381333–229 E50 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 5T3

Operator’sManual

7000 Series ATSAutomatic Transfer SwitchesD design, 30 through 230 A

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.

30---230 ampere

Refer to the outline and wiring drawings providedwith your 7000 Series ATS for all installation andconnection details and accessories.

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

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 injuryor 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 on the next page with its elements explained.

An experienced licensed electrician must install the ATS.

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

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

Catalog Number IdentificationTypical 7000 Series 7ATS catalog no. for overlapping neutral, 3 pole, 150 amp, 480 V, in Type 1 enclosure:

7ATS C 3 150 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

B 120

D 220

A 115

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

150

3070100

blank – none

blank – open type

Ddesignprefixletter

M –type 3R secure

N –type 4 secure

P –type 4X secure

Q –type 12 secure

230 **

200 **

** 200 and 230 amp.limited to 480 volts

terminals forengine startcontacts

Transfer Switch

Controller

normal powerconnections

emergency powerconnections

transfercontrol& lights

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

terminals for switchposition contacts

load powerconnections

cable spacers(see INSTALLATION)

maintenancehandle

(see WARNINGunder ManualOperation)

SECTION 1 INSTALLATION

1---1

The ASCO 7000 Series Automatic Transfer Switch (ATS)is factory wired and tested. Field installation requiresmounting, connecting service cables, and connectingengine start and auxiliary control circuits (if required).

Supporting Foundation

The supporting foundation for the enclosure must belevel and straight. Refer to the applicable enclosureoutline drawing included with the switch for allmounting details 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 specifiedarea and location. Provide cable bending space and ½inch minimum clearance to live metal parts. When aconcrete floor is poured, use interlocking conduit spacercaps or a wood or metal template to maintain properconduit alignment.

MountingRefer to the Outline and Mounting Diagram provided withthe ATS; it shows all mounting details and instructions.

Protect the switch from construction gritand metal chips to prevent malfunction orshortened life of the automatic switch switch.

Mount the ASCO ATS vertically to a rigid supportingstructure. Level all mounting points by using flat washersbehind the holes to avoid distortion of the switch.

The controller is mounted on the cabinet door. Anadd-on DIN rail is provided for some optional accesso-ries and is mounted below the controller on the door.

Line ConnectionsAWiring Diagram is furnished with the ASCO 7000Series ATS (separate from this manual). Refer to thisdrawing. All wiring must be made in accordance withthe National Electrical Code and local codes.

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 the OFF position.Make sure 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 hangers

often 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,they should be tested to verify that they are notdefective or have been damaged during installation.

Connecting Power Conductors

After the power cables have been tested, connect themto the appropriate terminal lugs on the transfer switchas shown on the wiring diagram provided with theswitch. Make sure the lugs provided are suitable for usewith the cables being installed. Standard terminal lugsare solderless screw type and will accept the wire sizeslisted on the drawings provided with the switch. Becareful when stripping insulation from the cables; avoidnicking or ringing the conductor. Remove surfaceoxides from cables by cleaning with a wire brush. Whenaluminum cable is used, apply joint compound toconductors. Tighten cable lugs to the torque specifiedon rating label.

Three cable spacers are included with 150, 200, & 230 Atransfer switches. When installing power cables, run thecables through the cable spacers as shown in Figure 1-1.Position the cable spacers within 1½ inches from the lugs.

The cable spacers must be located as shownfor 150, 200, and 230 ampere transfer switches.

cable spacer

cable spacers

1 ½ inch approximate

Figure 1-1. Cable spacer for 150, 200, and 230 amp.transfer switches.

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 strapmust be used between the enclosure and the door. Thisconnection provides proper grounding which does notrely upon the door hinges.

INSTALLATION (continued)

1---2

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

Engine Starting ContactsThe engine control contact connections (if used) arelocated on the transfer switch. Connect signal wires toappropriate terminals as specified in Table A and shownin Figure 1-2.

Table A. Engine Start Connections

When normalsource fails

Terminals ontransfer switch

contact closes TB14 and TB15contact opens TB14 and TB16

TB 14

TB 15TB 16

ENGINE STARTING CONTACTS( SHOWN DE–ENERGIZED )

TOPSTUD

MIDDLESTUD

BOTTOMSTUD

14

15

16

TS

NR

NR

Figure 1-2. Engine starting contact labeland location on left side of transfer switch.

Auxiliary Circuits

Connect auxiliary circuit wires to appropriate terminals onthe transfer switch. Note the control features that arefurnished on this switch. Make the necessary auxiliaryconnections by referring to the Wiring Diagram.

Functional TestThe Functional Test consists of three checks:

1 — Manual Operation Test, on this page

2 — Voltage Checks, page 1–3

3 — Electrical Operation, page 1–4

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 thecontrol features that are provided and review theiroperation before proceeding.

1 – Manual Operation Test

Amaintenance handle is provided on the Transfer Switchfor maintenance purposes only. Manual operation of thetransfer switch should be checked 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 the maintenance handleon the left side of the transfer switch. See Figure 1–3.

2. Grasp the attached maintenance handle and turn itwith thumb and fingers as shown to manually operateit. The maintenance handle turns the opposite

direction of the weight. Turn it up or down as shownto manually operate the transfer switch. It shouldoperate smoothly without any binding. If it does not,check for shipping damage or construction debris.

3. Return the transfer switch to the Normal position.

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

Now continue to 2 – Voltage Checks on next page.

maintenancehandle

With ALL POWER OFF graspmaintenance handle and turn it

quickly with your thumb and fingers.

weight marked N (normal)and E (emergency)

floatingweight

weight

Position of the transfer switch is indicated here

Figure 1–3. Maintenance handle and positions.

INSTALLATION (continued)

1---3

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 powerterminals; shock, burns, or death could result !

Perform steps 1 through 6 at the right. Observe thestatus lights. 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.The Automatic Transfer Switch will respond only to therated voltage specified on the Transfer Switchnameplate.

Note

Refer to Section 3 of Group 5 Controller User’s Guide381333–126 for how to display the Status of the ATSand the 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---4

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 door beforeproceeding to prevent personal injury in caseof 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 thestatus lights.

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 1–4.

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

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

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 the ATS enclosure.Brush and vacuum away any excessive dustaccumulation. Remove any moisture with a cleancloth.

Check the transfer switch contacts.Remove the transfer switch barriers and check con-tact condition. Replace the contacts if they becomepitted or worn excessively. Reinstall the barrierscarefully.

Maintain transfer switch lubrication.The transfer switch has been properly lubricated,and under normal operating conditions no furtherlubricating is required. Renew factory lubricationif the switch is subjected to severe dust orabnormal operating conditions. Relubricate theoperator if TS coil is replaced. Order lubrication625550–001 (Castrol Endurex 4000 lubricant).

Check all cable connections & retighten them.

REPLACEMENT PARTSReplacement parts are available in kit form. Whenordering parts provide the Serial No., Bill of MaterialNo. (BOM), and Catalog No. from the transfer switchnameplate. Contact your local ASCO Power Technolo-gies sales office or ASI. In the United States call1–800–800–ASCO (2726).

DISCONNECTING THE CONTROLLER

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

Disconnecting the Plugs

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

1. Observe the position of the transfer switch.

a. If the transfer switch is in the Normal position,first place standby engine starting control in theoff position. Second, then open the emergencysource circuit breaker. Third, open the normalsource circuit breaker.

b. If the transfer switch is in the Emergencyposition, first open the normal source circuitbreaker. Second, place the engine startingcontrol in the test or run position. Third, openthe emergency source circuit 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 step 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, besure that the standby engine starting control isstill in the off position.

b. If the transfer switch is in the Emergency posi-tion, first be sure that both normal and emer-gency source circuit breakers are open.

2. The two harness plugs and sockets are keyed.Carefully 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 circuitbreaker. Third, place the standby enginestarting control in the automatic position.

b. If the transfer switch is in the Emergencyposition, first close the emergency source circuitbreaker. Second close the normal source circuitbreaker.

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 break-ers).

2. Use the maintenance handle to manually operatethe transfer switch to the opposite source. SeeManual Operation on page 1–2.

3. If the transfer switch is in the Emergency positionmanually start the engine generator and theninstall emergency source fuse or close the circuitbreaker.

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. Furnish the Serial No., Bill of Material (BOM) No.,and Catalog No. from transfer switch nameplate.

INDEX

Printed in U.S.A. Copyright ASCO Power Technologies, L.P. 2009

Aauxiliary circuits, 1–2

Ccablelugs, 1–1preparation, 1–1spacers, 1–1illustration of, 1–1

catalog number, inside cover

cleaning, 2–1

connectionsline, 1–1

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

Eelectrical operation, 1–4

Emergency Source Accepted light,1–3, 1–4

Ffrequency, generator, 2–2

functional test, 1–2, 1–3, 1–4

Hharness, 1–2disconnect plugs, 2–1

HELPcustomercare@asco.com800–800–ASCO

Iinspection, 2–1

installation, 1–1

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

lights, 1–3, 1–4

lubrication, 2–1

Mmaintenance, preventive, 2–1

manual load transfer, 2–2warning, 2–2

manual operation, 1–2illustration of, 1–2warning, 1–2

Nnameplate, cover

Normal Source Accepted light, 1–3,1–4

Ooperationelectrical, 1–4manual, 1–2illustration of, 1–2warning, 1–2

sequence ofsee Controller User’s Guide

optional accessoriessee Controller User’s Guide

Pparts, 2–1

phase rotation check, 1–3

problem, 2–2

Rrating label, cover

replacement parts, 2–1

Sservice, 2–2

settingssee Controller User’s Guide

Ttest, functional, 1–2, 1–3, 1–4

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

Transfer Control selector switchRetransfer Delay Bypass, 1–4Transfer Test, 1–4

Transfer Switch Connected toEmergency light, 1–3, 1–4

Transfer Switch Connected toNormal light, 1–3, 1–4

transfer test, 1–4

transfer to emergency, 1–4

transfer to normal, 1–4

trouble–shooting, 2–2

Vvoltage checks, 1–3

voltage, pickup and dropout settingssee Controller User’s Guide