InFocus Switch 165 User's Manual
Contents
1. 1 Put both the preferred source circuit breaker and the alternate source circuit breaker feeding the automatic transfer switch in the OFF position Verify that ALL POWER IS OFF See page 2 for handle location 2 Grasp the maintenance handle and turn it quickly with your thumb and fingers to manually operate the transfer switch The switch should operate smoothly without binding If it does not check for shipping damage or construction debris maintenance handle With ALL POWER OFF grasp maintenance handle and turn it quickly with your thumb and i weight marked P preferred and A alternate 3 After checking the manual operation operate the handle again quickly to return the transfer switch to the preferred position letter P on the round weight facing you 2 VOLTAGE CHECKS The Series 165 automatic transfer switch is rated for nominal 240 V ac at 60 Hz as stated on the nameplate Verify that both your preferred and alternate sources are also 240 V ac nominal 60 Hz See the wiring diagram 3 ELECTRICAL OPERATION This procedure checks the electrical operation of the automatic transfer switch If the actual operation does not follow this procedure consult the Troubleshooting section A WARNING PERSONAL INJURY HAZARD Install front cover before operation An electrical system fault could cause a flash and cause injury 1 Install the enclosure cover and tighten the screws2. 2 Verify that the generator battery is connected and that the generator s starting controls are set for automatic source acceptable lights UTILITY test button Automatic Generator Exerciser transfer switch on utility preferred source light transfer switch on generator alternate source light Turn on the preferred source utility circuit breaker Turn on the alternate source generator circuit breaker Verify that UTILITY preferred source acceptable light is on Verify that the TRANSFER SWITCH on utility preferred source light is on 7 This step will start the generator Press and hold the Push to Test button until the GENERATOR alternate source acceptable light comes on and stays on Then release the button oak w This light indicates that the generator is running and that its output voltage and frequency are acceptable Under typical conditions the light should come on after about 5 to 10 seconds If the generator is running and fails to produce the proper voltage and frequency after 60 seconds then a malfunction has occurred consult the Troubleshooting section 8 About 15 seconds after the GENERATOR alternate source acceptable light comes on the automatic transfer switch transfers the load from the utility to the generator The TRANSFER SWITCH on generator alternate source light comes on 9 The transfer switch stays connected to the generator for 5 minutes Then the load i
3. 4 F to 122 F 20 C to 50 C Storage 67 F to 149 F 55 C to 65 C TRANSFER SWITCH POlGS i m e a aia at a Ea a elie S a eia N AN 2 Voltage nominal 220 240 V ac single phase Frequency nominal 0 0 cee eee eee eee 60 Hz Current depending upon the unit 100 200 or 230 amps Withstand Close On Current 10 000 amps RMS Symmetrical amps 240 V ac max for any circuit breaker manufacturer or Type per National Electrical Code NEC NFPA 70 100 amp Transfer Switch power terminals accept wire sizes one 14 to 4 0 AWG AL or CU 200 amp Transfer Switch power terminals accept wire sizes one 14 to 4 0 AWG CU copper only 230 amp Transfer Switch power terminals accept wire sizes one 14 to 4 0 AWG CU copper only CONTROLLER Voltage nominal 0040 220 240 V ac Pickup source acceptable 204 V ac Dropout Source unacceptable 180 V ac Frequency nominal alternate generator source 60 Hz Pickup source acceptable 57 Hz Dropout Source unacceptable Generator control contacts Start Stop spdt 5 A max 300 mA min at 30 V dc max terminals accept 22 to 14 AWG stranded copper wire per terminal Time Delays Ignore preferred utility source outages 3 sec Ignore alternate generator source outages 15 sec Load transfer to alternate generator source 15 sec Load retransfer to preferred
4. utility source 5 min Generator cooldown period after load retransfer 1 min Automatic Generator Exerciser Repeat time 00 05 every 14 days DURATION oaiae 5 coun eerie eck ee See as 20 minutes INTRODUCTION INTRODUCTION ASCO Series 165 Automatic Transfer Switches are Listed under the Underwriter s Laboratories Standard for Transfer Switch Equipment UL 1008 They are intended for use only in optional standby systems in accordance with the National Electrical Code NEC NFPA 70 Article 702 This automatic transfer switch is intended for standby power applications in residential or light commercial use only A WARNING The Series 165 Automatic Transfer Switch is not for emergency or life support systems This product is not intended for emergency or life support systems If you have more stringent application requirements contact ASCO for other products suitable for critical applications The automatic transfer switch helps provide safe connection of the alternate source generator to the electrical load after disconnecting the preferred source utility It contains a double throw electromechanical switching device for inherent isolation of the preferred and alternate sources This isolation prevents the danger of connecting the utility to the generator which could cause damage or personal injury The automatic transfer switch s digital controller provides continuous m
5. eee Installation sorei 002 Yo 4Q5Gh vroAG iad Leek uuu A wend 4 Utility Failure vis Geena seas awe dad el EATARRA Electrical Line Connections 00 cee eens 4 Automatic Generator Exerciser 000e eee Cable Spacers 200 amp unit 0 0c eee 4 Manual Generator Testing 0 cece eens Cable Connections 06 c cece e een nes 4 Generator Test with Load Transfer 05 Generator Starting Contacts 0 eee eee 4 Generator Test without Load Transfer Functional Test after installation 5 Troubleshooting 00 c eects Operation ea a it i a i a a 6 load power connections alternate source generator power a connections digital controller with control display neutral terminal cable spacers maintenance handle next to wheel weight see DANGER under Manual Operation ground terminal preferred source utility power connections transfer switch Series 165 Automatic Transfer Switch in Type 1 enclosure cover removed SPECIFICATIONS ENCLOSED AUTOMATIC TRANSFER SWITCH Enclosure Size TYPEM i a sue ite 24 H x 14 W x 8 D 610 mm H x 362 mm W x 203 mm D Type 3R 25 H x 14 W x 8 D 635 mm H x 375 mm W x 216 mm D Weight Type 1 enclosure 0 67 Ib Type 3R enclosure 22 00 5 82 Ib Temperature Operating
6. ITHOUT LOAD TRANSFER During the test the generator cranks and starts and the GENERATOR light comes on if it is acceptable After running for 20 minutes it stops Throughout the test the load remains connected to the utility the automatic transfer switch does not transfer the load to the generator 1 Press and release do not hold the Push to Test button The generator cranks and starts and the GENERATOR acceptable light comes on and stays on 2 The generator runs for 20 SWITCH on generator alternate source light comes on 3 After 5 minutes the auto matic transfer switch re transfers the load back to the utility To bypass the time delay press and release the Push to Test button again The TRANS FER SWITCH on utility preferred source light comes on UTILITY load transfer test button 4 After load retransfer the generator will continue to run unloaded for one min ute for engine cooldown Then it is stopped The GENERATOR acceptable light goes off transfer switch on utility preferred source light source acceptable lights transfer switch on generator minutes The automatic transfer switch does not transfer the load to the generator The TRANS FER SWITCH on utility preferred source light stays on 3 To bypass the time delay or cancel the test press and release the Push to Test button again 4 The generator stops and the GENERATOR accept able light goes off Aut
7. Owner s ASCO Series 165 Automatic Transfer Switches rated 100 200 amp 230 amps single phase 240 V ac for automatic 2 wire start generators A DANGER DANGER is used in this manual to warn of risk of electrical shock Manual from high voltages capable of A causing shock burns or death A WARNING WARNING is used in this manual to warn of possible personal injury A CAUTION CAUTION is used in this manual to warn of possible equipment damage Installation should be performed by a licensed electrician and in accordance with the National Electrical Code NEC and all local electrical code requirements Read and understand all instructions before installing servicing or operating Failure to do so could result in serious personal injuries or property damage ASCO Series 165 Automatic Transfer Switches are Listed under the Underwriter s Laboratories Standard for Transfer Switch Equipment UL 1008 They are intended for use only in optional standby systems in accordance with the National Electrical Code NEC NFPA 70 Article 702 This ATS is for use with 2 wire automatic start generators only Refer to Application Information 381339 219 to confirm that you have selected the appropriate product for the intended installation Rating Label Each Automatic Transfer Switch ATS has rating labels to define the loads and fault current withstand closing ratings Refer to th
8. ZARD Turn off utility power and turn off the generator to prevent electrocution when wiring the transfer switch CABLE SPACERS 200 and 230 amp units Three cable spacers are included with 200 and 230 ampere size transfer switches Run the power cables through the cable spacers as shown here and position the cable spacers approximately 1 inches from the terminal lugs Use copper cables for 200 and 230 amp transfer switches cable spacers g DA nA alternate source generator 1 inch approximate from terminal lugs 200 amp 230 amp transfer switches require cable spacers and copper cables cable spacer preferred source utility A CAUTION CABLE LOOSENING DUE TO SHORT CIRCUIT Install 3 cable spacers 11 2 in from terminal lugs to prevent cables from loosening in a short circuit condition CABLE CONNECTIONS see wiring diagram Prepare the wires for connection as follows strip the insulation avoid nicking or ringing the conductors when stripping the cable Remove surface oxides from conductors by cleaning with a wire brush Apply electrical joint compound and wipe away excess Insert prepared cable into lug and tighten the lug to the torque specified on the rating label on the transfer switch Connect the preferred source utility line 1 and 2 wires to the terminal lugs marked L1 and L5 at the bottom Connect the alternate source generator line 1 and 2 wires to the termina
9. ce acceptable light still does not come on see Problems 3 and 4 Problem 6 The automatic transfer switch does not transfer the load back to the utility TRANSFER SWITCH on utility light does not come on Verify that the UTILITY source acceptable light is on The transfer switch will not retransfer the load to the utility until the utility source is acceptable and the light is on If light is off verify that the circuit breaker from the utility feed is ON Wait 5 minutes There is a 5 minute delay on retransfer to the utility Problem 7 The GENERATOR source acceptable light does not go off after the automatic transfer switch retransfers the load back to the utility Wait 1 minute After load retransfer to the utility there is a 1 minute delay for generator cooldown before shut down Verify proper operation of the generator see the generator manual Problem 8 Both TRANSFER SWITCH position lights are flashing this indicates an error condition Count the number of times the Automatic Generator Exerciser light flashes repeats after pause This number is the error code Error codes 2 Generator failed to start See Problems 3 and 4 3 Generator failed after starting See generator manual 4 Generator over frequency See generator manual 5 Transfer Switch did not transfer the load to the generator Service required 6 Transfer Switch did not transfer the load to the utility Service required 7 Con
10. en the Push to Test button is pressed Verify that the generator starting controls are set for automatic operation Verify engine start low voltage wiring between controller terminal block TB7 plug on the left and the generator Check that TB7 plug is properly seated in TB7 receptacle Verify that the generator battery is connected and that the battery voltage meets the generator manufacturer s recommendation Verify that the correct contact normally open or normally closed is being utilized see the generator manual Problem 4 Generator cranks but does not start when the utility source fails or when the Push to Test button is pressed Verify engine start low voltage wiring between controller terminal block TB7 plug on the left and the generator Check that TB7 plug is properly seated in TB7 receptacle Verify proper generator operation see generator manual 8 Problem 5 The automatic transfer switch does not transfer the load to the generator TRANSFER SWITCH on generator light does not come on Verify that the GENERATOR source acceptable light is on The transfer switch will not retransfer the load to the genera tor until the generator output is acceptable If the light is off verify that the circuit breaker for the generator feed is ON Wait 15 seconds There is a 15 second delay after the generator output becomes acceptable to permit the generator to warm up If the GENERATOR sour
11. his light indicates that the load is connected to the generator alternate source O Automatic Generator Exerciser light above button at the right of display When the utility is acceptable and the load is on the utility this light flashes the number of days until the next exercise period When it is off no exerciser period is set The light is also off any time the generator is running PUSH BUTTONS On the front control display are two push buttons that control the operation of the generator and the automatic transfer switch Push to Test button on the left side This button is used to test the system See the Manual Generator Testing section on the next page This button can be used to cancel any active time delay Press and release the button to bypass the time delay This button can be used to clear displayed error codes See Troubleshooting section Problem 8 Automatic Generator Exerciser right button This button is used to set the automatic generator exerciser See the next page UTILITY FAILURE The load is normally connected to the preferred source utility if that source is acceptable If the preferred source utility fails the following sequence occurs The UTILITY source acceptable light goes off 1 2 The automatic transfer switch waits three seconds to pre vent nuisance starting of the generator from momentary dips of the utility voltage If the utility is restored dur
12. ing the three seconds the UTILITY source acceptable light comes on and no further action is taken 3 If the utility remains unacceptable for three seconds the automatic transfer switch cranks and starts the generator 4 Once the generator starts the automatic transfer switch waits until the generator voltage and frequency are acceptable Then the GENERATOR source acceptable light comes on 5 When the generator is acceptable the automatic transfer switch waits 15 seconds to allow the generator to warm up Then it transfers the load to the generator The TRANSFER SWITCH on generator alternate source light comes on 6 The automatic transfer switch waits for the utility source to be restored When the utility again becomes acceptable the UTILITY source acceptable light comes on 7 The automatic transfer switch then waits 5 minutes to allow the utility to stabilize Then it retransfers the load back to the utility The TRANSFER SWITCH on utility preferred source light comes on 8 After load retransfer the generator will continue to run unloaded for one minute for engine cooldown Then it is stopped The GENERATOR acceptable light goes off AUTOMATIC GENERATOR EXERCISER The automatic generator exerciser automatically exercises the generator for 20 minutes once every 14 days TO SET EXERCISER Press and release the Automatic Generator Exerciser but ton After about 8 seconds the exerciser light flashes 14 times to i
13. l lugs marked L2 and L6 at the upper middle Connect the load line 1 and 2 wires to the terminal lugs marked L3 and L7 at the top of the transfer switch Neutral and ground terminals are provided GENERATOR STARTING CONTACTS Before wiring the generator starting contacts refer to the generator manufacturer s installation manual for require ments Make all connections to the controller with the gen erator battery disconnected Verify that the ignition switch is in the OFF position Connect the generator starting con tacts to the appropriate terminals on terminal block TB7 on the Controller CP See the wiring diagram provided with the unit For wiring convenience terminal block TB7 has a removable plug Reconnect the plug with terminal screws facing inward A CAUTION CONTROLLER DAMAGE Observe polarity when connecting the generator battery to the controller Refer to wiring diagram Be sure to reinstall the TB7 block with terminal screws facing inward removable terminal block TB7 Be sure to reinstall with terminal screws facing inward digital controller FUNCTIONAL TEST after installation After installing the Series 165 automatic transfer switch perform the following three part functional test 1 MANUAL OPERATION A DANGER ELECTROCUTION FLASH HAZARD Do not manually operate the transfer switch until utility and generator are disconnected open circuit breakers
14. ndicate that the exerciser has been set The number of flashes indicates the number of days until the next exercise pe riod at approximately the same time the button was pressed TO DISABLE EXERCISER Press and hold the Automatic Generator Exerciser button until the light above the button goes off light flashes then goes off The exerciser is now disabled and the light is off TO ENABLE EXERCISER Press and hold the Automatic Generator Exerciser button until the light goes off light flashes then goes off Exerciser is now enabled After about 8 seconds exerciser light flashes 14 times to indicate that the exerciser has been re enabled Note With a total power failure utility failure and generator fails to start the exerciser must be reset after power is restored automatic generator exerciser light UTILITY Automatic Generator Exerciser set exerciser button MANUAL GENERATOR TESTING GENERATOR TEST WITH LOAD TRANSFER During this test a utility failure is simulated The generator starts and the load transfers to the generator Then the load retransfers back to the utility and generator stops 1 Press and hold the Push to Test button until the GENERATOR acceptable light comes on and stays on the generator cranks and starts 2 The automatic transfer switch waits 15 seconds to allow the generator to warm up Then it transfers the load to the generator The TRANSFER GENERATOR TEST W
15. omatic Generator Exerciser alternate source light TROUBLESHOOTING This troubleshooting guide describes some of the simple causes of problems with the installation of the automatic transfer switch Troubleshooting beyond the scope of this guide should not be attempted by the installer A licensed electrician must perform all internal troubleshooting ASCO can be contacted at 800 937 ASCO or www asco com A DANGER ELECTROCUTION FLASH HAZARD Do not work on the transfer switch until both the utility and generator are off Turn OFF both circuit breakers Problem 1 The UTILITY acceptable light does not come on when utility power is connected to the automatic transfer switch Verify that the utility feed is 240 V ac nominal and 60 Hz Verify that the utility feed is wired to the terminal lugs on the bottom of the transfer switch marked L1 and L5 Verify that the utility feed is connected and that its circuit breaker is ON With ALL POWER OFF verify that the transfer switch harness is connected properly to the controller plug at the bottom Problem 2 Power is connected UTILITY acceptable light and or GENERATOR acceptable lights are on but both TRANSFER SWITCH position lights are off With ALL POWER OFF verify that the transfer switch harness is connected properly to the controller plug at the bottom Problem 3 Generator does not crank when the utility source fails or wh
16. onitoring of both power sources and a start stop signal to the generator INSTALLATION Installation of the ASCO Series 165 automatic transfer switch must be performed by a licensed electrician It must be installed according to the National Electrical Code and all local electrical code requirements Refer to the installation drawing and wiring diagram A CAUTION MALFUNCTION or SHORTENED LIFE Protect the unit from construction grit and metal chips to prevent malfunction or shortened life Remove the enclosure cover and inspect the unit for ship ping damage If damage is evident do not install the unit Type 1 enclosure is for indoor use only refer to local codes for Type 4 use Mount the automatic transfer switch vertically to a rigid supporting structure Level all mounting points with flat washers behind the holes to avoid distortion of enclosure ELECTRICAL LINE CONNECTIONS Installation wiring must be performed by a licensed electrician in accordance with the National Electrical Code NEC and all local electrical code requirements The automatic transfer switch must be protected by suitably sized circuit breakers feeding the preferred and alternate source terminals The ratings of the circuit breakers must be based on the requirements of the National Electrical Code for its nameplate ampere and short circuit withstand ratings See the wiring diagram provided with the unit A DANGER ELECTROCUTION HA
17. ose label on the Transfer Switch for specific values A WARNING INJURY or SWITCH DAMAGE Do not exceed the rating label values it can cause personal in jury or serious switch damage ASCO Series Nameplate 165 The Transfer Switch nameplate includes data for each specific ASCO Series 165 ATS Use the switch only within the Automatic Transfer Switch for use on Standby Systems Cat No 165A2200F3C Ser No 123456 200 A BOM 999999 limits shown on this 240 V 60 Hz nameplate A typical Catalog Number is also shown below with its elements explained Ty pi Do Not 4 al Only Use Value s a number lues Se a 2 200 F aa neutral A piae neutral poles 2 2 lines ampere rating 100 200 or 230 amps ASCO Power 50 Hanover Road Florham Park New Jersey 07932 1591 USA Technologies 4 800 937 2726 ASCO for service call 1 800 800 2726 ASCO www asco com ASCO POWER TECHNOLOGIES CANADA PO Box 1238 17 Airport Road Brantford Ontario Canada N3T 5T3 telephone 519 758 8450 fax 519 758 0876 for service call 1 888 234 2726 ASCO www asco ca TL enclosure C Type 1 F Type 3R ome group code automatic nee code 240 VAC 381333 163 C EMERSON Network Power TABLE OF CONTENTS SPECHICALIONS 3 beF ies ee he tae een Ge ede eek 3 Indicator Lights ose egiaren cece eee ees Introduction i egies ede eek oe eee 3 PUSH BUTLONS 355855 tenet nar a a ete
18. s transferred back to the utility To bypass time delay press and release the Push to Test button again 10 After load retransfer to utility the generator runs 1 minute without load then shuts down The GENERATOR acceptable light goes off indicating that generator is off This completes the Functional Test Proceed to next page OPERATION utility preferred source acceptable light generator alternate source acceptable light UTILITY GENERATOR exerciser light Automatic Generator Exerciser transfer switch on utility transfer switch on generator preferred source light alternate source light INDICATOR LIGHTS On the front control display are five lights that indicate the status of the sources and the automatic transfer switch O Utility preferred source acceptable light at the top left of the display When on this light indicates that the utility voltage is acceptable for connection to the load O Generator alternate source acceptable light at the top right of the display When on this light indicates that the generator voltage and frequency are acceptable for connection to the load O Transfer Switch on utility preferred source light at the center left of display When on this light indicates that the load is connected to the utility preferred source O Transfer Switch on generator alt source light at the center right of display When on t
19. troller error Service required To clear error code press and release Push to Test button NOTE These lights will flash only when controller power is available from either of the two power sources
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