Emerson 300 Series Switch User Manual
Contents
1. SEQUENCE OF OPERATION 2 1 TESTING amp SERVICE 005 3 1 Preventive Maintenance 3 1 Transfer Test 0 ccc eee eens 3 1 Trouble Shooting 0 000ee 3 2 ADJUSTMENTS 000 c eee ees 4 1 Sensor Adjustments 0005 4 1 How to Change a Setting 4 1 OPTIONAL FEATURES 5 1 Motor Load Transfer 005 5 1 Load Disconnect 20 5 5 1 INDEX 000 cece ee back of manual G design 1000 1200 A sizes NA Power 50 Hanover Road Florham Park New Jersey 07932 1591 USA e ASCO Technologies For sales or service call 1 800 800 2726 ASCO www ascopower com 381333 086 D ASCO POWER TECHNOLOGIES CANADA PO Box 1238 17 Airport Road Brantford Ontario Canada N3T 5T3 EMERSON Network Power SECTION 1 ASCO 386 Non Automatic Transfer Switches N ATSs are factory wired and tested Field installation simply requires mounting and connection of service cables and auxiliary control circuits if required Remove the Shipping Skid large N ATSs For large N ATSs open the front door and remove the four lag screws 2 in front 2 in rear securing enclosure to the wood skid Supporting Foundation The supporting foundation for the enclosure must be level and straight Refer to the applicable enclosure outline drawing included with the switch for all mounting details including door opening space If bottom2. cable entry is used the foundation must be prepared so that the conduit stubs are located correctly Refer to the enclosure outline drawing for specified area and location Provide cable bending space and clearance to live metal parts When a concrete floor is poured use interlocking conduit spacer caps or a wood or metal template to maintain proper conduit alignment Mounting Refer to the Outline and Mounting Diagram provided with the N ATS it shows all mounting details and instructions NOTICE Protect the non automatic transfer switch from construction grit and metal chips to prevent malfunction or shortened life of the N ATS Mount the ASCO 386 vertically to a rigid supporting structure Level all mounting points by using flat washers behind the holes to avoid distortion of the switch Auxiliary Cable Boxes for 1000 and 1200 A For G design 1000 and 1200 ampere sizes auxiliary cable boxes are required for all normal emergency amp load bottom or top entry Be sure to install auxiliary cable boxes if both service and load cables are entering through the top or bottom of enclosure Consult ASCO Power Technologies Insulator Backing Piece for 260 and 400 A E design transfer switches rated 260 and 400 ampere are mounted on an insulator backing piece installed behind the transfer switch If the transfer switch is removed from the cabinet and then reinstalled this insulator piece must be placed behind the transfer s
3. making any line or auxiliary circuitry connections Be sure that Normal and Emergency line connections are in proper phase rotation Place engine generator starting control in the OFF position Make sure engine generator is not in operation Testing Power Conductors Do not connect the power conductors to the transfer switch until they are tested Installing power cables in conduit cable troughs and ceiling suspended hangers often requires considerable force The pulling of cables can damage insulation and stretch or break the conductor s strands For this reason after the cables are pulled into position and before they are connected they should be tested to verify that they are not defective or have been damaged during installation Connecting Power Conductors After the power cables have been tested connect them to the appropriate terminal lugs on the transfer switch as shown on the wiring diagram provided with the switch Make sure the lugs provided are suitable for use with the cables being installed Standard terminal lugs are solderless screw type and will accept the wire sizes listed on the drawings provided with the switch Be careful when stripping insulation from the cables avoid nicking or ringing the conductor Remove surface oxides from cables by cleaning with a wire brush When aluminum cable is used apply joint compound to conductors Tighten cable lugs to the torque specified on rating label Do not run cables
4. to Transfer to Emergency The transfer switch will operate to the Emergency position The Load Connected To Emergency light should come on and the Load Connected to Normal light should go off Turn the door mounted Transfer Control switch counterclockwise to Transfer to Normal The transfer switch will operate to the Normal position The Load Connected to Normal light should come on and the Load Connected to Emergen cy light should go off Checklist for Yearly Inspection A DANGER Hazardous voltage capable of causing shock burns or death is used in this switch Deenergize both Normal amp Emergency power sources before performing inspections Clean the switch enclosure Brush and vacuum away any excessive dust accumulation Remove any moisture with a clean cloth Check the Switch Contacts Remove transfer switch barriers and check the condition of the contacts Replace the contacts if they become pitted or worn excessively Reinstall barriers carefully Maintain transfer switch lubrication If switch is subjected to severe dust or abnormal operating conditions renew factory lubrication on all move ments and linkages Relubricate solenoid operator if TS coil is replaced For 260 400 A order lubri cation 625550 001 Castrol Endurex 4000 lubri cant For 1000 3000 A order lubricant kit 75 100 O Check all cable connections and retighten them REPLACEMENT PARTS Replacement parts are available in kit form
5. voltage between transfer switch terminals EA and EC or EL1 and EL2 for 2 pole switches Generator frequency must be at least 57 Hz These are factory settings Transfer switch does not Turn Transfer Control switch counterclock Voltmeter should read at least 90 of nominal transfer the load to the normal wise to Transfer to Normal position phase to phase voltage between transfer switch source terminals NB and NC NC and NA and NA and NB or NL1 and NL2 for 2 pole switches Trouble Shooting Motor Load Transfer Optional Feature 27 refer to page 5 1 3 Turn the TRANSFER TO EMERGENCY control A DANGER switch clockwise The load should transfer to Use extreme caution when using a meter to emergency source when meter needle is near 0 measure voltages in the following steps Do not volts If transfer does not occur the Motor Load touch power terminals shock burns or death Transfer accessory is not operating could result 4 Turn the TRANSFER TO NORMAL control 1 Connect a voltmeter set for twice system switch counterclockwise The load should phase to phase voltage between Transfer Switch retransfer back to the normal source when the terminals NA and EA needle is near 0 volts If retransfer does not occur after the time delay the Motor Load Transfer 2 Manually start generator Voltmeter needle should accessory is not operating sweep back and forth at a regular rate between 0 and about twice system v
6. Operator s ASCO Series 386 Manual Non Automatic Transfer Switches E design 260 400 A G design 1000 3000 A A DANGER Refer to the outline and wiring drawings provided with the ASCO Series 386 N ATS for all installation details DANGER is used in this manual to warn of a hazardous situation which if not avoided will result in death or serious injury Rating Label Each non automatic transfer switch contains a rating label to define the loads and fault circuit withstand j f closing ratings Refer to the label on the transfer switch WARNING is used in this manual to warn of a for specific values hazardous situation which if not avoided could result in death or serious injury A WARNING A CAUTION Do not exceed the values on the rating label CAUTION is used in this manual to warn of a Exceeding the rating can cause personal injury or hazardous situation which if not avoided could serious equipment damage result in minor or moderate injury Identification Label The identification label on the Transfer Switch includes data for each specific ASCO Series 386 Use the switch only within the limits shown on identification label An experienced licensed electrician must install the Non Automatic Transfer Switch N ATS a se TABLE OF CONTENTS section page INSTALLATION 0 cece eens 1 1 Mounting and Line Connections 1 1 Functional Test 00 000s 1 2 1 3
7. When ordering parts provide the Serial No Bill of Material No BOM and Catalog No from the transfer switch nameplate Contact your local ASCO Power Technolo gies sales office or ASI In the United States call 1 800 800 ASCO 2726 DISCONNECTING THE CONTROLLER The harness disconnect plugs are furnished for repair purposes only and should not have to be unplugged If the controller must be isolated follow these steps Disconnecting the Plugs 1 Observe the position of the transfer switch a If the transfer switch is in the Normal position place standby engine starting control in the off position Then open the emergency source circuit breaker b Ifthe transfer switch is in the Emergency posi tion open the normal source circuit breaker Place the engine starting control in the test or run position 2 Separate the quick disconnect plugs by squeezing the latches Do not pull on the harness wires Reconnecting the Plugs 1 Observe the position of the transfer switch a Ifthe transfer switch is in the Normal position be sure that the standby engine starting control is still in the off position The emergency source circuit breaker still should be open b If transfer switch is in the Emergency position normal source circuit breaker still should be open 2 The harness plugs and sockets are keyed Carefully align the plugs with the sockets and press straight in until both latches click 3 Restore the opposi
8. as the normal source 6 Shut down engine driven generator if applicable 7 Close the cabinet door and tighten the screws 3 Electrical Operation This procedure will check the electrical operation of the Non Automatic Transfer Switch See Figure 1 4 Close the transfer switch enclosure door and tighten the screws before you test electrical operation Transfer Test Both normal and emergency sources must be available and above 90 of nominal voltage specified on nameplate 1 Turn the door mounted Transfer Control switch clockwise to Transfer To Emergency 2 The transfer switch will operate to the Emergency position The Load Connected To Emergency light should come on and the Load Connected To Normal light should go off 3 Turn the door mounted Transfer Control switch counterclockwise to Transfer To Normal 4 The transfer switch will operate back to the Normal position The Load Connected to Normal light should come on and the Load Connected To Emergency light should go off This completes the Functional Test of the ASCO 386 non automatic transfer switch os ASCO SERIES 386 ier ON Power Transfer Switch Network Power Transfer Load Control Load Connected To Normal Transfer Transfer T Connected o Normal Emergency To Emergency Figure 1 4 Operating Controls SECTION 2 SEQUENCE OF OPERATION Controller Code 1 Refer to Section 5 Optional Accessories for additional control func
9. behind the switch Cables can be bundled on the right side of the switch Maintain proper electrical clearance between the live metal parts and grounded metal 2 inch minimum for 260 400 amperes 1 inch minimum over 400 amperes Bus Connections If bus connection is used use SAE grade 5 hardware to connect bus to appropriate terminal plates on the transfer switch Wipe off bus surfaces before they are joined If bus is very dirty gently clean surfaces with a non flammable solvent Avoid touching cleaned surfaces A CAUTION Do not breathe cleaning solvent vapors Use SAE grade 5 hardware and tighten the bolted joints to the torque specified in Table A NOTICE The reliability of the connection depends on how clean and how tight the joint is Table A Tightening torque values for bolted joints Bolt Diameter Recommended Grade 5 hardware Tightening Torque in inches in foot pounds 5 16 12 3 8 20 1 2 50 5 8 95 3 4 155 Continue to 1 Manual Operation Test on next page INSTALLATION continued Functional Test The Functional Test consists of three checks manual operation voltage checks and electrical operation NOTICE Do these checks in the order presented to avoid damaging the non automatic transfer switch 1 Manual Operation Test A detachable maintenance handle is provided on the transfer switch for maintenance purposes only Manual operation of the switch shou
10. eventive 3 1 manual load transfer 3 2 warning 3 2 manual operation 1 3 illustration of 1 3 warning 1 3 motor load transfer feature 3 2 5 1 O operation electrical 1 4 manual 1 3 illustration of 1 3 warning 1 3 sequence of 2 1 optional features 5 1 load disconnect 5 1 motor load transfer 5 1 P parts 3 1 problem 3 2 R rating label cover replacement parts 3 1 retransfer to normal 1 4 2 1 3 1 S sequence of operation 2 1 settings changing 4 1 factory 4 1 frequency 4 1 T test functional 1 3 1 4 transfer control 1 4 2 1 3 1 transfer to emergency 1 4 2 1 3 1 transfer to normal 1 4 2 1 3 1 trouble shooting 3 2 inphase monitor 3 2 V voltage checks 1 4 Copyright ASCO Power Technologies L P 2011
11. l counterclockwise DOWN clockwise DOWN closes contacts closes the Emergency the Normal source contacts contact position indicators left side source contacts upper and opens the Normal source contacts lower lower and opens the Emergency source contacts upper Figure 1 3 Maintenance handle on 1000 3000 ampere G design transfer switches INSTALLATION continued Functional Test continued 2 Voltage Checks First check nameplate on the transfer switch for rated voltage It should be the same as the normal and emergency line voltages A DANGER Use extreme caution when using a meter to measure voltages in the following steps Do not touch power terminals shock burns or death could result 1 Close the normal source circuit breaker The Load Connected To Normal lamp should come on 2 Use an accurate voltmeter to check phase to phase and phase to neutral voltages present at the Transfer Switch normal source terminals 3 Close the emergency source circuit breaker Start the generator if necessary 4 Use an accurate voltmeter to check phase to phase and phase to neutral voltages present at the Transfer Switch emergency source terminals If necessary adjust the voltage regulator on the generator according to the manufacturer s recommenda tions The ASCO 386 will respond only to the rated voltage specified on the Transfer Switch nameplate 5 Check phase rotation it must be the same
12. ld be checked before it is energized operated electrically Do not manually operate the transfer switch until both power sources are disconnected open both circuit breakers 1 Select the appropriate switch amperage size design and follow the directions for installing the handle 260 and 400 amp E design See Figure 1 2 Insert the manual handle into the hole in the shaft left side of the operator 1000 3000 ampere G design See Figure 1 3 Install the hub onto the center operator shaft and insert the manual firmly into the hole in the side of the hub spring fully compressed Emergency contacts with both hands Grasp handle firmly handle Figure 1 2 Maintenance handle for E design 260 and 400 ampere 2 Move the handle as shown to manually operate the Transfer Switch The switch should operate smoothly without binding If it does not check for shipping damage or construction debris 3 Return the transfer switch to the N normal position Remove manual operator handle if detachable and store it on the transfer switch in the place provided NOTICE Verify that the maintenance handle has been removed before proceeding Now continue to 2 Voltage Checks on next page Turn counterclockwise to Emergency Turn clockwise to Normal Insert handle into hole i window spring fully compressed Slide hub indicators onto shaft OPEN or CLOSED Norma
13. o the Transfer To Normal position When the Transfer Control switch is operated to Transfer To Normal the voltage sensor begins monitoring the normal source The SE relay energizes when the sensor accepts the normal source voltage SE relay energizes The TS coil is energized the transfer switch operates and all switch contacts mains controls auxiliaries reverse position The transfer switch is now supplying the load from the normal source again The SE relay de energizes when the Transfer Control switch is released The transfer switch will remain in the Normal position until the Transfer Control switch is operated to the Transfer To Emergency position Note Activation of standard control features shown in Section 5 will alter the sequence of operation and introduce additional time delays during transfer operations SECTION 3 TESTING amp SERVICE PREVENTIVE MAINTENANCE Reasonable care in preventive maintenance will insure high reliability and long life for the switch An annual preventive maintenance program is recommended ASCO Services Inc ASI is ASCO Power Technologies s national service organization ASI can be contacted at 1 800 800 2726 for infor mation on preventive maintenance agreements TESTING Operate the switch at least once a month by following this four step Electrical Operation Test Transfer Switch Test Turn the door mounted Transfer Control switch clockwise
14. oltage 5 Disconnect the voltmeter If the problem is isolated to circuits on the controller or the transfer switch call your local ASCO Power Technologies sales office or ASI In the United States call 1 800 800 2726 Furnish the Serial No Bill of Material BOM No amp Catalog No from transfer switch nameplate SECTION 4 ADJUSTMENTS Sensor Adjustments Voltage and frequency sensor pickup and dropout points are factory set as specified on the Wiring Diagram The frequency setting can be set for 50 or 60 Hz To change this setting follow the procedure below Use Table 4 1 for the setting and corresponding DIP switch actuator NOTICE Do not change any other factory settings Any change in these settings may affect the normal operation of the ASCO 386 This change could allow the load circuits to remain connected to a low voltage source Table 4 1 Frequency Settings Oo Shaded DIP switch is standard factory setting FACTORY ADJUSTMENT DESCRIPTION LABEL SETTING RANGE S1 DIP SWITCH 60 Hz Actuator 4 off a Frequency 60 50 Hz 60 Hz 50 Hz Actuator 4 on pn thumb Cover latch hook on left side Figure 4 1 Controller cover latch How to Change a Setting NOTICE Do not make any setting changes while the controller is energized 1 Deenergize all power then open the enclosure door 2 Disconnect both harness
15. plugs from controller by squeezing the latches Do not pull on the wires 3 Remove cover from the controller by releasing latch on right side with your thumb See Figure 4 1 4 Locate the appropriate adjustment DIP switch for the setting that you want to change Refer to Table 4 1 above and Figure 4 2 and Figure 4 3 5 Use aball point pen or similar pointed tool to slide the switch actuators left or right so they match the illustration next to the setting left off right on Recheck the setting See Figure 4 3 6 Install the cover on the controller by hooking it on the left side and latching the right side 7 Reconnect both harness plugs to the controller by aligning and pressing straight in until latches click 8 Close the enclosure door then restore both sources 4 1 o dL o O harness w uSr lugs ante plug wis a0 L stm Bhs p oe 3 s 0 m eo ga oe creer oe P a ipsa sey eam eww ob E S2 DIP load disconnect feature switch see page 5 1 S1 DIP switch Figure 4 2 Location of DIP switch DIP switch S1 D actuator 8 on each DIP switch Q off lt gt on Figure 4 3 Setting DIP switch actuator SECTION 5 OPTIONAL FEATURES MOTOR LOAD TRANSFER Inphase moni
16. te source as follows a If the transfer switch is in the Normal position place the standby engine starting control in the automatic position Then close the emergency source circuit breaker b Ifthe transfer switch is in the Emergency position close the normal source circuit breaker TESTING amp SERVICE continued MANUAL LOAD TRANSFER 1 Open normal and emergency source circuit breakers This procedure will manually transfer the load if the Controller is disconnected 2 Use manual handle to manually operate transfer switch to the opposite source Remove the handle A WARNING See Section 1 Manual Operation Do not manually operate the transfer switch 3 If the transfer switch is in the Emergency position until both power sources are disconnected manually start the engine generator and then close open both circuit breakers the emergency source circuit breaker TROUBLE SHOOTING Note the Control Features that are activated or furnished A WARNING on the switch and review their operation Refer to Section 5 Optional Features Proceed with care The ASCO 386 is energized Table 3 1 Trouble Shooting Checks CHECK IN NUMERICAL SEQUENCE PROBLEM 1 OPERATION 2 VOLTAGE Transfer switch does not Turn Transfer Control switch clockwise to Generator ouput circuit breaker must be transfer the load to the Transfer to Emergency position closed Voltmeter should read at least 90 emergency source of nominal phase to phase
17. tions Refer to Wiring Diagram furnished with the ASCO 386 Note Control Features furnished on this switch and review operation Transfer Control Transfer Transfer To Emergency Transfer To Emergency The sequence for load transfer to the emergency source begins when you turn the door mounted Transfer Control switch clockwise to the Transfer To Emergency position When the Transfer Control switch is operated to Transfer To Emergency the voltage and frequency sensor begins monitoring the emergency source The sensor will accept the emergency source only when both voltage and frequency reach preset pickup points If the emergency source is available immediately the sensor may accept it as soon as the Transfer Control switch is operated When the emergency source is accepted by the sensor relay ER picks up to transfer the load to the emergency source ER relay energizes the TS coil is energized the transfer switch operates and all switch contacts mains controls auxiliaries reverse position The transfer switch is now supplying the load from the emergency source The transfer switch will remain in the Emergency position until the Transfer Control switch is operated to the Transfer To Normal position Transfer Control Transfer Transfer To Emergency Retransfer to Normal The sequence for load retransfer to the normal source begins when you turn the door mounted Transfer Control switch counterclockwise t
18. toring logic controls transfer and retransfer of motor loads so that inrush currents do not exceed normal starting currents It avoids nuisance tripping of circuit breakers and mechanical damage to motor couplings The Motor Load Transfer feature is built into the controller DIP switch S1 actuator 5 activates this feature right ON left OFF FUNCTION S1 DIP SWITCH enable Actuator 5 on o disable Actuator 5 off o 0 Shaded DIP switches are standard factory settings Note If the Motor Load Transfer feature is enabled it will be activated following the Load Disconnect Feature Delay Before Transfer delay Also the transfer switch may not operate immediately after the transfer control switch is operated even if both sources are available This delay is intentional introduced if the two power sources are not inphase Depending on the frequency difference it may take a few seconds for the sources to reach synchronism LOAD DISCONNECT FEATURE Connect external circuits to the terminals indicated on the Wiring Diagram in the back of this manual The double throw Form C contact is rated for 28 VDC or 120 VAC 6 amps resistive The contact operates prior to a selectable 0 3 10 or 20 second delay before transfer of the Non Automatic Transfer Switch The contact resets either immediately following transfer or after the same delay as set for pre signal before transfer Time delay bet
19. ween the load disconnect control signal and initiation of transfer is set on the controller with DIP switch S2 actuators 6 7 8 as shown below Delay Before Transfer LD TDBT S2 DIP SWITCH oasa Aauacroce M somas Aasa o S osna Aesan T aoso Raga E al O Shaded DIP switches are standard factory settings Delay After Transfer LD TDAT S2 DIP SWITCH enable Actuator 6 on disable Actuator 6 off D Enabling the Delay After Transfer will cause the control signal to reset after the same delay as set for the Delay Before Transfer A auxiliary circuits 1 1 B barriers 1 2 bus connections 1 2 C cable lugs 1 1 1 2 preparation 1 1 1 2 catalog number inside cover cleaning 3 1 connections line 1 2 controller 4 1 code inside cover cover removal 4 1 disconnecting 3 1 D DIP Switches 4 1 5 1 E electrical operation 1 4 F frequency 50 or 60 Hz setting 4 1 functional test 1 3 1 4 H harness 1 1 disconnect plugs 3 1 HELP 800 800 2726 ASCO customercare asco com Printed in U S A INDEX identification label cover inphase monitor 5 1 inspection 3 1 installation 1 1 L labels rating cover lights 1 4 3 1 load connected to emergency 1 4 3 1 load connected to normal 1 4 3 1 load disconnect feature 5 1 lubrication 3 1 M maintenance pr
20. witch See Figure 1 1 INSTALLATION Be sure that the insulator piece is behind the 260 and 400 ampere transfer switches insulator backing piece Figure 1 1 Insulator for E design 260 and 400 ampere Controller Ground The controller is mounted on the cabinet door The transfer switch is connected to the left side of the controller by a plug in harness two plugs An add on DIN rail is provided for some optional accessories and is mounted below the controller on the door A grounding wire must be connected to the controller s lower left mounting stud Because the controller is mounted on the enclosure door a conductive strap must be used between the enclosure and the door This connection provides proper grounding which does not rely upon the door hinges Auxiliary Circuits Connect auxiliary circuit wires to appropriate terminals on transfer switch terminal block TB as shown on the wiring diagram provided with this Non Automatic Transfer Switch Read all instructions on the Wiring Diagram and labels affixed to the non automatic transfer switch Note the control features that are provided and review their operation before proceeding INSTALLATION continued Line Connections A Wiring Diagram is furnished with the ASCO 386 separate from this manual Refer to this drawing All wiring must be made in accordance with the National Electrical Code and local codes A DANGER De energize the conductors before
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