Asco 911 series User manual

381333–241 C
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 1 800–800 ---2726 (ASCO)
Operator’s
Manual
Series 911
Remote Control Switches
100 through 1200 amp. sizes
DANGER is used in this manual to warn of high
voltages capable of causing shock, burns, or death.
WARNINGisusedinthismanualtowarn
of possible personal injury.
CAUTIONisusedinthismanualtowarn
of possible equipment damage.
TABLE OF CONTENTS
page
Installation 1–4............................
Optional Accessories 5–7...................
Wiring Diagram & Outlines back of manual...
Maintenance & Troubleshooting 8...........
ASCO Series 911 Remote Control (RC) Switches are
factory wired and tested. Installation requires mounting
and connection of service cables and appropriate control
circuits. An experienced licensed electrician should install
the RC Switch. A typical Catalog Number is shown below.
Catalog Number Identification with Elements Explained
Typical Series 911 catalog no. for a H design, 3 pole, 600 ampere, 240 volt 60 Hz control, open type Remote Control Switch:
911
A
3 600 F 1
Phase Poles
Neutral Amperes Voltage Accessories
X–if
accessories
ordered
3–threeØ
2–singleØ
D220
C208
E230
K415
M460
J400
L440
N480
G277
F240
H380
blank – none
design prefix
letter **
H
A–solid
Q575
P550
R600
Enclosure
C–type1
F–type3R
G–type4
L–type12
blank – open type
C
Code
1–
internal
code
100
225
260
400
600
800
1000
1200
200
150
** design prefix letter
E for 260–400 amp
H for 600–1200 amp
B120*
A115*
* voltage codes A (115 V) and B (120 V)
available only for 100–400 amp sizes
H911 600 amp size

INSTALLATION Series 911
1381333–241
ASCO Series 911 Remote Control (RC) Switches are
all–purpose single–throw switches available in capacities
from 100 to 1200 amps. They can be used for all classes
of loads to 480 volts ac to their full ratings, open or
enclosed. Loads may be 100% tungsten rated at 250 volts
ac. Inrush or stalled–rotor motor currents do not affect
the switch rating. Thermal capacity is 20 times full load
rating.
Series 911 RC Switches are ideally suited for use as panic
switch control, where transformer type dimmers are used.
They are capable of withstanding high fault currents until
the overcurrent protective device operates. Series 911
RC Switches can interrupt 600% of rated current at 480
volts, 60 Hz, 0.4 to 0.5 power factor; thus all Series 911
RC Switches may be used for switching ac motor circuits.
Inspection
Inspect packaging carefully for shipping damage. If any
damage is discovered, leave the packing material as is
and immediately file a claim with the shipper. After the
carrier has inspected the damage contact your local
ASCO Power Technologies source for assistance.
Unpacking
When you are ready to install the switch, carefully
unpack or uncrate it. Protect the switch at all times from
moisture, construction grit, and metal chips.
Handling
Handle the RC Switches by grasping the back panel. Do
not lift the RC Switch at any other points. Protect the
arc barriers at all times from impact.
Nameplate / Rating Label
The Series 911 RC Switch contains a nameplate / rating
label which includes data for that specific RC Switch. It
defines the loads and fault current withstand/closing
ratings. Refer to the label on the RC Switch for specific
values and use the RC Switch only within their limits.
Do not exceed the values on the nameplate /
rating label. Exceeding the rating can cause
personal injury or serious equipment damage.
Mounting
Two Composite Outline drawings are furnished in the
back of this manual. Use drawing 405386 for 100–400
amp size open–type RC Switches, or use drawing 405387
for 600–1200 amp size open–type RC Switches. Use
drawing 405388 for enclosed RC Switches. The diagrams
show all mounting details and instructions.
To prevent malfunction or shortened
life for the RC Switch protect it from
construction grit and metal chips.
RC Switches rated 100–225 amperes must be mounted on
supplied insulator bushings and backing insulators
(installed behind the switch). Likewise, mount open–
type 260 and 400 ampere RC Switches on supplied
insulator backing piece. If the switch is removed from
the enclosure and then reinstalled, these insulator
bushings and backing insulators must be placed behind
the RC switch. See Figures 1 and 2.
Be sure that the insulator pieces are behind the
100, 150, 200, and 225 ampere RC Switches.
Also be sure to use the insulator bushings under
the hardware.
Figure 1. Required insulator bushings and backing
insulators for 100–225 amp. RC Switches.

INSTALLATION (continued)Series 911
2
381333–241
Be sure that the insulator piece is behind
the 260 and 400 ampere RC Switches.
insulator
backing
piece
Figure 2. Required insulator backing piece
for 260 and 400 amp. RC Switches.
Mount the RC Switch vertically in the back of the
enclosure as shown on the Composite Outline drawings
provided. Level all mounting points of the rigid
supporting structure by using flat washers behind the
holes to avoid forced distortion of the transfer switch.
Power connections
Use Wiring Diagram 355634 furnished at the back of this
manual for 100–400 amp RC Switches. Use Wiring
Diagram 724242 furnished at the back of this manual for
600–1200 amp RC Switches. All wiring must be made in
accordance with the local codes. Table A shows the range
of conductor sizes and number of conductors accepted by
RC Switch terminals and the corresponding tightening
torque recommended.
De–energize the conductors before making
any power or control circuitry connections.
Be sure that the load L1, load L2, and Line
connections are in the same phase sequence.
It is unnecessary to remove the barriers from the RC
Switches. H–design 600–1200 amp size RC Switches have
interphase barriers that have cutouts to access cable
terminals. These interphase barriers should not be
removed. Always protect internal components from
damage and metal chips and construction debris. Do not
run cables behind the RC Switch. Conductors can be
bundled on the right side of the switch. Maintain proper
electrical clearance between live metal parts and
grounded metal: ½ inch minimum up to 400 amps., 1
inch minimum over 400 amps..
Connect main source and load conductors to clearly
marked power terminals on the RC Switch. Be careful
when stripping insulation from conductors; avoid nicking
or ringing the conductor. Remove surface oxides from
conductors by cleaning with a wire brush. Follow
conductor manufacturer’s instructions when aluminum
conductor is used. Apply joint compound to conductor,
then carefully wipe away excess compound. Tighten the
terminals to the torque specified in Table A.
Table A. Transfer switch terminals for power conductors (use stranded–type conductors).
RC Switch
Rating (amps)
Maximum Number of
Conductors per Terminal
Range of Conductor Sizes
Al–Cu AWG
Recommended
Tightening Torque
#14 to #10 35 in–lb
1
0
0
o
n
e
#8 40 in–lb
100 one #6 to #4 45 in–lb
#3 to 1/0 50 in–lb
150, 200, 225 one #6 to 350 MCM 375 in–lb
2
6
0
4
0
0
two #1/0 to 250 MCM
6
0
0
i
n
l
b
260, 400 one #4 to 600 MCM 600
i
n
–
l
b
600, 800, 1000 two
#
1
t
o
6
0
0
M
C
M
3
7
5
i
n
l
b
1200 four #1 to 600
M
C
M
375
i
n
–
l
b

INSTALLATION (continued) Series 911
3381333–241
Control Line Connections
Control circuit connections designated 1, 2, and 3 are
located on terminal block TB on the RC Switch (lower
left on 100–225 amp., upper left on 260–400 amp., lower
left on 600–1200 amp). Each terminal accepts one #14
to 10 AWG wire. Refer to Wiring Diagrams at the back of
this manual.
Tables B, C, D, and E list the maximum distances and
minimum wire sizes that can be run between a control
station and one Series 911 RC Switch for 120 and 240 V
60Hzcontrol. Thelineruncanbeextendedbytheuse
of auxiliary control relays (refer to the Optional
Accessories sectioninthismanual).
Do not exceed the control line run distances
specified for proper RC Switch operation.
Table B. Inrush Current, Control Line Run, Minimum Fuse for 100 amp. 911 RC Switches
C
o
n
t
r
o
l
V
o
l
t
a
g
e
I
n
r
u
s
h
C
u
r
r
e
n
t
Control Line Run (distance in feet) 1
M
i
n
i
m
u
m
F
u
s
e
2
C
ontro
l
V
o
l
tage
I
nrus
h
C
urrent #14 AWG #12 AWG #10 AWG
M
i
n
i
mum
F
use
2
120 V 60 Hz 24 amps. 465 740 1175 8amps.
240 V 60 Hz 12 amps. 1860 2960 4700 4amps.
Note 1: Maximum distance between RC Switch and remote control station. Note 2: Fuse must be rated fro 100,000 amperes,
Based on 90% line voltage and minimum operating voltage of 75%. symmetrical @ 600 V.
Table C. Inrush Current, Control Line Run, Minimum Fuse for 150, 200, 225 amp. 911 RC Switches
C
o
n
t
r
o
l
V
o
l
t
a
g
e
I
n
r
u
s
h
C
u
r
r
e
n
t
Control Line Run (distance in feet) 1
M
i
n
i
m
u
m
F
u
s
e
2
C
ontro
l
V
o
l
tage
I
nrus
h
C
urrent #14 AWG #12 AWG #10 AWG
M
i
n
i
mum
F
use
2
120 V 60 Hz 30 amps. 395 630 1000 10 amps.
240 V 60 Hz 15 amps. 1580 2520 4000 5amps.
Note 1: Maximum distance between RC Switch and remote control station. Note 2: Fuse must be rated fro 100,000 amperes,
Based on 90% line voltage and minimum operating voltage of 75%. symmetrical @ 600 V.
Table D. Inrush Current, Control Line Run, Minimum Fuse for 260 & 400 amp. E–design 911 RC Switches
C
o
n
t
r
o
l
V
o
l
t
a
g
e
I
n
r
u
s
h
C
u
r
r
e
n
t
Control Line Run (distance in feet) 1
M
i
n
i
m
u
m
F
u
s
e
2
C
ontro
l
V
o
l
tage
I
nrus
h
C
urrent #14 AWG #12 AWG #10 AWG
M
i
n
i
mum
F
use
2
120 V 60 Hz 36 amps. 100 156 250 10
240 V 60 Hz 17 amps. 425 660 1060 4
Note 1: Maximum distance between RC Switch and remote control station. Note 2: Fuse must be rated fro 100,000 amperes,
Based on 90% line voltage and minimum operating voltage of 75%. symmetrical @ 600 V.
Table E. Inrush Current, Control Line Run, Minimum Fuse for 600, 800, 1000, 1200 amp. H–design 911 RC Switches
C
o
n
t
r
o
l
V
o
l
t
a
g
e
I
n
r
u
s
h
C
u
r
r
e
n
t
Control Line Run (distance in feet) 1
M
i
n
i
m
u
m
F
u
s
e
2
C
ontro
l
V
o
l
tage
I
nrus
h
C
urrent #14 AWG #12 AWG #10 AWG
M
i
n
i
mum
F
use
2
208–240 V 60 Hz 18 amps. 320 510 810 10 amps.
Note 1: Maximum distance between RC Switch and remote control station. Note 2: Fuse must be rated fro 100,000 amperes,
Based on 90% line voltage and minimum operating voltage of 75%. symmetrical @ 600 V.

INSTALLATION (continued)Series 911
4
381333–241
Functional Test
The Functional test consists of three checks: manual
operation, voltage checks, and electrical operation. Read
all instructions on the Wiring Diagram and all labels.
1 – Manual operation
A manual operator handle is provided on the RC Switch
for maintenance purposes only. Manual operation must
be checked before the RC Switch is electrically energized.
Do not manually operate the RC Switch
until all power sources (service & control)
and all loads are deenergized (open CBs).
1. After deenergizing both power sources, open the
enclosure door. Locate and the maintenance handle
ontheleftsideoftheRCSwitch.SeeFigure3.
2. Selecttheappropriateswitchamperagesize/design
and follow the directions for using the handle. Move
it up or down as shown to manually operate the RC
Switch. It should operate smoothly without any
binding. If it does not, check for shipping damage or
construction debris.
100 – 225 amp. See Figure 3.
Insert medium screwdriver as shown to turn the
slotted socket in the switch cover; ¼ turn clokwise to
close, ¼ turn counterclockwise to open.
260 and 400 amp. E–design SeeFigure4.
Insert the manual handle into the hole in the shaft,
left side of the operator.
600 – 1200 amp. H–design SeeFigure5.
Locate and remove the maintenance handle from the
clips on the left side. Insert the handle into the hole
in the molded hub on the left side of the operator.
3. Remove manual operator handle (if detachable) and
store it on the RC Switch in the place provided.
Verify that maintenance handle has been removed
(260–1200 amp. switches) before proceeding!
Figure 3. Maintenance Handle (screwdriver)
for 100–225 ampere RC Switches.
handle
Figure 4. Maintenance Handle
for 260–400 ampere RC Switches.
frame
handle
hub
window
indicator
Ois open
Cis closed
contact position
indicator (right side)
Figure 5. Maintenance Handle and positions
for 600–1200 ampere RC Switches.
Useextremecautionwhenusingameterto
measure voltages in the following steps.
Do not touch power terminals.
2 – Voltage Checks
Check the nameplate on RC Switch for rated service
voltage. It should be same as the load and line voltages.
1. Energizethelinesource. Useavoltmetertocheck
phase to phase voltages present at RC Switch line
terminals. The voltages should be the same as listed
on the RC Switch nameplate.
2. Close the enclosure door and tighten the screws.
3 – Electrical operation
After you check manual operation and verify correct line
and control voltages, you should check the electrical
operation. Electrical control is provided by others.
Refer to the Wiring Diagram provided at the back of this
manual. Carefully electrically test the operation of the
RC Switch.
This completes the Functional test of the Series 911.

OPTIONAL ACCESSORIES Series 911
5381333–241
Two–Wire Control
Optional Accessory 47 Auxiliary Relay
This auxiliary relay, Figure 6, if furnished, is connected
and mounted for enclosed RC switches, or is supplied
loose for open–type switches. The auxiliary relay can be
added later by ordering Catalog 321A40.Specify the
control voltage for the relay (see Table F below).
The auxiliary relay is intended for two–wire control of
the RC switch. The relay must be energized to close the
RC switch Load 1 contacts, and de–energized to close the
RC switch Load 2 contacts. Therefore, use a single pole,
maintained–type control station (such as Acc. 53B or
53C) to operate the auxiliary relay.
There are three different Accessory 47 auxiliary relays.
Each one is suitable only for the control voltage(s)
marked below the lower terminal block. Barrier
screw–type terminals accept #22–12 AWG Cu control
wiring. Refer to the Wiring Diagram forproperhookup
of the auxiliary. relay.
Table F. Acc. 47 Auxiliary Relay Voltages & Burdens.
A
ccessor
y
Relay
Control Voltages
Burden
of Relay
A
c
c
e
s
s
o
r
y
ac (60 Hz) dc ac dc
47 C 24 24
2
5
47 A 120 120 3.0 VA 2.5
w
a
t
t
s
47 B 208, 240, 277 —
3
.
0
V
A
wa
t
t
s
24 V ac/dc and 120 V ac/dc relay shown below
208, 240, 277 V ac relay (not shown) has a transformer
Figure 6. Accessory 47 auxiliary relay.
Three–Wire Control
Optional Accessory 48 Auxiliary Relay
This auxiliary relay, Figure 7, if furnished, is connected
and mounted for enclosed RC switches, or is supplied
loose for open–type switches. The auxiliary relay can be
added later by ordering Catalog 321A36.Specify the
control voltage for the relay (see Table G below).
The auxiliary relay is intended for three–wire control of
the RC switch. The auxiliary relay panel has two relays.
One relay must be energized to close the RC switch Load
1 contacts; the other relay must be energized to close the
RC switch Load 2 contacts. If neither relay or both
relays are energized, no output will occur. Therefore,
use a single pole, double–throw, momentary–type control
station (such as Acc. 53A) to operate the auxiliary relay.
There are ten different Accessory 48 auxiliary relays.
Each one is suitable only for the control voltage marked
on the two plug–in relays. Barrier screw–type terminals
accept #22–12 AWG Cu control wiring. Refer to the
Wiring Diagram for proper hookup of the auxiliary. relay.
Table G. Acc. 48 Auxiliary Relay Voltages & Burdens.
A
ccessor
y
Relay
Control Voltages
Burden
of Relay
A
c
c
e
s
s
o
r
y
ac (60 Hz) dc ac dc
48 A 24 —
48 B 120 —
48 C 208 —2.0 VA —
48 D 240 —
2
.
0
V
A
48 E 277 —
48 F —12
48 G —24
1
2
48 H —32 —1.2
w
a
t
t
s
48 I —48 wa
t
t
s
48 J —110
Figure 7. Accessory 48 auxiliary relay.

OPTIONAL ACCESSORIES (continued)
Series 911
6
381333–241
Form 3 Control
Optional Accessory 49 Auxiliary Relay
This auxiliary relay, Figure 8, if furnished, is connected
and mounted for enclosed RC switches, or is supplied
loose for open–type switches. The auxiliary relay can be
added later by ordering mounting socket kit 295855 and
the appropriate plug–in relay part no. listed in Table I.
The auxiliary relay is intended for Form 3 (start–stop
control of the RC switch. The relay must be energized to
close the RC switch Load 1 contacts, and de–energized to
close the RC switch Load 2 contacts. Therefore, use one
normally closed and one normally open separate control
stations (such as Acc. 53D) to operate the auxiliary relay.
There are ten different Accessory 49 auxiliary relays.
Each one is suitable only for the control voltage marked
on the plug–in relay. Clamp–type terminals in the
mounting socket accept #22–12 AWG Cu control wiring.
Refer to the Wiring Diagram for proper hookup of the
auxiliary. relay.
Table H. Acc. 49 Auxiliary Relay Voltages & Burdens.
A
ccessor
y
Relay
Control Voltages
Burden
of Relay
A
c
c
e
s
s
o
r
y
ac (60 Hz) dc ac dc
49 A 24 —
49 B 120 —
49 C 208 —2.0 VA —
49 D 240 —
2
.
0
V
A
49 E 277 —
49 F —12
49 G —24
1
2
49 H —32 —1.2
w
a
t
t
s
49 I —48 wa
t
t
s
49 J —110
Figure 8. Accessory 49 auxiliary relay.
Plug–in relay and mounting socket.
Table I. Acc. 49 Plug–In Auxiliary Relay Part Nos.
A
ccessor
y
Relay
Control Voltages
Plug–In
Rela
y
A
c
c
e
s
s
o
r
y
ac (60 Hz) dc
R
e
l
a
y
Part Nos.
49 A 24 —321969
49 B 120 —197660
49 C 208 —269638
49 D 240 —197661
49 E 277 —255219
49 F —12 245774
49 G —24 255102
49 H —32 263707
49 I —48 285637
49 J —110 269639
Solid Neutral Plate
Optional Accessory 22
Neutral plates, if furnished, are mounted in the enclosure
for 260–400 amp. size RC switches or supplied loose for
open–type 260–400 amp. size RC switches. For 30–150
amp. size RC switches the neutral plate is mounted on
the RC switch mounting plate (both enclosed and
open–type RC switches). Neutral plates can be ordered
later by ordering the appropriate kit listed in Table J.
The kits include a neutral plate assembly and hardware
to mount it. Refer to Table H.
The Accessory 22 assembly is suitable as a solid neutral
with full–rated terminals for aluminum or copper wire.
TightenlugstotorquespecifiedinTableK.
Table J. Acc. 22 Solid Neutral Plates.
RC Switch Amp. Size Acc. 22 Kit Number
30–150 K727566
260 319900–022–C
400 319900–022–D
Table K. Tightening Torque Values for Acc. 22
Neutral Socket–Head Screw Connectors.
Socket Size across flats
in inches
Tightening Torque
in inch pounds
1/4 200
1/2 500

OPTIONAL ACCESSORIES (continued) Series 911
7381333–241
Control Line Fuses
Optional Accessory 52
Control line fuses, if furnished, are mounted for enclosed
RC switches, or are supplied loose for open type
switches. The fuses can be added later by ordering the
appropriate kit listed in Table L. The kits include fuse(s)
and fuse holder.
The cartridge fuses are suitable for the ac control
voltages specified in the following table. Fuse blocks that
hold the fuses have #10–32 terminal screws for control
wiring. Refer to the Wiring Diagram forproperhookup
of control line fuses.
TableL. Acc.52ControlLineFuses.
A
c
c
e
s
s
o
r
y
RC Switch Control
V
olta
g
eNumber Fuse Fuse
F
u
s
e
K
i
t
N
u
m
b
e
r
A
ccessory
R
C
S
w
i
t
c
h
C
o
n
t
r
o
l
V
o
l
t
a
g
e
and Line Confi
g
uration
N
u
m
b
e
r
of Fuses
F
u
s
e
T
y
pe
F
u
s
e
Ratin
g
F
use
K
i
t
N
um
b
er
52 A up to 300 V ac, grounded 1SC 15 A, 300 V ac 333272
52 B up to 300 V ac, ungrounded 2SC 15 A, 300 V ac 333273
52 C 301 to 600 V ac, ungrounded 2KTK 15 A, 600 V ac 333274
Door–Mounted Controls
Optional Accessory 53
Manual controls, if furnished, are connected and mounted
on the enclosure door, or are supplied loose for open type
switches. The controls can be added later by ordering the
appropriatekitlistedinTableMbelow.Thekitsinclude
switch(es) and nameplate. The switches mount in a 1/2 inch
diameter hole and have #6–32 terminal screws for control
wiring. Refer to the Wiring Diagram for proper hookup of
control switches.
Table M. Acc. 53 Door–Mounted Controls.
A
c
c
e
s
s
o
r
y
F
o
r
U
s
e
W
i
t
h
Control Line
C
o
n
t
r
o
l
S
w
i
t
c
h
e
s
Control
K
it
A
ccessory
F
or
U
se
W
i
t
h
C
o
n
t
r
o
l
L
i
n
e
Confi
g
uration
C
ontro
l
S
w
i
tc
h
es
C
o
n
t
r
o
l
K
i
t
Number
53 A RC Switch direct or
Accessory 48 auxiliary relay 3 wire control 1 double throw toggle, momentary on with center off K734627–004
53 B Accessory 47 auxiliary relay 2 wire control 1 double throw toggle,
maintained on with center off K734627–005
53 C Accessory 47 auxiliary relay 2 wire control 1 single throw toggle,
maintained on K734627–006
53 C Accessory 49 auxiliary relay Form 3 control 2 single throw toggles,
1 momentary off, 1 momentary on K734627–008
Auxiliary contacts
One set of auxiliary contacts are mounted on the RC
switch. Connect external circuits to the terminals as
specifiedinTableNandshownontheWiring Diagram.
Table N. Auxiliary contact connections.
RC Switch closed on
Load 2
Te r m i n a l s o n
RC Switch
contact closed P3 and P4
contact open P1 and P2