381333–202 C50 Hanover Road, Florham Park, New Jersey 07932–1591 USAFor 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 5T3telephone 519 758–8450, fax 519 758–0876, for service call 1 888 234–2726 (ASCO) www.asco.ca

Operator’sManual

7000 Series ATSAutomatic Transfer Switches

H–design 600 through 1200 amps

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 1-2, 1-3, 1-4, 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. . . . . . . . . . . . . . . . . . . . . . . . .

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

An experienced licensed electrician must install the ATS.

600---1000 amp. size

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.

Refer toGroup 5 Controller User’s Guide 381333–126for ATS status display messages, time delays, pickup& dropout settings, and adjustments.

1200 amp. size

Rating Label

Each Automatic Transfer Switch contains a rating label todefine 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.

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

Catalog Number IdentificationTypical 7000 Series ATS catalog no. for overlappingneutral, 3 pole, 600 amp, 480 V, ATS in Type 1 enclosure:

H7ATS C 3 600 N 5 C

Phase PolesNeutral

A – solid

C – overlapping

Amperes Voltage Controller Enclosure

B – switched 5X – if

accessories

ordered

5 – standard

G – type 4 *

C – type 1

F – type 3R

L – type 12 *

3 – three Ø

2 – single Ø

D 220

C 208

E 230

K 415

M 460

J 400

L 440

N 480

G 277

F 240

H 380 Q 575

P 550

R 600

12001000800

blank – none

blank – open type

600

* available 600–1000 amp. sizes only

TransferSwitch

powerconnections

Group 5Controller

TransferControl& lights

600–1000 amp. size 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 Transfer Switches (ATSs)are factory wired and tested. Field installation requiresrequires mounting and connection of service cables, andauxiliary control circuits (if required).

Remove the Shipping Skid (large ATSs)

For large ATSs, open the front door and remove the fourlag screws (2 in front, 2 in rear) securing enclosure to thewood skid.

Supporting Foundation

The 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.

Mounting

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

Line Connections

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

It is not necessary to remove pole covers from thetransfer switch for cabling. 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 Conductors

Do 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 theconductor’s strands. For this reason, after the cables arepulled into position, and before they are connected, theyshould be tested to verify that they are not defective orhave been damaged during installation.

Protect the switch from construction gritand metal chips to prevent malfunction or

shortened life of the automatic switch switch.

Connecting Power Conductors

After 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 Ground

A 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.

Harnesses

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

INSTALLATION (continued)

1---2

Engine Starting Contacts

All 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 Circuits

Connect 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:

❐ 1 — Manual Operation Test, page 1–3

❐ 2 — Voltage Checks, page 1–4

❐ 3 — Electrical Operation, page 1–5

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

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.

Continue to 1 – Manual Operation Test on next page.

INSTALLATION (continued)

1---3

1 – Manual Operation Test

Adetachable 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 the mainte-nance handle from the clips on the left side of thetransfer switch frame. Insert the handle into the holein the molded hub on the left side of the operator.See Figures 1–3 and 1–4 and Table B.

2. Move the maintenance handle up or down as shown tomanually operate the transfer switch. It should operatesmoothly without any binding. If it does not, check forshipping damage or construction debris.

3. Return the transfer switch to the Normal position.Observe that the window indicators (right side) showthe top shaftO (open) and the bottom shaft C (closed).

Table B. Maintenance handle positions.

ATS Position Handle Indicators

Normal

E

N

up E = Oupper contacts open

N = Clower contacts closed

Emergency

E

N down

E = Cupper contacts closed

N = Olower contacts open

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

maintenancehandle

left side oftransfer switch

storage clips

Figure 1-2. Maintenance handle and its storage clips.

4. Remove the maintenance handle and store it on theframe (left side) in the clips provided.

Verify that the maintenance handlehas been removed before proceeding!

Now continue to 2 – Voltage Checks on next page.

handle

hub

UP closes theNormal sourcecontacts (lower)

DOWN closes theEmergency sourcecontacts (upper)

frame

windowindicatorsO is openC is closed

Emergencycontacts

Normalcontacts

contact positionindicators (right side)

Figure 1-3. Maintenance handle operation and contact position indicators.

INSTALLATION (continued)

1---4

RED

REDGREEN

GREEN

observethese lights

Figure 1-4. Standard controls and indicators.

2 – Voltage Checks

First check nameplate on transfer switch; rated voltagemust be the same as normal and emergency line voltages.

Verify that the feeders have beenconnected to the proper lugs.

Use extreme caution when using a meterto measure voltages. Do not touch power

terminals; shock, burns, or death could result !

Perform steps 1 through 6 at the right. Observe the statuslights. See Figure 1–4.

■ 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.

Note

Refer to Section 3 of Group 5 Controller User’s Guide381333–126 for how to display the Status of the ATS andthe Voltage and Frequency of each source.

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

RED

REDGREEN

GREEN

observethese lights

operatethis switch

Figure 1-5. Standard controls and indicators.

3 – Electrical Operation

This procedure will check the electrical operation of theAutomatic Transfer Switch. See Figure 1–5.

Be sure to close the enclosure doorbefore proceeding to prevent personal injury

in case of electrical system fault.

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 5 at the right. Observe the statuslights.

■ Black square means light is on.

❐ White square means light is off.

This completes the Functional Test of the ATS.

1The Transfer Switch ConnectedTo Normal and Normal SourceAccepted lights should be on.

2

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

3

Transfer switch will operate tothe Emergency position afterFeature 2B time delay. TheTransfer Switch Connected ToEmergency light should comeon and Load Connected to Nor-mal light goes off.

4

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.

5

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 ATS 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 ATS. Anannual preventive maintenance program is recom-mended.

In the United States, ASCO Services, Inc. (ASI) isASCO Power Technologies’s national serviceorganization. ASI can be contacted at1-800-800-2726 (ASCO) for information onpreventive 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 switch.

Deenergize both Normal – Emergency powersources before performing inspections!

❐ Clean theATS enclosure. Brush and vacuumawayany excessive dust accumulation. Remove anymoisture with a clean cloth.

❐ 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.

❐ 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.

❐ 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:

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 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 unplug 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 themaintenancehandle tomanually operate thetransfer switch to the opposite source. See ManualOperation 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 automatic transfer switch (ATS) and review theiroperation. Refer to any separate drawings and/orinstructions 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 terminalsof the transfer switch!

Table 2-1. Trouble-Shooting Checks.

CHECK IN NUMERICAL SEQUENCEPROBLEM 1

OPERATION2

GEN-SET3

VOLTAGEEngine–generator set doesnot start when the TransferControl switch is turned andheld in Transfer Test positionor when the normal sourcefails.

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

Starting control must be in theautomatic position. Batteriesmust be charged andconnected. Check wiring toengine starting contacts oncustomer terminal block TB.Verify that the small plug J3 isconnected to receptacle P3.

–

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

Wait for Feature 2B time delayto time out (if used).

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

Voltmeter should read at least90% of nominal phase tophase voltage betweentransfer switch terminals EAand EC (or EL1 and EL2 for 2pole 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 (if used).

–

Voltmeter should read at least90% of nominal phase tophase voltage betweentransfer switch terminals NBand NC, NC and NA, and NAand NB (or NL1 and NL2 for 2pole switches).

Engine–generator-set doesnot stop after load retransferto the normal source.

Wait for Feature 2E time delayto time out (if used).

Starting control must be in theautomatic 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 Technologiessales 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 2007 ASCO Power Technologies, L.P.

Aauxiliary circuits, 1–2

Ccablelugs, 1–1preparation, 1–1

catalog number, inside cover

cleaning, 2–1

connectionsline, 1–1

contact position indicators, 1–3

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

Eelectrical operation, 1–5

Emergency Source Accepted light,1–4, 1–5

engine starting contacts, 1–2

Ffrequency, generator, 2–2

functional test, 1–2, 1–3, 1–4, 1–5

Gground, controller, 1–1

ground lugs, inside front cover

Hharness, 1–1disconnect plugs, 2–1

HELPcustomercare@asco.com800–800–ASCO

Iinspection, 2–1

installation, 1–1

indicators, contact position, 1–3

Llabels,field terminal block TB, 1–2rating, inside front cover

lights, 1–4, 1–5

lubrication, 2–1

Mmaintenance handle, 1–3illustration of, 1–3warning, 1–3

maintenance, preventive, 2–1

manual load transfer, 2–2warning, 2–2

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

Nnameplate, inside 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, inside cover

replacement parts, 2–1

Ssettingssee Controller User’s Guide

Ttest, functional, 1–2, 1–3, 1–4, 1–5

time delays, 1–5, 2–2see Controller User’s Guide

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

Transfer Switch Connected ToEmergency light, 1–4, 1–5

Transfer Switch Connected ToNormal 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

Vvoltage checks, 1–4

voltage, pickup and dropout settingssee Controller User’s Guide