Asco 7000 Series User manual

ASCO 7000 SERIES ACTB
Automatic Closed-Transition Transfer &
Bypass-Isolation Switches
H design 600 through 1200 A
Operator’s Manual
381333-194 B
9/2016
DANGER is used in this manual to warn of a
hazard situation which, if not avoided, will result
in death or serious injury.
WARNING is used in this manual to warn of a
hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION is used in this manual to warn of a
hazardous situation which, if not avoided, could
result in minor or moderate injury.
Refer to the outline and wiring drawings provided with
your 7000 Series ACTB for all installation and
connection details and accessories.
Refer to Group 5 Controller User’s Guide 381333–126
for ATS status display messages, time delays, pickup &
dropout settings, and adjustments.
Rating Label
Each 7000 Series 7ACTB contains a rating label to
define the loads and fault circuit withstand/closing
ratings. Refer to the label on the Transfer Switch for
specific values.
Do not exceed the values on the rating label.
Exceeding the rating can cause personal injury
or serious equipment damage.
An experienced licensed electrician must install the
7ACTB.
600-1200 amp sizes

Operator’s Manual 7000 Series ACTB
2 381333-194 B
This page left blank intentionally.

7000 Series ACTB Operator’s Manual
381333-194 B 3
Table of Contents
Rating Label ............................................................................................................................................................. 1
Nameplate ................................................................................................................................................................ 4
Catalog Number Identification .................................................................................................................................. 4
Installation .................................................................................................................................................................. 5
Remove the Skid ...................................................................................................................................................... 5
Supporting Foundation ............................................................................................................................................. 5
Mounting ................................................................................................................................................................... 5
Line Connections ...................................................................................................................................................... 5
Testing Power Conductors ....................................................................................................................................... 5
Connecting Power Conductors ................................................................................................................................. 5
Controller Ground ..................................................................................................................................................... 5
Harnesses ................................................................................................................................................................ 5
Engine Starting Contacts .......................................................................................................................................... 6
Auxiliary Circuits ....................................................................................................................................................... 6
Functional Test ......................................................................................................................................................... 6
Functional Test – Voltage Checks............................................................................................................................ 7
Functional Test - -Electrical Operation .................................................................................................................... 8
Testing & Service ...................................................................................................................................................... 9
Transfer Test ............................................................................................................................................................ 9
Preventive Maintenance ........................................................................................................................................... 9
Replacement Parts ................................................................................................................................................... 9
Disconnecting the Controller .................................................................................................................................... 9
Manual Load Transfer .............................................................................................................................................. 9
Trouble-Shooting .................................................................................................................................................... 10
Maintenance Handle .............................................................................................................................................. 10
Bypassing & Isolating ............................................................................................................................................ 12
Bypassing the ATS ................................................................................................................................................. 12
To Bypass Normal Source ..................................................................................................................................... 13
To Bypass Emergency Source ............................................................................................................................... 13
Isolating the ATS .................................................................................................................................................... 14
Contact Inspection .................................................................................................................................................. 15
Return to Service .................................................................................................................................................... 16
To Un-Bypass Normal Source ................................................................................................................................ 18
To Un-Bypass Emergency Source ......................................................................................................................... 18
Index .......................................................................................................................................................................... 19

Operator’s Manual 7000 Series ACTB
4 381333-194 B
Nameplate
The Transfer Switch nameplate includes data for each
specific 7000 Series ACTB. Use the switch only within
the limits shown on this nameplate. A typical catalog
number is shown below with its elements explained.
Catalog Number Identification
Typical 7000 Series ACTB catalog no. for switched
neutral, 3 pole, 600 amp, 480 V, in Type 1 enclosure:
H7
A
CTB B 3 600 N 5 C
Frame &
Series
Neutral Phase
Poles
Amperes Voltage Controller Enclosure
A-solid
B-switch
blank- none
2-single
3-three
600
800
1000
1200
C 208
D 220
E 230
F 240
G 277
H 380
J 400
K 415
L 440
M 460
N 480
P 550
Q 575
R 600
5- standard
5X- if
accessories
ordered
C- Type 1
F- Type 3R
G- Type 4
L- Type 12
blank- open
type
Open-type H7ACTB with the lower door open (transfer switch shown).
Status
Lights
&
Engine
Control
Transfer
Switch
Isolation
Handle
Bypass
Handle
Transfer
Control
& Lights
Group 5
Controller

Installation Operator’s Manual
381333-194 B 5
Installation
ASCO 7000 Series Automatic Transfer & Bypass–
Isolation Switches (7ACTBs) are factory wired and
tested. Field installation requires mounting and
connection of service cables, and auxiliary control
circuits (if required).
Remove the Shipping Skid
Open the enclosure’s lower front door and also remove
the lower rear access panel. Then remove the four lag
screws (2 in front, 2 in rear) securing the enclosure to
the shipping skid.
Supporting Foundation
The supporting foundation for the enclosure must be
level and straight. Refer to the applicable enclosure
outline drawing included with the switch for all mounting
details including door opening space.
If bottom cable entry is used, the foundation must be
prepared so that the conduit stubs are located correctly.
Refer to the enclosure outline drawing for specified area
and location. Provide cable bending space and
clearance to live metal parts. When a concrete floor is
poured, use interlocking conduit spacer caps or a wood
or metal template to maintain proper conduit alignment.
Mounting
Refer to the applicable enclosure outline drawing
furnished with this switch and mount the automatic
transfer switch according to details and instructions
shown on diagram.
Line Connections
Refer to the Wiring Diagram provided with the switch. All
wiring must be made in accordance with the National
Electrical Code and local codes.
Do not remove the barrier from the transfer switch.
Always protect the transfer switch, bypass switch, and
isolation contacts and mechanisms from construction
grit and metal chips when cabling.
De–energize the conductors before making any line
or auxiliary circuitry connections. Be sure that
Normal and Emergency line connections are in
proper phase rotation. Place engine generator
starting control in the OFF position. Make sure
engine generator is not in operation.
Testing Power Conductors
Do not connect the power conductors to the transfer
switch until they are tested. Installing power cables in
conduit, cable troughs and ceiling-suspended hangers
often requires considerable force. The pulling of cables
can damage insulation and stretch or break the
conductor’s strands. For this reason, after the cables are
pulled into position, and before they are connected, they
should be tested to verify that they are not defective or
have been damaged during installation.
Protect the switch from construction grit and metal
chips to prevent malfunction or shortened life of the
7ACTB switch.
Connecting Power Conductors
After the power cables have been tested, connect them
to the appropriate terminal lugs on the bypass switch as
shown on the wiring diagram provided with the switch.
Make sure the lugs provided are suitable for use with the
cables being installed. Standard terminal lugs are
solderless screw type and will accept the wire sizes
listed on the drawings provided with the 7ACTB. Be
careful when stripping insulation from the cables; avoid
nicking or ringing the conductor. Remove surface oxides
from cables by cleaning with a wire brush. When
aluminum cable is used, apply joint compound to
conductors. Tighten cable lugs to the torque specified
on rating label.
Controller Ground
A grounding wire must be connected to the controller’s
lower left mounting stud. Because the controller is
mounted on the enclosure door, a conductive strap must
be used between the enclosure and the door. This
connection provides proper grounding which does not
rely upon the door hinges.
Harnesses
The transfer switch is connected to the left side of the
controller by a plug–in harness (two plugs).

Operator’s Manual Installation
6 381333-194 B
Installation
Engine Starting Contacts
All customer connections, including the engine control
contact connections, are located on terminal block TB
which is mounted on the top right side of the enclosure.
Refer to the wiring diagram provided with the automatic
transfer switch and connect the engine start wires to the
appropriate terminals. See Figure 1 and Table A.
Table A. Engine start connections.
When normal
source fails
Terminals on
transfer switch
contact closes TB1 and TB2
contact opens TB1 and TB3
Auxiliary Circuits
Connect auxiliary circuit wires to appropriate terminals
on transfer switch terminal block TB as shown on the
wiring diagram provided with this automatic transfer
switch.
Figure 1. Customer terminal block on the top right side
of the enclosure.
Functional Test
The Functional Test consists of two checks:
□ 1 - Voltage Checks, page 7
□ 2 - Electrical Operation, page 8
Do these checks in the order presented to avoid
damaging the ACTB.
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.
Continue to 1 – Voltage Checks on next page.
engine start
connections
on
customer
terminal
block TB

Installation Operator’s Manual
381333-194 B 7
Installation
Figure 2. Standard controls and indicators.
Functional Test
Read all instructions on the Wiring Diagrams and labels
affixed to the 7ACTB. Note the control features that are
provided and review their operation before proceeding.
After installing the 7ACTB check the following:
– Bypass Handle should be in the NORMAL position.
– Isolation Handle should be in the CONN position.
– CN transfer switch should be C (closed)
– CE transfer switch should be O (open)
If handles are not in correct positions, follow instructions for
Bypassing and Isolating the automatic transfer switch on
pages 12-18. Do not force the handles. Electrical
interlocks prevent a wrong sequence of operation.
1 – Voltage Checks
First check nameplate on transfer switch; rated voltage
must be the same as normal and emergency line voltages.
Use extreme caution when using a meter to
measure voltages. Do not touch power terminals;
shock, burns, or death could result!
Perform steps 1 through 6 at the right. Observe the status
lights. See Figure 2
■ Black square means light is on.
□ White square means light is off.
* If necessary, adjust voltage regulator on generator per the
manufacturer’s recommendations. The ACTB will respond
only to rated voltage specified on the nameplate.
Now continue to 2 – Electrical Operation on next page.
1
Close the normal source circuit
breaker. The Transfer Switch
Connected To Normal and the
Normal Source Accepted lights
should come on.
2
Use an accurate voltmeter to
check phase to phase and phase
to neutral voltages present at the
transfer switch normal source
terminals.
3
Close the emergency source
circuit breaker. Turn the Engine
Control switch to Run to start
the generator. The Transfer
Switch Connected To Normal &
Emergency Source Accepted
lights should come on.
4
Use an accurate voltmeter to
check phase to phase and phase
to neutral voltages present at the
transfer switch emergency
source terminals.*
5
Use a phase rotation meter to
check phase rotation of
emergency source; it must be
the same as the normal source.
6
Turn the Engine Control switch
to Auto to stop the generator.
The Emergency Source
Accepted light should go off.
Then put the starting control
selector switch (on the generator
set) in the automatic position.
Close the enclosure door.
observe
these lights

Operator’s Manual Installation
8 381333-194 B
Installation
Figure 3. Standard controls and indicators.
2 – Electrical Operation
This procedure checks electrical operation of the ACTS.
Close enclosure door before proceeding to prevent
personal injury in case of electrical system fault.
Transfer Test
The ATS should still be bypassed. Both normal and
emergency sources must be available and the emergency
source generator (if used) must be capable of being
started; put engine starting control in automatic position.
The Transfer Switch Connected to Normal light and the
Normal Source Accepted light should be on.
1. Turn the Isolation Handle counterclockwise to the
TEST position.
NOTE: The engine generator may be signaled to start
while turning the Isolation Handle. If emergency source is
available, the ATS may operate to the emergency position.
If it does, operate Retransfer Delay Bypass switch.
2. Perform steps 1–5 at right. Observe the status lights.
See Figure 3.
■ Black square means light is on.
□ White square means light is off.
3. Turn the Isolation Handle clockwise to the CONN
(connected) position.
4. Turn the Bypass Handle clockwise to the OPEN
position.
** If you do not want closed–transition transfer, press
the Closed Transition Bypass pushbutton while the
controller display shows Waiting for In–Sync. This
action causes open–transition (momentary load
interruption) transfer to the opposite source, if
conditions permit. Also refer to the Group 5 Controller
User’s Guide 381333–126.
1
The Transfer Switch Connected To
Normal and Normal Source
Accepted lights should be on.
2
Turn and hold Transfer Control
switch clockwise to Transfer Test
until the engine starts and runs
(within 15 sec.). Emergency
Source Accepted light should come
on.
3
Transfer switch CE closes and
then transfer switch CN opens
(closed–transition overlap). The
Transfer Switch Connected To
Emergency light should come on
and the Transfer Switch Connected
to Normal light goes off (you might
see and hear the brief overlap
transfer). **
4
Transfer switch will operate back to
Normal position after Feature 3A
time delay. For immediate
retransfer turn Transfer Control
counter-clockwise to Retransfer
Delay Bypass. The Transfer Switch
Connected To Normal light should
come on; Transfer Switch
Connected to Emergency light
should go off.
5
The engine–generator will stop
after the Feature 2E time delay
(unloaded running engine
cooldown). The Emergency
Source Accepted light should go
off.
This completes the Functional Test of the 7ACTB
observe
these lights operate
this switch

Testing & Service Operator’s Manual
381333-194 B 9
Testing & Service
TRANSFER TEST
Test the Automatic Transfer Switch portion of the 7000
Series 7ACTB at least once a month. This procedure
checks the electrical operation of the Transfer Switch and
Controller. Put the engine–generator starting control (at
the engine–generator set) in automatic mode.
In the following test the generator will start, the load will
be transferred to the Emergency source, then back to the
Normal source. With both sources available the load will
be transferred in a closed–transition mode.
Be sure to close the enclosure door before
proceeding to prevent personal injury in case of
electrical system fault.
Perform the five–step Electrical Operation – Transfer
Test procedure on page 8.
PREVENTIVE MAINTENANCE
Reasonable care in preventive maintenance will insure
high reliability and long life for the 7000 Series 7ACTB.
An annual preventive maintenance program is
recommended.
ASCO Power Services, Inc. is ASCO Power
Technologies service organization for the United
States and Canada. Call 1-800-800-2726 (ASCO) to
request a service call and information on preventive
maintenance agreements.
Annual Inspection Checklist
Hazardous voltage capable of causing shock,
burns, or death is used in this switch. Deenergize
both Normal & Emergency power sources before
performing inspections!
□ Cleaning the 7ACTB enclosure
Brush and vacuum away any excessive dust
accumulation. Remove moisture with a clean cloth.
□ Check the transfer switch contacts.
Bypass, isolate, and withdraw the transfer switch.
Then remove the transfer switch interphase barriers
and check the condition of the contacts. Replace
contacts when pitted or worn excessively. Reinstall
the interphase barriers carefully. See page 15
□ Maintain transfer switch lubrication.
If switch is subjected to severe dust or abnormal
operating conditions, renew factory lubrication on all
movements and linkages. Relubricate solenoid
operator if TS coil is replaced. Don’t use oil; order
lubrication kit 75-100
□ Check all cable connections & retighten them.
REPLACEMENT PARTS
Replacement parts are available in kit form. When
ordering parts provide the Serial No., Bill of Material No.
(BOM), and Catalog No. from the transfer switch
nameplate. Contact your local ASCO Power
Technologies Sales Office or ASCO Power Services,
Inc.
In the United States and Canada
call 1 – 800 – 800 – ASCO ( 2726 )
DISCONNECTING THE CONTROLLER
The harness disconnect plugs are furnished for repair
purposes only and should not have to be unplugged. If
the controller must be isolated, follow these steps.
Bypass–Isolation Switch is energized! Do not
touch isolation contact fingers; shock, burns, or
death could result!
Disconnecting the Plugs
1. Bypass and Isolate the Automatic Transfer Switch.
2. Open the upper enclosure door.
3. Separate the two quick disconnect plugs by
squeezing the latches. Do not pull on the harness
wires.
Reconnecting the Plugs
1. The ATS should be still bypassed and isolated.
2. The two harness plugs and sockets are keyed.
Carefully align the plugs with the sockets and press
straight in until the latches click.
3. Close the enclosure doors.
4. Follow Return to Service instructions on page 16.
MANUAL LOAD TRANSFER
This procedure manually transfers load to other source if
the Transfer Switch or Control Panel are out of service.
Close enclosure doors to prevent personal
injury in case of electrical system fault.
1. Bypass the connected ACTB source. Turn Bypass
Handle to EMERGENCY or NORMAL (page 13).
2. Isolate to Test. Turn the Isolation Handle to TEST
position (see page 14).
3. Turn the Bypass Handle to OPEN, then to the other
source (see page 12). The load will be interrupted.
4. Turn the Isolation Handle clockwise to the CONN
[connected] position (see page 15).

Operator’s Manual Testing & Service
10 381333-194 B
Testing & Service
TROUBLE-SHOOTING
Note any optional accessories that may be furnished on the
7ACTB and review their operation. Refer to any separate
drawings and/or instructions that may be packed with the
7ACTB. See Table B.
Hazardous voltage capable of causing shock, burns,
or death is used in this switch. Do not touch the
power or load terminals of the bypass switch or
transfer switch!
Table B. Trouble-Shooting Checks.
PROBLEM CHECK IN NUMERICAL SEQUENCE
1 OPERATION 2 GEN-SET 3 VOLTAGE
Engine–generator set does
not start when the Transfer
Control switch is turned
and held in Transfer Test
position or when normal
source fails.
Hold Transfer Test switch 15
seconds or the outage must be
long enough to allow for Feature
1C time delay plus engine
cranking and starting time.
Starting control must be in the
automatic position. Batteries
must be charged and
connected. Check wiring to
engine starting contacts.
-
Transfer switch does not
transfer the load to the
emergency source after the
engine–generator set starts.
Wait for Feature 2B time delay to
time out (if used)
Generator output circuit breaker
must be closed. Generator
frequency must be at least 95%
of nominal (57 Hz for a 60 Hz
system.) *
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). *
Transfer switch does not
transfer the load to normal
source when normal returns
or when the Transfer
Control switch is released.
Wait for Feature 3A time delay to
time out (if used)
-
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).
Engine–generator-set does
not stop after load retransfer
to the normal source.
Wait for Feature 2E time delay to
time out (if used)
Starting control must be in the
automatic position. -
Failure to Synchronize
light comes on.
Conditions of Normal or Emergency Sources not suitable for closed transition transfer.
Recheck voltage and frequency of both sources. Press Alarm Reset pushbutton.
Extended Parallel Time
light comes on.
CN and CE contacts are closed longer than setting in the Controller. Open the disconnected source
circuit breaker, then call your nearest ASCO Service Center for assistance.
TS Locked Out
light comes on.
Transfer lockout operation has occurred; transfer switch is disabled from automatic operation. Open
the disconnected source circuit breaker, then call your nearest ASCO Power Services, Inc. for
assistance
These are factory settings. Refer to the Controller User’s Guide.
If the problem is isolated to circuits on the controller or the transfer switch, call your local ASCO Power Technologies
sales office or ASCO Power Services, Inc.: in the United States or Canada, call 1–800–800–2726. Furnish the Serial No.,
Catalog No., and Bill of Material (BOM) No. from the transfer switch nameplate.