PCS 3140 (1) 27JN05

ASCO 4000 Series Power Control System
Low Voltage Digital Generator Paralleling Control Switchgear
Selection & Application Guide

2005
ASCO Power Technologies, Florham Park, NJ 07932. 1-800-800-ASCO www.ascopower.com

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Table of Contents
I. General Information................................................................................................ 3
II. Primary Applications .............................................................................................. 5
III. Technical Data Overview ....................................................................................... 6
IV. Power Circuit Breakers Standard Options .............................................................. 7
V. Product Selection Basis........................................................................................... 9
VI. Controls Section Module Configurations ............................................................. 17
VII. Distribution Section Module Configurations........................................................ 19
VIII. Generator Paralleling Switchgear line-up configurations..................................... 24
IX. Optional and Standard Accessories ...................................................................... 27
X. Generator Breaker and Main Bus Ampacity Selection......................................... 29
XI. Switchgear Enclosure Type Options..................................................................... 31
XII. Communications Overview .................................................................................. 32
XIII. Dimensional and Shipping Weights Information ................................................. 33
XIV. Product ordering Information (catalog number) ................................................... 38
XV. Product selection and catalog numbering examples ............................................. 40
XVI. Engine Generator Controls Compatibility Information ........................................ 44
XVII. Product Ordering Process Summary..................................................................... 45

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I. General Information
The ASCO 4000 Series Digital Generator Paralleling Control Switchgear is designed,
constructed and tested to provide standardized and advanced multiple-engine generator
power control solutions.
The 4000 Series Power Control System combines user friendly, precision digital control
technology to provide ASCOs engine control and load management expertise.
Series 4000 Power Control System:
Starts, synchronizes, parallels, monitors and protects up to 8 engine generators

from most engine brands for emergency stand-by and prime power applications.
Automatically manages power transfer via downstream Transfer Switches (up to

64).
Communicates with Building Management System and Engine Generator control

Networks via Modbus and/or Ethernet protocols.
Series 4000 Power Control System Offers:
Flexibility and comprehensive functionality based on a wide array of control and

distribution modules as well as optional accessories which can be smoothly
integrated into one paralleling switchgear line up to meet the system
specifications and todays technical expectations.
Quick-ship opportunity.
Lower Installation/Maintenance cost.
Easier Operation.
State of the art Master Control and Monitoring Panel.

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Less floor space.
Standard high level Communication.
Easier expansion in the future.
ASCO Reliability.
This reliable product is supported by ASCOs:
Knowledgeable Sales Force.
Dependable and focused Project Management.
Professional Design and Applications Engineering Team.
Best in the business Field Service 24x7x365 via ASCO Services, Inc.
ASCO is a recognized world leader in Power Control and Power Switching Technology.
This new product along with our ATSs, Communication Systems, Engineering,
dependable Service and Project Management provides our customer with a Total Power
Solution.

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II. Primary Applications
The Series 4000 PCS can be utilized in the following applications:
Industrial
Heavy assembly
Semiconductor
Biotech
Pharmaceutical
Automotive
Petrochemical
Commercial
Large office buildings
Distribution Centers
Large warehouses
Department stores and Malls
Public Buildings
Parking Garages
Hotels and Restaurants
Religious Buildings
Casinos
Large Recreational Centers
Institutional
Sewage and Water treatment
Airports, Highways, Bridges & Tunnels
Subways and Railways
Medical facilities
Banks, Insurance and Brokerages
Universities
Correctional facilities
Health Care
Electrical and Gas Infrastructures
Data Centers

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III. Technical Data Overview
The Switchgear Basic Parameters and Features

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IV. Power Circuit Breakers Standard Options
Generator Paralleling Breakers:
Brand and Type: Siemens WL or Square D NW (ANSI C.37 / UL 1066 Rated).
Interrupting Current Rating: 100kAIC@ 480V.
Circuit Breakers: Draw out, electrically-operated, 120VAC charge and close, 24

VDC shunt trip, rating plug, Bell alarm, 4 auxiliary contacts for open and closed
indication, pushbutton cover, 1 each auxiliary contact for cell position
(Connected/Test/Disconnected), electronic trip unit with LSI overcurrent trip and
Ground-fault Alarm (LSIA) functions.
The following electronic trip units and their accessories can be used for the 4000 Series PCS
Switchgear:
CB Manufacturer, CB type Trip unit

Siemens, WL ETU 745 with fully adjustable LSI trip
and ground-fault alarm only functions,
alphanumeric display, power metering,
Modbus (com16) communication
modules plus neutral CT for Ground-
fault protection.
Square D, NW MICROLOGIC 5.0P with fully
adjustable LSI trip and ground-fault
alarm only functions, including power
metering, alphanumeric display,
Modbus RTU communication plus
neutral CT for Ground-fault protection.

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Distribution Feeder Breakers:
Brand and Type: Siemens WL or Square D NW (ANSI C.37/UL1066 Rated).
Interrupting Current Rating: 100kAIC @ 480V.
Circuit Breakers: Drawout, manually operated, rating plug, 4 auxiliary contacts for
open and closed indication, electronic trip unit with LSIG trip or LSI overcurrent
trip and Ground-fault Alarm (LSIA) functions.
The following electronic trip units and their accessories can be used for the 4000 Series PCS
Switchgear:
CB Manufacturer, CB type Trip unit

Siemens, WL ETU 745 with fully adjustable LSI trip
unit plus ground-fault trip or alarm
functions, alphanumeric display, power
metering and Modbus (com16)
communication modules and neutral
CT for Ground-fault protection.
Square D, NW MICROLOGIC 6.0P with fully
adjustable LSI trip and ground-fault trip
or alarm functions including power
metering, alphanumeric display,
Modbus RTU communication and
neutral CT for Ground-fault protection.
General Note:
LSI adjustable overcurrent trip only (with disabled Ground-fault alarm function)
can be used for Feeder Circuit Breakers within ETU-745 or Micrologic 6.0P Trip
units if required.

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V. Product Selection Basis
The typical single-line diagram:
The ASCO 4000 Series Digital Generator Paralleling Control Switchgear is designed for prime power and
standby multiple engine generator paralleling operational modes.
An electrical single-line diagram of a typical emergency standby power system is shown in Fig.1.
Fig.1. Electrical single-line diagram of the Emergency Standby Multiple Engine Generator
paralleling system (Where: 52G1-52G4 are Engine Generators; 52F1-52F4 are Distribution Circuit
Breakers; ATSs are downstream Automatic Transfer Switches).
The typical sequence of system operation:
A. The ASCO 4000 Series Digital Paralleling Control System is designed to start and
parallel all engine generator sets, upon receipt of a signal from an automatic transfer
switch (es) that emergency power is required.
B. Normal Mode
Whenever the individual engine generator control switches are placed in their automatic
position, the engine generator system is on standby operation mode in readiness for
automatic starting and synchronization in the event of the utility (normal) power failure
signal.

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C. Emergency Mode
In the event of the utility power failure, all generators automatically start and come up to
speed. The first generator set to achieve 90% of nominal voltage and frequency shall be
connected to the bus by closing its Circuit Breaker (52G). Interlocks permit the
connection of only one engine generator to the dead (deenergized) generator bus in the
event of simultaneous generator relay operation. Upon sensing the availability of
emergency power, the priority-1 load block* will be allowed to transfer their loads to the
emergency bus, either through direct control or through a permissive signal to the
automatic transfer switches (if equipped).
Note 1: Loads are divided (grouped) to blocks by their priority level with the number of
load blocks which are equal to number of engine generator sets within one isolated bus
system. The load blocks are usually sized such that the connectable load of each block is
not greater than the kW rating of the generator set connected.
Each synchronizer will automatically adjust the frequency of the on-coming generator(s)
to synchronize with the bus. After synchronism is achieved, the on-coming generator is
paralleled to the bus. When the second generators circuit breaker (52G) is closed the
priority-2 load block will be allowed to transfer their loads to the emergency bus. As each
generator parallels to the bus, another block of load is allowed to be added, until all
generators and all loads are online.
Upon sensing that normal utility power has been restored to acceptable limits, a
sequence shall begin to transfer the load back to the utility source. The re-transfer shall
be initiated after the retransfer to utility time delay has expired (adjustable at each ATS
from 0 minute to 30 minutes) allowing an open transition transfer return to utility. After all
the transfer switches have re-transferred their loads to the normal source, the generator
circuit breakers are simultaneously opened and the engine generators run for an
adjustable no-load cool-down period of zero to thirty minutes; factory set at 5-minutes.
The controls are released and the generators are placed in readiness for the next power
failure.
If a generator fails while operating in the automatic mode, it is disconnected from the bus
and shutdown. Audible and visual alarms will be activated to indicate the condition. If
Bus Load Optimization* is not activated, the lowest priority feeder loads (as
programmed by the operator via the Touch Screen) are signaled to shed so as to leave
one block of load online per generator.
A push-button permits override of the load-shed circuits for supervised operation (one for
each priority except priority 1). By pressing the Load Shed Bypass/Reset push-
button**, the system will transfer the priority-# load block to the emergency bus. By
pressing the Load Shed Bypass/Reset push-button a second time, the ENTIRE priority-#
load block will shed. Indication from the Touch Screen will annunciate the status of each
Priority load block, indicating if it is shed or manually bypassed. If the operator
inadvertently bypasses the load shed and overloads the Generator(s) resulting in a bus
under-frequency, all manually bypassed loads will be automatically shed along with
blocks of load such that the remaining load blocks shall be one less than the number of
generators remaining on the bus. The Bus Underfrequency condition will be
indicated.

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Note 2: Bus Optimization as described below under (E) is a standard control feature that
continuously monitors and evaluates the generator demand process and allows the
loading of the actual bus to the excess generator set kW bus capacity level (also known
as a Headroom) based on their priorities.
Note 3: Loads that have been block shed can be manually re-added using the priority- #
Load Shed Bypass/Reset push-button located on the Master control section Touch
Screen.
If the online load exceeds 100% of rated generator capacity, loads will be stepped off in
reverse priority at one second intervals. The Bus Overload indication will light to indicate
that the bus is overloaded. This condition will automatically reset as the overload is
corrected. Once the online load no longer exceeds the generating capacity, step
shedding will cease and the system will continue to power the remaining loads.
Indicators will annunciate the status of each Priority load block, indicating if any loads in
that block are shed or if the load block is manually bypassed. If the operator bypasses
the load shed to bring the shed loads back online, and the online load exceeds 100% of
the capacity again, the system will again step loads off in reverse priority at one second
intervals. This condition will automatically reset as the overload is corrected. This is done
in an attempt to prevent an Underfrequency condition, thereby preventing the entire load
block from being shed.
Note 4: Individual ATS loads shall step on the Emergency bus based on their Step Add
Time Delay values; these Time Delays are adjustable by the operator via the Touch
Screen OIP and are Factory set at zero.
D. Generator Load Demand Control
After all generators sets have been paralleled to the bus and all loads are connected, a
stabilization time delay (0 - 900 seconds) factory sets at 60 seconds will be initiated while
a Load Demand Mode* indication flashes. At the expiration of the time delay period, the
system will operate in a load demand mode at which time the mode indication remains
illuminated. The load demand logic controls the number of generating sets on the bus,
such that the on-line reserve capacity of the bus is not less than 10%, nor more than
110%, of the capacity of a single generator set.
Note 1: Load Demand is a standard control feature, which actively monitors loading on
the generators and determines the number of engine generator sets on the bus required
to support the facilitys actual load without overloading or subjecting generators to the
adverse effects of under loading.
Upon sensing that the connected load has decreased the reserve capacity to 10% or less
(field adjustable from 1-29% displayed as 81-99% of Generator rating), a 10 second time
delay is initiated and a Gen Start TD Active indication starts flashing. This time delay
will be field adjustable from 0 - 300 seconds. If the reserve capacity stays below 10% for
the duration of the 10-second time delay, the controls will initiate the starting and
paralleling of the next set in sequence. If, during the time delay period, the reserve
capacity decreased to 0 or less (signifying bus overload), the time delay will be bypassed
and the next set in sequence will be immediately started and paralleled. At the same
time, loads shall begin to shed in reverse order every second until the online load does
not exceed 100% of rated online generator capacity.

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If at any time, the online load exceeds 100% of available rated capacity, the system will
remove the last load that was added. If the online load does not decrease to less than
100% of rated capacity, loads will be shed one at a time, every second in reverse order
until the overload is corrected. The Bus Overload indication will light indicating that the
bus is overloaded and will automatically reset as the overload is corrected.
If the online load exceeds 120% of capacity, signals will be given to shed load such that
the connected priority blocks of load are reduced to equal the number of engine
generator sets on line. When the next set is paralleled to the bus, the shed load will be
reconnected and all controls automatically reset. If the next generator set does not come
online, the system will not automatically reset. The Bus Overload indication will blink
indicating that the bus was overloaded and will stay on solid (not blinking) if the bus
remains overloaded. Loads will not be added to the bus while the Bus Overload
indication is active (blinking or solid). Once the operator acknowledges the Bus
Overload indication by activating the Alarm Reset pushbutton, then the loads will be re-
added as capacity allows (in Bus Optimization mode).
If while operating in the load demand mode, an engine-generator set malfunction occurs,
the affected set will be removed from the bus. If the remaining loads online exceed 100%
of the remaining online generator capacity, the loads will step shed as described in the
previous paragraph. If the load does not exceed the online capacity, no loads will shed.
Generator Load Demand mode will momentarily reset and all generators will start.
Upon sensing that the on-line reserve capacity has increased to 120% or more (field
adjustable from 120-140 % displayed as 80-60% of Generator rating), a 10 second
(adjustable 0-300 seconds) time delay will be initiated and a Gen Stop TD Active
indication will start flashing. If the reserve capacity stays above 110% for the duration of
the time delay, the circuit breaker of the last set that went on line will be opened. The
engine will run for its cool down period, then shutdown.
E. Bus Optimization*
Each ATS load should be programmed with a priority value load**. A loads priority value
is a 3-digit number. The most significant digit refers to the loads block priority value (i.e.
201 => priority 2 load block, whereas 118 => priority 1 load block). The two lower
significant digits refer to the loads sub-priority value, or load step priority (i.e. 201 =>
priority 2 block, step 01; 118 => priority 1 block, step 18). Valid priority values are 1 8
while valid sub-priority values are 1 - 99. Therefore, valid three digit priority values are
101 - 899. Note: priority 1 loads (101 - 199) have insignificant sub-priority values since
priority 1 loads are never optimized, also 3 digit priority values of 200, 300 and 400, etc.
are not valid priority numbers. However, because of the dynamic nature of the adjustable
load priorities, all loads, even priority 1 needs to have sub-priority step values.
Note 1: * This feature can be activated by pressing a soft switch on the Master OIP in the
on position.
Note 2: * Field accessible and adjustable via the Master OIP Touch Screen.

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With the Bus Optimization soft switch in the "on" position during emergency mode and
with loads shed (loads requiring power), after a stabilization time delay (Bus Opt stable
delay) the optimization feature is activated and a Bus Optimize Active indication
illuminates. The Bus Optimize Active indication flashes through the duration of the
stabilization time delay. At this time, the Bus Optimization loading control will determine if
there is enough room to add the next load by checking the pre-set Load Value (field
adjustable, accessible via the Touch Screen on the master door) assigned to the first
sub-priority load (field adjustable, accessible via the Touch Screen on the master door)
within the highest priority block that is shed and compare it to the excess generator bus
capacity (also known as Headroom).
Should a Priority Block fail to be added to the bus while operating in the Emergency
Mode, loads may be added manually by the operator as described or automatically
through "Bus Optimization". This feature is provided to re-add shed loads one at a time
based on predetermined kW loading values up to the capacity of the on-line power.
If it is determined that the load can be added without overloading the bus, the load is
signaled to add. The real time kW demand is constantly measured and the next sub-
priority load is evaluated. Loads are evaluated at a preset time interval defined via the
operator interface (Bus Opt Step Time). When the bus has been loaded to a level such
that the next load would exceed 95% of bus capacity, the Next Load Exceeds Headroom
indication will activate and load adding will pause. The system will continuously monitor
the generator demand and evaluate if the next load step can fit on the bus. If building
demand decreases and the next load can fit (for the duration of the step time delay), the
system will add it and continue the evaluation process until as many loads as possible
are added to the bus.
If the load has already been added, there is no reason to compare it to see if it will fit; the
program will skip to the next available load.
If the load is not calling for an engine start, it will be skipped.
If at any time, the online load exceeds 100% of available rated capacity, the system will
remove the last load that was added. If the online load does not decrease to less than
100% of rated capacity, loads will be shed one at a time, every second in reverse order
until the overload is corrected. The Bus Overload indication will light indicating that the
bus is overloaded and will automatically reset as the overload is corrected. In this event,
the system will begin a 300 second stabilization delay time (fixed) before evaluating
another load to be added to the bus.
If a generator fails, it will be removed from the bus. If the remaining loads online exceed
100% of the remaining online generator capacity, the loads will step shed as described in
the previous paragraph. If the load does not exceed the online capacity, no loads will be
shed. The Bus Overload indication will activate indicating that the bus is overloaded and
will automatically reset as the overload is corrected.
If the connected load exceeds 120% of online capacity, all optimized loads will
immediately shed in an attempt to avoid an Underfrequency event. A Bus Overload
indication will activate and latch indicating that the bus is overloaded. The system will
NOT attempt to re-add loads until the Bus Overload indication is acknowledged by
pressing the Alarm Reset pushbutton.

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In the event of a bus Under-frequency, all optimized loads will be shed as well as any
additional unsupported blocks of load. Load blocks will be shed such that the remaining
load blocks shall be one less than the number of generators remaining on the bus. The
Bus Underfrequency condition will be indicated.
No loads can be manually added while an Underfrequency indication is active. The

operator must acknowledge the alarm by pressing the Alarm Reset push-button. If the
Bus Opt switch remains on, the stabilization timer will then re-initiate and the process of
stepping on the loads is repeated (after the bus Underfrequency has been reset).
If a load block is manually bypassed, all loads in that block will add, subject to their
individual step timers. If they were already optimized on, they will remain on. If the load
block is then manually shed, all loads in that load block will shed.
Once all loads in a priority load block have been added to the bus, the LOAD SHED
indication for the associated priority will turn off.
F. Generator No Load Test
A system test switch is provided in the master control Touch Screen to limit access to
authorized persons only. Operation of this switch will initiate an automatic system
operation as if an ATS Accessory 7 (engine start signal) from any of the automatic
transfer switches had operated. However, unless a normal source outage occurs during
this mode of operation, the transfer switches will not transfer its load to the emergency
bus. To terminate this test, the system test switch is reset to initiate a normal system
shutdown sequence.
G. Single Engine Test
Each engine can be started for test purposes by placing its generator control switch to
the test off-line position. In this mode, the generator circuit breaker will remain open.
Should a normal source outage occur during this mode of operation, the breaker will
close and the remaining units will be started. Upon restoration of normal power, the
system will revert to single engine test mode until the switch is returned to the
AUTOMATIC position. For on-line test, placing of the generator control switch to the test
on-line position will present a similar operation except that the generator breaker will
close when the generator achieves nominal voltage and frequency.

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H. ATS Hand Off Auto (H-O-A) Controls
The system shall be capable of H-O-A control for the ATSs provided the ATSs are
equipped with the load shed relay (Acc 30B signal). During Emergency Mode any ATS
can be individually added to the bus or shed via these controls. The operator can select
the ATS to be added by placing it in the HAND position. When placed in the HAND
position, the load shed relay (Acc 30B signal) at the ATS will be energized (if not
already energized via normal load control), allowing the ATS to transfer to Emergency. If
the operator inadvertently adds too much load, causing a Bus Underfrequency condition,
all HAND switches will be reset back to AUTO and the system will revert to Normal load
control.
When the ATS is placed back into the AUTO position, the ATS will function per normal
load control. Any switch that does not have an Acc 30B picked up by normal load control
(i.e. the switch is in Load Shed) will be immediately transferred back to Normal.
When an ATS first calls for an engine start, the system will immediately begin emergency
mode. Any ATS left in the HAND position will be returned to AUTO and normal load
control will commence.
If an ATS is placed in the OFF position, it will NEVER transfer to emergency. Any ATS
left in the OFF position will not automatically return to AUTO at the start of emergency
mode. An ATS left in the OFF position can only be taken out of OFF via the HOA switch.
If the system is running in emergency mode, placing an ATS in the OFF position will
immediately shed it from the emergency source.

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The System Selection basic criteria and considerations:

The ASCO 4000 Series paralleling Switchgear is based on a modular design principle that can be
configured in many ways by combining different section module types as well as optional standard
accessories.
All section modules and optional accessories, described below, can be selected through the ASCO
Catalog number, which will allow the smooth integration of selected items into one paralleling Switchgear
lineup.
The 4000 Series PCS is designed to fill the packaged power market segment, as well as, Industrial and
Commercial facilities. However, this system can be used in many other applications where a quick
delivery, a lower cost, a smaller foot print along with standard options/features will attract the customer.
In this case, ASCO will require that complete exception be taken to the existing Specifications in order to
provide this standard product per ASCOs 4000 Series PCS suggested Specification (ASCO Info Web,
Publication No. 3135).
The following specific design parameters of the 4000 Series standard PCS product must be
considered during the system selection process:
Load Control - The 4000 Series PCS will include standard manually operated
distribution circuit breakers with the load control scheme via ATSs ( 32 standard
and 64 optional) only. All existing and/or new ATSs, located downstream of 4000
Series PCS shall be equipped with accessory 7 (engine start contacts) and 30B
(load shed relays).
Future Generator Controls if there is a requirement for a future engine

generator, the controls for the future generator will be provided along with the
draw out circuit breaker cell as a standard package.
Bus duct risers or provisions are not provided in this product offering. (Included
in the 7000 Series PCS options).
Governor (speed control) interface and voltage regulator must be mounted

by others outside of the ASCO gear due to standardization and reduced footprint.
Remote Annunciation Panel can be provided as a second (duplicate) Master

Operator Interface Panel type with virtual monitoring capability (no control) or as
an LED Status Panel type, both are optional accessories.
Graphic Mimic Display (LCD display or mosaic tile type) is not included in
the ASCO 4000 Series options.

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VI. Controls Section Module Configurations

The following standard control modules can be used for the Switchgear line-up:
Master Control Module:

Includes 12 color touch screen type Operator Interface Panel
(OIP) for control and monitoring.
Controls up to 8 Engine Generators.
Manages the power transfer via up to 64 ATSs.
Main bus continuous Current: 3000A, 6000A, or 10000A.
Without main bus (optional, module selection code -MX).
Dimensions: (32-36)W x 91H x (72-84)D.
Module selection code MB or MX.
Optional Capability to add Master PLC Redundancy.
Master / Single Generator Breaker and Control Module:
Combines the Master Controls with a single

Generator Control and Generator Breaker.
Controls up to 8 Engine Generators.
Manages the power transfer via up to 64 ATSs.
Compact solution for odd quantities of Generators.
Module selection code MG.
Redundancy is not available.
The Master / Single Generator section must be the LAST generator in the
system. For example Generator 3 in a 3 engine generator system,
Generator 5 in a 5 engine generator system etc.

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Single Generator Breaker and Control Module:
Starts, synchronizes and parallels to the main bus
one Engine Generator set.
Can be provided with 12 color touch screen OIT (optional).
Main bus continuo us Current: 3000A, 6000A, or 10000A.
Suitable for odd quantities of generators to be paralleled.
Module Selection Code -1G.
If mixing Single and Dual Generator Sections in one line-up, the Single Generator
Section must be the LAST Generator.
Dual Generator Breaker and Control Module:
Starts, synchronizes and parallels to the main bus
two Engine Generator sets.
Can be provided with 12 color touch screen OIT (optional).
Compact and cost saving solution for multiple engine
generator paralleling switchgear.
Module Selection Code -2G.

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VII. Distribution Section Module Configurations
General Notes:
UL 1558 construction and UL1558 label.
NEMA 1 type enclosure.
NEMA 3R type enclosure (for up to 3000A main bus only).
Circuit Breaker: Siemens WL or Square D NW (ANSI C.37/UL1066. Rated),

drawout, manually operated, 100kAIC @ 480V (600V class).
Circuit Breaker electronic trip units: with LSIG trip or LSI trip and Ground-fault
Alarm only (LSIA) functions.
Power Metering and Modbus RTU Communication Capability.

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Standard distribution modules for the Paralleling Switchgear line-up:
Distribution Section Module with 3000A Main Bus
General Notes:
Dimensions: 26W x 91H x 72D (except notes, see below).
Enclosure paint: Light Gray, ANSI 61.
Sum of the Trip Amp sizes for Circuit Breakers stacked in one Section shall not
exceed 3000A.
Maximum Number & Frame Amp size of

Code
Breakers and/or Cells in one Section
A03 4 x 800AF
B03 3 x 800AF and 1 x 1600AF
C03 2 x 800AF and 2 x 1600AF
D03 1 x 800AF and 3 x 1600AF
E03 3 x 800AF and 1 x 2000AF
Note 1:
Dimensions: approx. 30W x 96H x 84D for NEMA 3R type enclosure.
Note 2:
For Panel Board type Distribution (including more than 4 Molded Case Feeder
Breakers only) consult factory for application guidelines and quotations.

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Standard distribution modules for the Paralleling Switchgear

Line-up:

Code
A06 4 x 800AF
B06 3 x 800AF and 1 x 1600AF
C06 2 x 800AF and 2 x 1600AF
D06 1 x 800AF and 3 x 1600AF
E06 3 x 800AF and 1 x 2000AF
F06 4 x 1600AF
G06 1 x 800AF, 1 x 1600AF and 2 x 2000AF
H06 1 x 800AF, 2 x 1600AF and 1 x 2000AF
I06* 1 x 800AF, 1 x 1600AF and 1 x 3200AF
General Notes:
exceed 6000A.
Note 1*:
Section with 3200AF Breaker shall be 32 wide.
Note 2:
For Panel Board type Distribution (including more than four Molded Case Feeder
Breakers) consult factory for application guidelines and quotations.

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Standard distribution modules for the Paralleling Switchgear line-up:

Code
A10 4 x 800AF
B10 3 x 800AF and 1 x 1600AF
C10 2 x 800AF and 2 x 1600AF
D10 3 x 800AF and 1x 1600AF
E10 3 x 800AF and 1 x 2000AF
F10 4 x 1600AF
G10 1 x 800AF, 1 x 1600AF and 2 x 2000AF
H10 1 x 800AF, 2 x 1600AF and 1 x 2000AF
I10* 1 x 800AF, 1 x 1600AF and 1 x 3200AF
J10* 1 x 800AF, 1 x 2000AF and 1 x 3200AF
K10* 2 x 800AF and 1 x 3200AF
L10** 2 x 800AF and 1 x 4000AF

M10** 1 x 800AF, 1 x 1600AF and 1 x 4000AF
N10** 1 x 5000AF
General Notes:
exceed 6000A.

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Note 1:
Sections with 3200AF Breaker are 32 wide.
Note 2:
*Sections with 4000AF or 5000AF Breaker are 36 wide.
Note 3:
**A Switchgear line-up consisting of a 5000AF Breaker will not be UL labeled.

Note 4:
For Panel Board type Distribution (including more than four Molded Case Feeder
Breakers) consult factory for application guidelines and quotations.

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VIII. Generator Paralleling Switchgear line-up configurations
The typical elevation / plan view of a Four Engine Generator

Paralleling Switchgear line-up with one Distribution Section
(Four-stack Feeder Breakers).
Type A:
Where:
MX - Master Control Section without the Main Bus.
2G - Dual Generator Breakers and Control Section.
D - Distribution Section.
52G1, 52G2, 52G3 and 52G4 Generator paralleling Circuit Breakers.
52F1, 52F2, 52F3 and 52F4 Distribution Feeder Circuit Breakers.

6/21/2005 24 Publication 3140
The typical elevation / plan view of a Five Engine Generator

Paralleling Switchgear line-up with two Distribution Sections on
both ends of the main bus (split bus load).
Type B:
Where:
MG Master/Single Generator Breaker and Control Section with Bus.
2G - Dual Generator Breakers and Control Section.
D - Distribution Section.
52G1 - 52G5 Generator paralleling Circuit Breakers.
52F1 - 52F8 Distribution Feeder Circuit Breakers.

6/21/2005 25 Publication 3140
The typical elevation/one-line block diagram of Four Engine

Generator Paralleling Switchgear without Distribution Sections in
the line-up utilizing standard Accessories L03/L06 and T03/T06
(see accessory description in the next paragraph).
Type C:
MASTER DUAL GEN DUAL GEN TRANSITION

CONTROLS
CB CB
TS
12"
CS CS CS
Acc: L03/
L06 CB CB
32" 32"-36" 32"-36" 26"-32"

MODULE MODULE MODULE MODULE
MB 2G 2G ACC: T03/
T06
ASCO 4000 SERIES DIGITAL PCS WITHOUT DISTRIBUTION IN LINE-UP

6/21/2005 26 Publication 3140
IX. Optional and Standard Accessories
Optional Accessories:
Table 1: List of required Accessories for Stand Alone Distribution
Note: Lugs are mechanical set screw type, one hole mounting,
scaled to appropriate size.
Code Accessory description

L03 3000A Lugs in Master Control Section
L06 6000A Lugs in Master Control Section
T03 Transition Section with 3000A Lugs, bussed (26Wide)
T06 Transition Section with 6000A Lugs, bussed (32Wide)
TRANSITION
MODULE
T03 / T06

6/21/2005 27 Publication 3140
Standard Accessories:
Table 2. Select Standard Distribution Section accessory codes from Table 2 below (see module
descriptions on pages 19, 20 and 21):
Accessory Codes:
@ 3000A Main Bus @ 6000A Main Bus @ 10 000A Main Bus
A03 A06 A10; J10
B03 B06 B10; K10
C03 C06 C10; L10
D03 D06 D10; M10
E03 E06 E10 ; N10
F06 F10;
G06 G10
H06 H10
I06 I10
Optional Accessories:
Table 3. Select Optional Accessories from Table 3 below:
Code Accessory description

RMP Redundant Master Control PLC
GTS Touch Screen Panel for Generator Controls (color, 12 inch)
ERD Ethernet Remote Diagnostic (IP connection type).
ADM Analog Remote Diagnostic Modem, industrial grade.
64A Load Control module for 64 Automatic Transfer Switches (ATSs)
RAT Remote Annunciation Panel, Touch Screen type, consisting of
one 12 inch color touch screen, which fully duplicates the Master
OIP to provide the system and individual generators remote
status, alarm and display functions. Includes alarm horn with
silencing push-button. Approximate dimensions: 18W x 18H x
4D in NEMA 1 enclosure. (Ethernet / EGD).
RAL Remote Annunciation Panel, LED type, consisting of discrete
LED Status tiles. (Ethernet / EGD).
CL1 Compression type Lugs, two hole mounting, long barrel.
BTK Breaker Test Kit, Portable/Handheld.
BLD Breaker Lifting Device, Portable.

6/21/2005 28 Publication 3140
X. Generator Breaker and Main Bus Ampacity Selection
Table 1: PCS Switchgear Generator Breaker and Main Bus Ampacity @ 480Y/277VAC,
0.8 pF.
Single EG
Breaker Breaker Trip, Main Bus, A @ Main Bus, A Main Bus, A Main Bus, A Main Bus, A @ Main Bus,A
Frame, A A* 2EG's @ 3EG's @ 4EG's @ 5EG's 6EG's @ 7-8EG's
SIZE, kW
230-500 800 400-800 3000 3000 3000 6000/3000(s) 6000 6000
350-650 1600 700-1000 3000 6000/3000(s) 6000 6000 6000 10000
450-800 1600 800-1200 3000 6000 6000 6000 6000(s) 10000
550-1000 1600 900-1500 3000 6000 6000 10000 6000(s) 10000(s)
650-1250 2000 1000-2000 6000/3000(s) 6000 10000 10000 10000(s) 10000(s)

1000-1500 3200 1500-2500 6000/3000(s) 10000 10000 10000(s) 10000(s) 10000(s)
1250-2000 3200 2000-3000 6000/3000(s) 10000 10000 10000(s) 10000(s) 10000(s)
1500-2500 4000 2500-4000 10000/6000(s) 10000 10000 10000(s) 10000(s) 10000(s)
0.8 pF.
Main
Single EG Breaker Breaker Main Bus, A Main Bus, A Main Bus, A Main Bus, A Main Bus,
Bus,A @ 7-
size, kW Frame, A Trip, A* @ 2EG's @ 3EG's @ 4EG's @ 5EG's A @ 6EG's
8EG's
230-400 800 450-800 3000 3000 3000 6000 6000 6000

450-800 1600 900-1600 3000 6000/3000(s) 6000 10000/6000(s) 6000 10000(s)
600-1000 2000 1200-2000 6000/3000(s) 6000 10000/6000s 10000 6000(s) 10000(s)
800-1500 3200 1600-3000 6000/3000(s) 10000/6000(s) 6000s 10000(s) 10000(s) N/A
1000-2000 4000 2000-4000 10000/6000(s) 10000 10000(s) 10000(s) N/A N/A

1250-2500 5000 2500-5000 10000 10000(s) 10000(s) N/A N/A N/A

6/21/2005 29 Publication 3140
0.8 pF.
Single EG Breaker Breaker Trip, Main Bus, A @ Main Bus, A @ Main Bus, A Main Bus, A @ Main Bus, A Main Bus,A
size, kW Frame, A A* 2EG's 3EG's @ 4EG's 5EG's @ 6EG's @ 7-8EG's
230-400 1600 800-1600 3000 6000 6000 6000s 10000 10000(s)
450-550 2000 1600-2000 6000/3000(s) 6000/3000(s) 6000(s) 10000/6000(s) 10000 10000(s)
600-850 3200 2200-3000 6000/3000(s) 10000/6000(s) 6000(s) 10000(s) 10000(s) N/A
900-1150 4000 1600-3000 10000/6000(s) 6000(s) 10000(s) 10000(s) N/A N/A
1200-1400 5000 4200-5000 10000/6000(s) 10000(s) 10000(s) N/A N/A N/A
General Notes:
Generator Circuit Breaker adjustable trip settings shall be within 40-100% of CB

Frame Amp size (A).
Symbol (s) is for an alternate Main Bus Amp when bus load is split (located on
both ends of the main bus).
For example: If selected from the tables above Value is 10000/6000(s)
your main bus Amp size shall be 10000A or 6000A when bus load is split.
For other system Nominal Voltages (indicated within ASCOs 4000 Series PCS
Catalog) and/or single EG kW sizes, contact factory for application guidelines
related to this paragraph.

6/21/2005 30 Publication 3140
XI. Switchgear Enclosure Type Options
Selection
Enclosure type
Code
C1 NEMA 1 (Indoor)
F1 NEMA 3R (Outdoor Non Walk-in)
Note:
NEMA 3R (outdoor Non walk-in) type enclosure is available for the PCS
Switchgear with 3000A rated main bus only. For main bus Amp ratings more than
3000A contact factory for outdoor housing (walk-in) pricing information (Florham
Park, NJ).

6/21/2005 31 Publication 3140
XII. Communications Overview
The 4000 Series PCS supports the following communication protocols:
Serial Modbus RTU ( Master/Slave RS485/232 ports)

Ethernet (100-base-T supporting Modbus/TCP Slave)
Typical Applications:
The 4000 Series PCS has the capability to interface with ASCII protocol (for
Caterpillar EG sets) and communicate directly with many engine generator
set manufacturers via serial based protocols.
The 4000 Series PCS can be simply connected to a Local Area Network (LAN) via
Ethernet to allow monitoring of the transfer switches, engine points and parameters
properly equipped and additional third party devices.
The 4000 Series PCS can be interfaced with an existing and/or new Building
Management System (BMS), via Serial RS485 Modbus Slave and/or Ethernet
Modbus TCP Slave communication protocols for remote monitoring purposes only.
The 4000 Series PCS can be interfaced with ASCOs existing custom SCADA/VPi
package via Ethernet.
Note: ASCOs standard SCADA/Power Quest Vpi32.15 system, due to absence of the
Modbus Serial & TCP/IP Interface is not compatible with 4000 Series PCS. ASCO is
developing a standard SCADA/Power Quest offering for the 4000 Series PCS, which is
coming soon.

6/21/2005 32 Publication 3140
XIII. Dimensional and Shipping Weights Information

6/21/2005 33 Publication 3140
Dimensional and Shipping Weights Information
3000A Main Bus, NEMA 1 type enclosure

Control Section Weights, Shown in pounds (lbs)
MX MB MG (32W) MG (36W) 2G (32W) 2G (36W)
1400 1800 2150 N/A 2600 N/A

MX MB MG (32W) MG (36W) 2G (32W) 2G (36W)
1400 2100 2500 3450 3100 3900

MX MB MG (32W) MG (36W) 2G (32W) 2G (36W)
1400 2800 3400 4450 4100 4950

6/21/2005 34 Publication 3140
Plan view:

6/21/2005 35 Publication 3140
Right side view:
3000A Main Bus, NEMA 1 type enclosure:

Distribution Section Weights, Shown in pounds (lbs)
One Two Three Four 2000AF

One 800-
800- 800- 800- 800- and
1600AF
1600AF 1600AF 1600AF 1600AF 3x800AF
CB Cell
CB CBs CBs CBs
1900 2300 2700 3100 3300 1500

6/21/2005 36 Publication 3140
6000A Main Bus, NEMA 1 type enclosure:

One Two Three

800- 800- 800- 2x2000AF, 2000AF, 3200AF,
2000AF 2000AF 2000AF 1600AF 2x1600AF 1600AF
CB CBs CBs and 800AF and 800AF and 800AF
2350 2750 3150 3550 3500 3350
10,000A Main Bus, NEMA 1 type enclosure:

One Two Three

800- 800- 800- 2x2000AF, 3200AF 4000AF,
2000AF 2000AF 2000AF 1600AF and 1600AF,
CB CB CB and 800AF 2x1600AF and 800AF
3100 3500 3900 4300 4300 4500
General notes:
Weights shown approximately in pounds (lbs) for shipping document evaluation

purpose only.
Add 1200 lbs for NEMA 3R type enclosure with 3000A main bus.
Weights shown do not include weight of circuit breaker removable element.
Up to four vertical sections, including transition section (accessory T03 or T06) can
be shipped together as a unit (maximum shipping split length is 140 in.).

6/21/2005 37 Publication 3140
XIV. Product ordering Information (catalog number)

6/21/2005 38 Publication 3140
Product ordering Information (catalog number)
Table 1 below includes a list of the minimum information* required before selecting the
4000 Series PCS and creating the product catalog number.
Table 1
System Parameters & Options Typical example
System Operation Mode Standby
Nominal Voltage, V 480Y / 277VAC 3P,4W

for 3 phase, 4 wire AC system
Frequency, Hz 60
Total Number of Paralleling Engine existing + new + future

Generators: 0+3+1
kW size of each Engine Generator 2x1000kW; 1 x 900kW and 1x1000 kW -

future
Enclosure type NEMA 1
Optional PCS Features (provide a list of Accessories: GTS; 64A; CL1 (per
required features within ASCOs 4000 description in this Guide)
Series Suggested Specification)
Is distribution required to be integrated Yes
in the Switchgear?
[Amp Frame/Amp Trip] 1 x 2000AF/2000AT;

1 x1600AF/1600AT,
1 x1600AF/1200AF;
3 x 800AF/800AT and 1 x 800AF/400AT
Note:
*Single-line diagram of the required system is desirable.

6/21/2005 39 Publication 3140
XV. Product selection and catalog numbering examples
Example 1: You have received a customer request to configure and propose the 4000 Series
PCS Switchgear with Distribution Sections in the lined-up.
Step 1: The System Info
The following minimum technical information (per Table 1 on page 39) you have to define
from an electrical single- line diagram and system description:
Standby Power system

480Y/277VAC, 3 phase, 4wire
60 Hz
3 new (2x1000kW and 1x 900kW ) plus one future (1 x1000kW Engine
Generators to be paralleled
Switchgear enclosure type - NEMA1
Optional accessories: GTS; 64A; CL1
Distribution sections shall be incorporated (lined up) into the Switchgear
Feeder Breakers: 1x2000AF/2000AT;
1 x1600AF/1600AF, 1x1600AF/1200AF, 3x800AF/800AT and
1 x 800AF/400AT (total of 7)
Based on information you have obtained, and by using catalog numbering system shown on page 38,
start with the following six symbols for the system catalog number:
4LSN64
Step 2: Generator Breaker and Main Bus Ampacity Selection
By using the Table 1 on page 29, at 480VAC, and for a single Engine Generator 1000
kW, (if engines are different kW sizes we shall use the greatest kW size number given) select the
following:
1600AF - for Generator Circuit Breaker Frame Ampacity

6000A - for Main Bus Ampacity for 4-EGs to be paralleled
Add new four symbols for the catalog number:
1606

6/21/2005 40 Publication 3140
Step 3: Control Section Module Selection
By using this Guide select and configure Control Modules for four EGs PCS (type A
Switchgear configuration) as a sum of MX + 2G +2G
Add the next two symbols for the catalog number (regarding selected Master Module type only):
MX
Step 4: Enclosure type Selection
Select NEMA 1 type enclosure by adding the next two symbols for catalog number:
C1
Step 5: Distribution Option Selection
Because Distribution Sections shall be incorporated (lined up) into the PCS Switchgear, add the next
symbol:
D
It means that along to completed catalog number you must select and attach a separate list of
Standard Distribution Sectional Module Codes:
Step 6: Distribution Section Module Selection
By using the Table (on page 21) select two distribution section modules with the following
codes:
A06 for 4 x 800AF CBs

H06 for 1 x 800AF, 2 x 1600AF and 1x 2000AF CBs (one additional 800AF Breaker can
be used as a spare)

6/21/2005 41 Publication 3140
Step 7: Optional Accessories Selection

If there is any PCS optional accessory is required, you shall add the last symbol to the previous
catalog number symbols you have created:
It means that along with completed catalog number you must select and attach a separate list of
the optional PCS Accessory Codes:
For example:
GTS - Touch Screen for Generator Controls.
64A - 64 ATSs for load control.
CL1 - Compression type Lugs.
Note: If there are no optional accessories required the last symbol shall not be entered (leave
blank) in the catalog number.
Summary:
1. The final 4000 Series PCS Ordering Catalog Number will be a sum of all the previously created
symbols above (18 characters maximum):
4LSN61606MXC1DX
Distribution Module Codes: A06; H06

Optional Accessory Codes: GTS; 64A; CL1

6/21/2005 42 Publication 3140
2. Switchgear line up configuration will be Type A as shown on the elevation block-diagram

below.
MASTER DUAL
GEN 1GEN
&2 DUAL
GEN 3GEN
&4 DISTRIB
800AF DISTRIB
800AF
CONTROLS CB & CB & 400AT 800AT
CONTROLS
CB CONTROLS
CB (Spare)
TS 800AF 1600AF
1600AF 1600AF
12" 800AT 1200AT
CS CS CS
800AF 1600AF
800AT 1600AT
1600AF 1600AF 800AF 2000AF

1500AT 1400AT 800AT 2000AT
32" 32" 32" 26" 26"

SECTION SECTION SECTION SECTION SECTION
1 2 3 4 6
MAIN BUS SIZE: 6000A OVERALL DIMENSIONS: 148" W x 91" H x 72" D

UL LABEL: UL 1558, NEMA 1 type MX+2G+2G+A06+H06 line-up
SYSTEM AIC: 100kA

6/21/2005 43 Publication 3140
XVI. Engine Generator Controls Compatibility Information
The following Governors and Voltage Regulators are suitable to Interface

with the ASCO 4000 Series PCS:
Governors:
Woodward EPG
Woodward 2301A
Woodward 2301D
Woodward SG-2D
FLO-TECH
Pro-ACT I & II
CSC
Woodward 2301A LSSC
701 or 701A
721
723 or 723 Plus
Caterpillar ADEM
Barber-Colman DYN1
Detroit Diesel DDEC
Cummins EFC
Voltage Regulators:
Basler SSR
Basler SR4A
Basler SR8A
Caterpillar DVR
Caterpillar VR3
KATO KCR 360 or 760
KATO K65-12B
KATO K125-10B
Marathon PM100
Marathon DVR 2000E
Newage MX321/341
Newage MA325

6/21/2005 44 Publication 3140
XVII. Product Ordering Process Summary
Product ordering process shall include the following steps:
1. The customer, based on 4000 Series Power Control System Product Brochure,
presents to ASCO Sales the system info (electrical one-line diagram or/and any
other necessary parameters). Sales Engineers shall provide technical guidance
(including presentation of 4000 Series PCS Suggested Specification - see
Publication # 3135 on Info Web) to the customers in order to obtain the
minimum required system info - as listed on page 40 of this Guide.
Factory PCS Application Engineering (Florham Park, NJ) Group shall provide to
Field Sales Engineers all necessary assistance regarding technical
interpretations of this Selection & Application Guide, Suggested Specifications
and other technical documents, issued for 4000 Series PCS product.
2. Field Project Manager or Sales Engineer, by using this Guide and other ASCO
publications located on Info Web, configures the required Power Control System
and creates the 4000 Series Switchgear Catalog Number.
3. Field Project Manager or Sales Engineer, by using standard 4000 Series PCS
module List Prices, calculates the total net price of the paralleling Switchgear
and creates the Bill of Material (temporary, for the first year from product launch
date, quotations and BOMs shall be provided by Application Engineering Group
located in Florham Park, NJ).
4. Field Project Manager or Sales Engineer sends the Catalog Number along with
Project Data Form (refer to Publication # 3136 on Info Web) and Purchase
Order (PO) to appropriate Regional Project Manager to process the order.

6/21/2005 45 Publication 3140

6/21/2005 46 Publication 3140

PCS 3140 (1) 27JN05

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ASCO 4000 Series Power Control System

Low Voltage Digital Generator Paralleling Control Switchgear

Selection & Application Guide

ASCO Power Technologies, Florham Park, NJ 07932. 1-800-800-ASCO www.ascopower.com

ASCO Power Technologies, Florham Park, NJ 07932. 1-800-800-ASCO www.ascopower.com

Series 4000 Power Control System:

Starts, synchronizes, parallels, monitors and protects up to 8 engine generators

Automatically manages power transfer via downstream Transfer Switches (up to

Communicates with Building Management System and Engine Generator control

Series 4000 Power Control System Offers:

Flexibility and comprehensive functionality based on a wide array of control and

Lower Installation/Maintenance cost.

State of the art Master Control and Monitoring Panel.

ASCO Power Technologies, Florham Park, NJ 07932. 1-800-800-ASCO www.ascopower.com

Less floor space.

Standard high level Communication.

Easier expansion in the future.

This reliable product is supported by ASCOs:

Knowledgeable Sales Force.

Dependable and focused Project Management.

Professional Design and Applications Engineering Team.

ASCO Power Technologies, Florham Park, NJ 07932. 1-800-800-ASCO www.ascopower.com

II. Primary Applications

The Series 4000 PCS can be utilized in the following applications:

ASCO Power Technologies, Florham Park, NJ 07932. 1-800-800-ASCO www.ascopower.com

III. Technical Data Overview

The Switchgear Basic Parameters and Features

ASCO Power Technologies, Florham Park, NJ 07932. 1-800-800-ASCO www.ascopower.com

IV. Power Circuit Breakers Standard Options

Generator Paralleling Breakers:

Brand and Type: Siemens WL or Square D NW (ANSI C.37 / UL 1066 Rated).

Interrupting Current Rating: 100kAIC@ 480V.

Circuit Breakers: Draw out, electrically-operated, 120VAC charge and close, 24

CB Manufacturer, CB type Trip unit

ASCO Power Technologies, Florham Park, NJ 07932. 1-800-800-ASCO www.ascopower.com

Distribution Feeder Breakers:

Brand and Type: Siemens WL or Square D NW (ANSI C.37/UL1066 Rated).

Interrupting Current Rating: 100kAIC @ 480V.

CB Manufacturer, CB type Trip unit

ASCO Power Technologies, Florham Park, NJ 07932. 1-800-800-ASCO www.ascopower.com

V. Product Selection Basis

The typical single-line diagram:

The typical sequence of system operation:

ASCO Power Technologies, Florham Park, NJ 07932. 1-800-800-ASCO www.ascopower.com

ASCO Power Technologies, Florham Park, NJ 07932. 1-800-800-ASCO www.ascopower.com

D. Generator Load Demand Control

ASCO Power Technologies, Florham Park, NJ 07932. 1-800-800-ASCO www.ascopower.com

ASCO Power Technologies, Florham Park, NJ 07932. 1-800-800-ASCO www.ascopower.com

If the load is not calling for an engine start, it will be skipped.

ASCO Power Technologies, Florham Park, NJ 07932. 1-800-800-ASCO www.ascopower.com

No loads can be manually added while an Underfrequency indication is active. The

F. Generator No Load Test

G. Single Engine Test

ASCO Power Technologies, Florham Park, NJ 07932. 1-800-800-ASCO www.ascopower.com

H. ATS Hand Off Auto (H-O-A) Controls

ASCO Power Technologies, Florham Park, NJ 07932. 1-800-800-ASCO www.ascopower.com

The System Selection basic criteria and considerations:

Future Generator Controls if there is a requirement for a future engine

Governor (speed control) interface and voltage regulator must be mounted

Remote Annunciation Panel can be provided as a second (duplicate) Master

ASCO Power Technologies, Florham Park, NJ 07932. 1-800-800-ASCO www.ascopower.com

VI. Controls Section Module Configurations

Master Control Module: