Operator's Manual
Series 300 Automatic Transfer Switches Ddesign, 30 through 230 A
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. An experienced licensed electrician must install the ATS.
Refer to the outline and wiring drawings provided with your ASCO Series 300 ATS for all installation details.
ASCO Series 300 Automatic Transfer Switches (ATSs) are Listed under Underwriters Laboratories UL 1008 Standard for Safety for Automatic Transfer Switches. ASCO Series 300s are also Listed under CSA C22.2 No. 178 Standard for Automatic Transfer Switches. All control features are UL Component Recognized, which assures that ASCO automatic transfer switches meet OSHA Safety Requirements and will be acceptable to electrical inspectors.
ASCO Series 300 Automatic Transfer Switches are suitable for emergency and standby system applications. They meet emergency system rating requirements as defined in National Electrical Code (NEC) Article 700 and UL 1008. Also, they are suitable for the requirements of NEC Article 517 Health Care Facilities, NEC Article 701 Legally Required Standby Systems, NEC Article 702 Optional Standby Systems, NFPA 99 Health Care Facilities, and NFPA 110 Emergency and Standby Power Systems.
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.
30200 amp. sizes
TABLE OF CONTENTS
section
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SEQUENCE OF OPERATION . . . . . . . . . . . . . 2
TESTING & SERVICE . . . . . . . . . . . . . . . . . . . . 3
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . 4
CONTROL FEATURES . . . . . . . . . . . . . . . . . . . 5
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . back cover
50 Hanover Road, Florham Park, New Jersey 079321591 USA For sales or service call 1 800 8002726 (ASCO) www.ascopower.com
381333228 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.
A typical Catalog Number is shown below with its elements explained. The example is for a Series 300 ATS with switched neutral, 3 pole, 200 amp, 480 V, in a Type 1 enclosure:
D 300
B3
200
N1 C
Neutral B switched C overlapping
blank solid
load power connections
Phase Poles 2 single Ø 3 three Ø
Amperes
30 70 104 150 200 *
* 200 amp. limited to 480 volts
Voltage
A 115 B 120 C 208 D 220 E 230 F 240 H 380 J 400
K 415 L 440 M 460 N 480 P 550 Q 575 R 600
Controller
1 standard 1X if
accessories ordered
terminals for switch position contacts
membrane controls
Enclosure C type 1 F type 3R G type 4 L type 12
blank open type
Controller
emergency power connections
Transfer Switch
maintenance handle
(see WARNING under Manual
Operation)
terminals for engine start
contacts
normal power connections
cable spacers (see INSTALLATION)
200 amp. size in typical enclosure with location of customer connections
Catalog Number Identification
A typical Catalog Number is shown below with its elements explained. The example is for a Series 300 ATS with switched neutral, 3 pole, 230 amp, 480 V, in a Type 1 enclosure:
D 300
B3
230
N1 C
Neutral
B switched C overlapping
blank solid
Phase Poles 2 single Ø 3 three Ø
Amperes 230 **
** 230 amp. limited to 480 volts
Voltage
A 115 B 120 C 208 D 220 E 230 F 240
H 380 J 400 K 415 L 440
M 460 N 480
Controller
1 standard 1X if
accessories ordered
terminals for switch position contacts
membrane controls
Enclosure
C type 1 F type 3R G type 4 L type 12
blank open type
load power connections
emergency power connections
Transfer Switch
maintenance handle (see WARNING under
Manual Operation)
terminals for engine start contacts
normal power connections
cable spacers (see INSTALLATION)
Controller
230 amp. 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.
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.
Protect the automatic transfer switch from construction grit and metal chips to prevent malfunction or shortened life of the ATS.
Mount the ASCO ATS vertically to a rigid supporting structure. Level all mounting points by using flat washers behind the holes to avoid distortion of the switch.
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 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.
Three cable spacers are included with 150, 200, and 230 ampere transfer switches. When installing power cables, run the cables through the cable spacers as shown in Figure 11. Position cable spacers within 1½ inches from lugs.
Line Connections
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.
The cable spacers must be located as shown for 150, 200, and 230 ampere transfer switches.
cable spacers
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.
It is unnecessary to remove pole covers from the transfer switch. If you do remove them, reinstall them carefully.
Testing Power Conductors
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.
1 ½ inch approximate
cable spacer
Figure 11. Cable spacers for 150, 200, & 230 amp. transfer switches.
1 --- 1
INSTALLATION (continued)
Engine Starting Contacts
Controller Ground
Customer connections for engine control contact connections are located on 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 12 and Table A.
Table A. Engine start connections.
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.
When normal source fails
contact closes
contact opens
Terminals on transfer switch
TB14 and TB15
TB14 and TB16
Harnesses
The transfer switch is connected to the left side of the controller by a plugin harness (two plugs).
ENGINE STARTING CONTACTS ( SHOWN DEENERGIZED )
left side of switch
TOP STUD
MIDDLE STUD
BOTTOM STUD
14
TS 15
NR
16 NR
TB 14 TB 16
TB 15
Figure 12. Engine starting contact label and terminals located on the transfer switch.
Auxiliary Circuits
Connect auxiliary circuit wires to appropriate terminals on transfer switch 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.
Connections to Controller for other Control Features (located on bottom of Controller)
Load Disconnect Programmable
Feature
Engine Exerciser
Connections
connection,
(see Wiring Diagram if provided
& refer to page 54 (refer to
for DIP switch settings) page 52)
Remote Control Features Connections (refer to the Wiring Diagram &
page 54 for DIP switch settings) Each control contact must be suitable
for a 5 V DC low energy circuit.
for factory use only
Figure 13. 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.
Position of the transfer switch is indicated here
weight marked N (normal) and E (emergency)
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.
maintenance handle
1 Manual Operation Test
A maintenance handle is provided on the Transfer Switch for maintenance purposes only. Manual operation of the transfer switch should be checked before it is energized (operated electrically).
weight
floating weight
Do not manually operate the transfer switch until both power sources are disconnected: open both circuit breakers.
1. After deenergizing both power sources, open the enclosure door. Locate and the maintenance handle on the left side of the transfer switch frame. See Figure 14.
2. Grasp the attached maintenance handle and turn it with thumb and fingers as shown to manually operate it. The maintenance handle turns the opposite direction of the weight. Move it up or down as shown to manually operate the transfer switch. It should operate smoothly without any binding. If it does not, check for shipping damage or construction debris.
3. Return the transfer switch to the Normal position.
Note: If Normal and Emergency connections are reversed this operation is also reversed.
Now continue to 2 Voltage Checks on next page.
With ALL POWER OFF grasp maintenance handle and turn it quickly with your thumb and fingers.
Figure 14. Maintenance handle and positions.
1 --- 3
INSTALLATION (continued)
observe these lights
Figure 15. 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.
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
Verify that the feeders have been connected to the proper lugs.
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 !
Perform steps 1 through 6 at the right. Observe the status lights. See Figure 15.
O Black circle means light is on. P White circle 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. Also see page 41 for the HILOW voltage adjust setting in the controller. The LOW setting shifts all voltage settings down 4.2%; for example, 240 V to 230V.
Use an accurate voltmeter to check phase to phase and 2 phase to neutral voltages present at the transfer switch normal source terminals.
Close the emergency source circuit breaker. (Start generator, 3 if necessary.) The Emergency Source Accepted light should come on.
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.*
Use a phase rotation meter to
5
check phase rotation of emergency source; it must be the
same as the normal source.
A BC
Shut down the enginegenerator, 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.
Source Accepted
Normal Emergency
Now continue to 3 Electrical Operation on next page.
1 --- 4
press this button
INSTALLATION (continued)
observe these lights
Figure 16. Standard controls and indicators.
3 Electrical Operation
First check nameplate on transfer switch; rated voltage must be the same as normal and emergency line voltages.
Close the enclosure door first !
Perform steps 1 through 8 at the right. Observe the status lights. See Figure 16.
O Black circle means light is on. P White circle means light is off.
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.
This completes the Functional Test of the ASCO Series 300 Automatic Transfer Switch. Leave the enginegenerator starting control in the automatic position.
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
2
button until the engine starts and runs. This should happen
within 15 sec.
Source Accepted Normal
Emergency
Transfer Test
3
The Emergency Source Accepted light should come on.
Source Accepted
Normal Emergency
The transfer switch should
transfer to the Emergency
4
position. The Emergency Transfer Switch Position light
should come on and the Normal
light should go off.
Transfer Switch Position
Normal Emergency
If the transfer to emergency
delay is used the transfer
5
should occurs after a time delay (up to 5 minutes).
For immediate transfer press
the Bypass Time Delay button.
Bypass Time Delay
The transfer switch should
transfer back to the Normal
6
position. The Normal Transfer Switch Position light should
come on and the Emergency
light should go off.
Transfer Switch Position
Normal Emergency
If the retransfer to normal delay
is used the retransfer should
7
occur after a time delay (up to 30 minutes).
For immediate retransfer press
the Bypass Time Delay button.
Bypass Time Delay
The unloaded running delay
keeps the generator running for
8
5 minutes (cooldown period). Then the generator should stop
and the Emergency Source
Accepted light should go off.
Source Accepted
Normal Emergency
1 --- 5
SECTION 2 SEQUENCE OF OPERATION
Lights show position of transfer switch. Lights show the sources accepted.
Transfer To Emergency
The sequence for load transfer to emergency source begins automatically when normal source voltage falls
Light for builtin engine exercise timer:
³ blinks rapidly when button is held 5 sec. while being set
below the preset dropout point or when Transfer Test button is pressed.
³ blinks slowly when button is released (set)
An under voltage condition on any phase of the normal source is de-
and during 20 min. exercise period.
tected by the sensor.
³ stays on after engine stops (exerciser is
When the normal
enabled for weekly
source voltage fails or
operation)
the Transfer Test
See page 51
button is pressed, the SE relay de-energizes and relay NR begins
Hold 15 sec. to Press to cancel the Hold 5 sec. to set start the engine active exercise period 20 min. engine exercise generator and to (stops engine now or period immediately (engine
for complete instructions
its timing cycle (1 or 3 transfer the load after cooldown) See starts) and weekly thereafter.
seconds, momentary
to emergency. page 51.
Figure 21. Membrane controls and indicator lights.
normal source outage
delay). The NR relay is provided with a time delay on
Retransfer to Normal
dropout to override momentary outages and prevent nuisance starting of the engine-driven generator. If the normal source voltage returns above the sensor dropout setting before the time delay expires, the NR relay timing cycle is reset to zero and relay SE energizes.
The sequence for load retransfer to the normal source automatically begins when the voltage sensor detects restoration of the normal source. The voltage level must rise above the preset pickup point on all phases 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.
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.
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.
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.
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.
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
DISCONNECTING THE CONTROLLER
For high reliability and long life for the ATS:
Operate the switch at least once a month. Perform this 4step Electrical Operation Test (test with load transfer).
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
Do not unplug the controller until step 1a. or 1b. below is completed.
Transfer Switch Test
1. Press and hold the door-mounted Transfer Test button
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.
3. The Transfer Switch will operate back to the Normal
position after the Retransfer To Normal Delay (up to 30 minutes). For immediate retransfer press Bypass Time Delay button.
4. Unloaded Running (Engine Cooldown) Delay allows
engine to run unloaded for 5 minutes.
Checklist for Yearly Inspection
S Clean the enclosure. Deenergize all sources, then brush and vacuum away any excessive dust accumulation. Remove moisture with a clean cloth.
S 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.
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 625550001 (Castrol EndurexR 4000 lubricant).
S Check all cable connections & retighten them. Torque to values shown on transfer switch label.
Replacement parts. When ordering parts provide the Serial and Catalog Nos. from the transfer switch nameplate. Contact ASI. In the US call 1800800ASCO (2726)).
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. 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.
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.
Reconnecting the Plugs
Do not reconnect the controller until step 1a. or 1b. and 2 below are 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. Reconnect the signal wires connected to the appropriate engine start terminals on the transfer switch. See Section 1, Engine Starting Contacts.
3. The harness plugs and sockets are keyed. Carefully align the plugs with the sockets and press straight in until both latches click.
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. 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.
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 13, 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
Proceed with care! The automatic
furnished on the switch and review their operation.
transfer switch is energized.
Refer to Section 5, Control Features.
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.
Transfer switch does not transfer the load to emergency source after the gen-set starts.
Transfer switch does not transfer the load to normal source when normal returns or when Transfer Test button is released.
Gen-Set does not stop after load retransfer to the normal source.
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.
3 VOLTAGE --
Wait for Transfer to Emergen- Generator output circuit cy Delay (0 to 5 min.) to time breaker must be closed. out. For immediate transfer, Generator frequency must be press the Bypass Time Delay at least 57 Hz. button. If Motor Load Transfer is active, wait for inphase condition (see below).
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.
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).
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).
Wait for the 5 minute
Starting control must be in
Unloaded Running Delay to automatic position.
--
time out.
Trouble-Shooting the Motor Load Transfer Feature (refer to page 54)
3. Press and hold Transfer Test button. The load
should transfer to emergency source when meter
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
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
phasetophase voltage) between Transfer Switch
should occur when the needle is near 0 volts. If
terminals NA and EA.
retransfer does not occur after the time delay, the
2. Manually start generator. Voltmeter needle should sweep back and forth at a regular rate between 0 and about twice system voltage.
Motor Load Transfer feature is not operating. 5. For immediate retransfer, press the Bypass Time
Delay button. Then disconnect the voltmeter.
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 18008002726. Furnish the Serial No., Bill of Material (BOM) No., and Catalog No. from transfer switch nameplate.
3 --- 2
SECTION 4 ADJUSTMENTS
Time Delay Adjustment
Standard time delays are set to customer specifications (if none specified, standard factory settings are used).
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.
Table 4-1. Time Delay Settings
DESCRIPTION
LABELS
Override Momentary Normal Source Outages
TD ES
Transfer to Emergency
Override Momentary Emergency S. Outages
Retransfer to Normal
Unloaded Running (Engine Cooldown)
TIMER N/E
--
TIMER E/N
--
FACTORY SETTING
3 seconds
0 minutes (full ccw) 4 seconds 30 minutes (full cw) 5 minutes
ADJUSTMENT RANGE 1 second
3 seconds 0 to 5
minutes
non-adjustable
1 second to 30 minutes
non-adjustable
S3 DIP SWITCH Actuator 1 on
Actuator 1 off
--
--
--
--
--
--
--
--
11
ADJUSTMENT POTENTIOMETER
--
P2 -- P1 --
Sensor Adjustments
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 42. Use Tables 4-2 and 43 for settings and corresponding DIP switch actuators.
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.
3 3 12 12 12 12
Table 4-2. Voltage and Frequency Settings. ( Shaded DIP switches are standard factory settings).
DESCRIPTION
LABELS SETTING
% of nominal FACT. SET ADJ RANGE
S1 DIP SWITCH
PU / N
Pickup
90 %
95 % * 90 %
Actuator 3 off Actuator 3 on
Normal Source Voltage
DO / N
Dropout
Emergency Source Voltage
Emergency Source Frequency
60 / 50 Hz
Pickup Dropout Pickup Dropout
60 / 50 Hz
85 %
90 % 75 % 95 % 85 % 60 Hz
90 % *
85 %
80 %
70 % non-adjustable non-adjustable non-adjustable non-adjustable
60 Hz 50 Hz
Actuator 1 off Actuator 2 off Actuator 1 on Actuator 2 off Actuator 1 off Actuator 2 on Actuator 1 on Actuator 2 on
Actuator 4 off
Actuator 4 on
4466
Voltage Phases
3, 1
3/1
3
3 phase 1 phase
Actuator 6 off Actuator 6 on
* 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)
DESCRIPTION Voltage Adjust (4.2%)
LABELS
LOW / HI
FACTORY SETTING HI
ADJUSTMENT LOW HI
S3 DIP SWITCH Actuator 2 off Actuator 2 on
4 --- 1
22
ADJUSTMENTS (continued)
Do not make any setting changes while the controller is energized.
cover
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.
4. Locate the appropriate adjustment potentiometer or DIP switch for the setting that you want to change. Refer to Table 4-1 and Table 42 on page 4-1 and Figure 4-2, Figure 43, Figure 44 on page 42.
5. Use a small screwdriver to turn the potentiometer clockwise to increase the time delay or counterclockwise to decrease it. See Figure 4-3.
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.
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.
harness plugs
S3 DIP switch S1 DIP switch
S2 DIP switch
J5 battery on/off jumper
P1 retransfer to normal time delay
P2 transfer to emergency time delay
Figure 4-2. Location of potentiometers.
clockwise to increase
P1 or P2 potentiometer
counterclockwise to decrease
Close the enclosure door.
Figure 4-3. Changing time delay potentiometers.
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.
DIP switches
SW1 SW2 SW3
actuator
(8 on each DIP switch)
off
on
10. Turn the engine starting control to automatic.
Figure 4-4. Setting DIP switch actuators.
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 42 for location of DIP switches, battery (provided), and jumper block in the controller.
BUILTIN ENGINE EXERCISER
The engine exerciser included in ASCO Series 300 Automatic Transfer Switches provides a once a week 20minute 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 42 on page 42.
Fill in day and time set. Week Day ______ Time _______.
DIP Switch Settings
55
FUNCTION
Std. Timer Enabled Std. Timer Disabled Exercise without
Load Exercise with Load
S1 DIP SWITCH Actuator 7 on Actuator 7 off
Actuator 8 off
Actuator 8 on
8
8
77
S2 DIP SWITCH
Actuator 5 on
Actuator 5 on
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
If Exercise with Load is set, retransfers load to
and every week hereafter (generator starts).
Normal, then stops generator after min. cooldown.
If Exerciser with Load is set,
transfers load to Emergency.
Figure 5-1. Operator panel pushbuttons and light.
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.
Exercise without Load, DIP Switch S1, Actuator 8 off
How to Set BuiltIn Timer
8 8
Step
1 2 3 4
Push Button Set Engine Exerciser hold 5 sec.
release
press Bypass Time Delay
--
Status Light
blinks rapidly OPOPOP
blinks slowly OPPOPP
O stays on
O stays on
Function
set exercise period exercise period now active cancel active exercise period
generator off
Explanation
Exercise the generator now and every week at this time hereafter.
Generator starts and runs. Generator stops.
Exerciser enabled; repeats every 7 days.
Exercise with Load, DIP Switch S1, Actuator 8 on
How to Set BuiltIn Timer
Step 1 2
Push Button Set Engine Exerciser hold 5 sec.
release
3
press Bypass Time Delay
4
--
Status Light
blinks rapidly OPOPOP
blinks slowly OPPOPP
blinks slowly OPPOPP
O stays on
Function
set exercise period exercise period now active cancel active exercise period
generator off
Explanation
Exercise the generator now and every week at this time hereafter.
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
2line display
3 buttons
connections for source availability signal contacts
Figure 52. 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 53 and the wiring diagram.
Contact ratings: 2 amps @ 30 Vdc, 0.5 amp. @ 125 Vac resistive
SOURCE AVAILABILITY SIGNALS
2 AMPS @ 30 VDC, resistive 0.5 AMP @ 125 VAC, resistive contacts shown deenergized
Figure 53. Source availability signal contacts.
Programmable Engine Exerciser
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 42 and page 53) must be turned on to maintain the settings and to allow programming with the normal and emergency power turned off (page 51).
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.
55
DIP Switch Settings in the Controller
(see page 42)
FUNCTION
Opt. Timer Enabled
Opt. Timer Disabled Exercise without
Load Exercise
with Load
S1 DIP SWITCH Actuator 7 off Actuator 7 off
Actuator 8 off
Actuator 8 on
8
8
77
S2 DIP SWITCH
Actuator 5 off
Actuator 5 on
Shaded DIP switches are standard factory settings.
5 --- 2
CONTROL FEATURES (continued) How to Set Optional Programmable Engine Exerciser (part of Acc. 11BG module)
Hazardous voltage capable of causing shock, burns, or death is used in this transfer switch. Deenergize both Normal & Emergency power sources before programming the exerciser.
Navigating the Menu
Use the UP and DOWN arrow keys to move through the displays.
Fast/Slow Adjust
Changing the Parameters
Use the UP and DOWN arrow keys to move though the displays to the parameter to be changed.
Daylight Saving Time Adjust
Date
Push the ENTER key to start the
editing process. The first
Time
parameter will flash. Use the UP
and DOWN arrow keys to adjust
the parameter to the desired value and press the ENTER key
Run TIme
to save the value. The next
parameter will now flash. Repeat
Start TIme
the process until each parameter
is properly configured.
Engine Exerciser Display
Engine Exerciser
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.
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 biweekly ("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"
Fill in your settings for future reference
NOTE: When choosing biweekly operation, the exerciser will always run on the week designated "(1)" on the date display.
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".
NOTE: During total power outages, power to the accessory is maintained by a battery in the Controller (see page 42). Be sure that the 9volt alkaline battery is fresh and enabled (jumper in ON position) so that the time and date settings are not lost.
Date Display
The Date Display shows the present system date. The format is "day of week (week) month/day of month/year".
NOTE: Week is either week 1 or week 2. This is used in conjunction with the biweekly timer.
Daylight Savings Time Adjust Display
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:
Part No. 629857001*
629857002*
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
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.
Weekly or Biweekly
Every = weekly Alt = biweekly
Day of Week Sun through Sat
Start Time
0 23 hour 0 59 minute
Run Time
0 23 hour 0 59 minute 30 min. is default setting
Date exerciser was set ______________________________________ 5 --- 3
CONTROL FEATURES (continued)
INPHASE MONITOR FOR MOTOR LOAD TRANSFER
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 enable
S1 DIP SWITCH Actuator 5 on
LOAD DISCONNECT FEATURE
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 amps 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 presignal before transfer.
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:
55
disable
Actuator 5 off
Delay Before Transfer
78 78 78 78
Shaded DIP switches are standard factory settings.
Note If the Motor Load Transfer feature is enabled, it will be activated following the Load Disconnect Feature Delay Before Transfer delay.
LD TDBT 0 (disable) 3 seconds 10 seconds 20 seconds
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 enable
S2 DIP SWITCH Actuator 6 on
disable
Actuator 6 off
66
*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 customersupplied 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 CP67)
RTSW disable
S2 DIP SWITCH Actuator 3 on
enable
Actuator 3 off
33
Remote Transfer to Emergency (CP89)
RT /E disable
S2 DIP SWITCH Actuator 2 on
22
enable
Actuator 2 off
Bypass Transfer Time Delay (CP1213)
TD E/N BYP. disable
S2 DIP SWITCH Actuator 1 on
11
enable
Actuator 1 off
Inhibit Transfer to Emergency (CP1011)
N/E INHIB. disable
S2 DIP SWITCH Actuator 4 on
44
enable
Actuator 4 off
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.
Turn the thermostat's dial to required setting as shown.
thermostat dial
turn counterclockwise to lower temperature
turn clockwise to raise temperature
Figure 54. Thermostat.
Controls
Description
AVAILABLE KITS FROM ASCO
Strip Heater Accessory 44
Accessory
Kit
Description
Accessory
Kit
Programmable Engine Exerciser & Source Availability Contacts
Serial Communication Module
11BG 72A
K629830 K601110
120 volt
customer supplied voltage
44A
K613127001
(without transformer)
208 480 volt ATS derived voltage
(with transformer)
44G
K613127002
380 volt ATS derived voltage
(with transformer)
44G
K613127
550 600 volt ATS derived voltage
(with transformer)
44G
K613127003
5 --- 5
A
accessories, 52, 55 auxiliary circuits, 12
B
battery, 42, 51 buttons, push, 31 bypass time delay, 15, 21, 31
C
cable lugs, preparation, 11
catalog number, cover cleaning, 31 connections
engine control contact, 12 line, 11 contacts auxiliary, 12 engine control, 12 main, 13, 31 source availability signal, 52 control features, 51 load disconnect, 54 motor load transfer, 54 plant exerciser, 51, 52, 53 controller, 41, 42 codes, cover cover removal, 42 disconnecting, 31 time delay potentiometers, 42
D
DIP Switches, 41, 42, 51, 52, 54
E
electrical operation, 15 engine exerciser, 51, 52, 53 engine starting contacts, 12
F
features, see control features frequency, pickup and dropout, 41 functional test, 13, 14, 15
G
ground, controller, 11
Printed in U.S.A.
INDEX
H
P
handle, maintenance, 13 warning, 13
harness, 12 disconnect plugs, 31
HELP 8008002726 (ASCO) customercare@asco.com
I
inphase monitor, 54
inspection, 31
installation, 11
L
labels, engine starting contacts, 12 inputs / outputs, 12 rating, cover
parts, 31 problem, 32 programmable engine exerciser, 52,
53
R
rating label, cover remote control features, 54
bypass transfer time delay, 54 inhibit transfer to emergency, 54 remote test, 54 remote transfer to emergency, 54 replacement parts, 31
S
service, call 8008002726 (ASCO) set engine exerciser, 51, 52, 53
lights, 14, 51
load disconnect feature, 54
lubrication, 31
M
maintenance, preventive, 31
manual load transfer, 32 warning, 32
manual operation, 13 illustration of, 13 warning, 13
motor load transfer feature, 54
N
nameplate, cover
O
operation electrical, 15 manual, 13 illustration of, 13 warning, 13 sequence of, 21
optional accessories programmable engine exerciser & source availability signal contacts, 52, 53 serial communication module, 55 strip heater, 55
settings changing, 41 factory, 41 frequency, 41 phase, 41 time delay, 41 voltage, 41
source accepted lights, 14, 15
T
terminal block, 12
test, functional, 13, 14, 15
time delay adjustment, 41 genset cooldown, 41 how to change, 42 override momentary outages, 41 settings, 41 transfer to emergency, 41 transfer to normal, 41
timer (plant exerciser), how to set, 51, 52, 53
transfer switch position lights, 14, 15
transfer test, 15, 31
troubleshooting, 32
V
voltage, phase, 41
voltage, pickup and dropout settings, 41
Copyright ASCO Power Technologies, L.P. 2009
Acrobat Distiller 8.1.0 (Windows)
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