asco serie 300 ats

7/24/2019 Asco Serie 300 Ats

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381333122 G50 Hanover Road, Florham Park, New Jersey 079321591 USAFor sales or service call 1 800 8002726 (ASCO) www.ascopower.com

ASCO POWER TECHNOLOGIES CANADA PO Box 1238, 17 Airport Road, Brantford, Ontario, Canada N3T 5T3

OperatorsManual

Series 300 Automatic Transfer Switches

Gdesign, 1000 through 3200 A

DANGER is used in this manual to warn of ahazardous situation which, if not avoided, willresult in death or serious injury.

WARNING is used in this manual to warn of ahazardous situation which, if not avoided, couldresult in death or serious injury.

CAUTION is used in this manual to warn of ahazardous situation which, if not avoided, couldresult in minor or moderate injury.

1000, 1200, 1600 A sizes

Refer to the outline and wiring drawings provided with your ASCO Series 300 ATS for all installation details.

Rating LabelEach automatic transfer switch contains a rating label todefine 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 orserious equipment damage.

An experienced licensed electrician must install the Automatic Transfer Switch (ATS).

TABLE OF CONTENTSsection-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 3-1. . . . . . . . . . . . . . . . . .Preventive Maintenance 3-1. . . . . . . . . . . . . . . .Transfer Test 3-1. . . . . . . . . . . . . . . . . . . . . . . . . .Disconnecting the Controller 3-1. . . . . . . . . . . .Manual Load Transfer 3-2. . . . . . . . . . . . . . . . . .Trouble-Shooting 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. . . . . . . . . . . . . . . . . . . . .


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NameplateThe Transfer Switch nameplate includes data foreach specific ASCO Series 300 ATS. Use the ATSonly within the limits shown on this nameplate.

Catalog Number Identification A typical Catalog Number is shown below with itselements explained. The example is for a GdesignSeries 300 ATS with switched neutral, 3 pole, 2000ampere, 480 V, in a Type 1 enclosure:

G 300 3 2000 N 1 C

Phase PolesNeutral

C overlapping

Amperes Voltage Controller Enclosure

B switched 1 standard

G type 4 *

C type 1F type 3R

L type 12 *

3 three 2 single

D 220C 208

E 230

K 415

M 460

J 400

L 440

N 480F 240H 380 Q 575

R 600

20001600

10001200

blank solid

blank open type

* type 4 & 12 enclosures are available

only for 1000, 1200, and 1600 A sizes

1X if accessories

ordered

30002600

3200

terminal block TB forengine start and switch

position contacts

TransferSwitch

Controller

powerconnections

powerconnections

membranecontrols

2000 ampere size in typical enclosure with location of customer connections

neutralconnections

neutralconnections


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SECTION 1 INSTALLATION

1--1

Series 300 Automatic Transfer Switches are factory wiredand tested. Installation requires skid removal thensecuring the enclosure to the supporting foundation.

Remove the Shipping SkidOpen the front doorand remove the four lag screws (two infront, two in rear) securing the enclosure to the wood skid.

Supporting FoundationThe supporting foundation for the enclosure must belevel and straight. Refer to the applicable enclosureoutline drawing included with the Series 300 for allmounting details including door opening space.

If bottom cable entry is used, the foundation must beprepared so that the conduit stubs are located correctly.Refer to the enclosure outline drawing for specified areaand location. Provide cable bending space and clearanceto live metal parts. When a concrete floor is poured, use

interlocking conduit spacer caps or a wood or metaltemplate to maintain proper conduit alignment.

MountingRefer to the applicable enclosure outline drawingfurnished with this switch and mount the Series 300according to details and instructions shown on diagram.

Auxiliary Cable Box for 10002000 ampere An auxiliary cable box is required if the power cables donot enter the enclosure directly adjacent to the terminallugs (for example, if all power cables enter the top orbottom). Order ASCO part no. 609027 if needed.

NOTICE

Do not route the power cables along the sides of the Transfer Switch.

Line ConnectionsRefer to the Wiring Diagram provided with your Series300 ATS. All wiring must be made in accordance withthe National Electrical Code and local codes.

It is unnecessary to remove pole covers from the transferswitch. If you do remove them, reinstall them carefully.

Deenergize the conductors before making anyline or auxiliary circuitry connections. Be surethat Normal and Emergency line connections arein proper phase rotation. Place engine generatorstarting control in the OFF position. Make sureengine generator is not in operation.

Testing Power ConductorsDo not connect the power conductors to the Series 300transfer switch until they are tested. Installing powercables in conduit, cable troughs and ceiling-suspendedhangers often requires considerable force. The pullingof cables can damage insulation and stretch or break theconductors strands. For this reason, after the cables are

pulled into position, and before they are connected, theyshould be tested to verify that they are not defective orhave been damaged during installation.

NOTICE

Protect the automatic transfer switch fromconstruction grit and metal chips to preventmalfunction or shortened life of the ATS.

Connecting Power Conductors After the power cables have been tested, connect themto the appropriate terminal lugs on the transfer switch as

shown on the wiring diagram provided with this Series300. Make sure the lugs provided are suitable for use with the cables being installed. Standard terminal lugsare solderless screw type and will accept the wire sizeslisted on the drawings provided with the Series 300. Becareful when stripping insulation from the cables; avoidnicking or ringing the conductor. Remove surface oxidesfrom cables by cleaning with a wire brush. Whenaluminum cable is used, apply joint compound toconductors. Tighten cable lugs to the torque specifiedon rating label.

Controller Ground A grounding wire must be connected to the controllerslower left mounting stud. Because the controller ismounted on the enclosure door, a conductive strap mustbe used between the enclosure and the door. Thisconnection provides proper grounding which does notrely upon the door hinges.

HarnessesThe transfer switch is connected to the left side of thecontroller by a plugin harness (two plugs).


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INSTALLATION (continued)

1--2

Engine Starting ContactsCustomer connections for engine control contact and TSauxiliary contacts connections are located on terminalblock TB which is mounted on the front of the transferswitch. Refer to wiring diagram provided with the Series300 ATS and connect the engine start wires to theappropriate terminals. See Figure 11 and Table A.

Table A. Engine start connections.

When normalsource fails

Terminals ontransfer switch

contact closes TB1 and TB2contact opens TB1 and TB3

Auxiliary CircuitsConnect auxiliary circuit wires to appropriate terminalson transfer switch terminal block TB as shown on the wiring diagram provided with this Series 300 AutomaticTransfer Switch. Make the necessary auxiliary connec-

tions by referring to Section 5, Control Features .

TB Terminal Block(field connections)accepts wire range2212 AWG

Engine StartingSignals

5 amps, 32 V DC5 amps resistive 28 V DC

or 120 V AC max.

TS Auxiliary ContactsFeature 14A & 14B

10 amps, 32 V DC10 amps 250 V ACgeneral purpose

F E A T U R E 7

c l o s e s t o s t a r t

F E A T U R E 8

o p e n s t o s t a r t

Figure 1-1. Connections to engine starting contactterminal block located on the Transfer Switch.

Connections to Controller for other Control Features (located on bottom of Controller):

for factoryuse only

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.

ProgrammableEngine Exerciser

connection,if provided

(refer topage 52)

Load DisconnectFeature

Connections(see Wiring Diagram& refer to page 54

for DIP switch settings)

Figure 1-2. Input / output label on the Controller showing possible connections to the lower terminal block.


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1--3

Functional TestThe Functional Test consists of three checks: manualoperation, voltage checks, and electrical operation.

NOTICE

Do these checks in the order presented to avoiddamaging the automatic transfer switch.

Read all instructions on the Wiring Diagram and labelsaffixed to the automatic transfer switch. Note thecontrol features that are provided and review theiroperation before proceeding.

1 Manual Operation Test A detachable maintenance handle is provided on the frameof the Transfer Switch for maintenance purposes only.Manual operation of the transfer switch should bechecked before it is energized (operated electrically).

Do not manually operate the transfer switch untilboth power sources are disconnected: openboth circuit breakers.

Table B. Maintenance handle positions.ATS Position Indicators

Normal

E

N

OPENupper contacts open

CLOSEDlower contacts closed

Emergency

E

N

CLOSEDupper contacts closed

OPENlower contacts open

Turn counterclockwiseto Emergency.

Turn clockwiseto Normal.

insert

handleinto hole

Grasphandlefirmly

slide hubonto shaft

Figure 1-3. Maintenance handle.

1. After deenergizing both power sources, open theenclosure door. Locate and remove the mainte-nance handle and hub stored on the transfer switchframe. Then install the hub onto the center operatorshaft and insert the handle firmly into the hole inthe side of the hub (spring fully compressed). SeeFigure 13 and 14 and Table B.

2. If the transfer switch is closed on Normal (windowshows CLOSED ), grasp handle firmly and turn itcounterclockwise. The transfer switch should operatesmoothly without binding. If it does not, check forshipping damage or construction debris.

3. Turn the handle clockwise to return the transfer switchto the Normal position. Observe that the windowindicators (left side) show the top shaft OPEN and thebottom shaft CLOSED .

Note: If Normal and Emergency connections arereversed this operation is also reversed.

4. Remove the maintenance handle and hub and store iton the frame in the place provided.

NOTICE

Verify that the maintenance handle has beenremoved before proceeding!

Now continue to 2 Voltage Checks on next page.

clockwise DOWN closesthe Normal source contacts(lower) and opens theEmergency sourcecontacts (upper)

counterclockwise DOWNcloses the Emergencysource contacts (upper)and opens the Normalsource contacts (lower)

windowindicators

OPEN orCLOSED

Emergencycontacts

Normalcontacts

contact positionindicators (left side)

Figure 1-4. Contact position indicators and maintenance handle operation.


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1--4

observe these lights

Figure 15. Standard controls and indicators.

2 Voltage ChecksFirst check nameplate on transfer switch; rated voltagemust be the same as normal and emergency line voltages.

Use extreme caution when using a meter tomeasure voltages in the following steps.Do not touch power terminals; shock, burns, ordeath could result !

Perform steps 1 through 6 at the right. Observe thestatus lights. See Figure 15.

Black circle means light is on.

White circle means light is off.

* If necessary, adjust voltage regulator on the generator

according to the manufacturers 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 adjustsetting in the controller. The LOW setting shifts all voltage settings down 4.2%; for example, 240 V to 230 V.

1

Close the normal source circuitbreaker. The Normal Transfer Switch Position and the Normal Source Accepted lights shouldcome on.

Source Accepted

NormalEmergency

2

Use an accurate voltmeter tocheck phase to phase andphase to neutral voltages pres-ent at the transfer switch normalsource terminals.

3

Close the emergency sourcecircuit breaker. (Start generator,if necessary.) The Emergency Source Accepted light shouldcome on.

Source Accepted

NormalEmergency

4

Use an accurate voltmeter to

check phase to phase andphase to neutral voltages pres-ent at the transfer switch emer-gency source terminals.*

5

Use a phase rotation meter tocheck phase rotation of emer-gency source; it must be thesame as the normal source.

A B C

6

Shut down the enginegenera-tor, if applicable. The Emergen-cy Source Accepted light should

go off. Then put the startingcontrol selector switch (on thegenerator set) in the automaticposition. Close enclosure door.

Source Accepted

NormalEmergency

Now continue to 3 Electrical Operation on next page.


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1--5

press this button

observe these lights

Figure 16. Standard controls and indicators.

3 Electrical OperationThis procedure will check the electrical operation of the Automatic Transfer Switch.

Close the transfer switch enclosure door andtighten the screws before you test electricaloperation.

Transfer Test

Both normal and emergency sources must be availableand the emergency source generator (if used) must becapable of being started in this procedure.Perform steps 1 through 8 at the right. Observe thestatus lights. See Figure 16.

Black circle means light is on.

White circle means light is off.

NOTE: If Motor Load Transfer featureis activated, then transfer may not occurimmediately after the respective timedelays. Transfer will only occur whenthe phase relationship between sourcesis correct.

This completes the Functional Test of the ASCO Series 300 Automatic Transfer Switch. Leave the enginegeneratorstarting control in the automatic position.

1

The normal source must beavailable and the generatormust be ready to start.Check that the Normal Source Accepted light is on.

Source Accepted

NormalEmergency

2

Press and hold the Transfer Test

button until the engine startsand runs. This should happenwithin 15 sec.

TransferTest

3 The Emergency Source Accepted light should come on.

Source Accepted

NormalEmergency

4

The transfer switch shouldtransfer to the Emergencyposition. The Emergency Transfer Switch Position lightshould come on and the Normal light should go off.

Transfer SwitchPosition

NormalEmergency

5

If the transfer to emergency delay is used the transfershould occurs after a time delay(up to 5 minutes).For immediate transfer pressthe Bypass Time Delay button.

BypassTime Delay

6

The transfer switch shouldtransfer back to the Normalposition. The Normal Transfer Switch Position light shouldcome on and the Emergency light should go off.

Transfer SwitchPosition

NormalEmergency

7

If the retransfer to normal delay

is used the retransfer shouldoccur after a time delay(up to 30 minutes).For immediate retransfer pressthe Bypass Time Delay button.

BypassTime Delay

8

The unloaded running delay keeps the generator running for5 minutes (cooldown period).Then the generator should stopand the Emergency Source Accepted light should go off.

Source Accepted

NormalEmergency


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Hold 15 sec. tostart the enginegenerator and totransfer the loadto emergency.

Press to cancel theactive exercise period(stops engine now orafter cooldown) Seepage 51.

Hold 5 sec. to set20 min. engine exerciseperiod immediately (enginestarts) and weekly thereafter.

blinks slowly whenbutton is released (set)

and during 20 min.exercise period.

blinks rapidly whenbutton is held 5 sec.

while being set

Lights show position of transfer switch. Lights show the sources accepted.Light for builtin

engine exercise timer:

See page 51for complete

instructions

Figure 21. Membrane controls and indicator lights.

stays on after enginestops (exerciser is

enabled for weeklyoperation)

SECTION 2 SEQUENCE OF OPERATION

2---1

Transfer To EmergencyThe sequence for load transfer toemergency source begins automatical-ly when normal source voltage fallsbelow the preset dropout point or when Transfer Test button is pressed. An under voltage condition on anyphase of the normal source is de-tected by the sensor.

When the normalsource voltage fails orthe Transfer Testbutton is pressed, theSE relay de-energizesand relay NR beginsits timing cycle (1 or 3seconds, momentary normal source outage

delay). The NR relay is provided with a time delay ondropout to override momentary outages and preventnuisance starting of the engine-driven generator. If thenormal source voltage returns above the sensor dropoutsetting before the time delay expires, the NR relay timingcycle is reset to zero and relay SE energizes.

If the normal source voltage does not return above thesensor dropout setting before the time delay expires, theNR relay de-energizes and signals the engine-driven gen-erator to start. At the same time, a voltage and frequen-cy sensor begins monitoring the emergency source. Thesensor will accept the emergency source only when both

voltage and frequency reach preset pickup points. Usual-ly about ten seconds elapse from dropout of the NR relayto acceptance by the sensor. This time span occurs be-cause the engine-driven generator must crank, start, andrun up to nominal pickup points. For this reason, if theTransfer Test button is pressed it must be held for 15 sec-onds. If the emergency source is available immediately,the sensor may accept it as soon as NR relay drops out.

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 5minutes) time delay on pickup to delay transfer of theload to the emergency source. For immediate transferpress Bypass Time Delay button.

ER relay energizes, the TS coil is energized, the transferswitch operates, and all switch contacts (mains, controls,auxiliaries) reverse position. The transfer switch is nowsupplying the load from the emergency source.The transfer switch will remain in the Emergencyposition until the normal source is restored. If theTransfer Test button is used, the transfer switch willremain on emergency until the retransfer to normal delay times out.

Retransfer to NormalThe sequence for load retransfer to the normal sourceautomatically begins when the voltage sensor detectsrestoration of the normal source. The voltage levelmust rise above the preset pickup point on all phasesbefore the sensor will accept the normal source.

When the normal source is accepted by the sensor,relay SE begins its timing cycle (adjustable 1 sec. to 30min., retransfer to normal delay ). For immediateretransfer press Bypass Time Delay button. SE relay isprovided with a time delay on pickup to preventimmediate load retransfer to the normal source. Thedelay insures that the normal source has stabilizedbefore reconnection of vital loads. If the normalsource voltage falls below the present dropout pointbefore the time delay expires, the timing cycle is resetto zero. If the emergency source fails for more than 4seconds during the timing cycle, ER relay drops outand the load is immediately retransferred to thenormal source, if that source is acceptable.

SE relay energizes and ER relay is dropped out. TheTS coil is energized, the transfer switch operates, andall switch contacts (mains, controls, auxiliaries) reverseposition. The transfer switch is now supplying the loadfrom the normal source again.

Upon retransfer to the normal source, NR relay beginsits timing cycle (unloaded running delay, engine cooldown ).NR relay is provided with a 5 min. time delay on pickupto keep the engine running for a cool-down period.

NR relay energizes after the time delay and signals theengine-driven generator to shut down. All circuits arereset for any future normal source failure.

Activationof standardcontrol features showninSection5 willalter thesequence ofoperation andintroduce additional timedelays during transfer operations.


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SECTION 3 TESTING & SERVICE

3---1

PREVENTIVE MAINTENANCE

For high reliability and long life for the ATS:

Operate the switch at least once a month . Perform this4step Electrical Operation Test (test with load transfer).

Transfer Switch Test

1. Press and hold the door-mounted Transfer Test button

until the engine starts and runs. This should happenwithin 15 seconds.

2. The transfer switch will operate to the Emergencyposition. If the Transfer To Emergency Delay is used,the transfer will occur after a time delay (up to 5minutes). For immediate transfer press BypassTime Delay button.

3. The Transfer Switch will operate back to the Normalposition after the Retransfer To Normal Delay (up to30 minutes). For immediate retransfer pressBypass Time Delay button.

4. Unloaded Running (Engine Cooldown) Delay allowsengine to run unloaded for 5 minutes.

Checklist for Yearly Inspection

Hazardous voltage capable of causing shock,burns, or death is used in this switch.Deenergize both Normal & Emergency powersources before performing inspections!

Clean the enclosure . Deenergize all sources,then brush and vacuum away any excessive dustaccumulation. Remove moisture with a clean cloth.

Check the transfer switch contacts . De-energizeall sources, then remove the transfer switch barriersand check contact condition. Replace the contacts if they become pitted or worn excessively. Reinstall thebarriers carefully.

Maintain transfer switch lubrication . Undernormal operating conditions no further lubricatingis required. Renew factory lubrication if the switchis subjected to severe dust or abnormal operatingconditions or if TS coil is replaced. Order lubricantkit 75100 .

Check all cable connections & retighten them .Torque to values shown on transfer switch label.

Replacement parts. When ordering parts provide theSerial and Catalog Nos. from the transfer switchnameplate. Contact ASI. In the US call1800800ASCO (2726)).

DISCONNECTING THE CONTROLLER

The harness disconnect plugs are furnished for repairpurposes only and should not have to be unplugged.If the controller must be isolated, follow these stepscarefully.

Disconnecting the Plugs1. 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 circuitbreaker.

b. If the transfer switch is in the Emergency position,open the normal source circuit breaker. Place theengine starting control in the test or run position.

2. Separate the quick disconnect plugs by squeezingthe latches. Do not pull on the harness wires.

3. Label, remove, and tape the signal wires connectedto the engine start terminals on the transfer switch:TB1 and TB3, or TB1 and TB2.

Reconnecting the Plugs1. Observe the position of the transfer switch.

a. If the transfer switch is in the Normal position, besure that the standby engine starting control isstill in the off position. The emergency sourcecircuit 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 theappropriate engine start terminals on the transferswitch. See Section 1 , Engine Starting Contacts .

3. The harness plugs and sockets are keyed.Carefully align the plugs with the socketsand 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 emergencysource 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 normalsource after the Retransfer to Normal Delay . Forimmediate retransfer, press Bypass Time Delaybutton. Place the engine starting control in the automatic position.


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TESTING & SERVICE (continued)

3---2

MANUAL LOAD TRANSFERThis procedure will manually transfer the load if thecontroller is disconnected.

Do not manually operate the transfer switchuntil both power sources are disconnected:

open both circuit breakers.

1. Open normal and emergency source circuit breakers.

2. Use the maintenance handle to manually operatetransfer switch to the opposite source. See page13, Manual Operation Test .

3. If the transfer switch is in the Emergency positionmanually start the engine generator and then closethe emergency source circuit breaker.

TROUBLE-SHOOTINGNote the control features that are activated orfurnished on the switch and review their operation.Refer to Section 5 , Control Features .

Proceed with care! The automatic transfer switchis energized.

Table 3-1. Trouble-Shooting Checks.CHECK IN NUMERICAL SEQUENCE

1 OPERATION 2 GEN-SET 3 VOLTAGEGen-Set does not start whenthe Transfer Test button ispressed and held for 15seconds or when the normalsource fails.

Hold the Transfer Test button15 sec. or the outage must belong enough to allow for the 1or 3 sec. Momentary Normal Source Outage Delay plusengine cranking and startingtime .

Starting control must be inautomatic position. Batteriesmust be charged andconnected. Check wiring toengine starting contacts.

Transfer switch does nottransfer the load toemergency source after thegen-set starts.

Wait for Transfer to Emergen-cy Delay (0 to 5 min.) to timeout. For immediate transfer,press the Bypass Time Delay button. If Motor Load Transferis active, wait for inphase con-dition (see below).

Generator output circuitbreaker must be closed.Generator frequency must beat least 57 Hz.

Voltmeter should read at least90% of nominal phase tophase voltage betweentransfer switch terminals EAand EC (or EL1 and EL2 for 2pole switches). ** These are factory settings.

Transfer switch does nottransfer the load to normalsource when normal returns

or when Transfer Test buttonis released.

Wait for Retransfer to Normal Delay (1 sec. to 30 min.) totime out. For immediate re

transfer, press Bypass TimeDelay button. If Motor LoadTransfer is active, wait for in-phase condition (see below).

Voltmeter should read at least90% of nominal phase tophase voltage between

transfer switch terminals NBand NC, NC and NA, and NAand NB (or NL1 and NL2 for 2pole switches).

Gen-Set does not stop afterload retransfer to the normalsource.

Wait for the 5 minuteUnloaded Running Delay totime out.

Starting control must be inautomatic position.

Trouble-Shooting the Motor Load Transfer Feature (refer to page 54)

Use extreme caution when using a meter tomeasure voltages in the following steps. Do not

touch power terminals; shock, burns, or deathcould result !1. Connect a voltmeter (set for twice system

phasetophase voltage) between Transfer Switchterminals NA and EA.

2. Manually start generator. Voltmeter needle shouldsweep back and forth at a regular rate between 0and about twice system voltage.

3. Press and hold Transfer Test button. The loadshould transfer to emergency source when meterneedle is near 0 volts. If transfer does not occur,Motor Load Transfer feature is not operating.

4. Release the Transfer Test button. The load shouldretransfer back to the normal source after the Retransfer to Normal Delay , if used. The retransfershould occur when the needle is near 0 volts. If retransfer does not occur after the time delay, theMotor 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 Technologiessales 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.


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ADJUSTMENTS (continued)

4---2

NOTICE

Do not make any setting changes while thecontroller is energized.

How to Change a Setting

1. Prevent the transfer switch from operating by discon-

necting 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 . Thenopen the normal source circuit breaker.

b. If the transfer switch is in the Emergencyposition, open the normal source circuit breaker.Turn engine starting control to test or run. Thenopen the emergency source circuit breaker.

2. Disconnect both harness plugs from controller bysqueezing the latches. Do not pull on the wires.

3. Remove cover from the controller by releasing latchon right side with your thumb. See Figure 4-1.

4. Locate the appropriate adjustment potentiometer orDIP switch for the setting that you want to change.Refer to Table 4-1 and Table 42 on page 4-1 andFigure 4-2, Figure 43, Figure 44 on page 42.

5. Use a small screwdriver to turn the potentiometerclockwise to increase the time delay or counter-clockwise to decrease it. See Figure 4-3.

6. Use a ball-point pen (or similar pointed tool) to slidethe switch actuators left or right so they match theillustration 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 onthe left side and latching the right side.

8. Reconnect both harness plugs to the controller byaligning and pressing straight in until latches click.

Close the transfer switch enclosure door.9. Close the enclosure door, then restore both sources:

a. If the transfer switch is in the Normal positionfirst close the normal source circuit breaker, thenclose the emergency source circuit breaker.

b. If the transfer switch is in the Emergencyposition, close the normal source circuitbreaker. The load will be automaticallyretransferred to the normal source. Then closethe emergency source circuit breaker.

10. Turn the engine starting control to automatic .

thumblatch

cover

hook onleft side

Figure 4-1. Controller cover latch.

9 voltalkalinebattery

batteryon/off

jumper

retransferto normal

time delay

transfer toemergencytime delay

harnessplugs

S3 DIPswitch

S1 DIPswitch

S2 DIPswitch

P1

P2

J5

Figure 4-2. Location of potentiometers.

P1 or P2potentiometer

clockwise toincrease

counterclockwiseto decrease

Figure 4-3. Changing time delay potentiometers.

DIPswitches

SW1SW2SW3

actuator

onoff

(8 on each DIP switch)

Figure 4-4. Setting DIP switch actuators.


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SECTION 5 CONTROL FEATURES ENGINE EXERCISERS

5---1

These timers periodically exercise the emergency engine-generator plant. They can be set to exercise with or withoutload transfer, or they can be completely disabled. The engine-generator should be exercised under load once a week fora minimum time period of 20 minutes, or follow the recommendations of the engine-generator set manufacturer. Referto page 42 for location of DIP switches, battery (provided), and jumper block in the controller.

BUILTIN ENGINE EXERCISERThe engine exerciser included in ASCO Series 300 Automatic Transfer Switches provides a once a week

20minute exercise period. It occurs immediately whenthe Set Engine Exerciser push button is pressed (andheld for at least 5 seconds), and then at the same time weekly thereafter. A 9 volt alkaline battery ( DuracellMN1604, Everready 522, or Panasonic 6AM6) isfurnished and installed in the controller to maintain thesetting. The battery jumper block must be shifted to theON position. See Figure 42 on page 42.

Fill in day and timeset. Week Day ______ Time _______.

DIP Switch Settings

FUNCTION S1 DIPSWITCHS2 DIP

SWITCHStd. TimerEnabled

Actuator7 on 7

Actuator5 on 5

Std. TimerDisabled

Actuator7 off 7

Actuator5 on 5

ExercisewithoutLoad

Actuator8 off

8

Exercisewith Load

Actuator8 on 8

Shaded DIP switches are standard factory settings.

status light

If Exerciser with Load is set,transfers load to Emergency.

If Exercise with Load is set, retransfers load toNormal, then stops generator after min. cooldown.

Press to cancel an active exerciseperiod (stops generator). Press and hold for 5 sec. or until status light

blinks rapidly to set exercise period immediatelyand every week hereafter (generator starts).

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. Theload 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 8 How to Set BuiltIn Timer

Step Function ExplanationPush Button Status Light

1Set EngineExerciser

hold 5 sec.

blinks rapidly set exercise period Exercise the generator now andevery week at this time hereafter.

2 release blinks slowly exercise period now active Generator starts and runs.

3 press BypassTime Delay stays on cancel active exercise period Generator stops.

4 stays on generator off Exerciser enabled; repeats every 7 days.

Exercise with Load , DIP Switch S1, Actuator 8 on 8 How to Set BuiltIn Timer

Step Function ExplanationPush Button Status Light

1Set EngineExerciser

hold 5 sec.

blinks rapidly set exercise period Exercise the generator now andevery week at this time hereafter.

2 release blinks slowly exercise period now active Generator starts and runs;the load transfers to Emergency.

3 press BypassTime Delay blinks slowly cancel active exercise period

The load retransfers to Normal; thengenerator runs for 5 minute cooldown( light blinks slowly during cooldown ).

4 stays on generator off Exerciser enabled; repeats every 7 days.

NOTE : Every time SET ENGINE EXERCISER push button is pressed (held 5 seconds) the exercise period is changed.


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CONTROL FEATURES (continued)

5---2

Optional Accessory 11BG SOURCE AVAILABILITY SIGNAL& PROGRAMMABLE ENGINE EXERCISER MODULE

2linedisplay

3 buttons

connectionsfor sourceavailabilitysignal 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 ContactsThe module provides one Form C contact each for thenormal and emergency sources signal the acceptabilityof the source as sensed by the controller. The signalcontacts operate in conjunction with the Source Accepted lights on the operator interface. Field wiringterminals 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, resistive0.5 AMP @ 125 VAC, resistivecontacts shown deenergized

Figure 53. Source availability signal contacts.

Programmable Engine ExerciserThe module includes a programmable engine exerciserthat provides for weekly or biweekly operation. Thisoptional 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 inthe controller (see page 42 and page 53) must beturned on to maintain the settings and to allowprogramming with the normal and emergency powerturned off (page 51).

The programmable engine exerciser incorporates a 7day or 14 day time base. Proper controller settings mustbe made to determine whether or not the test will bedone with or without load transfer (S1 DIP switchactuator 8).See next page for instructions on setting the timer.

DIP Switch Settings in the Controller(see page 42)

FUNCTION S1 DIPSWITCHS2 DIP

SWITCHOpt. Timer

Enabled Actuator

7 off 7 Actuator

5 off 5

Opt. TimerDisabled

Actuator7 off

7 Actuator

5 on 5

ExercisewithoutLoad

Actuator8 off 8

ExercisewithLoad

Actuator8 on 8



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Fast/Slow Adjust

Daylight SavingTime Adjust

Date

Time

Start TIme

Engine Exerciser

Run TIme


5---3

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 and Emergency powersources before programming the exerciser.

Navigating the MenuUse the UP and DOWN arrowkeys to move through the displays.

Changing the ParametersUse the UP and DOWN arrowkeys to move though the displaysto the parameter to be changed.Push the ENTER key to start theediting process. The first

parameter will flash. Use the UPand DOWN arrow keys to adjustthe parameter to the desired value and press the ENTER keyto save the value. The nextparameter will now flash. Repeatthe process until each parameteris properly configured.

Engine Exerciser DisplayThe Engine Exerciser Display shows the status of theengine exerciser. When the unit is shipped from the

factory the programmable engine exerciser isDisabled and must be set to Enabled by thecustomer. When the engine exerciser is running, thisdisplay will count down the remaining time until theend of the exercise period.

Start Time DisplayThe Start Time Display shows the engine exerciser starttime. There are four parameters that determine the starttime:

weekly (Every) or biweekly (Alt) operationday 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 everyother Saturday at 3 PM, the proper configuration wouldbe: Alt Sat @ 15:00

NOTE: When choosing biweekly operation, theexerciser will always run on the week designated (1)on the date display.

Run Time DisplayThe Run Time Display shows the run time for the engineexerciser. The default setting from the factory is 30 min.

Time DisplayThe Time Display shows the present system time. Theformat is hours:minutes:seconds.NOTE: During total power outages, power to theaccessory is maintained by a battery in the Controller(see page 42). Be sure that the 9volt alkaline batteryis fresh and enabled (jumper in ON position) so thatthe time and date settings are not lost.

Date DisplayThe Date Display shows the present system date. Theformat is day of week (week) month/day of month/year.NOTE: Week is either week 1 or week 2. This is usedin conjunction with the biweekly timer.

Daylight Savings Time Adjust DisplayThis display shows whether the automatic daylightsaving time adjustment is active. The factory default isNO. If enabled, the unit will automatically adjust fordaylight 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 DisplayThis display shows the automatic fast/slow adjustment value. The factory default is 0. This feature can beused to trim a clock that runs fast or slow. For example,if your clock runs 10 seconds slow per week, change thefast/slow adjust value to +10 and the unit willautomatically 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 AMon Sunday, you cannot use this feature and theadjustment must be set to 0.

Date exerciser was set ___________________________

Fill in your settings for future referenceWeekly or Biweekly Day of Week Start Time Run Time

Every = weekly Alt = biweekly Sun through Sat

0 23 hour0 59 minute

0 23 hour0 59 minute

30 min. is default setting


17/20


5---4

INPHASE MONITORFOR MOTOR LOAD TRANSFER

Inphase monitoring logic controls transfer andretransfer of motor loads, so that inrush currents do notexceed normal starting currents. It avoids nuisancetripping of circuit breakers and mechanical damage tomotor couplings.

The Motor Load Transfer feature is built into thecontroller. DIP switch S1 (actuator 5) activates thisfeature: right = ON, left = OFF.

FUNCTION S1 DIP SWITCH

enable Actuator 5 on 5

disable Actuator 5 off 5


If the Motor Load Transfer feature is enabled, it will be activated following the Load DisconnectFeature Delay Before Transfer delay.

Note

LOAD DISCONNECT FEATUREConnect external circuits to the terminals indicated onthe Wiring Diagram provided with the ATS.

The double throw (Form C) contact is rated for28 VDC or 120 VAC (5 amperes resistive). The contactoperates prior to a selectable 0, 3, 10, or 20 seconddelay before transfer of the Automatic Transfer Switch.

The contact resets either immediately following transferor after the same delay as set for presignal beforetransfer.

Time delay between the load disconnect control signaland initiation of transfer is set on the controller withDIP switch S2 (actuators 6, 7, 8) as shown below:

Delay Before TransferLD TDBT S2 DIP SWITCH

0 (disable) Actuator 7 on Actuator 8 on 8 7

3 seconds Actuator 7 on

Actuator 8 off 8 7

10 seconds Actuator 7 off Actuator 8 on 8 7

20 seconds Actuator 7 off Actuator 8 off 8 7


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 thecontrol signal to reset after the same delay as set for theDelay Before Transfer.

REMOTE CONTROL FEATURESThese remote control features require a customersupplied normally closed contact suitable for a 5 V dc low energycircuit. Refer to the Wiring Diagram provided with the ATS. Activate appropriate DIP switch S2 actuators below.

Remote Test (terminals CP67)

RTSW S2 DIP SWITCHdisable Actuator 3 on 3

enable Actuator 3 off 3

Bypass Transfer Time Delay (CP1213)TD E/N BYP. S2 DIP SWITCH

disable Actuator 1 on 1


Remote Transfer to Emergency (CP89)

RT /E S2 DIP SWITCHdisable Actuator 2 on 2


Inhibit Transfer to Emergency (CP1011)N/E INHIB. S2 DIP SWITCH

disable Actuator 4 on 4



18/20


5---5

OPTIONAL STRIP HEATER (Accessory 44)

Accessory 44 Strip Heater is designed to keep ambienttemperatures within the Automatic Transfer Switchenclosure at acceptable levels. This accessory consistsof a mounting bracket with strip heater, thermostat, andterminal 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 customerpowered assembly does not include a transformer. Thisoptional accessory is available factory installed or in kitform.

Turn the thermostats dial to required setting as shown.

dial

turn counterclockwiseto lower temperature

turn clockwiseto raise temperature

thermostat

Figure 54. Thermostat.

AVAILABLE KITS

ControlsDescription Accessory Kit

Programmable Engine Exerciser& Source Availability Contacts

11BG K629830

Serial Communication Module 72A K601110

Strip Heater Accessory 44Description Accessory Kit

120 voltcustomer supplied voltage

(without transformer)44A K613127001

208 480 volt ATS derived voltage

(with transformer)44G K613127002

380 volt ATS derived voltage


550 600 volt ATS derived voltage



19/20


20/20

INDEX

Aaccessories, 52, 55

auxiliary circuits, 12

Bbattery, 42, 51

buttons, push, 31

bypass time delay, 15, 21, 31

Ccable

lugs, preparation, 11

catalog number, inside cover

cleaning, 31

connectionsengine control contact, 12line, 11

contactsauxiliary, 12engine control, 12main, 13, 31source availability signal, 52

control features, 51load disconnect, 54motor load transfer, 54plant exerciser, 51, 52, 53

controller, 41, 42codes, covercover removal, 42disconnecting, 31time delay potentiometers, 42

DDIP Switches, 41, 42, 51, 52, 54

E

electrical operation, 15engine exerciser, 51, 52, 53

engine starting contacts, 12

Ffeatures, see control features

frequency, pickup and dropoutsettings, 41

functional test, 13, 14, 15

Gground, controller, 11

Hhandle, maintenance, 13

warning, 13

harness, 12disconnect plugs, 31

HELP8008002726 (ASCO)[email protected]

Iinphase monitor, 54

inspection, 31

installation, 11

Llabels,

engine starting contacts, 12inputs / outputs, 12rating, cover

lights, 14, 51

load disconnect feature, 54

lubrication, 31

Mmaintenance, preventive, 31

manual load transfer, 32 warning, 32

manual operation, 13illustration of, warning, 13

motor load transfer feature, 54

Nnameplate, inside cover

O

operationelectrical, 15manual, 13

illustration of, 13 warning, 13

sequence of, 21

optional accessoriesprogrammable engine exerciser

& source availability signalcontacts, 52, 53

serial communication module, 55strip heater, 55

Pparts, 31

problem, 32

programmable engine exerciser, 52,53

Rrating label, inside cover

remote control features, 54bypass transfer time delay, 54inhibit transfer to emergency, 54remote test, 54remote transfer to emergency, 54

replacement parts, 31

Sservice, call 8008002726 (ASCO)

set engine exerciser, 51, 52, 53settings

changing, 41factory, 41frequency, 41phase, 41time delay, 41 voltage, 41

source accepted lights, 14, 15

T

terminal block, 12test, functional, 13, 14, 15

time delayadjustment, 41genset cooldown, 41how to change, 42override momentary outages, 41settings, 41transfer to emergency, 41transfer 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

asco serie 300 ats

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