381333–203 AASCO POWER TECHNOLOGIES L.P. 50 Hanover Road, Florham Park, New Jersey 07932 USA www.asco.com

Operator’sManual

7000 Series ACTSAutomatic Closed–Transition

Transfer Switches, 600–1200 amps

600---1000 amp. sizes

An experienced licensed electrician must install the ACTS.

DANGER is used in this manual to warn of highvoltages capable of causing shock, burns, or death.

WARNING is used in this manual to warnof possible personal injury.

!

CAUTION is used in this manual to warnof possible equipment damage.

!

Note: Refer to the outline and wiring drawingsprovided with your 7000 Series ACTS for allinstallation and connection details and accessories.

Note: Refer to Group 5 Controller User’s Guide381333–126 for ATS status display messages, timedelays, pickup & dropout settings, and adjustments.

1200 amp. size

TABLE OF CONTENTSsection-page

INSTALLATION 1-1. . . . . . . . . . . . . . . . . . . . . . . .Mounting and Line Connections 1-1. . . . . . . . .Auxiliary Circuits and Harness 1-2. . . . . . . . . . .Engine Starting Contacts 1-2. . . . . . . . . . . . . . .Functional Test 1-3, 1-4, 1-5, 1-6. . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . . . . . .

Rating LabelEach Automatic Closed–Transition Transfer Switch containsa rating label to define the loads and fault circuit withstand/closing ratings. Refer to the label on the Transfer Switch forspecific values.

Do not exceed the values on the rating label.Exceeding the rating can cause personal injury

or serious equipment damage.

!

NameplateThe Transfer Switch nameplate includes data for eachspecific 7000 Series ACTS. Use the switch only within thelimits shown on this nameplate. A typical Catalog Numberis shown on the next page with its elements explained.

Catalog Number IndentificationTypical 7000 Series ACTS catalog no. for switched neutral,3 pole, 800 amp, 480 V, ATS in Type 1 enclosure:

H7ACTS B 3 800 N 5 C

Phase PolesNeutral

A – solid

Amperes Voltage Controller Enclosure

B – switched 5X – ifaccessories

ordered

5 – standard

G – type 4 *

C – type 1F – type 3R

L – type 12 *

3 – three Ø2 – single Ø

D 220C 208

E 230

K 415

M 460

J 400

L 440

N 480G 277F 240

H 380 Q 575P 550

R 600

12001000800

blank – none

blank – open type

600

* available 600–1000 amp. sizes only

TransferSwitch

powerconnections

Group 5Controller

TransferControl& lights

800–1000 amp. sizes in typical enclosure with location of customer connections

powerconnections

field connectionsterminal block TB

ground lug

ground lug

TransferSwitch

powerconnections

Group 5Controller

TransferControl& lights

1200 amp size in typical enclosure with location of customer connections

powerconnections

field connectionsterminal block TB ground lug

SECTION 1 INSTALLATION

1---1

ASCO 7000 Series Automatic Closed–Transition Trans-fer Switches (ACTSs) are factory wired and tested. Fieldinstallation requires mounting and connection of servicecables, and auxiliary control circuits (if required).

Remove the Shipping Skid (large ACTSs)For large ACTSs, open the front door and remove thefour lag screws (2 in front, 2 in rear) securing enclosure tothe wood skid.

Supporting FoundationThe supporting foundation for the enclosure must belevel and straight. Refer to the applicable enclosureoutline drawing included with the switch for allmountingdetails including door opening space.

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

MountingRefer to the applicable enclosure outline drawing fur-nished with this switch and mount the automatic transferswitch according to details and instructions shown ondiagram.

Line ConnectionsRefer to the Wiring Diagram provided with the switch.All wiring must be made in accordance with the NationalElectrical Code and local codes.

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

De–energize the conductors before making anyline or auxiliary circuitry connections. Be surethat Normal and Emergency line connectionsare in proper phase rotation. Place engine gen-erator starting control in theOFF position. Makesure engine generator is not in operation.

Testing Power ConductorsDo not connect the power conductors to the transferswitch until they are tested. Installing power cables inconduit, cable troughs and ceiling-suspended hangersoften requires considerable force. The pulling of cablescan damage insulation and stretch or break the conduc-tor’s strands. For this reason, after the cables are pulledinto position, and before they are connected, they shouldbe tested to verify that they arenot defective or havebeendamaged during installation.

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

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Connecting Power ConductorsAfter the power cables have been tested, connect them tothe appropriate terminal lugs on the transfer switch asshown on the wiring diagram provided with the switch.Make sure the lugs provided are suitable for use with thecables being installed. Standard terminal lugs are solder-less screw type and will accept the wire sizes listed on thedrawings provided with the switch. Be careful whenstripping insulation from the cables; avoid nicking orringing the conductor. Remove surface oxides fromcables by cleaning with a wire brush. When aluminumcable is used, apply joint compound to conductors.Tighten cable lugs to the torque specified on rating label.

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

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

INSTALLATION (continued)

1---2

Engine Starting ContactsAll customer connections, including the engine controlcontact connections, are located on terminal block TBwhich is mounted on the top right side of the enclosure.Refer to the wiring diagram provided with the automatictransfer switch and connect the engine start wires to theappropriate terminals. See Figure 1–1 and Table A.

Table A. Engine start connections.

When normal sourcefails

Terminals onTerminal Block TB

contact closes TB1 and TB2contact opens TB1 and TB3

Note: To temporarily disable engine control fromthe automatic transfer switch you can unplug J3from the small P3 receptacle at the bottom of theassembly. Be sure to reconnect plug J3 to the P3receptacle for automatic transfer switch operation.

Auxiliary CircuitsConnect auxiliary circuit wires to appropriate terminalson transfer switch terminal block TB as shown on thewiring diagram provided with this automatic transferswitch.

engine startconnections

oncustomerterminalblock TB

Figure 1-1. Customer terminal block on the top rightside of the enclosure.

Functional Test

The Functional Test consists of three checks:

V 1 — Manual Operation Test, page 1–3

V 2 — Voltage Checks, page 1–4

V 3 — Electrical Operation, page 1–5

Do these checks in the order presentedto avoid damaging the ACTS.

!

Read all instructions on the Wiring Diagram and labelsaffixed to the automatic transfer switch. Note the controlfeatures that are provided and review their operationbefore proceeding.

Note the position of the contact shafts as shown below.

window indicatorsO is openC is closed

Emergency contacts(upper shaft)

Normal contacts(lower shaft)

contactpositionindicators(right side)

Figure 1-2. Contact position indicators.Shown with Emergency open and Normal closed.

Continue to 1 – Manual Operation Test on next page.

INSTALLATION (continued)

1---3

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

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

open both circuit breakers.

!

1. After deenergizing both power sources, open theenclosure door. Locate and remove themaintenancehandle from the clips on the left side of the transferswitch frame. Insert the handle into the hole in themolded hub on the left side of the operator. SeeFigures 1–3 through 1–5 and Table B.

2. Move the maintenance handle up or down as showntomanually operate the transfer switch. The transferswitch should operate smoothly without binding. If itdoes not, check for shipping damage or constructiondebris. Operate both upper and lower contact shafts.

3. Return the transfer switch to the Normal position.Observe that the window indicators (right side) showthe upper shaft O (Emergency open) and the lowershaft C (Normal closed). Remove the maintenancehandle and store it on the frame in the clips provided.

Table B. Maintenance handle positions.

ATS Position Handle Indicators

Normal

E

up

E = Oupper contacts open

Normal

Nup

N = Clower contacts closed

Emergency

Edown

E = Cupper contacts closed

Emergency

N

down

N = Olower contacts open

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

Now continue to 2 – Voltage Checks on the next page.

maintenancehandle

left side oftransfer switch

clip

Emergency sourcecontact shaft hub

Normal sourcecontact shaft hub

Figure 1-3. Maintenance handle storage location.Hubs shown with Normal closed & Emergency open.

handle

hub

UP opens theEmergency sourcecontacts

DOWN closes theEmergency sourcecontacts

frame

UPPER SHAFT

Figure 1-4. Emergency (upper shaft) operation.

handle

hub

UP closes theNormal sourcecontacts

DOWN opens theNormal sourcecontacts

frame

LOWER SHAFT

Figure 1-5. Normal (lower shaft) operation.

INSTALLATION (continued)

1---4

Transfer SwitchConnectedTo

Normal

Transfer SwitchConnectedTo

Emergency

NormalSourceAccepted

EmergencySourceAccepted

TransferControl

RetransferDelayBypass

TransferTestHOLD FOR15 SECONDS

RED

REDGREEN

GREEN

( )

Automatic Closed TransitionTransfer Switch

observethese lights

ExtendedParallelTime

FailureTo

Synchronize

TSLockedOut

AlarmReset

ClosedTransitionBypass

RED RED RED

Figure 1-6. Standard controls and indicators.

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

Before energizing the switch check to be surethat both normal and emergency contacts arenot left in the closed position.

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Verify that the feeders have beenconnected to the proper lugs.

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Use extreme caution when using a meter tomeasure voltages. Do not touch power termi-nals; shock, burns, or death could result !

Perform steps 1 through 6 at the rights. Observe thestatus lights. See Figure 1---6.

� Black square means light is on.

❐ White square means light is off.

* If necessary, adjust voltage regulator on the generatoraccording to the manufacturer’s recommendations. TheAutomatic Transfer Switch will respond only to the ratedvoltage specified on the Transfer Switch nameplate.

Now continue to 3 --- Electrical Operation on next page.

1

Close the normal source circuitbreaker. The Transfer SwitchConnected To Normal and theNormal Source Accepted lightsshould come on.

2

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

3

Close the emergency sourcecircuit breaker. (Start generator,if necessary.) The TransferSwitch Connected To Normal &Emergency Source Acceptedlights should come on.

4

Use an accurate voltmeter tocheck phase to phase andphase to neutral voltages pres-ent at the transfer switch emer-gency source terminals.*

5

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

A B C

6

Shut down the engine–genera-tor, if applicable. The Emergen-cy Source Accepted light shouldgo off. Then put the startingcontrol selector switch (on thegenerator set) in the automaticposition. Close enclosure door.

INSTALLATION (continued)

1---5

Transfer SwitchConnectedTo

Normal

Transfer SwitchConnectedTo

Emergency

NormalSourceAccepted

EmergencySourceAccepted

TransferControl

RetransferDelayBypass

TransferTestHOLD FOR15 SECONDS

RED

REDGREEN

GREEN

( )

Automatic Closed TransitionTransfer Switch

observethese lights

ExtendedParallelTime

FailureTo

Synchronize

TSLockedOut

AlarmReset

ClosedTransitionBypass

RED RED RED

operatethis switch

Figure 1-7. Standard controls and indicators.

3 --- Electrical OperationThis procedure will check the electrical operation of theAutomatic Closed–Transition Transfer Switch. SeeFigure 1---7.

Close the enclosure door first.

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Transfer Test

Both normal and emergency sources must be availableand the emergency source generator (if used) must becapable of being started in this procedure.

Perform steps 1 through 4 at the rights. Observe thestatus lights.

� Black square means light is on.

❐ White square means light is off.

** If you do not want closed–transition transfer, press theClosed Transition Bypass pushbutton while thecontroller display showsWaiting for In–Sync. This actioncauses open–transition (momentary load interruption)transfer to the opposite source, if conditions permit.Also refer to the Group 5 Controller User’s Guide381333–126.

This completes the Functional Test of the ACTS.

1

Turn and hold Transfer Controlswitch clockwise to TransferTest until the engine startsand runs (within 15 sec.).Emergency Source Acceptedlight should come on.

2

Transfer switch CE closes andthen Transfer Switch CN opens(closed–transition overlap). TheTransfer Switch Connected ToEmergency light should comeon and the Transfer Switch Con-nected to Normal light goes off(you might see and hear thebrief overlap transfer). **

3

Transfer switch will operateback to Normal position afterFeature 3A time delay. For im-mediate retransfer turn TransferControl counterclockwise toRetransfer Delay Bypass. TheTransfer Switch Connected ToNormal light should come on;Transfer Switch Connected toEmergency light should go off.

4

The engine–generator will stopafter the Feature 2E time delay(unloaded running engine cool-down). The Emergency SourceAccepted light should go off.

SECTION 2 TESTING & SERVICE

2---1

TRANSFER TESTOperate the 7000 Series ACTS at least once a month byfollowing the five–step Electrical Operation TransferTest procedure on page 1–5.

PREVENTIVE MAINTENANCEReasonable care in preventive maintenance will insurehigh reliability and long life for the 7000 Series ACTS.An annual preventive maintenance program is recom-mended.

ASCO Services, Inc. (ASI) is ASCO PowerTechnologies’s national service organization. ASIcan be contacted at 1-800-800-2726 for informationon preventive maintenance agreements.

Checklist for Yearly Inspection

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

j Clean the ACTS enclosure. Brush and vacuumaway any excessive dust accumulation. Remove anymoisture with a clean cloth.

j Check the transfer switch contacts. Remove thetransfer switch barriers and check contact condition.Replace the contacts if they become pitted or wornexcessively. Reinstall the barriers carefully.

j Maintain transfer switch lubrication. If thetransfer switch is subjected to severe dust orabnormal operating conditions, renew factorylubrication on all movements and linkages.Relubricate the solenoid operator if the TS coil isreplaced. Do not use oil; order lubrication kit 75-100.

j Check all cable connections & retighten them.

REPLACEMENT PARTSReplacement parts are available in kit form. When or-dering parts provide the Serial No., Bill of Material No.(BOM), and Catalog No. from the transfer switch name-plate. Contact your local ASCO Power TechnologiesSales Office or ASI:

call 1 – 800 – 800 – ASCO ( 2726 )

DISCONNECTING THE CONTROLLER

The harness disconnect plugs are furnished for repairpurposes only and should not have to be unplugged. Ifthe controller must be isolated, follow these steps:

Disconnecting the Plugs

Do not unplug the controlleruntil steps 1a or 1b is completed.

!

1. Observe the position of the transfer switch.

a. If the transfer switch is in theNormal position, firstplace standby engine starting control in the offposition. Second, then open the emergency sourcecircuit breaker. Third, open the normal sourcecircuit breaker.

b. If the transfer switch is in theEmergency position,first open the normal source circuit breaker. Sec-ond, place the engine starting control in the testor run position. Third, open the emergency sourcecircuit 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 controlleruntil steps 1a or 1b is completed.

!

1. Observe the position of the transfer switch.

a. If the transfer switch is in the Normal position,first be sure that both normal and emergencysource circuit breakers are open. Second, be surethat the standby engine starting control is still inthe off position.

b. If the transfer switch is in the Emergency position,first be sure that both normal and emergencysource circuit breakers are open.

2. The two harness plugs and sockets are keyed. Care-fully align the plugs with the sockets and pressstraight 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 break-er. Third, place the standby engine startingcontrol in the automatic position.

b. If the transfer switch is in theEmergency position,first close the emergency source circuit breaker.Second close the normal source circuit breaker.

TESTING & SERVICE (continued)

2---2

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

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

(all conductors deenergized).

!

1. Deenergize both the normal and emergency sourceconductors (remove fuses or open circuit breakers).

2. Use the maintenance handle to manually operate thetransfer switch to the opposite source. First open theclosed contacts, then close the other contacts. Do notleave both closed. SeeManual Operation on page 1–3.

3. Then remove themaintenancehandle. See page1–3.

Verify that the maintenance handlehas been removed before proceeding!

!

4. If the transfer switch is in the Emergency positionmanually start the engine generator and then installemergency source fuse or close the circuit breaker.

TROUBLE-SHOOTING

Note any optional accessories that may be furnished onthe ACTS and review their operation. Refer to anyseparate drawings and/or instructions that may bepacked with the ACTS.

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.

PROBLEMCHECK IN NUMERICAL SEQUENCE

PROBLEM1 OPERATION 2 GEN-SET 3 VOLTAGE

Engine–generator set doesnot start when the TransferControl switch is turned andheld in Transfer Test positionor when normal source fails.

Hold Transfer Test switch 15seconds or the outage mustbe long enough to allow forFeature 1C time delay plusengine cranking and starting.

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

---

Transfer switch does nottransfer the load to theemergency source after theengine–generator set starts.

Wait for Feature 2B time delayto time out.

Generator output circuitbreaker must be closed.Generator frequency must beat least 95% of nominal (57Hz for a 60 Hz system.) *

Voltmeter should read atleast 90% of nominal phase tophase voltage betweenterminals EA and EC (or EL1and EL2 for 2 pole switches)*

Transfer switch does nottransfer the load to normalsource when normal returnsor when the Transfer Controlswitch is released.

Wait for Feature 3A time delayto time out.

---

Voltmeter should read at least90% of nominal phase tophase voltage betweenterminals NB and NC, NC andNA, and NA and NB (or NL1and NL2 for 2 pole switches).

Gen. does not stop after loadretransfer to normal source.

Wait for Feature 2E time delayto time out.

Starting control must be in theautomatic position. ---

Failure to Synchronizelight 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 Timelight comes on.

CN and CE contacts are closed longer than setting in the Control Panel. Open the discon-nected source circuit breaker, then call your nearest ASCO Service Center for assistance.

TS Locked Outlight comes on.

Transfer lockout operation has occured; transfer switch is disabled from automatic operation.Open the disconnected source circuit breaker, then call your nearest ASI for assistance.

* These are factory settings. Refer to 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 Technologiessales office or ASI at 1–800–800–2726. Furnish the Serial No. and Catalog No. from the transfer switch nameplate.

INDEX

Printed in U.S.A. ASCO Power Technologies, L.P. 2001E

Aalarm reset, 1–5, 2–2

auxiliary circuits, 1–2

Ccablelugs, 1–2preparation, 1–2

catalog number, inside cover

cleaning, 2–1

closed transition bypass, 1–5, 2–2

connectionsline, 1–1

contact position indicators, 1–3

controller, 1–1disconnecting, 2–1see Controller User’s Guide

Eelectrical operation, 1–5

emergency source accepted light,1–4

extended parallel time, 2---2

Ffailure to synchronize, 2---2

frequency, generator, 2–2

functional test, 1–2, 1–3, 1–4, 1–5

Gground, controller, 1–1

Hharness, 1–1disconnect plugs, 2–1

Iinspection, 2–1

installation, 1–1

indicators, contact position, 1–3

Llabels,engine start contacts, 1–2rating, cover

lights, 1–4, 1–5

lubrication, 2–1

Mmaintenance handle, 1–3

maintenance, preventive, 2–1

manual load transfer, 2–2warning, 2–2

manual operation, 1–3illustration of, 1–3warning, 1–3

Nnameplate, cover

normal source accepted light, 1–4

Ooperationelectrical, 1–5manual, 1–3illustration of, 1–3warning, 1–3

optional accessoriessee Controller User’s Guide

Pparts, 2–1

phase rotation check, 1–4

problem, 2–2

Rrating label, cover

replacement parts, 2–1

Ssettingssee Controller User’s Guide

Ttest, functional, 1–2, 1–3, 1–4, 1–5

time delays, 2–1see Controller User’s Guide

Transfer Control selector switchRetransfer Delay Bypass, 1–5Transfer Test, 1–5

Transfer Switch Connected ToEmergency light, 1–5, 2–1

Transfer Switch Connected ToNormal light, 1–4, 2–1

transfer test, 1–5

transfer to emergency, 1–5

transfer to normal, 1–5, 2–1

trouble–shooting, 2–2

TS locked out, 2---2

Vvoltage checks, 1–4

voltage, pickup and dropout settingssee Controller User’s Guide