Asco 7000 Series User manual

381333–283 B
50 Hanover Road, Florham Park, New Jersey 07932–1591 USA
For sales or service call 1 800 800–2726 (ASCO) www.ascopower.com
ASCO POWER TECHNOLOGIES CANADA PO Box 1238, 17 Airport Road, Brantford, Ontario, Canada N3T 5T3
telephone [phone], fax [phone], for service call 1 888 234–2726 (ASCO) www.asco.ca
Operator’s
Manual
7000 Series ATS
Automatic Transfer Switches
J–design, 260, 400, & 600 A
DANGER is used in this manual to warn of high
voltages capable of causing shock, burns, or death.
WARNINGisusedinthismanualto
warn of possible personal injury.
CAUTIONisusedinthismanualto
warn of possible equipment damage.
260 amp. size
Refer to the outline and wiring drawings provided
with your 7000 Series ATS 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 automatic transfer switch (ATS) has 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.
Nameplate
The Transfer Switch nameplate includes data for each
specific ASCO 7000 Series ATS. Use the ATS only within
the limits shown on this nameplate.
An experienced licensed electrician must install the ATS.
TABLE OF CONTENTS
section-page
INSTALLATION 1-1........................
Mounting and Line Connections 1-1.........
Auxiliary Circuits and Harness 1-2...........
Engine Starting Contacts 1-2...............
Functional Test 1-2 through 1-5..............
TESTING & SERVICE 2-1..................
Transfer Test 2-1..........................
Preventive Maintenance 2-1................
Disconnecting the Controller 2-1............
Manual Load Transfer 2-2..................
Trouble-Shooting 2-2......................
INDEX back cover.........................
Cross Reference RA Part Number PN-234325

Catalog Number Identification
A typical Catalog Number is shown below with its elements explained. The example is for a 7000 Series 7ATS
with overlapping neutral, 3 pole, 600 amp, 480 V, in a Type 1 enclosure:
7ATS C 3 600 N 5 C
Phase Poles
Neutral
A–solid
Amperes Voltage Controller Enclosure
B–switched 5X –if
accessories
ordered
5–standard
G–type4
C–type1
F–type3R
H–type4X
3–threeØ
2–singleØ
B120
D220
A115
C208
E230
K415
M460
J400
L440
N480
G277
F240
H380
Q575
P550
R600
600
blank – none
blank – open type
J
design
prefix
letter
260
400
L–type12
C– overlapping
Transfer
Switch
Controller
normal power
connections
emergency
power
connections
transfer
control
&lights
260 amp. size in typical enclosure with location of customer connections
customer terminals block
load power
connections
A
400
R
5X
7ATS A3 0400 R5X0,6D,18B,18G,31Z,37B
Mfr MArt Number Accessories included:

14
Time Delays
2C Provides an extended time delay on engine starting.
The standard feature one time delay is adjustable
from zero to six seconds. Accessory 2C allows this
time delay to be adjustable from zero to sixty minutes
in one second intervals factory set at five minutes.
1G Similar to accessory 2C except using 24 volt DC
external input signal. 7000 SERIES controller remains
active when both power sources are de-energized*
1GB Same as accessory 1G except using 120 volt AC
external input*
* add suffix 1 to include external power to power manager or
power meter when applicable
Manual Controls for Automatic
Transfer Switches
6C Reset switch for manual retransfer to normal with
automatic retransfer in the event of emergency
source failure.
6D Selector switch for automatic/manual retransfer to
normal. Automatic bypass if emergency fails.
Indicators
14A/14B Additional auxiliary contact sets to indicate switch
position. Two sets are standard. Specify total num-
ber of sets if more are required.
18B Two-pole, double-throw contacts operate when
emergency source voltage is present at transfer
switch terminals.
18G Two-pole, double-throw contacts operate when normal
source voltage is present at transfer switch terminals.
99 “Push-to-Test” feature on all pilot light indicators.
Customer Control Circuits
30A Load-shedding circuit initiated by opening of a
customer-supplied contact.
30B* Load-shedding circuit initiated by removal of
customer-supplied control voltage. *(Specify voltage).
31Z Selective load disconnect control contacts (two
provided) which operate with time delay prior to
and/or after load transfer and retransfer.
43R Terminal block for all customer control connections
on 30-150 amp only (standard on all other sizes).
Neutral Conductor Options
• Solid neutral, with fully-rated terminals. (AL-CU) UL Listed.
• Conventional neutral switching pole.
• Overlapping neutral transfer contacts. Allows for proper
ground-fault sensing and avoids generator voltage
transients during transfer.
Note: Specify neutral option in catalog number, see page 22 for instructions.
Extension Harness
37B
Six foot (6’) extension harness to increase distance between
transfer switch and control panel on open-type units.
Communications
72E 5150 Ethernet Connectivity Module offers
communication to transfer switch and metering
with embedded webpages.
72SW An Industrial Ethernet Switch mounted in the
enclosure used in conjunction with 5150
Connectivity Module (acc. 72E) metering device.
Includes 2 available Ethernet ports and 2
multimode ST Fiber connectors.
Surge Protection
ASCO Pulsar 450 rated 65KA
73AC1 Normal source protection. (3Ø, 4wire WYE)
73AC2 Emergency source protection. (3Ø, 4wire WYE)
73AC3 Load side protection. (3Ø, 4wire WYE)
Note: Other distribution voltages available (Contact ASCO).
Special Applications
45 Custom Alphanumeric nameplate mounted on the front
of the switch
111A Generator - to - Generator for Standby Applications
111B Generator - to - Generator for Prime Power
Applications
125 Seismic Certification to the requirements of the
international building code for electrical equipment
131 Certification of compliance with the American
Recovery & Reinvestment ACT (Buy American Provision)
- Must be specified at time of order placement
Bypass-Isolation Switch Options
14A1 Auxiliary contact to close in “Bypass to Normal”
position.
14B1
Auxiliary contact to close in “Bypass to Emergency” position.
14T Auxiliary contact to close when transfer switch is in
“Automatic” position.
14U Auxiliary contact to close when transfer switch is in
“Isolate” position.
14V Auxiliary; contact to close when transfer switch is in
“Test” position.
82C Automatic shutters for bus isolation when transfer
switch is withdrawn. (see page 6 for details)
82E LED Bypass status indicator, optional on G frame
1600A-4000A only. Standard for all other size switches
Note: An externally operable quick-make, quick-break (QMQB), manual handle is avail-
able on some 7000 SERIES product configurations. (Consult ASCO for guidance.)
7000 SERIES Optional Accessories
11240_Brochure_r1_92344_Broch 10/15/12 8:00 AM Page 14

SECTION 1 INSTALLATION
1 --- 1
ASCO 7000 Series Automatic Transfer Switches (ATSs)
are factory wired and tested. Field installation requires
requires mounting and connection of service cables,
and auxiliary control circuits (if required).
Remove the Shipping Skid (large ATSs)
For large ATSs, open the front door and remove the
four lag screws (2 in front, 2 in rear) securing enclosure
to the wood skid.
Supporting Foundation
The supporting foundation for the enclosure must 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
spaceandclearancetolivemetalparts. Whena
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
shownondiagram.
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.
It is not necessary to remove pole covers from the
transfer switch for cabling. If you do remove them,
reinstall them carefully.
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 automatic transfer switch from
construction grit and metal chips to prevent
malfunction or shortened life of the ATS.
Connecting Power Conductors
After the power cables have been tested, connect them
to the appropriate terminal lugs on the transfer switch
as shown on the wiring diagram provided with the
switch. Makesurethelugsprovidedaresuitablefor
use with the cables being installed. Standard terminal
lugs are solderless screw type and will accept the wire
sizes listed on the drawings provided with the switch.
Be careful when stripping insulation from the cables;
avoid nicking or ringing the conductor. Remove
surface oxides from cables by cleaning with a wire
brush. When aluminum cable is used, apply joint
compound to conductors. Tighten cable lugs to the
torque specified on rating label.
Controller Ground
A grounding wire must be connected to the controller’s
lower left mounting stud. Because the controller is
mounted on the enclosure door, a conductive strap
must be used between the enclosure and the door. This
connection provides proper grounding which does not
rely upon the door hinges.
Harnesses
The transfer switch is connected to the left side of the
controller by a plug–in harness (two plugs).

INSTALLATION (continued)
1 --- 2
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
1–1 and Table A.
Table A. Engine start connections.
When normal source
fails
Te r m i n a l s o n
Te r m i n a l B l o c k T B
contact closes TB1 and TB2
contact opens TB1 and TB3
Note: To temporarily disable engine control from
the automatic transfer switch you can unplug J3
from the small P3 receptacle at the bottom of the
assembly. BesuretoreconnectplugJ3totheP3
receptacle for automatic transfer switch operation.
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.
engine start
connections
on
customer
terminal
block TB
Figure 1-1. Customer terminal block on the top right
side of the enclosure.
Functional Test
The Functional Test consists of three checks:
S1 — Manual Operation Test, page 1–3
S2—VoltageChecks,page1–4
S3 — Electrical Operation, page 1–5
Do these checks in the order presented to
avoid damaging the automatic transfer switch.
Read all instructions on the Wiring Diagram and labels
affixed to the automatic transfer switch. Note the
control features that are provided and review their
operation before proceeding.
Continue to 1–ManualOperationTest on next page.

INSTALLATION (continued)
1 --- 3
1 – Manual Operation Test
A detachable maintenance handle is provided on the
frame of the Transfer Switch for maintenance purposes
only. Manual operation of the transfer switch should be
checked before it is energized (operated electrically).
Do not manually operate the transfer switch
until both power sources are disconnected:
open both circuit breakers.
1. After deenergizing both power sources, open the
enclosure door. Locate and remove the mainte-
nance handle from the clips on the left side of the
transfer switch frame. Insert the handle into the
holeinthemoldedhubontheleftsideofthe
operator. See Figures 1–2 and 1–3 and Table B.
2. Move the maintenance handle up or down as shown
to manually operate the transfer switch. It should
operate smoothly without any binding. If it does not,
check for shipping damage or construction debris.
3. Return the transfer switch to the Normal position.
Observe that the window indicators (right side) show
the top shaft O (open) and the bottom shaft C
(closed).
Table B. Maintenance handle positions.
ATS Position Handle Indicators
Normal
E
N
up E=O
upper contacts open
N=C
lower contacts closed
Emergency
E
Ndown
E=C
upper contacts closed
N=O
lower contacts open
Note: If Normal and Emergency connections are
reversed this operation is also reversed.
maintenance
handle
left side of
transfer switch
storage clip
Figure 1-2. Maintenance handle and its storage clips.
4. Remove the maintenance handle and store it on the
frame (left side) in the clips provided.
Verify that the maintenance handle
has been removed before proceeding!
Now continue to 2–VoltageCheckson next page.
handle
hub
UP closes the
Normal source
contacts (lower)
DOWN closes the
Emergency source
contacts (upper)
frame
window
indicators
Ois open
Cis closed
Emergency
contacts
Normal
contacts
contact position
indicators (right side)
Figure 1-3. Maintenance handle operation and contact position indicators.

INSTALLATION (continued)
1 --- 4
RED
RED
GREEN
GREEN
observe
these lights
Figure 1-4. Standard controls and indicators.
2–VoltageChecks
First check nameplate on transfer switch; rated voltage
mustbethesameasnormalandemergencylinevoltages.
Verify that the feeders have been
connected to the proper lugs.
Useextremecautionwhenusingameter
to measure voltages in the following
steps. Do not touch power terminals;
shock, burns, or death could result !
Perform steps 1 through 6 at the right. Observe the
status lights. See Figure 1–4.
QBlack square means light is on.
SWhite square means light is off.
* If necessary, adjust voltage regulator on the generator
according to the manufacturer’s recommendations. The
Automatic Transfer Switch will respond only to the rated
voltage specified on the Transfer Switch nameplate.
Note
Refer to Section 3 of Group 5 Controller User’s Guide
381333–126 for how to display the Status of the ATS
and the Voltage and Frequency of each source.
Now continue to 3 – Electrical Operation on next page.
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 pres-
entatthetransferswitchnormal
source terminals.
3
Close the emergency source
circuit breaker. (Start generator,
if necessary.) 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 pres-
ent at the transfer switch emer-
gency source terminals.*
5
Useaphaserotationmeterto
check phase rotation of emer-
gency source; it must be the
same as the normal source.
ABC
6
Shut down the engine–genera-
tor, if applicable. The Emergen-
cy Source Accepted light should
go off. Then put the starting
control selector switch (on the
generator set) in the automatic
position. Close enclosure door.

INSTALLATION (continued)
1 --- 5
RED
RED
GREEN
GREEN
observe
these lights
operate
this switch
Figure 1-5. Standard controls and indicators.
3 – Electrical Operation
This procedure will check the electrical operation of
the Automatic Transfer Switch. See Figure 1–5.
Be sure to close the enclosure door
before proceeding to prevent personal
injury in case of electrical system fault !
Transfer Test
Both normal and emergency sources must be available
and the emergency source generator (if used) must be
capable of being started in this procedure.
Perform steps 1 through 5 at the right. Observe the
status lights.
QBlack square means light is on.
SWhite square means light is off.
This completes the Functional Test of the ATS.
1
The Transfer Switch Connected
To Normal and Normal Source
Accepted lights should be on.
2
Turn a nd 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 will operate to
the Emergency position after
Feature2Btimedelay.The
Transfer Switch Connected To
Emergency light should come
on and Load Connected to Nor-
mal light goes off.
4
Transfer switch will operate
back to Normal position after
Feature3Atimedelay.Forim-
mediate retransfer turn Transfer
Control counterclockwise 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 cool-
down). The Emergency Source
Accepted light should go off.

SECTION 2 TESTING & SERVICE
2 --- 1
TRANSFER TEST
Operate the 7000 Series ATS at least once a month by
following the five–step Electrical Operation Transfer
Tes t procedure on page 1–5.
PREVENTIVE MAINTENANCE
Reasonable care in preventive maintenance will insure
high reliability and long life for the 7000 Series ATS.
An annual preventive maintenance program is recom-
mended.
In the United States, ASCO Services, Inc. (ASI) is
ASCO Power Technologies’s national service
organization. ASI can be contacted at
1-800-800-2726 (ASCO) for information on
preventive maintenance agreements.
In Canada, for service call 1-800-234-2726 (ASCO).
Checklist for Yearly Inspection
Hazardous voltage capable of causing shock,
burns, or death is used in this transfer switch.
Deenergize both Normal – Emergency power
sources before performing inspections!
SClean the ATS enclosure.Brush and vacuum
away any excessive dust accumulation. Remove any
moisture with a clean cloth.
SCheck the transfer switch contacts.Remove
the transfer switch barriers and check contact
condition. Reinstall barriers carefully. The
non–replaceable main contacts are designed to last
thelifeofthetransferswitch.
SMaintain transfer switch lubrication.Ifthe
transfer switch is subjected to severe dust or
abnormal operating conditions, renew factory
lubrication on all movements and linkages.
Relubricate the solenoid operator if the TS coil is
replaced. Do not use oil; order lubrication kit
75-100.
SCheck 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 Technolo-
gies Sales Office or ASI:
in United States call 1 800 – 800 – ASCO (2726)
or in Canada call 1 800 – 234 – 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:
Disconnecting the Plugs
Do not unplug the controller until step
1a. or 1b. below is completed.
1. Observe the position of the transfer switch.
a. If the transfer switch is in the Normal position,
first place standby engine starting control in the
off position. Second, then open the emergency
source circuit breaker. Third, open the normal
source circuit breaker.
b. If the transfer switch is in the Emergency posi-
tion, first open the normal source circuit break-
er. Second, place the engine starting control in
the test or run position. Third, open the emer-
gency source circuit breaker.
2. Separate the two quick disconnect plugs by squeez-
ing the latches. Do not pull on the harness wires.
Reconnecting the Plugs
Do not reconnect the controller until step
1a. or 1b. below is completed.
1. Observe the position of the transfer switch.
a. If the transfer switch is in the Normal position,
firstbesurethatbothnormal and emergency
source circuit breakers are open. Second, be
sure that the standby engine starting control is
still in the off position.
b. If the transfer switch is in the Emergency posi-
tion, first be sure that both normal and emer-
gency source circuit breakers are open.
2. The two harness plugs and sockets are keyed.
Carefully align the plugs with the sockets and press
straight in until both latches click. Close the door!
3. Restore the two sources in sequence as follows:
a. If the transfer switch is in the Normal position,
first close the normal source circuit breaker.
Second, close the emergency source circuit
breaker. Third, place the standby engine
starting control in the automatic position.
b. If the transfer switch is in the Emergency
position, first close the emergency source circuit
breaker. Second close the normal source circuit
breaker.

TESTING & SERVICE (continued)
2 --- 2
MANUAL LOAD TRANSFER
This procedure will manually transfer the load if the
controller is disconnected.
Do not manually operate the transfer switch
until both power sources are disconnected:
open both circuit breakers.
1. Deenergize both the normal and emergency source
conductors (remove fuses or open circuit
breakers).
2. Use the maintenance handle to manually operate
the transfer switch to the opposite source. See
Manual Operation on page 1–3.
3. Then remove the maintenance handle. See page 1–3.
Verify that the maintenance handle
has been removed before proceeding!
4. If the transfer switch is in the Emergency position
manually start the engine generator and then
install emergency source fuse or close the circuit
breaker.
TROUBLE-SHOOTING
Note any optional accessories that may be furnished on
the automatic transfer switch (ATS) and review their
operation. Refer to any separate drawings and/or
instructions that may be packed with the ATS.
Hazardous voltage capable of causing shock,
burns, or death is used in this switch.
Do not touch the power or load terminals
of the transfer switch!
Table 2-1. Trouble-Shooting Checks.
CHECK IN NUMERICAL SEQUENCE
PROBLEM 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 the normal source
fails.
Hold Transfer Test switch 15
seconds or the outage must
be long enough to allow for
Feature1Ctimedelayplus
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 on
customer terminal block TB.
Verify that the small plug J3 is
connected to receptacle P3.
–
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
(57Hzfora60Hzsystem.)*
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. –
* These are factory settings. Refer to the Group 5 Controller User’s Guide.
If the problem is isolated to circuits on the controller or the transfer switch, call your local ASCO Power
Technologies sales office or ASI. In the United States, call 1–800–800–2726. In Canada, call 1–800–234–2726.
Furnish the Serial No. and Catalog No. from the transfer switch nameplate.

INDEX
Printed in U.S.A. Copyright --- ASCO Power Technologies, L.P. 2007
A
auxiliary circuits, 1–2
C
cable
lugs, 1–1
preparation, 1–1
catalog number, inside cover
cleaning, 2–1
connections
line, 1–1
contact position indicators, 1–3
controller, 1–1
disconnecting, 2–1
see Controller User’s Guide
grounding, 1–1
E
electrical operation, 1–5
Emergency Source Accepted light,
1–4, 1–5
engine starting contacts, 1–2
F
frequency, generator, 2–2
functional test, 1–2, 1–3, 1–4, 1–5
G
ground, controller, 1–1
ground lugs, inside front cover
H
harness, 1–1
disconnect plugs, 2–1
HELP
800–800–2726 (ASCO)
[e-mail]
I
inspection, 2–1
installation, 1–1
indicators, contact position, 1–3
L
labels,
field terminal block TB, 1–2
rating, inside front cover
lights, 1–4, 1–5
lubrication, 2–1
M
maintenance handle, 1–3
illustration of, 1–3
warning, 1–3
maintenance, preventive, 2–1
manual load transfer, 2–2
warning, 2–2
manual operation, 1–3
illustration of, 1–3
warning, 1–3
N
nameplate, inside cover
Normal Source Accepted light, 1–4
O
operation
electrical, 1–5
manual, 1–3
illustration of, 1–3
warning, 1–3
optional accessories
see Controller User’s Guide
P
parts, 2–1
phase rotation check, 1–4
problem, 2–2
R
rating label, inside cover
replacement parts, 2–1
S
settings
see Controller User’s Guide
T
test, functional, 1–2, 1–3, 1–4, 1–5
time delays, 1–5, 2–2
see Controller User’s Guide
Transfer Control selector switch
Retransfer Delay Bypass, 1–5
Transfer Test, 1–5
Transfer Switch Connected To
Emergency light, 1–4, 1–5
Transfer Switch Connected To
Normal light, 1–4, 1–5
transfer test, 1–5, 2–1
transfer to emergency, 1–5
transfer to normal, 1–5
trouble–shooting, 2–2
V
voltage checks, 1–4
voltage, pickup and dropout settings
see Controller User’s Guide