section-page Table 1. Transfer switching device ratings. Conditional short circuit current

Transcription

1 Operator s Manual 7000 Series ATS Automatic Transfer Switching Equipment D design 30 through 200 amperes TABLE OF CONTENTS section-page INSTALLATION Enclosures and Mounting Power Connections Engine Starting Contacts Functional Test , 1-4, 1 5 TESTING & SERVICE Preventive Maintenance Transfer Test Disconnecting the Controller Manual Load Transfer Trouble-Shooting INDEX... back cover An experienced licensed electrician should install the ATSE. Note: Refer to the outline and wiring drawings provided with your 7000 Series ATS for all installation and connection details and accessories. Note: Refer to Group 5 Controller User s Guide for status display messages, time delays, pickup and dropout settings, and adjustments. Nameplate / rating Label The 7000 Series Automatic Transfer Switching Equipment (ATSE) contains a nameplate / rating label which includes data for that specific ATSE. It defines the loads and fault circuit withstand/closing ratings. Refer to the labels on the Transfer Switching device for specific values and use the ATSE only within their limits. See Table 1 below. Do not exceed the values on the nameplate/ rating label. Exceeding the rating can cause personal injury or serious equipment damage. Used in this manual to warn of risk of electrical shock from high voltages capable of causing shock, burns, or death. Used in this manual to warn of possible personal injury. Automatic Transfer Switching Equipment IEC Class PC Cat No D7ATS3100J5X Ser No Ue 400 V 50 Hz AC 33A Ie 100 A 7000 Series Used in this manual to warn of possible equipment damage. Notes: Switching overvoltage not declared. The controller meets Class A limits; suitable for establishments other than domestic. Table 1. Transfer switching device ratings. Rated size in amperes 30, 70, 100, 150, 200* Rated short circuit making capacity I cm Rated short time withstand current I cw Conditional short circuit current 5000 A Short circuit protective device circuit breaker permitting I 2 tmax 4,1 x 10 5 ;I p max 7580 A Minimum clearance live metal to ground 13 mm * 200 ampere is limited to 240 volts. ASCO POWER TECHNOLOGIES L.P. 50 Hanover Road, Florham Park, New Jersey USA

2 SECTION 1 The ASCO Series 7000 Automatic Transfer Switching Equipment (ATS) consists of a transfer switching device, monitoring and transfer control device (controller), and controls (for door mounting). Installation requires mounting the devices into an appropriate size enclosure (Table 1 1) and connection of power conductors, engine start signal wires, and auxiliary circuits. Enclosures The Outline and Mounting Diagram furnished with the ATS shows all mounting details and instructions. Table 1 1 shows the minimum enclosure sizes required for 7000 Series ATS (suitable for IP 65 enclosures). Table 1-1. Minimum enclosure sizes required. Height (mm) Width (mm) Depth (mm) To prevent overheating and damage use a suitable enclosure with dimensions equaltoorlargerthanthese. To prevent malfunction or shortened life for the transfer switching device protect it from construction grit and metal chips. Mounting Refer to the Outline and Mounting Diagram provided with the ATS; it shows all mounting details and instructions. Mount the transfer switching device vertically in the back of the enclosure as shown on the Outline and Mounting Diagram. Level all mounting points by using flat washers behind the holes to avoid distortion of the transfer switching device. Mount the controller and the control / indicator plate on the inside of the enclosure door as shown on the Outline and Mounting Diagram. Their display, membrane controls, switches, and indicators must be accessible through cutouts in the door. An add-on DIN rail is provided for some optional accessories; it should be mounted below controller on the inside of the door. INSTALLATION Grounding Grounding (earthing) is accomplished by mounting the automatic transfer switching equipment in a metal enclosure. The controller s lower left mounting hole must be connected to equipment (enclosure or clean earth) ground via the door stud (with paint removed). Because the controller is mounted on a 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. See Figure plugs for transfer switching device harness connect ground to lower left mounting hole Figure 1-1. Controller grounding (clean earth) and harness connections. The controller must be grounded forproperoperation. Testing Power Conductors Do not connect the power conductors to the transfer switching device until they are tested. Installing power cables in conduit, cable troughs and ceiling-suspended hangers often requires considerable force. The pulling of conductors can damage insulation and stretch or break the conductor s strands. For this reason, after the conductors 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. De energize the conductors before making any power or auxiliary circuitry connections. Place engine generator starting control intheoffposition.makesureengine generator is not in operation. Be sure that Normal and Emergency power connections are in proper phase rotation. 1--1

3 INSTALLATION Table 1-2. Transfer switching device terminals for power conductors (use stranded type conductors). Transfer Switching Device Rating (amps) 30, 70, 100, 150, 200* Maximum Number of Conductors per Terminal Range of Al Cu Conductor Sizes ISO Cross Section (mm 2 ) 1--2 Recommended Tightening Torque 2,5 to 6 11,3 Nm one 10 to 95 use Cu only for 200 amperes 22,6 Nm *200 ampere is limited to 240 volts. Use copper conductors only for 200 amperes. Power connections A Wiring Diagram is furnished with the ASCO 7000 Series ATS. All wiring must be made in accordance with the local codes. Table 1 2 shows the range of conductor sizes and the number of conductors accepted by the transfer switching device terminals and the corresponding tightening torque recommended. Do not run cables in front of the transfer switching device. Conductors can be bundled on the right side of the transfer switching device. Maintain proper electrical clearance between the live metal parts and grounded metal: 13 mm minimum. It is not necessary to remove the barriers from the transfer switching device to install the conductors. If you do remove them, however, be sure to reinstall the barriers carefully. Connect main source and load conductors to clearly marked power terminals on the transfer switching device. Be careful when stripping insulation from the conductors; avoid nicking or ringing the conductor. Remove surface oxides from conductors by cleaning with a wire brush. Follow conductor manufacturer s instructions when aluminum conductor is used. Apply joint compound to conductor, then carefully wipe away excess compound. Tighten the terminals to the torque specified in Table 1 2. Three conductor spacers are included with 100 ampere transfer switching devices. When installing power conductors, run them through the conductor spacers as shown in Figure 1 2. Position the spacers within 38 mm of the power terminals. Three conductor spacers must be located as shown for 100, 150, & 200 amp transfer switching devices. conductor spacers 38 mm approximate conductor spacer Figure 1-2. Required conductor spacers for 100, 150, & 200 amp transfer switching devices. Engine Starting Contacts The engine control contact connections (if used) are located on the transfer switchingdevice. Connect signal wires to appropriate terminals as specified in Table 1 3 and shown in Figure 1 3. Table 1-3. Engine start connections When normal source fails contact closes contact opens ENGINE STARTING CONTACTS ( SHOWN DE ENERGIZED ) TOP STUD MIDDLE STUD BOTTOM STUD TS NR NR Terminals on transfer switching device TB1 and TB2 TB1 and TB3 TB 1 TB 3 TB 2 Figure 1-3. Engine starting contact label and location on left side of transfer switching device. Interconnecting harness Connect the plug in harness (two plugs) from the transfer switching device to left side of the controller, if not already connected. Auxiliary Circuits Connect auxiliary circuit wires (if necessary) to appropriate terminals by referring to the Wiring Diagram.

4 Functional Test INSTALLATION Position of the transfer switch is indicated here The Functional Test consists of three checks: manual operation, voltage checks, and electrical operation. Do these checks in the order presented to avoid damaging the ATS. Read all instructions on the Wiring Diagrams and labels affixed to the ATS. Note the control features that are provided and review their operation before proceeding. weight marked N (normal) and E (emergency) maintenance handle 1 Manual Operation A detachable manual operator handle is provided on the Transfer Switching device for maintenance purposes only. Manual operation of the transfer switching device must be checked before it is operated electrically. Do not manually operate the transfer switching device until both power sources are disconnected: open both circuit breakers. 1. After deenergizing both power sources, open the enclosure door. Locate and the maintenance handle on the left side of the transfer switching device. See Figure Grasp the attached maintenance handle and turn it with thumb and fingers as shown to manually operate it. The maintenance handle turns the opposite direction of the weight. Turn it up or down as shown to manually operate the transfer switching device. It should operate smoothly without any binding. If it does not, check for shipping damage or construction debris. floating weight weight With ALL POWER OFF grasp maintenance handle and turn it quickly with your thumb and fingers. Figure 1-4. Maintenance handle and positions. 3. Return the transfer switching device to the N (normal) position. Now continue to 2 VoltageCheckson next page. 1--3

5 INSTALLATION Automatic Transfer Switch Transfer Switch Connected To Normal Transfer Switch Connected To Emergency Retransfer Delay Bypass Transfer Control Transfer Test HOLD FOR ( 15 SECONDS ) GREEN RED observe these lights Normal Source Accepted Emergency Source Accepted GREEN RED Figure 1-5. Standard controls and indicators. 2 VoltageChecks First check the nameplate on the transfer switching device; the rated voltage must be the same as the normal and emergency power voltages. Verify that the conductors have been correctly connected to the power terminals. Useextremecautionwhenusingameterto measure voltages. Do not touch power terminals; shock, burns, or death could result Perform steps 1 through 6 at the right. Observe the status lights. See Figure 1 5. Black square means the light is on. Whitesquaremeansthelightisoff Close the normal source circuit breaker. The Transfer Switch Connected To Normal and the Normal Source Accepted lights should come on. Use an accurate voltmeter to check phase to phase and phase to neutral voltages present at the transfer switching device normal source terminals. Close the emergency source circuit breaker. (Start generator, if necessary.) The Transfer Switch Connected To Normal & Emergency Source Accepted lights should come on. Use an accurate voltmeter to check phase to phase and phase to neutral voltages present at the transfer switching device emergency source terminals.* * If necessary, adjust the voltage regulator on the generator according to the manufacturer s recommendations. The Automatic Transfer Switching Equipment willrespondonlytotheratedvoltagespecifiedonthe transfer switching device nameplate. Now continue to 3 Electrical Operation on next page. 5 6 Useaphaserotationmeter to check phase rotation of emergency source; it must be the same as the normal source. Shut down the engine generator, if applicable. The Emergency Source Accepted light should go off. Then put the starting control selector switch (on the generator set) in the automatic position. Close enclosure door. U V W 1--4

6 INSTALLATION Automatic Transfer Switch Transfer Switch Connected To Normal Transfer Switch Connected To Emergency Retransfer Delay Bypass Transfer Control Transfer Test HOLD FOR ( 15 SECONDS ) GREEN RED operate this switch observe these lights Normal Source Accepted Emergency Source Accepted GREEN RED Figure 1-6 Standard controls and indicators. 3 Electrical Operation This procedure will check the electrical operation of the Automatic Transfer Switching Equipment. See Figure 1 6. Close the enclosure door first. Transfer Test Both normal and emergency sources must be available and the emergency source generator (if used) must be capable of being started in this procedure. Perform steps 1 through 4 at the right. Observe the status lights. Black square means the light is on. Whitesquaremeansthelightisoff. NOTE: If the inphase monitor feature is enabled, then transfer may not occur immediately after the respective time delays. Transfer will only occur when the phase relationship between sources is correct. NOTE: The operating transfer time of the transfer switching device is 0,17 second maximum, which is measured from the time that power is applied to the operating coil of the transfer switching device until the main contacts close on the alternate source. This completes the Functional Test of the ATS The Transfer Switch Connected To Normal and Normal Source Accepted lights should be on. Turn and hold Transfer Control switch clockwise to Transfer Test until the engine starts and runs (within 15 sec.). Emergency Source Accepted light should come on. Transfer switching device will operate to the Emergency position after Feature 2B time delay. The Transfer Switch Connected To Emergency light should come on and Load Connected to Normal light goes off. Transfer switching device will operate back to Normal position after Feature 3A time delay. For immediate retransfer turn Transfer Control counterclockwise to Retransfer Delay Bypass. The Transfer Switch Connected To Normal light should come on; Transfer Switch Connected to Emergency light should go off. The engine generator will stop after the Feature 2E time delay (unloaded running engine cooldown). The Emergency Source Accepted light should go off. 1--5

7 SECTION 2 TESTING & SERVICE TRANSFER TEST Operate the 7000 Series ATS at least once a month by following the five step Electrical Operation Transfer Test procedure on page 1 5. PREVENTIVE MAINTENANCE Reasonable care in preventive maintenance will ensure high reliability and long life for the 7000 Series ATS. An annual preventive maintenance program is recommended. Deenergize both Normal and Emergency power sources before performing inspections Checklist for Yearly Inspection Hazardous voltage capable of causing shock, burns, or death is used in this equipment. Deenergize both Normal & Emergency power sources before performing inspections j Clean the ATSE enclosure. Brush and vacuum away any excessive dust accumulation. Remove anymoisturewithacleancloth. j Check the transfer switching device contacts. Remove transfer switching device barriers and check the condition of the contacts. Replace contacts when pitted or worn excessively. Reinstall the barriers carefully. j Maintain transfer switching device lubrica tion. If the equipment is subjected to severe dust or abnormal operating conditions, renew factory lubrication on all movements and linkages. Relubricate the solenoid operator if a coil is replaced. Do not use oil. Order lubrication (Castrol EndurexR 4000 lubricant). j Check all conductor connections & retighten them. REPLACEMENT PARTS Replacement parts are available. When ordering parts provide the Serial No., Bill of Material No. (BOM), and Catalog No. from the transfer switching device nameplate. Contact your local ASCO Power Technologies sales office. 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 Do not unplug the controller until steps 1a or 1b is completed. 1. Observe the position of the transfer switching device. a. If the transfer switching device is in the Normal position, place the standby engine starting control in the off position. Then open the emergency source circuit breaker. b. If the transfer switching device is in the Emergency position, open the normal source circuit breaker. Place the engine starting control in the test or run position. 2. Separate the two quick disconnect plugs by squeezing the latches. Do not pull on the harness wires. Reconnecting the Plugs Do not reconnect the controller until steps 1 and 2 are completed. 1. Observe the position of the transfer switching device. a. If the transfer switching device 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 the transfer switching device is in the Emergency position, normal source circuit breaker still should be open. 2. The two harness plugs and sockets are keyed. Carefully align the plugs with the sockets and press straight in until both latches click. 3. Restore the opposite source as follows: a. If the transfer switching device is in the Normal position, place the standby engine starting control in the automatic position. Then close the emergency source circuit breaker. b. If the transfer switching device is in the Emergency position, close the normal source circuit breaker. 2--1

8 TESTING & SERVICE MANUAL LOAD TRANSFER This procedure will manually transfer the load if the controller is disconnected. Do not manually operate the transfer switching device until both power sources are disconnected (all conductors deenergized). 1. Deenergize both the normal and emergency source conductors (remove fuses or open circuit breakers). 2. Use the maintenance handle to manually operate transfer switch to the opposite source. Then remove the handle. See Manual Operation on page If the transfer switching device 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 ATS and review their operation. Refer to any separate drawings and/or instructions 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 terminals of the transfer switching device PROBLEM Engine generator set does not start when the Transfer Control is turned and held in the Transfer Test position or when normal source fails. The transfer switching device does not transfer the load to the emergency source after the engine generator set starts. The transfer switching device does not transfer the load to the normal source when normal returns or when the Transfer Control is released. Gen. does not stop after load retransfer to normal source. Table 2-1. Trouble-Shooting Checks. CHECK IN NUMERICAL SEQUENCE 1 OPERATION 2 GEN-SET 3 VOLTAGE Hold the Transfer Control in the Transfer Test position for 15 seconds, or the outage must be long enough to allow for Feature 1C time delay plus engine cranking and starting. Wait for Feature 2B time delay to time out. Wait for Feature 3A time delay to time out. Wait for Feature 2E time delay to time out. Starting control must be in the automatic position. Batteries must be charged and connected. Check wiring to engine starting contacts. Generator output circuit breaker must be closed. Generator frequency must be at least 95% of nominal (48Hzfora50Hzsystem.)* Starting control must be in the automatic position. * These are factory settings. Refer to Controller User s Guide. Voltmeter should read at least 90% of nominal phase to phase voltage between terminals U2 and W2 (or L2 andl6for2poleswitches)* Voltmeter should read at least 90% of nominal phase to phase voltage between terminalsv1andw1,w1and U1, and U1 and V1 (or L1 and L5 for 2 pole switches). If the problem is isolated to circuits on the controller or the transfer switching device, call your local ASCO Power Technologies sales office. Furnish the Serial No. and Catalog No. from the transfer switching device nameplate. 2--2

9 A auxiliary circuits, 1 2 B barriers, 1 2 C catalog number, inside cover CAUTION, cover cleaning, 2 1 conductor spacers, 1 2 caution, 1 2 terminals, 1 2 connections auxiliary circuits, 1 2 engine starting contacts, 1 2 power, 1 2 controller, cover, 1 1 disconnecting, 2 1 D DANGER, cover E electrical operation, 1 5 enclosures, minimum size, 1 1 engine starting contacts, 1 2 F frequency, generator, 2 2 functional test, 1 3, 1 4, 1 5 G grounding, 1 1 H harness, 1 2 disconnect plugs, 2 1 I INDEX inspection, 2 1 installation, 1 1 interconnecting harness, 1 2 L labels, engine start contacts, 1 2 rating, cover lights, 1 4, 1 5 load connected to emergency, 1 5, 2 1 load connected to normal, 1 4, 2 1 lubrication, 2 1 M maintenance, preventive, 2 1 minimum clearance, live metal to ground, cover, 1 2 minimum size enclosures, 1 1 manual load transfer, 2 2 warning, 2 2 manual operation, 1 3 illustration of, 1 3 warning, 1 3 N nameplate, cover O operation electrical, 1 5 manual, 1 3 illustration of, 1 3 warning, 1 3 sequence of, 2 1 optional accessories P parts, 2 1 phase rotation check, 1 5 power conductors terminals, 1 2 testing, 1 2 tightening torque, 1 2 power connections, 1 2 problem, 2 2 R rating label, cover ratings, cover replacement parts, 2 1 S settings short circuit conditional current, cover protective device, cover test, functional, 1 3, 1 4, 1 5 testing power conductors, 1 2 tightening torque power terminals, 1 2 time delays, 2 1 Transfer Control selector switch Retransfer Delay Bypass, 1 5 Transfer Test, 1 5 transfer test, 1 5 transfer to emergency, 1 5 transfer to normal, 1 5, 2 1 trouble shooting, 2 2 V voltage checks, 1 4 voltage, pickup and dropout settings W WARNING, cover Printed in U.S.A. E ASCO Power Technologies, L.P. 2002