of standard control features shown in Section 5 will alter the sequence of operation and introduce additional time delays during transfer operations. 2---1 SECTION 3 TESTING & SERVICE PREVENTIVE MAINTENANCE S Check all cable connections & retighten them. Torque to values shown on transfer switch label. For high reliability and long life for the ATS: Replacement parts. When ordering parts provide the Serial and Catalog Nos. from the transfer switch nameplate. Contact ASI. In the US call 1–800–800–ASCO (2726)). Operate the switch at least once a month. Perform this 4–step Electrical Operation Test (test with load transfer). DISCONNECTING THE CONTROLLER The harness disconnect plugs are furnished for repair purposes only and should not have to be unplugged. If the controller must be isolated, follow these steps carefully. Disconnecting the Plugs 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. Transfer Switch Test 1. Press and hold the door-mounted Transfer Test button b. If the transfer switch is in the Emergency position, open the normal source circuit breaker. Place the engine starting control in the test or run position. until the engine starts and runs. This should happen within 15 seconds. 2. The transfer switch will operate to the Emergency position. If the Transfer To Emergency Delay is used, the transfer will occur after a time delay (up to 5 minutes). For immediate transfer press Bypass Time Delay button. 2. Separate the quick disconnect plugs by squeezing the latches. Do not pull on the harness wires. 3. Label, remove, and tape the signal wires connected to the engine start terminals on the transfer switch: TB1 and TB3, or TB1 and TB2. 3. The Transfer Switch will operate back to the Normal 4. position after the Retransfer To Normal Delay (up to 30 minutes). For immediate retransfer press Bypass Time Delay button. Unloaded Running (Engine Cooldown) Delay allows engine to run unloaded for 5 minutes. Reconnecting the Plugs 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. Checklist for Yearly Inspection b. If the transfer switch is in the Emergency position, normal source circuit breaker still should be open. 2. Reconnect the signal wires connected to the appropriate engine start terminals on the transfer switch. See Section 1, Engine Starting Contacts. Hazardous voltage capable of causing shock, burns, or death is used in this switch. Deenergize both Normal & Emergency power sources before performing inspections! 3. The harness plugs and sockets are keyed. Carefully align the plugs with the sockets and press straight in until both latches click. S Clean the enclosure. De–energize all sources, then brush and vacuum away any excessive dust accumulation. Remove moisture with a clean cloth. 4. Restore the opposite source as follows: a. If the transfer switch is in the Normal position, place the standby engine starting control in the automatic position. Then close the emergency source circuit breaker. S Check the transfer switch contacts. De-energize all sources, then remove the transfer switch barriers and check contact condition. Replace the contacts if they become pitted or worn excessively. Reinstall the barriers carefully. b. If the transfer switch is in the Emergency position, close the normal source circuit breaker. The load will be automatically retransferred to the normal source after the Retransfer to Normal Delay. For immediate retransfer, press Bypass Time Delay button. Place the engine starting control in the automatic position. S Maintain transfer switch lubrication. Under normal operating conditions no further lubricating is required. Renew factory lubrication if the switch is subjected to severe dust or abnormal operating conditions or if TS coil is replaced. Order lubricant kit 75–100. 3---1 TESTING & SERVICE (continued) MANUAL LOAD TRANSFER 1. Open normal and emergency source circuit breakers. This procedure will manually transfer the load if the controller is disconnected. 2. Use the maintenance handle to manually operate transfer switch to the opposite source. See page 1–3, Manual Operation Test. Do not manually operate the transfer switch until both power sources are disconnected: open both circuit breakers. 3. If the transfer switch is in the Emergency position manually start the engine generator and then close the emergency source circuit breaker. TROUBLE-SHOOTING Note the control features that are activated or furnished on the switch and review their operation. Refer to Section 5, Control Features. Proceed with care! The automatic transfer switch is energized. Table 3-1. Trouble-Shooting Checks. PROBLEM Gen-Set does not start when the Transfer Test button is pressed and held for 15 seconds or when the normal source fails. CHECK IN NUMERICAL SEQUENCE 1 OPERATION 2 GEN-SET Hold the Transfer Test button Starting control must be in 15 sec. or the outage must be automatic position. Batteries long enough to allow for the 1 must be charged and or 3 sec. Momentary Normal connected. Check wiring to Source Outage Delay plus engine starting contacts. engine cranking and starting time. Transfer switch does not transfer the load to emergency source after the gen-set starts. Wait for Transfer to Emergency Delay (0 to 5 min.) to time out. For immediate transfer, press the Bypass Time Delay button. If Motor Load Transfer is active, wait for inphase condition (see below). Transfer switch does not transfer the load to normal source when normal returns or when Transfer Test button is released. Wait for Retransfer to Normal Delay (1 sec. to 30 min.) to time out. For immediate re– transfer, press Bypass Time Delay button. If Motor Load Transfer is active, wait for inphase condition (see below). Gen-Set does not stop after load retransfer to the normal source. Wait for the 5 minute Unloaded Running Delay to time out. Generator output circuit breaker must be closed. Generator frequency must be at least 57 Hz. — 3 VOLTAGE — Voltmeter should read at least 90% of nominal phase to phase voltage between transfer switch terminals EA and EC (or EL1 and EL2 for 2 pole switches). * * These are factory settings. Voltmeter should read at least 90% of nominal phase to phase voltage between transfer switch terminals NB and NC, NC and NA, and NA and NB (or NL1 and NL2 for 2 pole switches). Starting control must be in automatic position. — Trouble-Shooting the Motor Load Transfer Feature (refer to page 5–4) 3. Press and hold Transfer Test button. The load should transfer to emergency source when meter needle is near 0 volts. If transfer does not occur, Motor Load Transfer feature is not operating. 4. Release the Transfer Test button. The load should retransfer back to the normal source after the Retransfer to Normal Delay, if used. The retransfer should occur when the needle is near 0 volts. If retransfer does not occur after the time delay, the Motor Load Transfer feature is not operating. 5. For immediate retransfer, press the Bypass Time Delay button. Then disconnect the voltmeter. Use extreme caution when using a meter to measure voltages in the following steps. Do not touch power terminals; shock, burns, or death could result ! 1. Connect a voltmeter (set for twice system phase–to–phase voltage) between Transfer Switch terminals NA and EA. 2. Manually start generator. Voltmeter needle should sweep back and forth at a regular rate between 0 and about twice system voltage. If the problem is isolated to circuits on the controller or the transfer switch, call your local ASCO Power Technologies sales office, representative, or ASI. In the United States, call 1–800–800–2726. Furnish the Serial No., Bill of Material (BOM) No., and Catalog No. from transfer switch nameplate. 3---2 SECTION 4 ADJUSTMENTS Time Delay Adjustment To change a setting, follow procedure on page 4-2. Use Table 4-1 as a guide to time delay values and their corresponding adjustment DIP switch or potentiometer. Standard time delays are set to customer specifications (if none specified, standard factory settings are used). Table 4-1. Time Delay Settings DESCRIPTION LABELS FACTORY SETTING Override Momentary Normal Source Outages TD ES 3 seconds Transfer to Emergency TIMER N/E Unloaded Running (Engine Cooldown) 1 second Actuator 1 on 3 seconds Actuator 1 off 0 minutes (full ccw) 0 to 5 minutes — — P2 — 4 seconds non-adjustable — — — TIMER E/N 30 minutes (full cw) 1 second to 30 minutes — — P1 — 5 minutes non-adjustable — — — Sensor Adjustments Any change in these settings may affect the normal operation of the automatic transfer switch. This change could allow the load circuits to remain connected to a low voltage source. Table 4-2. Voltage and Frequency Settings. ( PU / N Pickup 90 % 95 % * Actuator 3 off 90 % Actuator 3 on 80 % Emergency Source Voltage 60 / 50 Hz 60 Hz 3 1 3, 3/1 3 –– –– 60 Hz Actuator 4 off 50 Hz Actuator 4 on 3 phase Actuator 6 off 1 phase Actuator 6 on 6 60 / 50 Hz non-adjustable non-adjustable non-adjustable non-adjustable 6 90 % 75 % 95 % 85 % 4 Voltage Phases Pickup Dropout Pickup Dropout 4 Emergency Source Frequency eque cy –– –– –– –– 1 2 70 % 1 2 Dropout 85 % 1 2 DO / N 85 % Actuator 1 off Actuator 2 off Actuator 1 on Actuator 2 off Actuator 1 off Actuator 2 on Actuator 1 on Actuator 2 on 1 2 90 % * Normal Source Voltage S1 DIP SWITCH 3 SETTING Shaded DIP switches are standard factory settings). % of nominal FACT. SET ADJ RANGE 3 LABELS — NOTICE Voltage and frequency sensor pickup and dropout points are set to customer specifications (if none specified, standard factory settings are used). To change a setting, follow procedure on page 4–2. Use Tables 4-2 and 4–3 for settings and corresponding DIP switch actuators. DESCRIPTION ADJUSTMENT POTENTIOMETER 1 Retransfer to Normal S3 DIP SWITCH 1 Override Momentary Emergency S. Outages ADJUSTMENT RANGE * If dropout voltage is set to 90%, the pickup voltage must be set to 95%. Table 4-3. Transformer Voltage Adjust. (Low setting shifts all voltage settings down 4.2%; for example, 240 V to 230 V, or 480 V to 460 V) FACTORY SETTING Voltage Adjust (4.2%) (4 2%) LOW / HI HI 4---1 ADJUSTMENT S3 DIP SWITCH LOW Actuator 2 off HI Actuator 2 on 2 LABELS 2 DESCRIPTION ADJUSTMENTS NOTICE (continued) cover Do not make any setting changes while the controller is energized. thumb latch How to Change a Setting 1. Prevent the transfer switch from operating by disconnecting one source first, then the other, as follows: a. If the transfer switch is in the Normal position, open the emergency source circuit breaker. Turn the engine starting control to off. Then open the normal source circuit breaker. b. If the transfer switch is in the Emergency position, open the normal source circuit breaker. Turn engine starting control to test or run. Then open the emergency source circuit breaker. hook on left side Figure 4-1. Controller cover latch. 2. Disconnect both harness plugs from controller by squeezing the latches. Do not pull on the wires. 9 volt alkaline battery 3. Remove cover from the controller by releasing latch on right side with your thumb. See Figure 4-1. J5 battery on/off jumper harness plugs 4. Locate the appropriate adjustment potentiometer or DIP switch for the setting that you want to change. Refer to Table 4-1 and Table 4–2 on page 4-1 and Figure 4-2, Figure 4–3, Figure 4–4 on page 4–2. P1 retransfer to normal time delay 5. Use a small screwdriver to turn the potentiometer clockwise to increase the time delay or counterclockwise to decrease it. See Figure 4-3. S1 DIP switch S2 DIP switch 6. Use a ball-point pen (or similar pointed tool) to slide the switch actuators left or right so they match the illustration next to the setting (left = off, right = on). Recheck the setting. See Figure 4-4. Figure 4-2. Location of potentiometers. clockwise to increase P1 or P2 potentiometer 7. Install the cover on the controller by hooking it on the left side and latching the right side. 8. Reconnect both harness plugs to the controller by aligning and pressing straight in until latches click. counterclockwise to decrease Figure 4-3. Changing time delay potentiometers. Close the transfer switch enclosure door. 9. Close the enclosure door, then restore both sources: a. If the transfer switch is in the Normal position first close the normal source circuit breaker, then close the emergency source circuit breaker. b. If the transfer switch is in the Emergency position, close the normal source circuit breaker. The load will be automatically retransferred to the normal source. Then close the emergency source circuit breaker. P2 transfer to emergency time delay S3 DIP switch DIP switches SW1 SW2 SW3 actuator (8 on each DIP switch) off on Figure 4-4. Setting DIP switch actuators. 10. Turn the engine starting control to automatic. 4---2 SECTION 5 CONTROL FEATURES – ENGINE EXERCISERS These timers periodically exercise the emergency engine-generator plant. They can be set to exercise with or without load transfer, or they can be completely disabled. The engine-generator should be exercised under load once a week for a minimum time period of 20 minutes, or follow the recommendations of the engine-generator set manufacturer. Refer to page 4–2 for location of DIP switches, battery (provided), and jumper block in the controller. BUILT–IN ENGINE EXERCISER DIP Switch Settings 5 8 Actuator 8 on 8 Fill in day and time set. Week Day ______ Time _______. Actuator 8 off S2 DIP SWITCH Actuator 5 on Actuator 5 on 5 Std. Timer Enabled Std. Timer Disabled Exercise without Load Exercise with Load 7 S1 DIP SWITCH Actuator 7 on Actuator 7 off FUNCTION 7 The engine exerciser included in ASCO Series 300 Automatic Transfer Switches provides a once a week 20–minute exercise period. It occurs immediately when the Set Engine Exerciser push button is pressed (and held for at least 5 seconds), and then at the same time weekly thereafter. A 9 volt alkaline battery (Duracell MN1604, Everready 522, or Panasonic 6AM6) is furnished and installed in the controller to maintain the setting. The battery jumper block must be shifted to the ON position. See Figure 4–2 on page 4–2. Shaded DIP switches are standard factory settings. status light Press to cancel an active exercise period (stops generator). Press and hold for 5 sec. or until status light blinks rapidly to set exercise period immediately and every week hereafter (generator starts). If Exercise with Load is set, retransfers load to Normal, then stops generator after min. cooldown. Figure 5-1. Operator panel pushbuttons and light. If Exerciser with Load is set, transfers load to Emergency. Select below either Exercise without Load or Exercise with Load according to the setting of DIP switch S1, actuator 8. The load transfers from the Normal source to Emergency source (generator) and back again if Exercise with Load is selected. Step 1 2 3 4 Push Button Set Engine Exerciser hold 5 sec. release press Bypass Time Delay — Explanation blinks rapidly OPOPOP set exercise period Exercise the generator now and every week at this time hereafter. blinks slowly OPPOPP exercise period now active Generator starts and runs. O stays on cancel active exercise period Generator stops. O stays on generator off Exerciser enabled; repeats every 7 days. Status Light 8 Step 1 How to Set Built–In Timer Function Exercise with Load, DIP Switch S1, Actuator 8 on Push Button Set Engine Exerciser hold 5 sec. 8 Exercise without Load, DIP Switch S1, Actuator 8 off How to Set Built–In Timer Function Explanation blinks rapidly OPOPOP set exercise period Exercise the generator now and every week at this time hereafter. Status Light 2 release blinks slowly OPPOPP exercise period now active 3 press Bypass Time Delay blinks slowly OPPOPP cancel active exercise period 4 — O stays on generator off Generator starts and runs; the load transfers to Emergency. The load retransfers to Normal; then generator runs for 5 minute cooldown ( light blinks slowly during cooldown ). Exerciser enabled; repeats every 7 days. NOTE: Every time SET ENGINE EXERCISER push button is pressed (held 5 seconds) the exercise period is changed. 5---1 CONTROL FEATURES (continued) Optional Accessory 11BG – SOURCE AVAILABILITY SIGNAL & PROGRAMMABLE ENGINE EXERCISER MODULE 2–line display connections for source availability signal contacts 3 buttons Figure 5–2. Accessory 11BG module (mounted behind operator interface and connected to the controller) includes source availability signal contacts and a programmable engine exerciser. Source Availability Signal Contacts The module provides one Form C contact each for the normal and emergency sources signal the acceptability of the source as sensed by the controller. The signal contacts operate in conjunction with the Source Accepted lights on the operator interface. Field wiring terminals are provided as shown in Figure 5–3 and the wiring diagram. SOURCE AVAILABILITY SIGNALS 2 AMPS @ 30 VDC, resistive 0.5 AMP @ 125 VAC, resistive contacts shown de–energized Contact ratings: 2 amps @ 30 Vdc, 0.5 amp. @ 125 Vac resistive Figure 5–3. Source availability signal contacts. Programmable Engine Exerciser DIP Switch Settings in the Controller The module includes a programmable engine exerciser that provides for weekly or biweekly operation. This optional exercise timer may have to be turned on (enabled) by setting the S1 DIP switch actuator 7 to off, and S2 DIP switch actuator 5 to off. A backup battery in the controller (see page 4–2 and page 5–3) must be turned on to maintain the settings and to allow programming with the normal and emergency power turned off (page 5–1). (see page 4–2) 8 5 Actuator 8 on S2 DIP SWITCH Actuator 5 off Actuator 5 on 5 8 5---2 Actuator 8 off 7 The programmable engine exerciser incorporates a 7 day or 14 day time base. Proper controller settings must be made to determine whether or not the test will be done with or without load transfer (S1 DIP switch actuator 8). See next page for instructions on setting the timer. Opt. Timer Enabled Opt. Timer Disabled Exercise without Load Exercise with Load S1 DIP SWITCH Actuator 7 off Actuator 7 off 7 FUNCTION Shaded DIP switches are standard factory settings. CONTROL FEATURES (continued) How to Set Optional Programmable Engine Exerciser (part of Acc. 11BG module) NOTE: When choosing bi–weekly operation, the exerciser will always run on the week designated “(1)” on the date display. Hazardous voltage capable of causing shock, burns, or death is used in this transfer switch. Deenergize both Normal and Emergency power sources before programming the exerciser. Navigating the Menu Use the UP and DOWN arrow keys to move through the displays. Changing the Parameters Use the UP and DOWN arrow keys to move though the displays to the parameter to be changed. Push the ENTER key to start the editing process. The first parameter will flash. Use the UP and DOWN arrow keys to adjust the parameter to the desired value and press the ENTER key to save the value. The next parameter will now flash. Repeat the process until each parameter is properly configured. Run Time Display The Run Time Display shows the run time for the engine exerciser. The default setting from the factory is 30 min. Time Display The Time Display shows the present system time. The format is “hours:minutes:seconds”. Fast/Slow Adjust NOTE: During total power outages, power to the accessory is maintained by a battery in the Controller (see page 4–2). Be sure that the 9–volt alkaline battery is fresh and enabled (jumper in ON position) so that the time and date settings are not lost. Daylight Saving Time Adjust Date Date Display Time The Date Display shows the present system date. The format is “day of week (week) month/day of month/year”. Run TIme NOTE: Week is either week 1 or week 2. This is used in conjunction with the bi–weekly timer. Start TIme Daylight Savings Time Adjust Display Engine Exerciser This display shows whether the automatic daylight saving time adjustment is active. The factory default is “NO”. If enabled, the unit will automatically adjust for daylight saving time at 2 AM on Sunday as follows: Engine Exerciser Display The Engine Exerciser Display shows the status of the engine exerciser. When the unit is shipped from the factory the programmable engine exerciser is “Disabled” and must be set to “Enabled” by the customer. When the engine exerciser is running, this display will count down the remaining time until the end of the exercise period. Part No. 629857–001* 629857–002* Start first Sunday in April 2nd Sunday in March Stop last Sunday in Oct first Sunday in Nov * Part no. on back of circuit board. New DST starts in 2007. Fast / Slow Adjust Display Start Time Display The Start Time Display shows the engine exerciser start time. There are four parameters that determine the start time: weekly (”Every”) or bi–weekly (”Alt”) operation day of week (”Sun” through “Sat”) start hour (0 through 23) start minutes (0 through 59) For example, if the user wants the exerciser to run every other Saturday at 3 PM, the proper configuration would be: “Alt Sat @ 15:00” This display shows the automatic fast/slow adjustment value. The factory default is 0. This feature can be used to trim a clock that runs fast or slow. For example, if your clock runs 10 seconds slow per week, change the fast/slow adjust value to “+10” and the unit will automatically add 10 seconds to the clock every week. NOTE: Adjustments are made Sunday morning at 2 AM. If you want your exerciser period to start at 2 AM on Sunday, you cannot use this feature and the adjustment must be set to 0. Date exerciser was set ___________________________ Fill in your settings for future reference Weekly or Bi–weekly Day of Week Start Time Every = weekly Alt = bi–weekly Sun through Sat 0 – 23 hour 0 – 59 minute 5---3 Run Time 0 – 23 hour 0 – 59 minute 30 min. is default setting CONTROL FEATURES (continued) INPHASE MONITOR FOR MOTOR LOAD TRANSFER LOAD DISCONNECT FEATURE Inphase monitoring logic controls transfer and retransfer of motor loads, so that inrush currents do not exceed normal starting currents. It avoids nuisance tripping of circuit breakers and mechanical damage to motor couplings. The Motor Load Transfer feature is built into the controller. DIP switch S1 (actuator 5) activates this feature: right = ON, left = OFF. FUNCTION S1 DIP SWITCH enable Actuator 5 on 5 disable Actuator 5 off Connect external circuits to the terminals indicated on the Wiring Diagram provided with the ATS. The double throw (Form C) contact is rated for 28 VDC or 120 VAC (5 amperes resistive). The contact operates prior to a selectable 0, 3, 10, or 20 second delay before transfer of the Automatic Transfer Switch. The contact resets either immediately following transfer or after the same delay as set for pre–signal before transfer. 5 Time delay between the load disconnect control signal and initiation of transfer is set on the controller with DIP switch S2 (actuators 6, 7, 8) as shown below: Delay Before Transfer Shaded DIP switches are standard factory settings. LD TDBT 7 8 20 seconds 7 8 10 seconds 7 8 3 seconds If the Motor Load Transfer feature is enabled, it will be activated following the Load Disconnect Feature Delay Before Transfer delay. 7 8 0 (disable) Note S2 DIP SWITCH Actuator 7 on Actuator 8 on Actuator 7 on Actuator 8 off Actuator 7 off Actuator 8 on Actuator 7 off Actuator 8 off Shaded DIP switches are standard factory settings. Delay After Transfer* LD TDAT S2 DIP SWITCH enable Actuator 6 on 6 disable Actuator 6 off 6 *Enabling the Delay After Transfer will cause the control signal to reset after the same delay as set for the Delay Before Transfer. REMOTE CONTROL FEATURES These remote control features require a customer–supplied normally closed contact suitable for a 5 V dc low energy circuit. Refer to the Wiring Diagram provided with the ATS. Activate appropriate DIP switch S2 actuators below. Remote Test (terminals CP6–7) RTSW Remote Transfer to Emergency (CP8–9) S2 DIP SWITCH enable Actuator 2 off 2 Actuator 3 off Actuator 2 on 2 enable disable 3 Actuator 3 on Bypass Transfer Time Delay (CP12–13) TD E/N BYP. Inhibit Transfer to Emergency (CP10–11) S2 DIP SWITCH Actuator 4 on enable Actuator 4 off 4 Actuator 1 off S2 DIP SWITCH disable 4 enable N/E INHIB. 1 Actuator 1 on 1 disable S2 DIP SWITCH 3 disable RT /E 5---4 CONTROL FEATURES (continued) OPTIONAL STRIP HEATER (Accessory 44) Accessory 44 Strip Heater is designed to keep ambient temperatures within the Automatic Transfer Switch enclosure at acceptable levels. This accessory consists of a mounting bracket with strip heater, thermostat, and terminal block. A transformer with fuses is included when the power for the assembly is derived from voltages above 120 V ac. The 120 V ac customer powered assembly does not include a transformer. This optional accessory is available factory installed or in kit form. thermostat dial turn counterclockwise to lower temperature Turn the thermostat’s dial to required setting as shown. turn clockwise to raise temperature Figure 5–4. Thermostat. AVAILABLE KITS Controls Strip Heater – Accessory 44 Description Accessory Kit Description Accessory Kit Programmable Engine Exerciser & Source Availability Contacts 11BG K629830 120 volt customer supplied voltage (without transformer) 44A K613127–001 Serial Communication Module 72A K601110 208 – 480 volt ATS derived voltage (with transformer) 44G K613127–002 380 volt ATS derived voltage (with transformer) 44G K613127 550 – 600 volt ATS derived voltage (with transformer) 44G K613127–003 5---5 A accessories, 5–2, 5–5 auxiliary circuits, 1–2 B battery, 4–2, 5–1 buttons, push, 3–1 bypass time delay, 1–5, 2–1, 3–1 C G INDEX strip heater, 5–5 P ground, controller, 1–1 H parts, 3–1 problem, 3–2 handle, maintenance, 1–3 warning, 1–3 programmable engine exerciser, 5–2, 5–3 harness, 1–2 disconnect plugs, 3–1 R HELP 800–800–2726 (ASCO) customercare@asco.com rating label, cover cable lugs, 1–1 preparation, 1–1 inphase monitor, 5–4 catalog number, inside cover remote control features, 5–4 bypass transfer time delay, 5–4 inhibit transfer to emergency, 5–4 remote test, 5–4 remote transfer to emergency, 5–4 inspection, 3–1 replacement parts, 3–1 cleaning, 3–1 installation, 1–1 connections engine control contact, 1–2 line, 1–1 contact position indicators, 1–3 contacts auxiliary, 1–2 engine control, 1–2 main, 1–3, 3–1 source availability signal, 5–2 control features, 5–1 load disconnect, 5–4 motor load transfer, 5–4 plant exerciser, 5–1, 5–2, 5–3 controller, 4–1, 4–2 codes, cover cover removal, 4–2 disconnecting, 3–1 time delay potentiometers, 4–2 D DIP Switches, 4–1, 4–2, 5–1, 5–2, 5–4 E electrical operation, 1–5 engine exerciser, 5–1, 5–2, 5–3 engine starting contacts, 1–2 F features, see control features frequency, pickup and dropout settings, 4–1 functional test, 1–3, 1–4, 1–5 Printed in U.S.A. I S L service, call 800–800–2726 (ASCO) labels, engine starting contacts, 1–2 inputs / outputs, 1–2 rating, cover set engine exerciser, 5–1, 5–2, 5–3 settings changing, 4–1 factory, 4–1 frequency, 4–1 phase, 4–1 time delay, 4–1 voltage, 4–1 lights, 1–4, 5–1 load disconnect feature, 5–4 lubrication, 3–1 M source accepted lights, 1–4, 1–5 maintenance, preventive, 3–1 T manual load transfer, 3–2 warning, 3–2 terminal block, 1–2 test, functional, 1–3, 1–4, 1–5 manual operation, 1–3 warning, 1–3 time delay adjustment, 4–1 gen–set cooldown, 4–1 how to change, 4–2 override momentary outages, 4–1 transfer to emergency, 4–1 transfer to normal, 4–1 motor load transfer feature, 5–4 N nameplate, cover O timer (plant exerciser), how to set, 5–1, 5–2, 5–3 operation electrical, 1–5 manual, 1–3 illustration of, 1–3 warning, 1–3 sequence of, 2–1 transfer switch position lights, 1–4, 1–5 transfer test, 1–5, 3–1 trouble–shooting, 3–2 optional accessories programmable engine exerciser & source availability signal contacts, 5–2, 5–3 serial communication module, 5–5 V voltage, phase, 4–1 voltage, pickup and dropout settings, 4–1 Copyright --- ASCO Power Technologies, L.P. 2011
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