Operator’s 7000 Series ACTS

Manual Automatic Closed–Transition Transfer Switches

H–design 600 through 1200 amp.
TABLE OF CONTENTS
section-page DANGER is used in this manual to warn of high
voltages capable of causing shock, burns, or death.
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Mounting and Line Connections . . . . . . . . . 1-1
Auxiliary Circuits and Harness . . . . . . . . . . . 1-2 WARNING is used in this manual to warn
Engine Starting Contacts . . . . . . . . . . . . . . . 1-2 of possible personal injury.
Functional Test . . . . . . . . . . . . . 1-2, 1-3, 1-4, 1-5
TESTING & SERVICE . . . . . . . . . . . . . . . . . . 2-1
Transfer Test . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 CAUTION is used in this manual to warn
Preventive Maintenance . . . . . . . . . . . . . . . . 2-1 of possible equipment damage.
Disconnecting the Controller . . . . . . . . . . . . 2-1 Refer to Group 5 Controller User’s Guide 381333–126
Manual Load Transfer . . . . . . . . . . . . . . . . . . 2-2 for ATS status display messages, time delays, pickup
Trouble-Shooting . . . . . . . . . . . . . . . . . . . . . . 2-2 & dropout settings, and adjustments.
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . back cover

Note: Refer to the outline and wiring drawings

provided with your 7000 Series ACTS for all
installation and connection details and accessories.

An experienced licensed electrician must install the ACTS.

1200 amp. size

600---1000 amp. size
50 Hanover Road, Florham Park, New Jersey 07932–1591 USA 381333–203 D
For sales or service call 1 800 800–2726 (ASCO) www.ascopower.com

ASCO POWER TECHNOLOGIES CANADA PO Box 1238, 17 Airport Road, Brantford, Ontario, Canada N3T 5T3
telephone 519 758–8450, fax 519 758–0876, for service call 1 888 234–2726 (ASCO) www.asco.ca
 Rating Label Nameplate
Each Automatic Closed–Transition Transfer Switch contains The Transfer Switch nameplate includes data for each
a rating label to define the loads and fault circuit withstand/ specific 7000 Series ACTS. Use the switch only within the
closing ratings. Refer to the label on the Transfer Switch for limits shown on this nameplate. A typical Catalog
specific values. Number is shown on the next page with its elements
explained.

Do not exceed the values on the rating label. Catalog Number Identification
Exceeding the rating can cause personal injury Typical 7000 Series ACTS catalog no. for switched
or serious equipment damage. neutral, 3 pole, 800 amp, 480 V, ATS in Type 1 enclosure:

H7ACTS B 3 800 N 5 C

Neutral Phase Poles Amperes Voltage Controller Enclosure

A – solid 2 – single Ø 600 C 208 K 415 5 – standard C – type 1
B – switched 3 – three Ø 800 D 220 L 440 5X – if F – type 3R
1000 E 230 M 460 accessories G – type 4 *
ordered
blank – none 1200 F 240 N 480 L – type 12 *
G 277 P 550 blank – open type

H 380 Q 575
* available 600–1000 amp. sizes only
J 400 R 600
field connections
terminal block TB
power
connections Transfer
Control
& lights

ground lug

Group 5
Transfer Controller
Switch

ground lug

power
connections

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

 field connections
terminal block TB ground lug

Transfer
Control
& lights

power
connections

Group 5
Controller

Transfer
Switch

power
connections

1200 amp. size in typical enclosure with location of customer connections

 SECTION 1 INSTALLATION
ASCO 7000 Series Automatic Closed–Transition Testing Power Conductors
Transfer Switches (ACTSs) are factory wired and
Do not connect the power conductors to the transfer
tested. Field installation requires mounting and
switch until they are tested. Installing power cables in
connection of service cables, and auxiliary control
conduit, cable troughs and ceiling-suspended hangers
circuits (if required).
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
Remove the Shipping Skid (large ACTSs) are pulled into position, and before they are
For large ACTSs, open the front door and remove the connected, they should be tested to verify that they are
four lag screws (2 in front, 2 in rear) securing enclosure not defective or have been damaged during
to the wood skid. installation.

Supporting Foundation Protect the switch from construction grit

and metal chips to prevent malfunction or
The supporting foundation for the enclosure must be
shortened life of the automatic switch switch.
level and straight. Refer to the applicable enclosure
outline drawing included with the switch for all
mounting details including door opening space. Connecting Power Conductors
If bottom cable entry is used, the foundation must be After the power cables have been tested, connect them
prepared so that the conduit stubs are located to the appropriate terminal lugs on the transfer switch
correctly. Refer to the enclosure outline drawing for as shown on the wiring diagram provided with the
specified area and location. Provide cable bending switch. Make sure the lugs provided are suitable for
space and clearance to live metal parts. When a use with the cables being installed. Standard terminal
concrete floor is poured, use interlocking conduit lugs are solderless screw type and will accept the wire
spacer caps or a wood or metal template to maintain sizes listed on the drawings provided with the switch.
proper conduit alignment. Be careful when stripping insulation from the cables;
avoid nicking or ringing the conductor. Remove
surface oxides from cables by cleaning with a wire
Mounting brush. When aluminum cable is used, apply joint
Refer to the applicable enclosure outline drawing compound to conductors. Tighten cable lugs to the
furnished with this switch and mount the automatic torque specified on rating label.
transfer switch according to details and instructions
shown on diagram.
Controller Ground
Line Connections A grounding wire must be connected to the controller’s
lower left mounting stud. Because the controller is
Refer to the Wiring Diagram provided with the switch. mounted on the enclosure door, a conductive strap
All wiring must be made in accordance with the must be used between the enclosure and the door.
National Electrical Code and local codes. This connection provides proper grounding which does
not rely upon the door hinges.
It is unnecessary to remove pole covers from the
transfer switch. If you do remove them, reinstall them
carefully. Harnesses
The transfer switch is connected to the left side of the
controller by a plug–in harness (two plugs).
De–energize the conductors before 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.

1---1
 INSTALLATION (continued)
Engine Starting Contacts
All customer connections, including the engine control
contact connections, are located on terminal block TB
which is mounted on the top right side of the enclosur-
e. Refer to the wiring diagram provided with the
automatic transfer switch and connect the engine start
wires to the appropriate terminals. See Figure 1–1 and
Table A.
Table A. Engine start connections.

When normal source Terminals on

fails Terminal Block TB
contact closes TB1 and TB2
engine start
contact opens TB1 and TB3 connections
on
Note: To temporarily disable engine control customer
from the automatic transfer switch you can terminal
unplug J3 from the small P3 receptacle at the block TB
bottom of the assembly. Be sure to reconnect
plug J3 to the P3 receptacle for automatic
transfer switch operation.

Auxiliary Circuits
Connect auxiliary circuit wires to appropriate terminals
on transfer switch terminal block TB as shown on the
wiring diagram provided with this automatic transfer
switch.
Figure 1-1. Customer terminal block on the top right
side of the enclosure.

Functional Test
The Functional Test consists of three checks: Note the position of the contact shafts as shown below.

S 1 — Manual Operation Test, page 1–3 Emergency contacts

(upper shaft)
S 2 — Voltage Checks, page 1–4 contact
window indicators
position
S 3 — Electrical Operation, page 1–5 O is open
indicators
C is closed
(right side)

Normal contacts
Do these checks in the order presented (lower shaft)
to avoid damaging the ACTS.
Figure 1-2. Contact position indicators.
Read all instructions on the Wiring Diagram and labels Shown with Emergency open and Normal closed.
affixed to the automatic transfer switch. Note the
control features that are provided and review their
Continue to 1 – Manual Operation Test on next page.
operation before proceeding.

1---2
 INSTALLATION (continued)
1 – Manual Operation Test
A detachable maintenance handle is provided on the
frame of the Transfer Switch for maintenance purposes
only. Manual operation of the transfer switch should be
checked before it is energized (operated electrically).
left side of
transfer switch
Do not manually operate the transfer switch
until both power sources are disconnected:
open both circuit breakers.
1. After deenergizing both power sources, open the
enclosure door. Locate and remove the maintenance
handle from the clips on the left side of the transfer Emergency source
switch frame. Insert the handle into the hole in the contact shaft hub
molded hub on the left side of the operator. See
Figures 1–3 through 1–5 and Table B. maintenance
2. Move the maintenance handle up or down as handle
shown to manually operate the transfer switch.
The transfer switch should operate smoothly
without binding. If it does not, check for shipping clip
damage or construction debris. Operate both
upper and lower contact shafts.
Normal source
3. Return the transfer switch to the Normal position. contact shaft hub
Observe that the window indicators (right side) show
the upper shaft O (Emergency open) and the lower
shaft C (Normal closed). Remove the maintenance
handle and store it on the frame in the clips
provided. Figure 1-3. Maintenance handle storage location.
Table B. Maintenance handle positions. Hubs shown with Normal closed & Emergency open.

ATS Position Handle Indicators

up handle UP opens the
Emergency source
E=O contacts
E upper contacts open
UPPER SHAFT
Normal
up hub
N=C DOWN closes the
N
lower contacts closed
Emergency source
contacts
frame
Figure 1-4. Emergency (upper shaft) operation.
E=C
E UP closes the
down
upper contacts closed
handle
Emergency Normal source
N=O contacts
N
lower contacts open
LOWER SHAFT
hub
down DOWN opens the
Note: If Normal and Emergency connections are Normal source
reversed this operation is also reversed. contacts
frame
Figure 1-5. Normal (lower shaft) operation.
Now continue to 2 – Voltage Checks on the next page.

1---3
 INSTALLATION (continued)

GREEN RED RED RED RED

observe
these lights

GREEN RED

Figure 1-6. Standard controls and indicators.

Close the normal source circuit
2 --- Voltage Checks breaker. The Transfer Switch
1 Connected To Normal and the
First check nameplate on transfer switch; rated voltage Normal Source Accepted lights
must be the same as normal and emergency line voltages. should come on.

Use an accurate voltmeter to

check phase to phase and
Before energizing the switch check to be
2 phase to neutral voltages pres-
sure that both normal and emergency
ent at the transfer switch normal
contacts are not left in the closed position.
source terminals.
Close the emergency source
circuit breaker. (Start generator,
Verify that the feeders have been if necessary.) The Transfer
connected to the proper lugs. 3
Switch Connected To Normal &
Emergency Source Accepted
lights should come on.
Use extreme caution when using a meter to Use an accurate voltmeter to
measure voltages. Do not touch power check phase to phase and
terminals; shock, burns, or death could result ! 4 phase to neutral voltages pres-
ent at the transfer switch emer-
Perform steps 1 through 6 at the right. Observe the
gency source terminals.*
status lights. See Figure 1---6.
A B C
Q Black square means light is on. Use a phase rotation meter to
S White square means light is off. check phase rotation of emer-
5
gency source; it must be the
* If necessary, adjust voltage regulator on the generator same as the normal source.
according to the manufacturer’s recommendations. The
Automatic Transfer Switch will respond only to the rated Shut down the engine–genera-
voltage specified on the Transfer Switch nameplate. tor, if applicable. The Emergen-
cy Source Accepted light should
Note: Refer to Section 3 of Group 5 Controller User’s 6 go off. Then put the starting
Guide 381333–126 for how to display the Status of the control selector switch (on the
ATS and the Voltage and Frequency of each source. generator set) in the automatic
position. Close enclosure door.
Now continue to 3 --- Electrical Operation on next page.

1---4
 INSTALLATION (continued)

GREEN RED RED RED RED

observe operate
these lights this switch

GREEN RED

Figure 1-7. Standard controls and indicators.

3 --- Electrical Operation The Transfer Switch Connected

1 To Normal and Normal Source
This procedure will check the electrical operation of Accepted lights should be on.
the Automatic Closed–Transition Transfer Switch.
See Figure 1---7.
Turn and hold Transfer Control
switch clockwise to Transfer Test
until the engine starts and runs
2 (within 15 sec.). Emergency
Close the enclosure door first !
Source Accepted light should
come on.
Transfer switch CE closes and
Transfer Test then Transfer Switch CN opens
Both normal and emergency sources must be available (closed–transition overlap). The
Transfer Switch Connected To
and the emergency source generator (if used) must be 3 Emergency light should come on
capable of being started in this procedure. and the Transfer Switch
Connected to Normal light goes
Perform steps 1 through 5 at the right. Observe the off (you might see and hear the
status lights. brief overlap transfer). **
Q Black square means light is on. Transfer switch will operate back
to Normal position after Feature
S White square means light is off. 3A time delay. For immediate
retransfer turn Transfer Control
counterclockwise to Retransfer
** If you do not want closed–transition transfer, press 4
Delay Bypass. The Transfer
the Closed Transition Bypass pushbutton while the Switch Connected To Normal light
controller display shows Waiting for In–Sync. This should come on; Transfer Switch
Connected to Emergency light
action causes open–transition (momentary load should go off.
interruption) transfer to the opposite source, if
conditions permit. Also refer to the Group 5 Controller The engine–generator will stop
User’s Guide 381333–126. after the Feature 2E time delay
5 (unloaded running engine cool-
This completes the Functional Test of the ACTS. down). The Emergency Source
Accepted light should go off.

1---5
 SECTION 2 TESTING & SERVICE
TRANSFER TEST DISCONNECTING THE CONTROLLER
Operate the 7000 Series ACTS at least once a month The harness disconnect plugs are furnished for repair
by following the five–step Electrical Operation purposes only and should not have to be unplugged.
Transfer Test procedure on page 1–5. If the controller must be isolated, follow these steps:

Disconnecting the Plugs

PREVENTIVE MAINTENANCE
Reasonable care in preventive maintenance will insure
high reliability and long life for the 7000 Series ACTS. Do not unplug the controller
An annual preventive maintenance program is recom- until step 1a or 1b is completed.
mended.
1. Observe the position of the transfer switch.
In the United States, ASCO Services, Inc.
(ASI) is ASCO Power Technologies’s national a. If the transfer switch is in the Normal position,
service organization. ASI can be contacted at first place standby engine starting control in the
1-800-800-2726 (ASCO) for information on off position. Second, then open the emergency
preventive maintenance agreements. source circuit breaker. Third, open the normal
source circuit breaker.
In Canada, for service call 1-888-234-2726 (ASCO). b. If the transfer switch is in the Emergency
position, first open the normal source circuit
breaker. Second, place the engine starting
Checklist for Yearly Inspection control in the test or run position. Third, open
the emergency source circuit breaker.
2. Separate the two quick disconnect plugs by squeez-
Hazardous voltage capable of causing shock,
ing the latches. Do not pull on the harness wires.
burns, or death is used in this transfer switch.
Deenergize both Normal – Emergency power
Reconnecting the Plugs
sources before performing inspections!

S Clean the ACTS enclosure. Brush and vacuum

away any excessive dust accumulation. Remove any Do not unplug the controller
moisture with a clean cloth. until step 1a or 1b is completed.
1. Observe the position of the transfer switch.
S Check the transfer switch contacts. Remove the
transfer switch barriers and check contact condition. a. If the transfer switch is in the Normal position,
Replace the contacts if they become pitted or worn first be sure that both normal and emergency
excessively. Reinstall the barriers carefully. source circuit breakers are open. Second, be sure
that the standby engine starting control is still in
S Maintain transfer switch lubrication. If the the off position.
transfer switch is subjected to severe dust or
abnormal operating conditions, renew factory b. If the transfer switch is in the Emergency position,
lubrication on all movements and linkages. first be sure that both normal and emergency
Relubricate the solenoid operator if the TS coil is source circuit breakers are open.
replaced. Do not use oil; order lubrication kit 75-100. 2. The two harness plugs and sockets are keyed. Care-
fully align the plugs with the sockets and press
S Check all cable connections & retighten them. straight in until both latches click. Close the door!
3. Restore the two sources in sequence as follows:

REPLACEMENT PARTS a. If the transfer switch is in the Normal position,

first close the normal source circuit breaker.
Replacement parts are available in kit form. When Second, close the emergency source circuit
ordering parts provide the Serial No., Bill of Material breaker. Third, place the standby engine
No. (BOM), and Catalog No. from the transfer switch starting control in the automatic position.
nameplate. Contact your local ASCO Power Technolo-
gies Sales Office or ASI: b. If the transfer switch is in the Emergency position,
first close the emergency source circuit breaker.
in United States call 1 800 – 800 – ASCO (2726) Second close the normal source circuit breaker.
or in Canada call 1 888 – 234 – ASCO (2726)

2---1
 TESTING & SERVICE (continued)

MANUAL LOAD TRANSFER 2. Use the maintenance handle to manually operate the
This procedure will manually transfer the load if the transfer switch to the opposite source. First open the
controller is disconnected. closed contacts, then close the other contacts.
Do not leave both closed. See Manual Operation on
page 1–3.
Do not manually operate the transfer switch 3. Then remove the maintenance handle. See page 1–3.
until both power sources are disconnected
(all conductors deenergized).
Verify that the maintenance handle
1. Deenergize both the normal and emergency source has been removed before proceeding!
conductors (remove fuses or open circuit breakers).
4. If the transfer switch is in the Emergency position
manually start the engine generator and then
install emergency source fuse or close the circuit
breaker.

TROUBLE-SHOOTING
Note any optional accessories that may be furnished on
the ACTS and review their operation. Refer to any
separate drawings and/or instructions that may be Hazardous voltage capable of causing
packed with the ACTS. 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.

CHECK IN NUMERICAL SEQUENCE
PROBLEM
1 OPERATION 2 GEN-SET 3 VOLTAGE
Engine–generator set does Hold Transfer Test switch 15 Starting control must be in the
not start when the Transfer seconds or the outage must automatic position. Batteries
Control switch is turned and be long enough to allow for must be charged and ---
held in Transfer Test position Feature 1C time delay plus connected. Check wiring to
or when normal source fails. engine cranking and starting. engine starting contacts.
Transfer switch does not Wait for Feature 2B time delay Generator output circuit Voltmeter should read at least
transfer the load to the to time out. breaker must be closed. 90% of nominal phase to
emergency source after the Generator frequency must be phase voltage between
engine–generator set starts. at least 95% of nominal (57 Hz terminals EA and EC (or EL1
for a 60 Hz system.) * and EL2 for 2 pole switches)*
Transfer switch does not Wait for Feature 3A time delay Voltmeter should read at least
transfer the load to normal to time out. 90% of nominal phase to
source when normal returns phase voltage between
---
or when the Transfer Control terminals NB and NC, NC and
switch is released. NA, and NA and NB (or NL1
and NL2 for 2 pole switches).
Gen. does not stop after load Wait for Feature 2E time delay Starting control must be in the
---
retransfer to normal source. to time out. automatic position.
Failure to Synchronize Conditions of Normal or Emergency Sources not suitable for closed transition transfer.
light comes on. Recheck voltage and frequency of both sources. Press Alarm Reset pushbutton.
Extended Parallel Time CN and CE contacts are closed longer than setting in the Control Panel. Open the discon-
light comes on. nected source circuit breaker, then call your nearest ASCO Service Center for assistance.
TS Locked Out Transfer lockout operation has occured; transfer switch is disabled from automatic operation.
light comes on. 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
Technologies sales office or ASI. In the United States, call 1–800–800–2726. In Canada, call 1–888–234–2726.
Furnish the Serial No. and Catalog No. from the transfer switch nameplate.

2---2
 INDEX

A I S
alarm reset, 1–5, 2–2 inspection, 2–1 settings
auxiliary circuits, 1–2 installation, 1–1 see Controller User’s Guide

indicators, contact position, 1–3

C T
cable
L test, functional, 1–2, 1–3, 1–4, 1–5
lugs, 1–2 labels, time delays, 2–1
preparation, 1–2 engine start contacts, 1–2 see Controller User’s Guide
rating, cover
catalog number, inside cover Transfer Control selector switch
lights, 1–4, 1–5 Retransfer Delay Bypass, 1–5
cleaning, 2–1
lubrication, 2–1 Transfer Test, 1–5
closed transition bypass, 1–5, 2–2
Transfer Switch Connected To
connections M Emergency light, 1–5, 2–1
line, 1–1
maintenance handle, 1–3 Transfer Switch Connected To
contact position indicators, 1–3 Normal light, 1–4, 2–1
maintenance, preventive, 2–1
controller, 1–1 transfer test, 1–5
manual load transfer, 2–2
disconnecting, 2–1
warning, 2–2 transfer to emergency, 1–5
see Controller User’s Guide
manual operation, 1–3 transfer to normal, 1–5, 2–1
illustration of, 1–3
E warning, 1–3
trouble–shooting, 2–2
TS locked out, 2---2
electrical operation, 1–5
emergency source accepted light, N V
1–4
nameplate, cover
extended parallel time, 2---2 voltage checks, 1–4
normal source accepted light, 1–4
voltage, pickup and dropout settings
F O see Controller User’s Guide

failure to synchronize, 2---2 operation

electrical, 1–5
frequency, generator, 2–2
manual, 1–3
functional test, 1–2, 1–3, 1–4, 1–5 illustration of, 1–3
warning, 1–3
G optional accessories
see Controller User’s Guide
ground, controller, 1–1

H P
harness, 1–1 parts, 2–1
disconnect plugs, 2–1
phase rotation check, 1–4
HELP
problem, 2–2
800–800–2726 (ASCO)
customercare@asco.com
R
rating label, cover
replacement parts, 2–1

Printed in U.S.A. Copyright --- ASCO Power Technologies 2007