ASCO POWER TECHNOLOGIES Series 300 User manual

SERIES 300
Quick Connect Input and Output Power Panels
2000 - 4000 Amp Pad Mount
Installation Manual
381333-476 A
11/2020
DANGER is used in this manual to warn of a
hazard situation which, if not avoided, will result
in death or serious injury.
WARNING is used in this manual to warn of a
hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION is used in this manual to warn of a
hazardous situation which, if not avoided, could
result in minor or moderate injury.
Important:
This manual contains information critical to the proper
installation
and operation of the ASCO SERIES 300 Quick
Connect Power Panels.
Be certain to read and understand all
instructions prior to installation
and operation.
The ASCO SERIES 300 Quick Connect Power
Panel must be installed in
conjunction with a
transfer switch.
ASCO SERIES 300 Quick Connect Input Power panels
are ETL listed to UL1008 standards. ASCO SERIES 300
Quick Connect Output Panels are ETL listed to UL 891
Standards for Switchboards.
Limited Warranty
When this ASCO SERIES 300 Quick Connect Power Panel is
installed and operated
according to the manual’s instructions
ASCO Power Technologies will repair or
replace any of its
mechanical or electrical parts if they are found
to be defective in
material or workmanship within two year of the
purchase date.
Maintenance
The ASCO SERIES 300 Quick Connect Power Panels will
require periodic
maintenance. ASCO Power Technologies
recommends annual inspections to keep
the panel in safe
operating condition. ASCO Power Technologies recommends
that
the Pre-Operation and Maintenance Checklist under
Appendix A
serve as a basis for annual inspection.
Technical Support
ASCO Power Services are available to assist in resolving
issues by calling 1-800-800 2726 (ASCO) or emailing
[e-mail]. For any other information,
please refer to ascopower.com

SERIES 300 Quick Connect Power Panel Installation Manual
2 381333-476 A
Table of Contents
Limited Warranty ......................................................................................................................................................1
Maintenance .............................................................................................................................................................1
Technical Support.....................................................................................................................................................1
Prior to Installation ...................................................................................................................................................... 3
Shipment: Unpacking and Inspection ...................................................................................................................... 3
Initial Installation (for Input and Output Panels) ..................................................................................................... 4
Step 1: Fasten the ASCO SERIES 300 Quick Connect Power Panel to secure base................................................4
Step 2: Installing the Conduit....................................................................................................................................4
Installation – Input Panels ......................................................................................................................................... 5
Step 3: Wiring the Lug Terminals ..............................................................................................................................5
Step 4: Determine Phase Rotation .............................................................................................................................5
Step 5: Configuring the Phase Rotation Monitor .......................................................................................................6
Set-up ........................................................................................................................................................................... 6
Step 6: Review Pre-Operation Checklist under Appendix A prior to operation .......................................................6
Step 7: Determining phase rotation of generator .....................................................................................................6
Step 8: Conduct a safety test to ensure proper installation......................................................................................6
Step 9: Making Cam Connections............................................................................................................................6
Step 10: Connect 2 wire auto start circuit.................................................................................................................7
Step 11:Close and lock lower chamber door,
allowing cables to exit through smaller cable door .............................7
Step 12: Powering Up...............................................................................................................................................8
Step 13: Disconnection.............................................................................................................................................8
Installation – Output Panels ...................................................................................................................................... 9
Step 3: Wiring the Bus Bars ......................................................................................................................................9
Step 4: Conduct a safety test to ensure proper installation ..........................................................................................9
Set-up ........................................................................................................................................................................... 9
Step 5: Review Pre-Operation Checklist under Appendix A prior to operation .......................................................9
Step 6: Making Cam Connections............................................................................................................................9
Step 7:Close and lock lower chamber door,
allowing cables to exit through smaller cable door .............................10
Step 8: Powering Up...............................................................................................................................................10
Step 9: Disconnection.............................................................................................................................................10
Appendix A.................................................................................................................................................................11
Pre-Operation and Maintenance Checklist.............................................................................................................11
Index .......................................................................................................................................................................... 12

Installation Manual SERIES 300 Quick Connect Power Panel
381333-476 A 3
Prior to Installation: Site Preparation
Prepare installation site according to local codes.
The ASCO SERIES 300 Quick Connect Power Panels are to be
set on an exterior pad
and secured to a building or secured to
a pad using 3/8“ fasteners
(See Figure 1).
The surface where the ASCO SERIES 300 Quick Connect
Power Panel is to be
secured must be capable of supporting
the weight of the cabinet as
well as the cable attached to it.
The following should be taken into consideration when locating
the
ASCO SERIES 300 Quick Connect Power Panel:
- The ASCO SERIES 300 Quick Connect Power Panel is
designed for exterior
operation ONLY
- Identify and meet local codes and local Authority Having
Jurisdiction (AHJ)
- Toprevent carbon monoxide poisoning from improperly
ventilated
generator emissions, the Power Panelmust be
mounted
outdoors only. The mounting location is to be
carefully selected to
allow convenient connection to a
generator and located a suitable
distance away from any
building openings or HVAC inlets.
- Proper clearance must be allowed in front of the ASCO
SERIES 300 Quick Connect Power Panel to allow for
opening of access doors and
attachment of externally
connected cables. This distance should be
no less than six
(6) feet from the face of the panel.
- While lockprotectionis provided, access by unauthorized
personnel and vandals should be taken into consideration
when
locating this device.
Shipment: Unpacking and Inspection
Be careful in the use of sharp object when cutting
packaging
as damage to the outer enclosure may result.
Perform a visual inspection to ensure the door and all hasps
are in
functioning condition and that the panel integrity is intact.
Secure with 3/8” fasteners
Figure 1-Bottom View

SERIES 300 Quick Connect Power Panel Installation Manual
4 381333-476 A
Initial Installation
ASCO SERIES 300 Quick Connect Power Panels are
front heavy
(See Figure 2). Care must be taken to
secure the device when it is lifted and
moved.
– Please note that the 2000 Amp versions weigh
approximately
2 20 pounds and the 2400-4000 Amp
versions range from
317-360 pounds for aluminum
enclosures. Stainless steel enclosures are approximately 200
pounds heavier at their respective amperage levels.
The installation of the ASCO SERIES 300 Quick
Connect Power Panel should
be carried out by
qualified personnel in accordance with
local
electrical codes.
The ASCO SERIES 300 Quick Connect Power
Panel must be installed in
conjunction with a
transfer switch.
The transfer switch shall not have a rating
greater than the ASCO SERIES 300 Quick
Connect Power Panel.
Figure 2
Step 1: Fasten the ASCO SERIES 300 Quick
Connect Power Panel to secure base
1. Base must be level and plumb to allow for proper drainage
from ASCO SERIES 300 Quick Connect Power Panel
weep holes
2.
Fastening onto an external wall using 3/8” fasteners must
be
completed prior to proceeding with any terminations
(See Figure 1
for hole spacing)
Step 2: Installing the Conduit
Conduit to enter through the bottom,rearand sides o f t he
unit. (See
Figure 3)
To maintain TYPE 3R Rating compliance for the
enclosure, proper sealing procedures must be followed.
This
is to include, but not limited to, the use of proper
gaskets.
1.
Remove rear and side panels to expose termination
chamber
2.
Conduit to be sized according to cabling rating
3.
It is recommended that a knockout punch be used to cut
hole for
conduit.
4.
Place the punch on the panel that was removed from the
enclosure and draw the
punch through to the die on the
outside.
Figure 3

Installation Manual SERIES 300 Quick Connect Power Panel
381333-476 A 5
Installation -Input Panels
This section is for Installation of Input Panels.
For Installation of Output Panels proceed to
Page 9.
Step 3: Wiring the Lug Terminals
Ensure circuit breakers are OFF and the transfer switch
is locked
out from utility power prior to connection.
Failure to install transfer switch will create the potential for the
generator to energize utility lines and endanger utility
personnel.
Conversely, utility lines may energize the ASCO
SERIES 300 Quick Connect Power
Panel and endanger
generator personnel.
The ASCO SERIES 300 Quick Connect Power Panel
is for use only for
connection of a generator to the source
terminals of a
transfer switch, such that the inlets are only
energized from
the generator.
1.
Pull the cables for the transfer switch to the ASCO
SERIES 300 Quick Connect Power
Panel
2.
Beginning with the ground, strip and install the cables in
the appropriate compression terminals
The terminals can accommodate #2 to 600MCM,
Copper wire only
3. Tighten terminal screws to 375 lb.-in torque each
4.
If metallic conduit is used, connect ground wire from
ground
bushing on conduit to the ground connection point
in the upper
right quadrant of the panel
5.
Ground conductor must be a minimum of #2 AWG
Conduit shall NOT be relied upon to provide grounding
protection to tap box
6. Continue to connect the neutral and then the phases
7.
Vacuum entire upper chamber to ensure no metal
shavings are left
behind
Three phase power systems consist of three phase or
hot
conductors that are shifted by 120 degrees. Three
phase loads such as motors may only work properly if
the phases are
connected in the correct order. Some
motors may work when
connected improperly, but will
operate backwards. Utility power
and electrical
generators may be wired either in a clockwise or
counter-clockwise order. It is important that any generator
connected to the ASCO SERIES 300 Quick Connect
Power Panel is connected in the same rotation
(clockwise or counter-clockwise) as the utility power.
Step 4: Determine Phase Rotation
This information will be needed when connecting a generator .
1. Determine phase rotation of the utility power.
2.
Connect a phase rotation meter to a three phase power
source in
the building and record whether the building is
wired clockwise or
counter-clockwise
3.
Apply the provided label to the inside of the ASCO
SERIES 300 Quick Connect Power
Panel on the inside of
the cam connection chamber door
. (Figure 4)
Place rotation label here
Figure 4

SERIES 300 Quick Connect Power Panel Installation Manual
6 381333-476 A
Step 5: Configuring the Phase Rotation
Monitor
A phase rotation monitor comes standard on all 2000A -4000A
pad mount Input panels. The Phase rotation monitor is prewired
from the factory for ABC rotation. (Figure 5)
1. Should the phase rotation monitor configuration and utility
power (label found on the inside of
the door for the Cam
connection chamber) match, proceed to Step 6.
2. Should the phase rotation monitor configuration and utility
power (label found on the inside of
the door for the Cam
connection chamber) differ, swap the A and B phase
rotation connection wires at the camlock connection so it
matches utility power and is consistent with the label found
inside the door.
Figure 5
Set-up
Step 6: Review Pre-Operation Checklist
under Appendix A prior to operation (pg. 8)
DO NOT ATTEMPT CONNECTION WHILE CIRCUITS
ARE LIVE
– Do not use cables if they appear frayed
– Do not use cable if connectors or plug do not seat properly
– Do not use cables if any copper cabling is exposed
– To limit risk of shock, disable generator automatic
start to
prevent unintended starting
Step 7: Determining phase rotation of
generator
1. Disconnect generator from all loads if needed
2.
Connect a phase rotation meter to the output phases of the
generator
3. Record generator phase rotation (clockwise or
counter-clockwise)
Step 8: Conduct a safety test to ensure
proper
installation
1. Do not attempt to use the ASCO SERIES 300 Quick Connect
Power Panel prior to
installation and completing the Pre-
Operation and Maintenance
Checklist under Appendix A.
2.
Complete the Ground (green)connections, beginning with
the furthest from the from door to the left
Proper connection (Figure 6):
A.
Grasp connector jacket and firmly insert cam connector into
cam
plug
B.
Push on cam connector jacket until connector fully seats in
cam
plug
C.
Rotate cam connector jacket counterclockwise until it stops
Step 9: Making Cam Connections
1. Open main chamber door.
Figure 6
2. Continue with connections, beginning with the rear of the
cabinet
and working forward
3.
Complete ALL Ground connections working from back to
front prior
to proceeding
4.
Complete the Neutral (white) connections, beginning with
the
furthest from the front door
Proper connection (Figure 6):
A.
Grasp connector jacket and firmly Insert cam connector into
cam
plug
B.
Push on cam connector jacket until connector fully seats in
cam
plug
C.
Rotate cam connector jacket counterclockwise until it stops

Installation Manual SERIES 300 Quick Connect Power Panel
381333-476 A 7
Set-up – Continued
D. Continue with connections, beginning with the rear of
the cabinet
and working forward.
E. Complete the Phase (hot) connections
i.
Should the phase rotation of the generator (as
determined in
Step 5.B.3. above) and utility power
(label found on the inside of
the door for the Cam
connection chamber) match, connect the
Hots as
follows:
Generator Hot ASCO SERIES 300 Quick Connect
Power Panel Hot
AA
B B
C C
ii. Should the phase rotation of the generator (as
determined in
Step 7.3. above) and utility power
(label found on the inside of
the door for the Cam
connection chamber) NOT match, connect
the
Hots as follows:
Generator Hot ASCO SERIES 300 Quick Connect
Power Panel Hot
A
B
B A
C C
Proper connection (Figure 6):
A.
Grasp connector jacket and firmly insert cam connector into
cam
plug
B.
Push on cam connector jacket until connector fully seats in
cam
plug
C.
Rotate cam connector jacket counterclockwise until it stops
5.
Continue with connections, beginning with the rear of the
cabinet
and working forward
6.
Complete ALL Phase connections working from back to front
prior
to proceeding
7.
Make sure all connections are right and secure
Step 10: Connect 2 wire auto start circuit
1. Connect 2 wire auto start circuit from transfer switch
to terminal post located in the upper right corner of
the Quick Connect Panel.(Figure 7)
2. Connect the 2 wire auto start circuit from generator
to terminal post.
Figure 7
Step 11: Close and lock lower chamber door,
allowing cables to exit through smaller cable
door (See Figure 8)
Figure 8

SERIES 300 Quick Connect Power Panel Installation Manual
8 381333-476 A
Step 12: Powering Up
Power MUST BE supplied from a single generator
1.
Start generator per manufacturer instructions
Toggle the transfer switch, diverting power from utility to
generator feed
Step 13: Disconnection
DO NOT ATTEMPT DISCONNECTING WHILE
CIRCUITS ARE LIVE
1. To limit risk of shock, disable generator automatic start to
prevent
unintended starting
– Open lower chamber door
– Order of disconnect
2.
Disconnect the Phase (hot) connections, beginning with the
closest to the front door to the right.
Proper disconnection (Figure 9):
A.
Grasp connector jacket firmly and rotate cam connector
clockwise until it stops
B.
Firmly pull on connector until it separates from the plug
C.
Set aside
3.
Continue with ALL Phase (hot) connections, beginning with
the front of the cabinet and working from front to back.
Figure 9
4. Complete disconnect of ALL hot connections prior to
proceeding
5. Disconnect the Neutral (white) connection, beginning with
the
closest to the front door.
Proper disconnection (See Figure 9):
A.
Grasp connector jacket firmly and rotate cam connector
clockwise until it stops
B.
Firmly pull on connector until it separates from the plug
C.
Set aside
6.
Continue with ALL Neutral (white) connections, beginning
with the
front of the cabinet and working from front to back
7. Complete disconnect of ALL Neutral connections prior to
proceeding
8. Disconnect the Ground (green) connections, beginning with
the
closest to the front door
Proper disconnection (See Figure 9):
A.
Grasp connector jacket firmly and rotate cam connector
clockwise until it stops
B.
Firmly pull on connector until it separates from the plug
C.
Set aside
9. Continue with ALL Ground (green) connections, beginning
with the
front of the cabinet and working rearward
10.
Complete disconnect of ALL Neutral connections prior to
proceeding
Step 14: Secure front door to complete.

Installation Manual SERIES 300 Quick Connect Power Panel
381333-476 A 9
Installation – Output Panels
Continued from page 4
Step 3: Wiring the Bus Bars
EnsurecircuitbreakersareOFFandthetransferswitchis
locked out from Source power prior to connection.
Failuretoinstalltransferswitchwillcreatethepotentialfor
thesource to energize
the ASCO SERIES 300 Quick
Connect Output Power Panel and
endanger
installation personnel.
The ASCO SERIES 300 Quick Connect Output
Power Panel is for the connection of a Load
Bank to the Output terminals of a transfer
switch.
1. Pull the cables for the transfer switch to the ASCO SERIES
300 Quick Connect Power
Panel
2.
Beginning with the ground, strip and install the cables in
the appropriate compression terminals
The terminals can accommodate #2 to 600MCM, Copper
wire only
3. Tighten terminal screws to 375 lb.-in torque each
4.
If metallic conduit is used, connect ground wire from
ground
bushing on conduit to the ground connection point
in the upper
right quadrant of the panel
5.
Ground conductor must be a minimum of #2 AWG
6.
Conduit shall NOT be relied upon to provide grounding
protection to tap box
7.
Vacuum entire upper chamber to ensure no metal shavings
are left
behind
Step 4: Conduct a safety test to ensure
proper installation
Do not attempt to use the ASCO SERIES 300 Quick Connect
Power Panel prior to
installation and completing the Pre-
Operation and Maintenance
Checklist under Appendix A.
Set-up
Step 5: Review Pre-Operation Checklist
under Appendix A prior to operation (pg. 8)
DO NOT ATTEMPT CONNECTION WHILE CIRCUITS
ARE LIVE
– Do not use cables if they appear frayed
– Do not use cable if connectors or plug do not seat properly
– Do not use cables if any copper cabling is exposed
– To limit risk of shock, disable generator automatic
start to
prevent unintended starting
Step 6: Making Cam Connections
1. Open lower chamber door
2. Complete the Ground (green)connections, beginning
with the furthest from the from door to the left
Proper connection (See Figure 10):
A. Grasp connector jacket and firmly insert cam connector
intocam plug
B. Push on cam connector jacket until connector fully seats
in cam plug
C. Rotate cam connector jacket counterclockwise until it
stops
Figure 10
3. Continue with connections, beginning with the rear of
the cabinet and working forward
4. Complete ALL Ground connections working from back
tofrontprior to proceeding
5. Continue with connections, beginning with the rear of
the cabinet and working forward

SERIES 300 Quick Connect Power Panel Installation Manual
10 381333-476 A
Set-up – Continued
6. Complete the Phase (hot) connections
Proper connection (See Figure 8):
A. Grasp connector jacket and firmly insert cam connector
intocam plug
B. Push on cam connector jacket until connector fully seats
in cam plug
C. Rotate cam connector jacket counterclockwise until it
stops
Step 7: Close and lock lower chamber door,
allowing cables to exit through smaller
cable door (See Figure 11)
Figure 11
Step 8: Powering Up
Power MUST BE supplied from a source wired to a
Transfer Switch
1. Toggle the transfer switch, diverting power from building
loads to load bank.
Step 9: Disconnection
DO NOT ATTEMPT DISCONNECTING WHILE
CIRCUITS ARE LIVE.
Open lower chamber door
Orderofdisconnect
1. Disconnect the Phase (hot) connections, beginning with the
closest to the front door to the right.
Proper disconnection (See Figure 12):
1. Grasp connector jacket firmly and rotate cam connector
clockwise until it stops
2. Firmly pull on connector until it separates from the plug
3. Set aside
4. Continue with ALL Phase (hot) connections, beginning with
the front of the cabinet and working from frontto
back
Figure 12
5. Complete disconnect of ALL hot connections prior
to
proceeding
6. Disconnect the Neutral (white) connection,
beginning
withthe closest tothe frontdoor.
Proper disconnection (See Figure 12):
A. Grasp connector jacket firmly and rotate cam
connector clockwise until it stops
B. Firmly pull on connector until it separates from the plug
C. Set aside

Installation Manual SERIES 300 Quick Connect Power Panel
381333-476 A 11
Set-up – Continued
7. Disconnect the Ground (green) connections, beginning
withtheclosesttothefrontdoor
Proper disconnection (See Figure 12):
A. Grasp connector jacket firmly and rotate cam connector
clockwise until it stops
B. Firmly pull on connector until it separates from the plug
C. Set aside
8. ContinuewithALLGround(green)connections,
beginning with the front of the cabinet and working
rearward
9. Complete disconnect of ALL Neutral connections prior to
proceeding
Step 10: Secure front door to complete.
Appendix A
Pre-Operation Checklist
1. Visual inspection of enclosure
– Ensure the ASCO SERIES 300 Quick Connect Power Panel
is firmly secured to its
base and/or building
– Review conduit connection for signs of leakage
– Ensure paint is intact with no signs of rust or corrosion
2.
Open main chamber door and remove rear and side panels
– Ensure unit is dry and free of debris
– Ensure that gaskets are pliable and no cracking exists
– Ensure that door hinges are secure and lubricated
– Ensure that keylocks are intact and operational
– Ensure that all load terminals are securely fastened and
that the
bolts are set at ninety-eight (98) foot pounds of
torque
– Ensure paint is intact with no signs of rusting or corrosion
– Ensure electrical connections are intact with no signs of
corrosion or cracking
3.
Review all safety labels and ensure that they are present
and legible
– Replace as needed
4.
Inspect all portable cables
– Do not use cables if they appear frayed
– Do not use cable if connectors or plug do not seat properly
– Do not use cables if any copper wiring is exposed
5. ASCO Power Services are available to assist in resolving
issues. If you have any questions or need technical advice
or
suggestions regarding this product, please contact
ASCO Power Technologies at
1-800-800-2726(ASCO) or
e-mail [email protected]

SERIES 300 Quick Connect Power Panel Installation Manual
12 381333-476 A
INDEX
A
annual inspection 1
B
bus bars 5, 9
C
cam connections 6, 9
chamber door 5, 6, 7, 8, 9, 10,
11
circuit breakers 5, 9
conduit, 5, 9 ,11
installing, 4
copper wiring, 11
D
disconnecting circuits 8, 10
G
gasket 4, 11
H
HELP
ASCO Power Services, Inc.
1-800-800-2726 (ASCO) 1, 6
[e-mail]
hot conductors 5
I
inspection 1, 3, 11
L
limited warranty 1
M
maintenance 1, 5, 9
P
phase rotation 5, 6, 7
plug 6,7, 8, 9,10, 11
portable cables 11
powering up, 7, 10
pre-operation checklist 6, 9, 11
S
safety test 5, 9
safety labels, 11
site preparation, 3
shipment 3
T
technical support 1
terminals 5, 9, 11
torque 5, 9, 11
U
unpacking 3
V
visual inspection 3, 11
ASCO Power Technologies
160 Park Avenue
Florham Park, NJ 07932-1591 USA
Phone: [phone] (ASCO) for sales or service
www.ascopower.com
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