7000 Series ACTS

Operator’s Automatic Closed–Transition Transfer Switches

Manual E–design 150–400A, F–design 600–800A,
G–design 1000–4000A, F–design 3000–4000A,
Refer to the outline and wiring drawings provided
with your 7000 Series ACTS for all installation and
DANGER is used in this manual to warn of high connection details and accessories.
voltages capable of causing shock, burns, or death.
Refer to Group 5 Controller User’s Guide
381333–126 for ATS status display messages, time
delays, pickup & dropout settings, and adjustments.
WARNING is used in this manual to warn
of possible personal injury.
An experienced licensed electrician must install the
ACTS.
Rating Label
CAUTION is used in this manual to warn
of possible equipment damage. Each automatic closed–transition transfer switch contains a
rating label to define the loads and fault circuit withstand /
closing ratings. Refer to the label on the transfer switch for
specific values.

Do not exceed the values on the rating label.

Exceeding the rating can cause personal injury
or serious equipment damage.

Nameplate
The Transfer Switch nameplate includes data for each
specific 7000 Series ACTS. Use the switch only within the
limits shown on this nameplate. A typical catalog number
is shown on the next page with its elements explained.

TABLE OF CONTENTS
section-page
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Mounting and Line Connections . . . . . . . . . 1-1
Auxiliary Circuits and Harness . . . . . . . . . . . 1-2
Engine Starting Contacts . . . . . . . . . . . . . . . 1-2
Functional Test . . . . . . . . . . . . . 1-2, 1-3, 1-4, 1-5
TESTING & SERVICE . . . . . . . . . . . . . . . . . . 2-1
Transfer Test . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preventive Maintenance . . . . . . . . . . . . . . . . 2-1
Disconnecting the Controller . . . . . . . . . . . . 2-1
Manual Load Transfer . . . . . . . . . . . . . . . . . . 2-2
Trouble-Shooting . . . . . . . . . . . . . . . . . . . . . . 2-2
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . back cover
150 – 400 ampere sizes

50 Hanover Road, Florham Park, New Jersey 07932–1591 USA 381333–128 E

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
 Catalog Number Identification
Typical 7000 Series catalog no. for E–design switched neutral, 3 pole, 400 amp, 480 V, ACTS in Type 1 enclosure:
E 7ACTS C 3 400 N 5 C
design
prefix
letter
Neutral Phase Poles Amperes Voltage Controller Enclosure
A – solid 2 – single Ø 150 1000 A 115 J 400 5 – standard C – type 1
B – switched 3 – three Ø 260 1200 B 120 K 415 5X – if F – type 3R
C – overlapping 400 1600 C 208 L 440 accessories G – type 4
ordered
blank – none 600 2000 D 220 M 460 L – type 12
800 3000 E 230 N 480 blank – open type

4000 F 240 P 550

G 277 Q 575
H 380 R 600

field connections
terminal block TB
power
connections Transfer
Control
& lights

Dual
Transfer
Switch

Group 5
Controller

power
connections

150–400 amp. sizes in typical enclosure with location of customer connections

 SECTION 1 INSTALLATION
ASCO Series 7000 Automatic Closed–Transition Transfer
Switches are factory wired and tested. Field installation
simply requires mounting and connection of service De–energize the conductors before making any
cables, and auxiliary control circuits (if required). line or auxiliary circuitry connections. Be sure
that Normal and Emergency line connections
Remove the Shipping Skid are in proper phase rotation. Place engine gen-
erator starting control in the OFF position.
For large switches, open the front door and remove the Make sure engine generator is not in operation.
four lag screws (2 in front, 2 in rear) securing enclosure
to the wood skid.
Testing Power Conductors
Supporting Foundation
Do not connect the power conductors to the transfer
The supporting foundation for the enclosure must level switch until they are tested. Installing power cables in
and straight. Refer to the applicable enclosure outline conduit, cable troughs and ceiling-suspended hangers
drawing included with the ACTS for all mounting often requires considerable force. The pulling of cables
details including door opening space. can damage insulation and stretch or break the
If bottom cable entry is used, the foundation must be conductor’s strands. For this reason, after the cables are
prepared so that the conduit stubs are located correctly. pulled into position, and before they are connected,
Refer to the enclosure outline drawing for specified area they should be tested to verify that they are not
and location. Provide cable bending space and clearance defective or have been damaged during installation.
to live metal parts. When a concrete floor is poured, use
interlocking conduit spacer caps or a wood or metal Connecting Power Conductors
template to maintain proper conduit alignment.
After the power cables have been tested, connect them
Mounting to the appropriate terminal lugs on the transfer switch
as shown on the wiring diagram provided with the
Refer to the outline and mounting diagram provided switch. Make sure the lugs provided are suitable for use
with the ACTS; it shows all mounting details and with the cables being installed. Standard terminal lugs
instructions. 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
Protect the switch from construction grit nicking or ringing the conductor. Remove surface
and metal chips to prevent malfunction or oxides from cables by cleaning with a wire brush. When
shortened life of the automatic switch switch. aluminum cable is used, apply joint compound to
Mount the ACTS vertically to a rigid supporting structure. conductors. Tighten cable lugs to the torque specified
Level all mounting points by using flat washers behind the on rating label.
holes to avoid distortion of the switch.
Do not run cables in front of or behind the switch.
The controller is mounted on the cabinet door. An Cables can be bundled on the right side of the switch.
add-on DIN rail is provided for some optional accesso- Maintain proper electrical clearance between the live
ries and is mounted below controller on the door. metal parts and grounded metal: ½ inch minimum for
150-400 amps, 1 inch minimum over 400 amps.
Auxiliary Cable Boxes It is not necessary to remove the barriers from the
For 1000 & 1200 amp. sizes, an auxiliary cable box is transfer switches to install the cables. If you do remove
required for all (normal, emergency, & load)bottom or them,however, be sure to reinstall the barriers carefully.
top entry. Order ASCO part no. 609027 if required.
Bus Connections
For large switches use grade 5 hardware to connect bus
On 1000 & 1200 amp. be sure to install auxiliary to appropriate terminal plates. Wipe off the bus
cable box if both service and load cables are surfaces before they are joined. If the bus is very dirty,
entering through the top or bottom of enclosure.
gently clean the surfaces with a non---flammable solvent.
Avoid touching the cleaned surfaces.
Line Connections
A Wiring Diagram is furnished with the ASCO Series
7000 ACTS (separate from this manual). Refer to this
drawing. All wiring must be made in accordance with Do not breathe cleaning solvent vapors.
the National Electrical Code and local codes.

1---1
 INSTALLATION (continued)
Tighten bolted joints to the torque specified in Table A. Engine Starting Contacts
The engine control contact connections (if used) are
located on the transfer switch. Connect signal wires to
The reliablility of the connection depends appropriate terminals as specified in Table B and shown
on how clean and how tight the joint is. in Figure 1–1.
Table A. Tightening torque values for bolted joints Table B. Engine start connections
(Grade 5 hardware) When normal Terminals on
Bolt Diameter Tightening Torque source fails transfer switch
in inches in foot pounds contact closes TB1 and TB2
1/4 7 contact opens TB1 and TB3
5/16 12
3/8 20
1/2 50
5/8 95
3/4 155

Note: To temporarily disable engine control from

the automatic transfer switch you can unplug J3
from the small P3 receptacle at the bottom of the
assembly. Be sure to reconnect plug J3 to the P3
receptacle for automatic transfer switch operation.

engine start
Controller Ground connections
A grounding wire must be connected to the controller’s on
lower left mounting stud. Because the controller is customer
terminal
mounted on the enclosure door, a conductive strap
block TB
must be used between the enclosure and the door. This
connection provides proper grounding which does not
rely upon the door hinges.
Harnesses
The transfer switch is connected to the left side of the
control panel by a plug-in harness (two plugs).

Auxiliary Circuits
Connect auxiliary circuit wires to appropriate terminals on Figure 1-1. Customer terminal block
the transfer switch. Note the control features that are on the top right side of enclosure.
furnished on this switch. Make the necessary auxiliary
connections by referring to the Wiring Diagram.

Functional Test
The Functional Test consists of three checks: Read all instructions on the Wiring Diagram and labels
affixed to the ACTS. Note the control features that are
S 1 — Manual Operation Test, page 1–3 provided and review their operation before proceeding.
S 2 — Voltage Checks, page 1–4
Continue to 1 – Manual Operation Test on next page.
S 3 — Electrical Operation, page 1–5

Do these checks in the order presented

to avoid damaging the ATS.

1---2
 INSTALLATION (continued)
handle
shafts

handle

handle

Figure 1-2. Figure 1-3. Figure 1-4

150 – 400 A (3 pole) 600 & 800 A (& 4 pole 400 A) 3000 & 4000 A
E–design switches F–design switches F–design transfer switches

1 – Manual Operation 1000 through 4000 amp. G–design See Figure 1-5.
Install the hub (with pin) onto the shaft and insert the
A detachable manual operator handle is provided on the
manual firmly into the side hole in the hub. Push in
Transfer Switches for maintenance purposes only.
or pull out hub to engage opposite source contacts.
Manual operation of both CN and CE transfer switches
must be checked before they are operated electrically. 3000 and 4000 amp. F–design See Figure 1-4.
Insert the manual handle into the hole in the weight.
2. Move the handle as shown to manually operate the
Do not manually operate the transfer switch Transfer Switch. The switch should operate smoothly
until both power sources are disconnected: without binding. If it does not, check for shipping
open both circuit breakers. damage or construction debris. Repeat the manual
operation check on the other Transfer Switch.
1. Select the appropriate switch amperage size above
and follow the directions for installing the handle: 3. Return the CN Transfer Switch to the C (closed)
position. Return the CE Transfer Switch to the O
150 through 400 amp. E–design See Figure 1-2. (open) position. Remove manual operator handle and
Insert the manual handle into the hole in the shaft, store it on the Transfer Switch in the place provided.
left side of the operator.
600 and 800 amp. F–design See Figure 1-3.
Attach the manual handle onto the pivot shaft Verify that the maintenance handle has been
removed and stored properly before proceeding!
extension, left side of the operator.
Now continue to 2 – Voltage Checks on next page.

Turn counterclockwise Insert handle

Emergency to OPEN contacts. into hole
Grasp handle (spring fully
contacts firmly with Turn clockwise to compressed)
both hands CLOSE contacts.

Slide the hub onto the

window shaft and insert the pin.
indicators
OPEN or
CLOSED

Normal
contacts counterclockwise DOWN clockwise DOWN
OPENS the contacts CLOSES the contacts
Pull out shaft to open Emergency Pull out shaft to close Emergency
contact position source contacts (upper) source contacts (upper)
Push in shaft to open Normal Push in shaft to close Normal
indicators (left side) source contacts (lower) source contacts (lower)
Figure 1-5. 1000 – 4000 ampere G–design transfer switches.

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
Verify that the feeders have been
2 phase to neutral voltages pres-
connected to the proper lugs.
ent at the transfer switch normal
source terminals.
Close the emergency source
Before energizing the switch check to be circuit breaker. (Start generator,
sure that both normal and emergency if necessary.) The Transfer
contacts are not left in the closed position. 3
Switch Connected To Normal &
Emergency Source Accepted
lights should come on.
Use extreme caution when using a meter Use an accurate voltmeter to
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.
First check nameplate on transfer switch; rated voltage
must be the same as normal and emergency line voltages.
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 the Accepted lights should be on.
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
Be sure to close the enclosure door 2 (within 15 sec.). Emergency
before proceeding to prevent personal Source Accepted light should
injury in case of electrical system fault. come on.
Transfer switch CE closes and
then Transfer Switch CN opens
Transfer Test (closed–transition overlap). The
Both normal and emergency sources must be available Transfer Switch Connected To
and the emergency source generator (if used) must be 3 Emergency light should come on
and the Transfer Switch
capable of being started in this procedure. Connected to Normal light goes
off (you might see and hear the
Perform steps 1 through 5 at the right. Observe the brief overlap transfer). **
status lights.
Transfer switch will operate back
Q Black square means light is on. to Normal position after Feature
3A time delay. For immediate
S White square means light is off. retransfer turn Transfer Control
counterclockwise to Retransfer
4
Delay Bypass. The Transfer
** If you do not want closed–transition transfer, press Switch Connected To Normal light
the Closed Transition Bypass pushbutton while the should come on; Transfer Switch
controller display shows Waiting for In–Sync. This Connected to Emergency light
action causes open–transition (momentary load should go off.
interruption) transfer to the opposite source, if
The engine–generator will stop
conditions permit. Also refer to the Group 5 Controller after the Feature 2E time delay
User’s Guide 381333–126. 5 (unloaded running engine cool-
down). The Emergency Source
This completes the Functional Test of the ACTS. 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 steps 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 service a. If the transfer switch is in the Normal position,
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.
b. If the transfer switch is in the Emergency posi-
Checklist for Yearly Inspection
tion, first open the normal source circuit break-
er. Second, place the engine starting control in
the test or run position. Third, open the emer-
Hazardous voltage capable of causing shock, gency source circuit breaker.
burns, or death is used in this switch.
Deenergize both Normal – Emergency power 2. Separate the two quick disconnect plugs by squeez-
sources before performing inspections! ing the latches. Do not pull on the harness wires.

S Clean the ACTS enclosure. Brush and vacuum Reconnecting the Plugs
away any excessive dust accumulation. Remove any
moisture with a clean cloth.
Do not unplug the controller
S Check the transfer switch contacts. Remove the until steps 1a or 1b is completed.
transfer switch barriers and check contact condition.
Replace the contacts if they become pitted or worn 1. Observe the position of the transfer switch.
excessively. Reinstall the barriers carefully.
a. If the transfer switch is in the Normal position,
S Maintain transfer switch lubrication. If the first be sure that both normal and emergency
transfer switch is subjected to severe dust or source circuit breakers are open. Second, be
abnormal operating conditions, renew factory sure that the standby engine starting control is
lubrication on all movements and linkages. still in the off position.
Relubricate the solenoid operator if the TS coil is b. If the transfer switch is in the Emergency posi-
replaced. Do not use oil; order lubrication kit tion, first be sure that both normal and emer-
75-100. gency source circuit breakers are open.
S Check all cable connections & retighten them. 2. The two harness plugs and sockets are keyed.
Carefully align the plugs with the sockets and press
straight in until both latches click. Close the door!
REPLACEMENT PARTS 3. Restore the two sources in sequence as follows:
Replacement parts are available in kit form. When a. If the transfer switch is in the Normal position,
ordering parts provide the Serial No., Bill of Material first close the normal source circuit breaker.
No. (BOM), and Catalog No. from the transfer switch Second, close the emergency source circuit
nameplate. Contact your local ASCO Power Technolo- breaker. Third, place the standby engine
gies Sales Office or ASI: starting control in the automatic position.

in United States call 1 800 – 800 – ASCO (2726) b. If the transfer switch is in the Emergency
position, first close the emergency source circuit
breaker. Second close the normal source circuit
breaker.

2---1
 TESTING & SERVICE (continued)

MANUAL LOAD TRANSFER 2. Use the maintenance handle to manually operate the
transfer switch to the opposite source. First open the
This procedure will manually transfer the load if the
closed contacts, then close the other contacts. Do not
controller is disconnected.
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 Technolo-
gies sales office or ASI. In the United States, call 1–800–800–2726. Furnish the Serial No., Catalog No., & BOM
No. from the transfer switch nameplate.

2---2
 INDEX

A I R
alarm reset, 1–5, 2–2 inspection, 2–1 rating label, cover
auxiliary circuits, 1–2 installation, 1–1 replacement parts, 2–1

C L S
labels,
cable engine start contacts, 1–2 settings
lugs, 1–2 rating, cover see Controller User’s Guide
preparation, 1–2
lights, 1–4, 1–5
catalog number, inside cover
lubrication, 2–1
T
cleaning, 2–1 test, functional, 1–2, 1–3, 1–4, 1–5
closed transition bypass, 1–5, 2–2 M time delays, 2–1
connections maintenance handle, 1–3 see Controller User’s Guide
line, 1–1 Transfer Control selector switch
maintenance, preventive, 2–1
controller, 1–1 Retransfer Delay Bypass, 1–5
manual load transfer, 2–2 Transfer Test, 1–5
disconnecting, 2–1
warning, 2–2
see Controller User’s Guide Transfer Switch Connected To
manual operation, 1–3 Emergency light, 1–5, 2–1
illustration of, 1–3
E warning, 1–3 Transfer Switch Connected To
Normal light, 1–4, 2–1
electrical operation, 1–5
emergency source accepted light, N transfer test, 1–5
1–4 transfer to emergency, 1–5
nameplate, cover
extended parallel time, 2---2 transfer to normal, 1–5, 2–1
normal source accepted light, 1–4
trouble–shooting, 2–2
F O TS locked out, 2---2
failure to synchronize, 2---2 operation
frequency, generator, 2–2 electrical, 1–5
manual, 1–3
V
functional test, 1–2, 1–3, 1–4, 1–5 illustration of, 1–3 voltage checks, 1–4
warning, 1–3 voltage, pickup and dropout settings
G optional accessories see Controller User’s Guide
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
[email protected]
800–800–ASCO

Printed in U.S.A. Copyright 2010 ASCO Power Technologies, L.P.