Installation Operator’s Manual 381333-203 E 7 Installation 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).
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ASCO 7000 SERIES ACTS Automatic Closed-Transition Transfer Switches H design 600-1200 A, P-design 600-800 A Operator's Manual 381333-203 E 9/2016 DANGER is used in this manual to warn of a hazard situation which, if not avoided, will result in death or serious injury. An experienced licensed electrician must install the ATS. Refer to the outline and wiring drawings provided with your 7000 Series ACTS for all installation and connection details and accessories. WARNING is used in this manual to warn of a hazardous situation which, if not avoided, could result in death or serious injury. Refer to Group 5 Controller User's Guide 381333126 for ATS status display messages, time delays, pickup & dropout settings, and adjustments. CAUTION is used in this manual to warn of a hazardous situation which, if not avoided, could result in minor or moderate injury. 600-1000 A size 1200 A size Operator's Manual 7000 Series ATS Table of Contents Rating Label..............................................................................................................................................................3 Nameplate ................................................................................................................................................................3 Catalog Number Identification ..................................................................................................................................4 Installation .................................................................................................................................................................. 5 Removing the Shipping Skid (large ACTSs) ............................................................................................................5 Supporting Foundation .............................................................................................................................................5 Mounting ...................................................................................................................................................................5 Line Connections......................................................................................................................................................5 Testing Power Conductors .......................................................................................................................................5 Connecting Power Conductors.................................................................................................................................4 Controller Ground .....................................................................................................................................................5 Harnesses ................................................................................................................................................................. 5 Engine Starting .........................................................................................................................................................6 Auxiliary Circuits .......................................................................................................................................................6 Functional Test ...............................................................................................................................................................6 Functional Test Manual Operation Test ................................................................................................................7 Functional Test Voltage Checks............................................................................................................................8 Functional Test - -Electrical Operation ....................................................................................................................9 Testing & Service ................................................................................................................................................... 10 Transfer Test ..........................................................................................................................................................10 Preventive Maintenance .........................................................................................................................................10 Replacement Parts .................................................................................................................................................10 Disconnecting the Controller ..................................................................................................................................10 Manual Load Transfer ............................................................................................................................................11 Trouble-Shooting ....................................................................................................................................................11 Index .......................................................................................................................................................................... 12 2 381333-203 E 7000 Series ATS Rating Label Each automatic closedtransition 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. Operator's Manual Nameplate The Transfer Switch nameplate includes data for each specific 7000 Series ACTS. Use the switch only within the limits shown on this nameplate. A typical catalog number is shown on next page with its elements explained. Do not exceed the values on the rating label. Exceeding the rating can cause personal injury or serious equipment damage. power connections ground lug Transfer Switch field connections terminal block TB Transfer Control & lights Group 5 Controller ground lug power connections 6001000 A sizes in typical enclosure with location of customer connections 381333-203 E 3 Operator's Manual 7000 Series ATS Catalog Number Identification Typical 7000 Series catalog no. for Jdesign switched neutral, 3 pole, 800 amp, 480 V, ACTS in Type 1 enclosure: H or P 7ACTS Frame & Series B Neutral A-solid B-switched blanknone 3 Phase Poles 2-single 3-three 800 Amperes 600 800 1000* 1200* *H design only N Voltage C 208 K 415 D 220 L 440 E 230 M 460 F 240 N 480 G 277 P 550 H 380 Q 575 J 400 R 600 5 Controller 5- standard 5X- if accessories ordered C Enclosure C- Type 1 F- Type 3R G- Type 4** L- Type 12** blank- open type ** available 6001000 A sizes only field connections terminal block TB ground lug power connections Transfer Switch Transfer Control & lights Group 5 Controller power connections 1200 A size in typical enclosure with location of customer connections 4 381333-203 E Installation Installation ASCO Series 7000 Automatic ClosedTransition 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 (large ACTSs) 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 ACTS 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 is poured, use interlocking conduit spacer caps or a wood or metal template to maintain proper conduit alignment Mounting Refer to the applicable enclosure outline drawing furnished with this switch and mount the automatic transfer switch according to details and instructions shown on diagram. Line Connections A Wiring Diagram is furnished with the ASCO Series 7000 ACTS (separate from this manual). Refer to this drawing. All wiring must be made in accordance with the National Electrical Code and local codes. Deenergize 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. Operator's Manual 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. Protect the automatic transfer switch from construction grit and metal chips to prevent malfunction or shortened life of the ATS. Connecting Power Conductors After the power cables have been tested, connect them to the appropriate terminal lugs on the transfer switch as shown on the wiring diagram provided with the switch. Make sure the lugs provided are suitable for use with the cables being installed. Standard terminal lugs are 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. Controller Ground A grounding wire must be connected to the controller's lower left mounting stud. Because the controller is mounted on the enclosure door, a conductive strap must be used between the enclosure and the door. This connection provides proper grounding which does not rely upon the door hinges. Harnesses The transfer switch is connected to the left side of the controller by a plugin harness (two plugs). 381333-203 E 5 Operator's Manual Installation Installation Engine Starting Contacts All customer connections, including the engine control contact connections, are located on terminal block TB which is mounted on the top right side of the enclosure. Refer to the wiring diagram provided with the automatic transfer switch and connect the engine start wires to the appropriate terminals. See Figure 1 and Table A. Table A. Engine start connections When normal source fails Terminals on transfer switch contact closes TB1 and TB2 contact opens TB1 and TB3 Note: To temporarily disable engine control from the automatic transfer switch you can unplug J3 from the small P3 receptacle at the bottom of the assembly. Be sure to reconnect plug J3 to the P3 receptacle for automatic transfer switch operation. Auxiliary Circuits Connect auxiliary circuit wires to appropriate terminals on the transfer switch. Note the control features that are furnished on this switch. Make the necessary auxiliary connections by referring to the Wiring Diagram. engine start connections on customer terminal block TB Figure 1. Customer terminal block on the top right side of enclosure Functional Test The Functional Test consists of three checks: · 1 - Manual Operation Test, page 7 · 2 - Voltage Checks, page 8 · 3 - Electrical Operation, page 9 Do these checks in the order presented to avoid damaging the ACTS. 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. Emergency contacts (upper shaft) window indicators O is open C is closed Normal contacts (lower shaft) contact positon indicators (right side) Figure 2. Contact position indicators. Shown with Emergency open and Normal closed Continue to 1 Manual Operation Test on next page. 6 381333-203 E Installation Installation 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). Left side of transfer switch Operator's Manual 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 3, 4, 5 Table B. 2. Move the maintenance handle up or down as shown to manually operate the transfer switch. The transfer switch should operate smoothly without binding. If it does not, check for shipping damage or construction debris. Operate both upper and lower contact shafts. 3. Return the transfer switch to the Normal position. Observe that the window indicators (right side) show the upper shaft O (Emergency open) and the lower shaft C (Normal closed). Remove the maintenance handle and store it on the frame in the clips provided. Table B. Maintenance handle positions ATS Position Handle Indicators up Normal E = O upper contacts open up N = C lower contacts closed Emergency down down E = C upper contacts closed N = O lower contacts open Note: If Normal and Emergency connections are reversed this operation is also reversed. Now continue to 2 Voltage Checks on next page Emergency source contact shaft hub Maintenance Handle Storage Clip Normal source contact shaft hub Figure 3 Maintenance handle and its storage clips. handle hub frame UP opens the Emergency source contacts UPPER SHAFT DOWN closes the Emergency source contacts Figure 4. Emergency (upper shaft) operation handle hub UP closes the Normal source contacts LOWER SHAFT frame DOWN open the Normal source contacts Figure 5. Normal (lower shaft) operation. 381333-203 E 7 Operator's Manual Installation Installation observe these lights Figure 6 Standard controls and indicators. 2 Voltage Checks First check nameplate on transfer switch; rated voltage must be the same as normal and emergency line voltages. Before energizing the switch check to be sure that both normal and emergency contacts are not left in the closed position. Verify that the feeders have been connected to the proper lugs. 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 6. Black square means light is on. 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 381333126 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 Close the normal source circuit breaker. The Transfer Switch 1 Connected To Normal and the Normal Source Accepted lights should come on. Use an accurate voltmeter to check phase to phase and phase 2 to neutral voltages present at the transfer switch normal source terminals. Close the emergency source circuit breaker. (Start generator, 3 if necessary.) The Transfer Switch Connected To Normal & Emergency Source Accepted lights should come on. Use an accurate voltmeter to check phase to phase and phase 4 to neutral voltages present at the transfer switch emergency source terminals.* Use a phase rotation meter to 5 check phase rotation of emergency source; it must be the same as the normal source. Shut down the enginegenerator, if applicable. The Emergency Source Accepted light should go 6 off. Then put the starting control selector switch (on the generator set) in the automatic position. Close enclosure door. 8 381333-203 E Installation Installation Operator's Manual observe these lights operate this switch Figure 7. Standard controls and indicators. 3 Electrical Operation This procedure will check the electrical operation of the Automatic ClosedTransition Transfer Switch. . See Figure 7. The Transfer Switch Connected To 1 Normal and Normal Source Accepted lights should be on. Be sure to close the enclosure door. 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. Black square means light is on. White square means light is off. ** If you do not want closedtransition transfer, press the Closed Transition Bypass pushbutton while the controller display shows Waiting for InSync. This action causes opentransition (momentary load interruption) transfer to the opposite source, if conditions permit. Also refer to the Group 5 Controller User's Guide 381333126. This completes the Functional Test of the ACTS. Turn and hold Transfer Control switch clockwise to Transfer Test until 2 the engine starts and runs (within 15 sec.). Emergency Source Accepted light should come on. Transfer switch CE closes and then Transfer Switch CN opens (closed transition overlap). The Transfer 3 Switch Connected To Emergency light should come on and the Transfer Switch Connected to Normal light goes off (you might see and hear the brief overlap transfer). ** Transfer switch will operate back to Normal position after Feature 3A time delay. For immediate retransfer turn Transfer Control counterclockwise to 4 Retransfer Delay Bypass. The Transfer Switch Connected To Normal light should come on; Transfer Switch Connected to Emergency light should go off. The enginegenerator will stop after the Feature 2E time delay (unloaded 5 running engine cooldown). The Emergency Source Accepted light should go off. 381333-203 E 9 Operator's Manual Testing & Service TRANSFER TEST Operate the 7000 Series ACTS at least once a month by following the fivestep Electrical Operation Transfer Test procedure on page 9. PREVENTIVE MAINTENANCE Reasonable care in preventive maintenance will insure high reliability and long life for the 7000 Series ACTS. An annual preventive maintenance program is recommended. ASCO Power Services, Inc. is ASCO Power Technologies service organization for the United States and Canada. Call 1-800-800-2726 (ASCO) to request a service call and information on preventive maintenance agreements. Annual Inspection Checklist 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 ACTS enclosure. Deenergize all sources, then brush and vacuum away any excessive dust accumulation. Remove moisture with a clean cloth. Check the transfer switch contacts. De-energize all sources, then remove the transfer switch barriers and check contact condition. The nonreplaceable main contacts are designed to last the life of the transfer switch. Reinstall the barriers carefully. Maintain transfer switch lubrication. If the transfer switch is subjected to severe dust or abnormal operating conditions, renew factory lubrication on all movements and linkages. Relubricate the solenoid operator if the TS coil is replaced. Do not use oil; order lubrication kit 75100. Check all cable connections & 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 Technologies Sales Office or ASCO Power Services, Inc. In the United States and Canada call 1 800 800 ASCO ( 2726 ) Testing & Service 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 steps 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. b. 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 squeezing 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, first be sure that both normal and emergency source circuit breakers are open. Second, be sure that the standby engine starting control is still in the off position. b. If the transfer switch is in the Emergency position, first be sure that both normal and emergency source circuit breakers are 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. Close the door! 3. 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. b. If the transfer switch is in the Emergency position, first close the emergency source circuit breaker. Second close the normal source circuit breaker. 10 381333-203 E Testing & Service Operator's Manual Testing & Service MANUAL LOAD TRANSFER This procedure will manually transfer the load if the controller is disconnected. Do not manually operate the transfer switch until both power sources are disconnected (all conductors deenergized). 1. Deenergize both the normal and emergency source conductors (remove fuses or open circuit breakers.) 2. Use the maintenance handle to manually operate the transfer switch to the opposite source. First open the closed contacts, then close the other contacts. Do not leave both closed. See Manual Operation on page 6. 3. Then remove the maintenance handle. See page 6. Verify that the maintenance handle has been removed before proceeding! 4. If the transfer switch is in the Emergency position manually start the engine generator and then install emergency source fuse or close the circuit breaker. TROUBLE-SHOOTING Note any optional accessories that may be furnished on the ACTS and review their operation. Refer to any separate drawings and/or instructions that may be packed with the ACTS. 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! PROBLEM Enginegenerator set does not start when the Transfer Control switch is turned and held in Transfer Test position or when normal source fails. Transfer switch does not transfer the load to the emergency source after the enginegenerator set starts. Transfer switch does not transfer the load to normal source when normal returns or when the Transfer Control switch is released. Gen. does not stop after load retransfer to normal source. Gen. does not stop after load retransfer to normal source. Extended Parallel Time light comes on. TS Locked Out light comes on. Table D. Trouble-Shooting Checks. CHECK IN NUMERICAL SEQUENCE 1 OPERATION 2 GEN-SET 3 VOLTAGE Hold Transfer Test switch 15 Starting control must be in the seconds or the outage must be automatic position. Batteries long enough to allow for must be charged and Feature 1C time delay plus connected. Check wiring to - engine cranking and starting engine starting contacts time. Wait for Feature 2B time delay Generator output circuit Voltmeter should read at to time out. breaker must be closed. least 90% of nominal phase to Generator frequency must be phase voltage between at least 95% of nominal transfer switch terminals EA (57 Hz for a 60 Hz system.) * and EC (or EL1 and EL2 for 2 pole switches). * Wait for Feature 3A time delay Voltmeter should read at least to time out, 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). Wait for Feature 2E time delay Starting control must be in the to time out. automatic position. - Conditions of Normal or Emergency Sources not suitable for closed transition transfer. Recheck voltage and frequency of both sources. Press Alarm Reset pushbutton. CN and CE contacts are closed longer than setting in the Control Panel. Open the disconnected source circuit breaker, then call your nearest ASCO Service Center for assistance. Transfer lockout operation has occurred; transfer switch is disabled from automatic operation. Open the disconnected source circuit breaker, then call your nearest ASCO Power Services, Inc. for assistance. * 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 ASCO Power Services, Inc.: in the United States or Canada, call 18008002726. Furnish the Serial No., Catalog No., and Bill of Material (BOM) No. from the transfer switch nameplate. 381333-203 E 11 Operator's Manual A alarm reset, 11 auxiliary circuits, 6 C cable lugs, 5 catalog number, 4 cleaning, 10 connections line, 5 contact position indicators, 6 controller 8,9, disconnecting, 10 see Controller User's Guide E electrical operation, 9 Emergency Source Accepted light, 8, 9 extended parallel time, 11 F frequency, generator, 11 functional test, 6, 7, 8, 9 G ground, controller, 5 H harness, 5, 10 disconnect plugs, 10 help customercare@ascopower.com 800800ASCO (2726) INDEX I inspection, 10 installation, 5, 6, 7, 8, 9 L labels, engine starting contacts, 6 rating, 3 lights, 8, 9 lubrication, 10 M maintenance, preventive, 10 manual load transfer, 11 warning, 11 manual operation, 7 illustration of, 7 warning, 7 N nameplate, 3 Normal Source Accepted light, 8, 9 O operation electrical, 9 manual, 7 illustration of, 7 warning, 7 sequence of, 11 optional accessories see Controller User's Guide Index P parts, 10 phase rotation check, 8 problem, 11 R rating label, 3 replacement parts, 10 S settings see Controller User's Guide T test, functional, 6, 7, 8, 9 time delays, 10 see Controller User's Guide Transfer Control selector switch Retransfer Delay Bypass, 9 Transfer Test, 10 Transfer Switch Connected to Emergency light, 8, 9 Transfer Switch Connected to Normal light, 8, 9 transfer test, 9 transfer to emergency, 9 transfer to normal, 9 troubleshooting, 11 TS locked out, 11 V phase rotation check, 8 voltage, pickup and dropout settings see Controller User's Guide ASCO Power Technologies 160 Park Avenue Florham Park, NJ 07932-1591 USA Phone: 1 800 800-2726 (ASCO) for sales or service www.ascopower.com ©2016 ASCO Power Technologies. 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