Generac Power Systems ATC-300+ Operation And Maintenance Manual

O & M Manual for ATC-300+ 40-400A (480/600Vac) ATC-300+ 3-Position Contactor Based Transfer Switch
Instruction Booklet
Description Page
Introduction . . . . . . . . . .
Operation . . . . . . . . . . . .
Testing and Problem Solving Adjustments
Maintenance . . . . . . . . . .
Renewal Parts Guide ATC-300+ Contactor Based ATS Quick Start Instructions . .26
Appendix A: Pickup / Dropout Tables . . . . . . . . . .
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Instruction Booklet
Cat No: ATC3C3X30400WRU Style No:
ASSEMBLED IN MEXICO WITH U.S. COMPONENTS 30 - 43465
ITEM: 001
PIECE: 001
CS#: 123456
J050412234
Volts: 240
Poles: 3
Amps: 400
Phase: 3
Hertz: 60
Wire: 3/4
GO No: ABC0123
OF: 001
Page 2 Effective: September 2011
40-400A (480/600Vac) ATC-300+ 3-Postion
Contactor Based Transfer Switch
Section 1: Introduction
WARNING
READ AND UNDERSTAND THE INSTRUCTIONS CONTAINED HEREIN­AFTER BEFORE ATTEMPTING TO UNPACK, ASSEMBLE, OPERATE, OR MAINTAIN THIS EQUIPMENT.
HAZARDOUS VOLTAGES ARE PRESENT INSIDE TRANSFER SWITCH
CLOSURES THAT CAN CAUSE DEATH OR SEVERE PERSONAL
EN INJURY. FOLLOW PROPER INSTALLATION, OPERATION, AND MAIN­TENANCE PROCEDURES TO AVOID THESE VOLTAGES
TRANSFER SWITCH EQUIPMENT COVERED BY THIS INSTRUCTION BOOK IS PLATE RATINGS. OPERATION OUTSIDE OF TH CAUSE THE EQUIPMENT TO FAIL RESULTING IN DEATH, SERIOUS BODILY INJURY, AND/OR PROPERTY DAMAGE. ALL RESPONSIBLE PERSONNEL SHOULD LOCATE THE DOOR MOUNTED EQUIPMENT NAMEPLATE AND BE FAMILIAR WITH THE INFORMATION PROVIDED ON THE NAMEPLATE. A TYPICAL EQUIPMENT NAMEPLATE IS SHOWN IN FIGURE 1.
DESIGNED AND TESTED TO OPERATE WITHIN ITS NAME-
Figure 1. Typical Automatic Transfer Switch (ATS) Equipment Nameplate.
All possible contingencies that may arise
during installation, oper­ation, or maintenance, and all details and va ment do no purport to be covered by these instructions. If further information is desired by the purchaser r
egarding a particular installation, operation, or maintenance of particular equipment, please contact an authorized Generac Sales Representative or the installing contractor.
.
ESE RATINGS MAY
riations of this equip-
1.1 Preliminary Comments and Safety Precautions
This technical document is intended to cover most aspects asso­ciated with the installation, application, operation, and mainte­nance of the Automatic Transfer Controller (ATC-300+) controlled c
ontactor based ATS with ratings from 40 through 400 amperes (A). It is provided as a guide for authorized and qualified personnel only. Please refer to the specific WARNING and CAUTION in Section 1.1.2 before proceeding. If further infor­mation is required by the purchaser regarding a particular installa­tion, application, or maintenance activity, plea
se contact an authorized Generac sales representative or the installing contrac­tor.
1.1.1 Warranty and Liability Information
No warranties, expressed or implied, including warranties of fit­ness for a particular purpose of merchant
ability, or warranties arising from course of dealing or usage of trade, are made regard­ing the information, recommendations and de
scriptions contained herein. In no event will Generac be responsible to the purchaser or user in contract, in tort (including negligence), strict liability or otherwise for any special, indirect, incidental or consequential damage or loss whatsoever, including but not limited to damage or loss of use of equipment, plant or power system, cost of capi­tal, loss of power, additional expenses in the use
of existing power facilities, or claims against the purchaser or user by its customers resulting from the use of the information and descrip­tions contained herein.
1.1.2 Safety Precautions
All safety codes, safety standards, and/or regulations must be strictly observed in the installation, operation, and maintenance of this device.
WARNING
THE WARNINGS AND CAUTIONS INCLUDED AS PART OF THE PRO­CEDURAL STEPS IN THIS DOCUMENT ARE FOR PERSONAL SAFETY AND PROTECT OF A TYPICAL WARNING LABEL HEADING IS SHOWN ABOVE TO FAMILIARIZE PERSONNEL WITH THE STYLE OF PRESENTATION. THIS WILL HELP TO INSURE THAT PERSONNEL ARE ALERT TO WARNINGS, WHICH APPEAR THROUGHOUT THE DOCUMENT. IN ADDITION, WARNINGS AND CAUTIONS ARE ALL UPPER CASE AND BOLDFACE.
ION OF EQUIPMENT FROM DAMAGE. AN EXAMPLE
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CAUTION
COMPLETELY READ AND UNDERSTAND THE MATERIAL PRESENTED IN THIS DOCUMENT BEFORE ATTEMPTING INSTALLATION, OPERA­TION, OR APPLICATION OF THE EQUIPMENT. IN ADDITION, ONLY QUALIFIED WORK ASSOCIATED WITH THIS EQUIPMENT. ANY WIRING INSTRUCTIONS PRESENTED IN THIS DOCUMENT MUST BE FOL­LOWED PRECISELY. FAILURE TO DO SO COULD CAUSE PERMANENT EQUI
PERSONS SHOULD BE PERMITTED TO PERFORM ANY
PMENT DAMAGE.
40-400A (480/600Vac) ATC-300+ 3-Postion
Source 1
Source 2
Load
LOGIC
PANEL
VOLTAGE SELECTION AND TRANSFORMER PANEL
POWER PANEL
Contactor Based Transfer Switch
Instruction Booklet
Effective: September 2011 Page 3
1.2 General Information
Transfer switches are used to protect critical electrical loads against loss of power. The load’s Source 1 power source is backed up by a Source 2 power source. A transfer switch is connected to both the Source 1 and Source 2 power sources and supplies the load with power from one of the two sources. In the event that power is lost from Source 1, the transfer switch trans­fers the load to the Source 2 power source. This transfer is auto­matic. Once Source 1 power is restored, the load is automatically trans (Figure 2).
ferred back to the Source 1 power source
and the Source 2 power source fails while the Source 1 power source is still unavailable, the ATS remains connected to the Source 2 power source.
ATSs automatically perform the transfer function and include
e basic elements:
thre
1. A power contactor to connect and disconnect the load to nd from either power source.
a
2. Solenoids to make the transfer of the main contacts from
source to source.
3. Intelligence/supervisory circuits
condition of the power sources and thus provide the intelli­gence necessary for the switch and related circuit operation.
to constantly monitor the
1.2.1 Design Configuration
The Generac contactor based ATS is a compact design that uses a power contactor to transfer essential loads from one power source to another (Figure 3 [400A]).
Figure 2. Typical Load Transfer Switch Schematic (Contactor Type).
In ATS equipment, the switch’s intelligence system initiates the
fer when the Source 1 power fails, falls below, or rises
trans above a preset voltage. If the Source 2 power source is a standby generator, the ATS initiates generator startup and trans­fers to the Source 2 power source when sufficient generator
age is available. When Source 1 power is restored, the ATS
volt automatically transfers back and initiates generator shutdown. In the event the Source 1 power source fails and the Source 2 power source does not appear, the ATS remains connected to the Source 1 power source until the Source 2 power source does appear. Conversely, if connected to the Source 2 power source
Figure 3. Typical Power Panel for a 400A Model.
The Generac contactor based ATS was designed with easy installation and simplified maint els comprise the contactor based ATS design:
1. Power panel;
2. Voltage selection and transformer panel (if required); and
3. Microprocessor-based logic panel.
enance in mind. Three main pan-
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Instruction Booklet
AT C 3 C3 X 3 0400 W R U
1to2 3 4 5 6 7 8 9to
12 13 14 15
to
Page 4 Effective: September 2011
40-400A (480/600Vac) ATC-300+ 3-Postion
Contactor Based Transfer Switch
Table 1. Withstand Ratings.
UL 1008 WITHSTAND AND CLOSE-ON RATINGS (kA)
UL 1008 Ampere Rating 480 Volts 600 Volts
Any
Breaker
100 30,000 30,000 22,000 35,000
200 30,000 30,000 22,000 35,000
260 30,000 50,000
320 30,000 50,000
400 30,000 50,000
1.3 ATS Catalog Number Identification
Transfer switch equipment catalog numbers provide a significant amount of relevant information that pertains to a particular piece of equipment. The Catalog Number Identification Table (Table 2) provides the required interpretation information. An example is offered here to initially simplify the process.
Example: C
atalog Number (circled numbers correspond to position
headings in Table 2).
Specific Breaker
Any
Breaker
Specific Breaker
Figure 4. Contactor Based ATS (400A).
Each panel is independently mounted with interconnecting wiring terminated at the connector receptacles on the ATC-300+ Con­troller. Door or individual panel removal is achieved without dis­turbing critical connections by removing the connectors from the
eptacles and cutting the wire ties that secure the wires to the
rec door.
Mounting the enclosure is simple using top and bottom mounting flanges with elonga ing holes, along with power panel positioning bolts and pre­tapped inse tial enclosure installation. Refer to Section 4 for specific mount­ing and modification details.
rts, insure proper power panel mounting after the ini-
ted (teardrop) mounting holes. These mount-
The catalog number ATC3C3X30400WRU describes an ATS with a 3-pole, 3 position Power Contactor mounted on a baseplate within the enclosure. The intelligence represented by the logic panel is ATC-300+ controller. The continuous current rating of this equipment is 400A and applicable at 240 Vac, 60 Hz. The transfer switch equipment is enclosed in a NEMA 3R enclosure and is listed for UL applications.
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Instruction Booklet
40-400A (480/600Vac) ATC-300+ 3-Postion Contactor Based Transfer Switch
Table 2. Transfer Switch Catalog Number Explanation
POSITIONS 1 TO 2 POSITION 3 POSITION 4 POSITIONS 5 TO 6
BASIC DEVICE SWITCHING DEVICE CONTROL PANEL SWITCHING DEVICE
Automatic Transfer Switch AT Contactor C ATC-300+ Controller 3 3 Position Power Contactor C3
POSITION 7 POSITION 8 POSITIONS 9 TO 12 POSITION 13 POSITION 14 POSITION 15
SWITCHING DEVICE
ARRANGEMENT
Fixed Mount X Two (2) 40A – 0040 208 Vac/60 Hz B Type 1 S UL/CSA Listing U
150A 0150 380 Vac/50 Hz H Open K
*For 225A to 400A, 600 Vac application, please refer to IB01602024E
NUMBER
OF POLES
Three (3) 80A – 0080 220 Vac/50 Hz G Type 12 J No Listing X
Four (4) 100A – 0100 240 Vac/60 Hz W Type 3R R
AMPERE
RATING
200A – 0200 415 Vac/50 Hz O
*225A – 0225 480 Vac/60 Hz X
*260A – 0260 600 Vac/60 Hz E
*400A – 0400
VOLTAGE/
FREQUENCY ENCLOSURE LISTING
Effective: September 2011 Page 5
1.4 Environmental Conditions
1.4.1 Operational Conditions
Normally, an ATS is applied indoors in an electrical equipment room. In the appropriate enclosure, it can be used for outdoor applications where the equipment is subject to falling rain, freez ing temperatures, and no greater than 90% humidity (non-con­densing). The ambient temperature range for operation is between -20 and 70°C (-4 to 158°F).
1.5 Glossary
With respect to their use within this document and as they relate to transfer switch and controller operation, the following termi nology is defined.
Available
A source is defined as “available” when it is within its undervolt­age/overvoltage/ underfrequency/overfrequency (if applicable) setpoint ranges for the nominal voltage and frequency setting.
Connected
Connected is defined as when the input is shorted by an external contact or connection.
Failed or Fails
A source is defined as “failed” when it is outside of the applica­ble voltage and frequency setpoint ranges for the nominal volt­age and frequency setting for a time exceeding 0.5 seconds after the time delay emergency fail (TDEF) time delays expires.
Failsafe
Failsafe is a feature that prevents disconnection from the only available power source and also forces a transfer or re-transfer operation to the only available power source.
-
Re-Transfer
Re-transfer is defined as a change of the load connection from the Source 2 to the Source 1.
Source 1
Source 1 is the primary source (normal source, normal power source, or normal).
-
Source 2
Source 2 is the secondary source (emergency source, emer­gency power source, emergency, standby, or backup source).
Source 1: Failed or Fails
Source 1 is defined as “failed” when it is outside of its under­voltage/overvoltage/ underfrequency/overfrequency (if applica­ble) setpoint ranges for the nominal voltage and frequency setting.
Source 2: Failed or Fails
Source 2 is defined as “failed” when it is outside of its under­voltage/overvoltage/ underfrequency/overfrequency (if applica­ble) setpoint ranges for the nominal voltage and frequency setting for a time exceeding 0.5 seconds after the Time Delay Emergency Fail (TDEF) time delay expires.
Transfer
Transfer is defined as a change of the load connection from the Source 1 to the Source 2 power source.
Unconnected
Unconnected is defined as when the input is not shorted by an external contact or connection.
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Instruction Booklet
Page 6 Effective: September 2011
40-400A (480/600Vac) ATC-300+ 3-Postion
Contactor Based Transfer Switch
Section 2: Receiving, Handling, and Storage
2.1 Receiving
Every effort is made to ensure that the ATS equipment arrives at its destination undamaged and ready for installation. Packing is designed to protect internal components as well as the enclo sure. Care should be exercised, however, to protect the equip­ment from impact at all times. Do not remove the protective packaging until the equipment is ready for installation.
When the ATS equipment reaches its destination, the customer should inspect the shipping container for any obvious signs of rough handling and/or external damage that occurred during transportation. Record any external and internal damage for reporting to the transportation carrier and Generac, once a thor ough inspection is complete. All claims should be as specific as possible and include the catalog and General Order numbers.
A shipping label affixed to the shipping container includes a vari­ety of equipment and customer information, such as General Order Number and catalog numbers. Make certain that this infor mation matches other shipping paper information.
Each transfer switch is packed securely with appropriate ship­ping materials to prevent damage during shipment. Do not remove or discard the packing material until the equipment is ready for installation.
Once the top packaging is removed from the shipment, the enclosure door can be opened. A plastic bag of documents will be found in the enclosure, usually attached to the inside of the enclosure. Important documents, such as test reports, wiring diagrams, and appropriate instruction leaflets, are enclosed within the bag and should be filed in a safe place.
-
2.3 Storage
Although well packaged, this equipment is not suitable for out­door storage. The equipment warranty will not be applicable if there is evidence of outdoor storage. If the equipment is to be stored indoors for any period of time, it should be stored with its protective packaging material in place. Protect the equipment at all times from excessive moisture, construction dirt, corrosive conditions, and other contaminants.
It is strongly suggested that the package-protected equipment be stored in a climate-controlled environment with temperatures from -30 to 85°C (-22 to 185°F) and with a relative humidity of 80% or less. DO NOT, under any circumstance, stack other equipment on top of a transfer switch equipment enclosure, whether packaged or not.
-
-
2.2 Handling
As previously mentioned, ATS equipment is packaged for forklift movement. Protect the equipment from impact at all times and DO NOT double stack.
Once the equipment is at the installation location and ready to be installed, packaging material can be removed and discarded. Once the enclosure is unbolted from the wooden pallet, it can be hand moved to its installation position. Be careful not to damage the top or bottom enclosure mounting flanges. Refer to Section 4 of this manual for specific installation instructions.
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40-400A (480/600Vac) ATC-300+ 3-Postion
POWER PANEL
LOGIC PANEL
VOLTAGE SELECTION
AND TRANSFORMER PANEL
Contactor Based Transfer Switch
Section 3: Equipment Description
3.1 General
The ATS consists of three basic panels:
1. The power panel;
2. The voltage selection and transformer panel (if required); and
3. The microprocessor-based logic panel.
These panels are interconnected via connector plugs and mounted in an enclosure (Figure 5
).
Instruction Booklet
Effective: September 2011 Page 7
Figure 5. Three Basic Panels of the ATS (40-400A).
3.2 Power Panel
The power panel is used for making load, power, and neutral con­nections. The power contactor is mounted on a steel baseplate (Figure 6).
3.2.1 Main Contacts
This ATS incorporates a power contactor. The main contacts connect and disconnect the load to and from the different power sources. The power contactor is mechanically and electrically interlocked to prevent the two sets of main contacts from being closed simultaneously.
Figure 6. Typical Power Panel for 40-400A Models.
3.3 Voltage Selection
3.3.1 Standard Voltage Selection (208, 240, 480, 600, 60 Hz and 220, 380, 415, 50 Hz.)
The Standard voltage selection panel consists of multi-tap trans­formers, contained in a steel case mounted in the enclosure (Fig­ure 7). The voltage is selected by the default primary taps of both transformers and installing them on the primary taps for the desired voltage. Taps are provided for 208 to 600 Vac to satisfy application voltage. The factory default position is 600 Vac.
simply removing the wires from
CAUTION
WHEN CHANGING THE SELECTED VOLTAGE, THE POWER MUST BE REMOVED FROM THE ATS AND THE WIRES MUST BE MOVED ON THE TAPS OF BOTH TRANSFORMERS.
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40-400A (480/600Vac) ATC-300+ 3-Postion
Contactor Based Transfer Switch
Figure 7. Standard Voltage Selection Terminals (Shown Connected to the 480 Vac Taps).
3.4 ATC-300+ Logic Panel
The ATC-300+ is a microprocessor-based transfer switch logic control package. The hardware and software of the controller contain the intelligence/supervisory circuits that constantly moni­tor the condition of the power sources. It provides the intelli­gence necessary for the operation of the ATS (Figure 8).
Figure 8. ATC-300+ Logic Control Panel.
The ATC-300+ controller has an operating temperature of
-20 to 70°C (-4 to 158°F).
The controller circuit board is protected by an insulating confor­mal coating.
The specifications, under normal operating conditions, are as fol­lows:
Tolerance for voltage sensing function: ±1% of full scale
Tolerance for frequency sensing function: ±0.3 Hz of setting
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40-400A (480/600Vac) ATC-300+ 3-Postion Contactor Based Transfer Switch
Instruction Booklet
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3.5 Features
A variety of standard and optional features are available for Gen­erac ATSs. All features or combinations of features may not be available on specific ATSs. All features and/or accessories are Underwriters Laboratories (UL) listed unless noted.
3.5.1 Standard Features
The following is a list of the standard features for the ATC­300+ATC-300+ Controlled ATS.
1. Time Delay Normal to Emergency (TDNE)
This feature provides a time delay when transferring from the Source 1 to the Source 2 power source. Timing begins when Source 2 becomes available. It permits controlled transfer of the load circuit to Source 2.
Adjustable 0 - 1800 Seconds
2. Time Delay on Engine Starting (TDES)
This feature provides a time delay of the signal to initiate
the engine/generator start cycle in order to override momentary power outages or voltage fluctuations of Source 1.
Adjustable 0 - 120 Seconds
3. Time Delay Emergency to Normal (TDEN)
This feature provides a time delay of the re-transfer opera­tion to permit stabilization of Source 1. Timing begins when Source 1 becomes available. If Source 2 fails during timing, then re-transfer is immediate overriding the time delay.
Adjustable 0 - 1800 Seconds
4. Time Delay for Engine Cool-down (TDEC)
This feature provides a time delay of the signal to initiate the engine/generator stop cycle after the re-transfer opera tion. This allows the engine/generator to cool down by run­ning unloaded. Timing begins on completion of the re­transfer cycle.
Adjustable 0 - 1800 Seconds
5. Source 2 Monitoring and Protection
This feature provides monitoring and protection based on the Source 2 voltage and/or frequency setpoints. All fea ture 5 functions are Failsafe operations.
-
5H. Phase Reversal
For a 3-phase wye source, this feature monitors the phase
sequence of the sources. If a source does not have the same ABC or CBA sequence as the setpoint value, that source will be considered “Unavailable.
For a 3-phase delta source, this feature should be turned off via the PHASE REV setpoint.
5J. All Phase Undervoltage and Underfrequency Protection
Adjustable Undervoltage:
Dropout: 78 - 97% of nominal Pickup: (Dropout +2%) to 99% of nominal
Adjustable Underfrequency:
Dropout: 90 - 97% of nominal Pickup: (Dropout +1Hz) to 99% of nominal
5K. All Phase Overvoltage/Overfrequency
Adjustable Overvoltage:
Dropout: 105 - 110% of nominal Pickup: 103% to (Dropout –2%) of nominal
Adjustable Overfrequency:
Dropout: 103 - 105% of nominal Pickup: 101% to (Dropout -1Hz) of nominal
-
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40-400A (480/600Vac) ATC-300+ 3-Postion
Contactor Based Transfer Switch
5L. Source 2 3-Phase Voltage Unbalance
For a 3-phase wye source, this feature monitors phase volt­age ratios. Voltage unbalance (%) is calculated as the dif­ference between the maximum and minimum phase voltage, divided by the minimum phase voltage. User­selectable setpoints are available for dropout and pickup unbalance settings (minimum 2% differential). Dropout is adjustable from 5 to 20%. Pickup is adjustable from 3 to (Dropout –2%). A setpoint for user-selectable time delay from 10 to 30 seconds is provided. The factory default set­points are: 5% dropout, 3% pickup, and 30 seconds time delay. A user-selectable setpoint for enable and disable is also provided.
When an unbalance condition is detected on Source 2, the Unbalance Timer (TD UNBAL) starts timing. After TD UNBAL times out, Source 2 is declared “failed”.
For a 3-phase delta source, this feature should be turned off via the VOLT UNBAL setpoint.
6. Test Operators
Generac ATSs are provided with a Test Pushbutton that simulates a loss of the Source 1 power source as standard (Feature 6B). All programmed time delays (TDNE, TDEN, etc.) will be performed as part of the Test. Engine run time of the Test is equal to the Plant Exerciser (Feature 23) pro grammed setpoint. All Tests are Failsafe protected.
6B. Test Pushbutton
Programmable setpoints include:
1. Load or No Load Testing, or Disabled
2. Engine run time equal to the plant exerciser (Feature 23) setting
7. Time Delay Emergency Fail (TDEF)
This feature provides a time delay that prevents a con­nected Source 2 power source from being declared “Failed” in order to override momentary generator fluctuations. If the Source 2 power source remains in the failed state then,
0.5 seconds after the TDEF timer expires, the transfer
switch will proceed with the programmed sequence for retransfer. This time delay is only implemented when the Source 2 power source is a generator.
Adjustable 0 - 6 Seconds
8. Time Delay Bypass Pushbutton
This feature provides a way (by pushing the Help and Step pushbutton simultaneously) to bypass the TDNE (Feature 1) and/or TDEN (Feature 2) time delays. The Time Delay Bypass function, when activated by pushing the Help and Step pushbutton simultaneously, will reduce any or all of the programmed time delay to zero.
8C. Bypass TDEN
This feature provides one set of pushbuttons to bypass the TDEN time delay.
8D. Bypass TDNE
This feature provides one set of pushbuttons to bypass the TDNE time delay.
12. Power Source Annunciation
This feature provides LEDs to give switch position and power source availability indications.
Switch Position
Provides LEDs to indicate the switch position
12C. Source 1 - Source Connected
This feature provides a green LED that, when lit, indicates
the load is connected to Source 1.
12D. Source 2 - Source Connected
This feature provides a red LED that, when lit, indicates the
load is connected to Source 2.
Power Source Availability
Provides LEDs to indicate if a power source is available.
LEDs may be integral or separate from the controller.
12G. Source 1 - Available
This feature provides a white LED that, when lit, indicates
Source 1 is available.
12H. Source 2 - Available
-
This feature provides an amber LED that, when lit, indi-
cates Source 2 is available.
14. Relay Auxiliary Contacts
14G. Source 1 Present: Provides two (2) normally open and two
(2) normally closed contacts. The relay is energized when Source 1 is available.
14H. Source 2 Present: Provides two (2) normally open and two
(2) normally closed contacts. The relay is energized when Source 2 is available.
15. Switch Position Indication Contact
This feature provides a contact that indicates if the power switching device is in the “Open” or “Closed” position.
15E. Source 1 Position Indication Contact
This feature provides 1 dry form “C” contact that indicates the position of the Source 1 power switching device.
15F. Source 2 Position Indication Contact
This feature provides 1 dry form “C” contact that indicates the position of the Source 2 power switching device.
23. Plant Exerciser (PE)
This feature provides a means for automatic testing of the
engine generator set or standby power system. All pro grammed time delays will be performed during plant exer­ciser operations.
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40-400A (480/600Vac) ATC-300+ 3-Postion Contactor Based Transfer Switch
Instruction Booklet
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23K. Plant Exerciser Selectable – Disabled/1/7/14/28 Day Inter-
val
This feature provides for automatic test operation of the
generator. Available test cycles are daily, 7, 14, or 28 days with duration equal to the programmed engine test time.
Programmable setpoints allow for selection of three test
cycles:
Engine Start/Run Only (No Load);
Exercise with Load Transfer; or
Disabled
This is a “Failsafe” operation.
26. Source 1 - Monitoring and Protection
This feature provides Source 1 monitoring and protection
functions. If the Source 1 power supply fails, then the Automatic Transfer Controller will begin the sequence of operations necessary to transfer the load circuit to the Source 2 power supply. All Feature 26 monitoring and protection functions are Failsafe operations.
26D. Go to Source 2
This feature provides the capability for an external contact opening to initiate a load circuit transfer to the Source 2 power source. This includes starting the engine/generator, performing the programmed time delays, and the transfer operation. Re-transfer will occur when the external con tact is closed or under a Failsafe condition.
26H. Phase Reversal Protection
For a 3-phase wye source, this feature monitors the phase
sequence of the sources. If a source does not have the same ABC or CBA sequence as the phase reversal set point, the source will be considered “Unavailable”.
For a 3-phase delta source, this feature should be turned
off via the PHASE REV setpoint.
26J. All Phase Undervoltage and Underfrequency Protection
Adjustable Undervoltage:
Dropout: 78 - 97% of nominal Pickup: (Dropout +2%) to 99% of nominal
Adjustable Underfrequency:
Dropout: 90 - 97% of nominal Pickup: (Dropout +1Hz) to 99% of nominal
26K. All Phase Overvoltage/Overfrequency
Adjustable Overvoltage:
Dropout: 105 - 110% of nominal Pickup:103% to (Dropout –2%) of nominal
Adjustable Overfrequency:
Dropout: 103 - 105% of nominal Pickup: 101% to (Dropout -1Hz) of nominal
-
-
26L. Source 1 3-Phase Voltage Unbalance
.For a 3-phase wye source, this feature monitors phase voltage ratios. Voltage unbalance (%) is calculated as the difference between the maximum and minimum phase voltage, divided by the minimum phase voltage. User­selectable setpoints are available for dropout and pickup unbalance settings (minimum 2% differential). Dropout is adjustable from 5 to 20%. Pickup is adjustable from 3 to (Dropout –2%)). A setpoint for user-selectable time delay from 10 to 30 seconds is provided. The factory default setpoints are: 5% dropout, 3% pickup, and 30 seconds time delay. A user-selectable setpoint for enable and dis­able is also provided.
When an unbalance condition is detected on Source 1, the Unbalance Timer (TD UNBAL) starts timing. After TD UNBAL times out, Source 1 is declared “failed”.
For a 3-phase delta source, this feature should be turned off via the VOLT UNBAL setpoint.
29. Alternate Transfer Modes of Operation
Provides standard or optional transfer modes, mode selec­tion devices, and operational methods for ATSs.
29J. Type of Operation (MANTR) Operation (new feature)
This feature provides for a selection between an automatic transfer and re-transfer mode or a manual pushbutton re­transfer to Normal from the Emergency Source mode. If this option is not selected the factory default selection is automatic.
32. Delayed Transition Transfer Modes for Open Transition Transfer Switches
This feature provides delayed transition transfer modes for an open transition transfer switch. Often used in sys tems with inductive loads, a delayed transition transfer switch may prevent or reduce in-rush currents due to out of phase switching of inductive loads.
32A. Time Delay Neutral
This feature provides a time delay in the neutral position during the transfer and re-transfer operations during which both Source 1 and Source 2 are disconnected from the load circuit. The time delay is programmable and is the same for both transfer and re-transfer operations.
Adjustable 0 - 120 Seconds
35. Pre-Transfer Signal
This feature provides a signal to a remote device prior to a
re-transfer operation. It provides one Form “C” contact (NO/NC) for interface with other equipment (typically ele vator controls). The contacts close/open on a timed basis prior to transfer in either direction. After TDNE/TDEN times out, this relay closes and the Pre-transfer Timer (TPRE) starts timing. After the TPRE times out, the trans fer proceeds by starting the TDN timer if enabled. The pre-transfer relay opens after the transfer is complete.
Adjustable 0 - 120 Seconds
35A. Pre-Transfer Signal with 1 N.O. and 1 N.C. Contacts
This feature provides pre-transfer signal and includes 1
N.O. and 1N.C. contacts.
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Instruction Booklet
Page 12 Effective: September 2011
40-400A (480/600Vac) ATC-300+ 3-Postion
Contactor Based Transfer Switch
36. Emergency Inhibit (new feature)
This feature enables the Emergency inhibit control input to
inhibit transfers to the Emergency Source. See Control Inputs section for more information.
This input is located on Pins 7 and 8 of Connector J8 and
is enabled when the Emergency Inhibit is enabled. The con tact is closed for normal operation. Opening this contact will activate the Emergency Inhibit input.
If the Emergency Inhibit contact is opened when the load is
connected to the Normal Source, no action will be taken if the Normal Source is available. If the Normal Source is not available, an immediate transfer to the neutral position will occur.
If the Emergency Inhibit contact is opened when the load is
connected to the Emergency Source, the ATC-300+ will transfer the load to the Normal Source if it is available. If the Normal Source is not available, an immediate transfer to the neutral position will occur.
The Emergency Inhibit input is only active when either
Source 1 or Source 2 is preferred. This input is not active when the Preferred Source selection is set to None.
The Emergency Inhibit input takes priority over the Go To
Emergency input if both inputs are activated at the same time. In this case, the generator will start but a transfer to the Emergency Source will be inhibited until the Emergency Inhibit input is de-activated.
42. Seismic Withstand Capability
Provides transfer switch with seismic capability exceeding
the worst case Zone 4 required per both the Uniform Build ing Code and the California Building Code.
48F. RS-485 with Modbus Option
Provides communications for the ATC-300+ via Modbus
through an integrated RS-485 port. Registers are available to read back status, voltages, frequencies, and historical data. Registers are also available for transfer switch con trol. Setpoints may be read back and/or programmed via a pass-through command. See the ATC-300+ Modbus Com munication Guide pn: 66A7787.
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3.5.2 Optional Features
The following is a list of the optional features for the ATC-300+ Controlled ATS. All features or combinations of features may not
be available on specific ATSs
9B. Maintenance Selector Switch (MSS)
Marked “OFF”, “ON”. This feature provides selector switch disconnection of control to transfer thus allowing testing of the transfer switch control logic circuitry with out initiating load transfer. Positioning the MSS in the “OFF” position isolates the control circuit, permitting man ual operation of the transfer switch or testing of logic cir­cuitry without load transfer. White indication light is lit ON and display on ATC-300 controller shows “ATS NOT IN AUTOMATIC” when the switch is in maintenance mode.
14. Relay Auxiliary Contacts: This feature provides form “C” relay auxiliary contacts.
14C. Source 1 Present: Provides four (4) normally open and four
(4) normally closed contacts. The relay is energized when Source 1 is available.
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14D. Source 2 Present: Provides four (4) normally open and four
(4) normally closed contacts. The relay is energized when Source 2 is available.
15. Switch Position Indication Contact
-
-
-
-
This feature provides a contact that indicates if the power switching device is in the “Open” or “Closed position.
15G. Source 1 Position Indication Contact
This feature provides 3 Dry Form “C” contacts that indi­cate the position of the Source 1 power-switching device.
15H. Source 2 Position Indication Contact
This feature provides 3 Dry Form “C” contacts that indi­cate the position of the Source 2 power-switching device.
18. Metering
This feature includes all required external devices (CTs, shorting blocks, fuses, etc.) for a fully functional metering system.
18AN. IQ 250/260 Normal (S1) Only
18AE. IQ 250/260 Emergency (S2) Only
18AL. IQ 250/260 Load
18CN. IQ 110/115 Normal (S1) Only
18CE. IQ 110/115 Emergency (S2) Only
18CL. IQ 110/115 Load
18DN. IQ 130/140/150 Normal (S1) Only
18DE. IQ 130/140/150 Emergency (S2) Only
18DL. IQ 130/140/150 Load
18EN. PXM2250/2260/2270 Normal (S1) Only
18EE. PXM2250/2260/2270 Emergency (S2) Only
18EL. PXM2250/2260/2270 Load
18O. IQ Analyzer Normal (S1) Only
18P. IQ Analyzer Emergency (S2) Only
18Q. IQ Analyzer Normal (S1) & Emergency (S2) Switch Select-
able
18V. IQ Analyzer Load
18R. IQ DP-4000 Normal (S1) Only
18S. IQ DP-4000 Emergency (S2) Only
18T. IQ DP-4000 Normal (S1) & Emergency (S2) Switch Select-
able
18U. IQ DP-4000 Load
18W. Ammeter
A single ammeter is a true RMS sensing device that dis­plays single phase current only.
The ammeter can be mounted on Source 1, Source 2, or load. The meter can also be configured for 1, 2, or 3-phase sensing by supplying one meter per phase for Source 1, Source 2, or load. Ammeters for both Source 1 and Source 2 can also be grouped together.
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40-400A (480/600Vac) ATC-300+ 3-Postion Contactor Based Transfer Switch
Instruction Booklet
Effective: September 2011 Page 13
23L. 24 Hour, 7day, 365 Day Programmable Plant Exerciser
This plant exerciser has two channel electronic time switches with 365-day, 7-day, 24-hour programming. Each channel can be independently programmed and can provide up to 400 events. The plant exerciser offers daily, weekly or annual programming capability with up to 99 separate holiday periods of any duration and priority. An LCD dis­play indicates load status, time-of-day, weekday and date.
29G. Auto/Manual Operation
This feature provides 2-position auto/manual selector
h marked “Auto/Manual” which permits the selec-
switc tion of automatic or manual operation. Once the selector
ch is transferred to manual mode, manual transfer
swit between Normal (S1) Neutral and Emergency (S2) can be achieved by operating 3-position selector switch marked “Normal-OFF-Emergency”. White indication light is lit ON and display on ATC-300+ controller shows “ATS NOT IN AUTOMATIC” when the switch is in manual mode.
38. Stainless Steel Logic Cover
38A. Stainless Steel Cover for Device Panel
Provides an added level of security by providing a pad
ble stainless steel cover for use with standard trans-
locka fer switch device panel. The cover is designed for NEMA 1, 3R, 4X, and 12 a
38B. Stainless Steel Cover for Controller
Provides an added level of security by providing a pad
ble stainless steel cover for use with standard trans-
locka fer switch logic controllers and/or associated device pan­els. These covers function with Generac’s ATC series logic controller designed for NEMA 1, 3R, 4X, and 12 applications.
41. Space Heater With Thermostat
This feature provides a space heater and non-adjustable
thermosta
41A. Space Heater With Thermostat - 100 Watt
This feature provides a 100 watt (W) spac
non-adjustable thermostat.
49B. Sensing Isolation Transformer (Up to 600 VAC only)
This feature provides 3-phase, 4-wire for Source-1 and
Sour tance grounded delta system.
51D1. 50kA CVX Surge Device
This feature gives protection for surge current capacity
ting 50kA, up to 480VAC by providing a low imped-
ra ance surge path to ground while supporting rated volt­age. It provides LED indication.
51F1. 100kA CVX Surge Device
This feature gives protection for surge current capacity
ting 100kA, up to 480VAC by providing a low imped-
ra ance surge path to ground while supporting rated volt­age. It provides LED indication.
t. External control power is not required.
ce-2 sensing input on ATC controller for a high resis-
pplications.
s and device panels. The covers are
e heater with a
3.6 Enclosure
The rugged steel ATS enclosure is supplied with three door hinges, regardless of enclosure size. They ensure proper support of the door and door mounted devices (Figure 9). The hinges have removable hinge pins to facilitate door removal. Certain procedures, such as switch mounting, are simplified with the door removed. The doors are supplied as standard with pad-lock­able latches.
Figure 9. Typical Type 1 Enclosure (Door Closed).
The door is used to mount a var push-buttons, depending upon the options required for a particu­lar ATS. All lights and switches are mounted in the plastic door­mounted pa
nel.
iety of lights, switches, and
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Instruction Booklet
Page 14 Effective: September 2011
40-400A (480/600Vac) ATC-300+ 3-Postion
Contactor Based Transfer Switch
The rear of the enclosure is supplied with teardrop shaped holes in the top and bottom mounting flanges to facilitate mounting. It is also supplied with two positioning bolts and various pre-tapped inserts to insure proper positioning of the power panel anytime the power panel must be repo sitioned to accommodate a different cable entry position. Cable entry holes are the responsibility of the customer.
ATS enclosures and all internal steel mounting plates, such
as the power panel mounting plate, go through a pretreat­ment cleaning system prior to painting to ensure a durable finish.
The standard ATS enclosure is NEMA 1 Type for general
use. However, a variety of enclosures are available to address almost any environmental circumstance (see Table 3).
Table 3. Transfer Switch Equipment Enclosures
NEMA TYPE DESIGN PROTECTION
Open Indoor
1 Indoor Enclosed Equipment
3R Outdoor Rain, Ice Formation
12 Indoor Dust, Dirt, and
Non-Corrosive Liquids
3.7 Standards
Generac ATS equipment, enclosed in any of the enclosures listed in Table 3, is listed for application by UL and ULC. In addition,
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Generac ATSs are listed in File E38116 by Underwriters Labora tories, Inc. under Standard UL 1008. This standard covers requirements for automatic transfer switches intended for use in ordinary locations to provide lighting and power as follows:
a. In emergency systems, in accordance with articles 517
and 700 in the National Electrical Code, ANSI/ NFPA 70, and the National Fire Protection Association No. 76A; and/or
b. In standby systems, in accordance with article 702 of the
National Electrical Code; and/or
c. In legally required standby systems in accordance with
article 701 of the National Electrical Code.
Generac ATSs are available to meet NFPA 110 for emergency and standby power systems, and NFPA 99 for health care facili ties when ordered with the appropriate options.
Standard UL 1008 for ATSs lists devices under the reexamination program which only require a continual physical reexamination of the components used in the product to ensure consistency with the originally submitted device. Follow-up testing is not required by UL 1008.
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40-400A (480/600Vac) ATC-300+ 3-Postion Contactor Based Transfer Switch
Instruction Booklet
Effective: September 2011 Page 15
Section 4: Installation and Wiring
4.1 General
Generac ATSs are factory wired and tested. Installation requires solidly mounting the enclosed unit and connecting power cables and auxiliary pilot circuits. Physical mounting procedures and power cable connections are covered in this section. All other required wiring or electrical connection references are covered in a separate Customer Wiring Booklet packaged with the ATS.
Locate the wiring schematic, review it, and ke able for reference purposes during installation and testing. Once an ATS and electrically checked for proper installation and operation. The procedures for these initial mechanical and electrical checks are outlined in Section 6 of this instruction manual.
is properly installed and wired, it should be mechanically
WARNING
BE CERTAIN THAT THE SOLID STEEL DOOR IS PROPERLY INSTALLED BEFORE THE TRANSFER SWITCH EQUIPMENT IS PUT INTO SERVICE. THE DOOR PROVIDES PROTECTION FROM DAN­GEROUS VOLTAGES AT THE LINE AND THE EQUIPMENT IS IN OPERATION. FAILURE TO DO SO COULD RESULT IN PERSONAL INJURY OR DEATH.
LOAD TERMINALS WHEN
4.2 Mounting Location
Choose a location that offers a flat, rigid mounting surface capa­ble of supporting the weight of the enclosed ATS equipment.
standard ATSs, avoid locations that are moist, hot, or dusty.
For However, Generac offers optional enclosure designs that can be used in special environments. If there are any doubts as to a location’s suitability, discuss them with your Generac representa­tive.
Check to make certain that there are no pipes, wires, or other mounting hazar ate a problem.
Carefully remove all packing mater ing location. Even though an equipment inspection should have been ma careful inspection of the enclosure and the enclosed ATS compo­nents as the packing material is removed and the enclosure read­ied for mounting. Be especially aler wires, or damaged components.
ds in the immediate mounting area that could cre-
ial from the ATS at the mount-
de when the equipment was received, make another
t for distorted metal, loose
ep it readily avail-
4.3 Mounting Procedure
CAUTION
SINCE THE ENCLOSED ATS MUST BE LIFTED INTO PLACE FOR MOUNTING, BE CERTAIN THAT ADEQUATE RESOURCES ARE AVAILABLE FOR LIFTING TO AVOID PERSONNEL INJURIES OR EQUIPMENT DAMAGE.
All equipment enclosures and power panels are of the same design. Only the overall physical dimensions change. Note that the enclosure is provided with four teardrop (elongated) mount­ing holes, two in the top mounting flange and two in the bottom.
Cable entry holes are not part of the enclosure when shipped from the factory and must be pr or after mounting the enclosure. Cable access may be from the top, bottom, and/or side.
ovided in the field, either before
CAUTION
EXTREME CARE SHOULD BE TAKEN TO PROTECT THE TRANSFER SWITCH FROM DRILL CHIPS, FILINGS, AND OTHER CONTAMI­NANTS WHEN MAKING THE CABLE ENTRY HOLES. EXTREME CARE SHOULD ALSO BE TAKEN WHEN MOUNTING THE ENCLO­SURE TO PREVENT COMPONENT DAMAGE OR A FUTURE MAL­FUNCTION.
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Figure 10.Typical (40A-400A) Contactor Based ATS Equipment (Door Open).
Instruction Booklet
ATC-300
Electrical
ase
ase
Source 1
Source 2
Available
Available
Connected
Connected
Load
Unit Status
Alarm Reset
Engine Test
Lamp Test
Help
Step
Enter
Bypass
TDNE / TDEN
Page 16 Effective: September 2011
40-400A (480/600Vac) ATC-300+ 3-Postion
Contactor Based Transfer Switch
With the enclosed ATS equipment unpacked and ready for mounting, proceed with the following steps.
Step 1: The ATS enclosure door is hinge mounted with remov-
able hinge pins. To simplify the mounting procedure and
void damaging the door-mounted logic panel, it is
a strongly suggested that the door be carefully removed and put it in a safe place until mounting is complete. To remove the door, open the door and disconnect the con­nectors at the back of the ATC-300+ logic panel. Remove the wire
ties securing the harness to the inside of the door. Carefully remove the hinge pins then the door from the enclosure.
Step 2: Insta
ll the required upper and lower mounting bolt anchors and the two upper mounting bolts in the mount­ing surface.
Step 3: Gently lift the enclosure and guide the tear
drop holes in the upper mounting flange over the upper mounting bolts. Do not completely tighten the bolts at this time.
Step 4: Wh
ile still supporting the enclosure, install the two lower mounting bolts in the lower mounting flange. Again, do not completely tighten the bolts at this time. Use shims, if required, to prevent deformation of the enclosure if the mounting surface is distorted.
Step 5: T
ighten all four mounting bolts after any required shim-
ming is completed.
4.4 Power Cable Connections
WARNING
POWER CONDUCTORS MAY HAVE VOLTAGE PRESENT THAT CAN CAUSE SEVERE PERSONAL INJURY OR DEATH. DE-ENERGIZE ALL POWER OR CONTROL CIRCUIT CONDUCTORS TO BE CONNECTED TO THE ATS EQUIPMENT BEFORE BEGINNING TO WORK WITH THE CONDUCTORS AND/OR TERMINATING THEM TO THE EQUIPMENT.
CAUTION
USE OF CABLE LUGS NOT DESIGNED FOR THE ATS MAY CAUSE HEATING PROBLEMS.
CAUTION
TO HELP PREVENT COMPONENT DAMAGE OR FUTURE MALFUNC­TIONS, USE EXTREME CARE TO KEEP CONTAMINANT THE ATS EQUIPMENT WHEN MAKING POWER CABLE CONNEC­TIONS.
S OUT OF
CAUTION
RUN THE POWER CABLE THROUGH THE GUTTER SPACE PROVIDED TO THE RIGHT OR LEFT OF POWER PANEL.
Figure 11.Typical Mounting of the ATS to a Mounting Surface.
Step 6: Double che
ck to ensure that all packing and shipping
materials have been removed.
Test all power cables prior to connection to the unit to ensure that the conductors or cable insulation have not been damaged while being pulled into position.
Power cables are to be connected to solderless screw type lugs
ted on the ATS switching devices. Refer to the separate Cus-
loca tomer Wiring Booklet supplied with the ATS equipment for power termination. Ve
rify that the lugs supplied will accommodate the power cables being used. Also verify that the cables comply with local electrical codes. Standard ATS equipment, as supplied from the factory, will accommodate the wire sizes shown in Table 4.
Carefully strip the insulation from
the power cables to avoid nick­ing or ringing of the conductor strands. Prepare the stripped con­ductor termination end by cleaning it with a
wire brush. If aluminum conductors are used, apply an appropriate joint com­pound to the clean conductor surface area.
WARNING
IMPROPER POWER CABLE CONNECTIONS CAN CAUSE EXCESSIVE HEAT AND SUBSEQUENT EQUIPMENT FAILURE.
Tighten the cable lugs to the torque identified on the label affixed to the door of the unit.
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Instruction Booklet
40-400A (480/600Vac) ATC-300+ 3-Postion Contactor Based Transfer Switch
Table 4. Transfer Switch Equipment Wire Sizes
TRANSFER SWITCH AMPERE RATING WIRE SIZE RANGES NUMBER OF CABLES PER PHASE TERMINAL TEMPERATURE RATING °C (°F)
100 #14-2/0 1 75 (167)
200 #6-250 KCMIL 1 75 (167)
320 #4-600 KCMIL or (2) 1/0-250 KCMIL 1 or 2 - depending on wire size used 75 (167)
400 #4-600 KCMIL or (2) 1/0-250 KCMIL 1 or 2 - depending on wire size used 75 (167)
4.5 Wiring
Effective: September 2011 Page 17
POWER CONDUCTORS AND CONTROL WIRING MAY HAVE VOLT­AGE PRESENT THAT CAN CAUSE SEV DEATH. DEENERGIZE ALL POWER OR CONTROL CIRCUIT CON­DUCTORS BEFORE BEGINNING TO PERFORM ANY WIRING ACTIV­ITY TO OR WITHIN THE ATS EQUIPMENT.
Power sources, load conductors, and control wiring should be connected to locations as indicated in the Customer Wiring Book­let supplied with the ATS equipment.
WARNING
ERE PERSONAL INJURY OR
CAUTION
ENSURE THE ATS VOLTAGE IS SET CORRECTLY. IT SHOULD BE THE SAME AS THE SOURCE 1 AND SOURCE 2 LINE VOLTAGES. OPERATING THE EQUIPMENT ON IMPROPER VOLTAGE CAN CAUSE EQUIPMENT DAMAGE.
Once the ATS equipment has been installed and wired, perform the initial mechanical and electrical procedures as outlined in Sec­tion 6 to verify that the equipment is installed and operating
ly.
proper
4.6 Engine Start Connection
The engine control contact connections are located on the logic panel of the ATS. Connect the engine start wires to the termi­nals marked 13 and 14 on J-5 connector on the ATC-300+ Con­troller (see Figure 12). A contact closes between these terminal when an e wiring diagram provides additional engine start connection infor­mation. Use the proper wire size as listed by the generator set (Ge
ngine start signal is provided by the ATS logic. The
nset) manufacturer.
NOTICE
PRIOR TO MAKING THE ENGINE START CONNECTION TO THE SWITCH, SET THE ENGINE GENERATOR CONTROLS SELECTOR SWITCH IN THE OFF POSITION TO PREVENT AN UNWANTED ENGINE START. CONTROL WIRING, SUCH AS THE ENGINE START WIRES, MUST BE RUN IN A SEPARATE CONDUIT FROM THE POWER CABLES.
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123
4
5678
9
10
11 12 13
14
123
4
5678
9
10
11 12 13
14
123
4
5678
9
10123
4
5678
9
10
J5
J7
J2
J1
J4
7
6
5
4
3
4
J3
Phase C
Phase B Phase A
Source 1
Phase C
Phase B Phase A
Source 1
Phase C
Phase B Phase A
Source 2
Phase C
Phase B Phase A
Source 2
S1 - Line S1 - Neut
S2 - Line
Control Power
S2 - Neut
Clk
In
Out
5V
Gnd
Programming
Port
K1 - (Com)
K1 - (NO)
K2 - (Com)
K2 - (NO)
Pretransfer - (Com)
Pretransfer - (NO)
Pretransfer - (NC)
Alarm - (Com)
Alarm - (NO)
Alarm - (NC)
Earth Ground
Gen Start - (Com)
Gen Start - (NO)
Output Relays
+32 VDC
Source 1 Closed
+32 VDC
Source 2 Closed
+32 VDC
Lockout
+32 VDC
Go To Source 2
+32 VDC
Monitor Mode
Control Inputs
8.0 in.
6.5 in.
3
4
1
2
7
8
5
6
Output Relays
Control Inputs
J8
K4 NO K4 C om
K3 NO K3 Com
2
1
Rx
Tx
Emergency Inhibit
Manual Re-Transfer
J10
3
4
2
1
RS485 Termination
RS-485 MODBUS
A
B
Com
SHD
1
ON
S2 Close
S1 Close
S2
Open
S1
Open
TERMINALS 13 & 14
ATC-300+ Controller - 2 Position Contactor type (In-Phase) - CAT#8160A00G27
ATC-300+ Controller - 3 Position Contactor type (TDN) - CAT#8160A00G28
Instruction Booklet
Page 18 Effective: September 2011
40-400A (480/600Vac) ATC-300+ 3-Postion
Contactor Based Transfer Switch
Figure 12. Location of Terminals 13 and 14 on the J-5 Connector of ATC-300+ Controller.
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40-400A (480/600Vac) ATC-300+ 3-Postion Contactor Based Transfer Switch
4.7 Voltage Selection Adjustments
Certain devices, such as the Voltage Selection Panel, sensing relays, and timers, need to be set and/or calibrated prior to plac­ing the ATS equipment in service. Adjustments for logic devices
described in the separate instructional document dedicated to
are the specific logic being used. Voltage selection adjustments are described in this section.
CAUTION
BE SURE THAT THE CORRECT VOLTAGE IS SELECTED TO MATCH THE SYSTEM VOLTAGE. AN IMPROPER SELECTION AND/OR CON­NECTION COULD RESULT IN EQUIPMENT DAMAGE.
4.7.1 Standard Voltage Selection Panels (208, 240, 480, 600 V, - 60 Hz & 220, 380, 415 V, -50 Hz
The Standard voltage selection panel consists of multi-tap trans­formers, contained in a steel case mounted in the enclosure. To
the voltage from the factory default 600 Vac, follow the
change steps detailed below.
Step1: Loos
Step 2: Remove th
en the six screws securing the cover of the Voltage Selection Transformer case. Slide the cover up, then away from the case.
formers and installed them on the taps for the desired volta former is moved since the second wire is the zero refer­ence.
e wires from the primary taps of both trans-
ge (Figure 13B). Note that only one wire per trans-
)
Instruction Booklet
Effective: September 2011 Page 19
Figure 13A. Standard Voltage Selection Panel.
CAUTION
WHEN CHANGING THE VOLTAGE, ONE WIRE MUST BE MOVED ON THE PRIMARY TAPS OF BOTH TRANSFORMERS.
Figure 13B. Standard Voltage Selection Panel.
Figure 13.
Step 3: Re
install the cover and tighten the four screws.
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Instruction Booklet
TOOL HOLE
WIRE HOLE
Page 20 Effective: September 2011
4.8 Terminal Block Wire Installation and Removal
Proceed with the following steps and associated figures to install or remove terminal block wiring.
Step 1: Figure 1
There is a large one and small one, but the operation is the same for both. A small tool, such as a screwdriver, will be pushed into the square hole next to the wire hole and a wire will be inserted into the larger circular hole on the outer edge.
4 shows two tension clamp terminal blocks.
40-400A (480/600Vac) ATC-300+ 3-Postion
Contactor Based Transfer Switch
Figure 16. Wire Inserted in the “Wire” Hole.
Step 4: Wh
ile holding the wire in place, pull the screwdriver out. The wire will now be held securely in the terminal block. Pull on the wire to insure that it is correctly inserted into the clamp.
Figure 14. Tension Clamp Terminal Blocks.
Step 2: Be
gin by inserting a small, flathead screwdriver into the square (tool) hole with the flat surface of the screwdriver against the back wall of the hole. With a little bit of force, push the screwdriver in on a slight angle toward the center of the clamp. Be sure to slide it in until it clicks. You will then see the clamp open in the wire hole.
Figure 17. Wire Securely Installed in the Terminal Block.
Figure 15. Screwdriver Inserted in the “Tool” Hole.
Step 3: Once the sc
(strip about 1/4 in.) and insert it into the larger circular wire hole. Push the wire in until it can go no further.
rewdriver is in place, obtain a stripped wire
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40-400A (480/600Vac) ATC-300+ 3-Postion Contactor Based Transfer Switch
Section 5: Operation
5.1 General
An ATS provides a power contactor to connect and disconnect the load to and from the Source 1 and Source 2 power sources (Section 3.2.1).
5.2 Manual Operation
Instruction Booklet
Effective: September 2011 Page 21
DO NOT ATTEMPT TO MANUALLY OPERATE THE ATS WITH SOURCE 1 OR SOURCE 2 AVAILABLE.
WARNING
WARNING
HIGH VOLTAGES ARE PRESENT IN AND AROUND TRANSFER SWITCH EQUIPMENT. BEFORE ATTEMPTING TO MANUALLY TRANSFER, DISCONNECT THE LINE POWER FROM THE EQUIP­MENT BEING SERVICED BY OPENING BLE, THE NEXT HIGHEST DISCONNECT DEVICE. FAILURE TO FOLLOW THIS PROCEDURE COULD CAUSE SEVERE PERSONAL INJURY AND/OR DEATH.
ALWAYS TURN THE SOURCE 1 POWER OFF AND TURN THE
URCE 2 (IF A GENERATOR) CONTROL SELECTOR SWITCH TO
SO THE “OFF” POSITION BEFORE ATTEMPTING A MANUAL TRANS­FER.
To manually operate:
1. Disconnect all sources of power.
2. Disconnect the J7 connector from the ATC-300+ controller.
3. Locate the manual lever on the left side of the contactor.
4. Locate the handle used to manually transfer the switch.
5. Attach the handle to the manual lever (See Figure 18).
6. Rotate the lever down to go to open or trip the unit.
7. Depress the “close” button located on the operating mecha­nism of the contactor to bring the contactor position.
8. Rotate the lever down to open or trip the unit.
9. Depress the “source select” button on the operating mecha­nism of the contactor and depress the “close” button while
ping the “source select” button depressed to go to
kee Source-2.
AND LOCKING OUT, IF POSSI-
to the Source-1
Figure 18. ATS Manual Operating Handle in Use.
10. Once the manual operation is complete and automatic opera­tion is desired, connect the sources of power.
11. Check for 120 Vac at J7-2 to J7-1 if Source 1 is available.
12. Check for 120 Vac at J7-4 to J7-3 if Source 2 is available. See the Tr 800 Controller Instruction Booklet I.B. ATS-C103) if values are above 130 Vac or below 110 Vac.
13. Insert the J7 connector into the controller.
14. Follow the testing procedure in Section 6 to ensure proper
utomatic operation.
a
oubleshooting Guide (Table 3, Section 6 of ATC-
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Instruction Booklet
Page 22 Effective: September 2011
40-400A (480/600Vac) ATC-300+ 3-Postion
Contactor Based Transfer Switch
5.3 Automatic Transfer
The operating sequence of an ATS is dictated by the switch's standard features and selected options. Operation of an ATS dur­ing Source 1 power source failure and Source 1 power source
ration will be described here with only standard options
resto included on the switch. Additional options, as described in Sec­tion 3, can change sequences and timing, depending upon the
ns selected. It is strongly suggested that you become famil-
optio iar with additional options selected with the particular ATS and their effect on the
5.3.1 Source 1 Power Source Failure
Standard Source 1 power source failure is defined as a reduction or loss of voltage. If this occurs, the sequence of operation is as follows.
1. Failure of Source 1 is detected by
2. When the controller detects a failure, the engine contacts
3. When the Source 2 voltage reaches its operation rating, the
4. The load is now transferred to the Source 2 power source.
(after delay if programmed) and start the engine-driven
close generator.
K2 and K4 re transfer operation to Source 2. This operating sequence causes the contactor to open Source 1 and close on Source 2.
5.3.2 Source 1 Power Source Restoration
1. A return to the Source 1 power source begins when the volt­age in all phases of a 3-phase sensing unit, or phase-to-pha in a single sensing unit, is restored to a preset value.
2. At the preset voltage, K1 and K3 relays inside ATC 300 con­troller operate to start transfer
3. During this sequence, the contactor opens Source 2 and
4. Simultaneously, the engine cool-down timer initiate
5. Transfer of the load back to the Source 1 power source is
s on Source 1.
close
down of the engine driven generator.
now complete.
normal operation of an ATS.
the controller intelligence.
lays inside ATC 300 controller operate to start
se
operation to Source 1.
s the shut
Section 6: Testing and Problem Solving
6.1 Testing
After the ATS equipment is initially installed or during planned outages, the installation should be tested to ensure that all equip­ment operates properly. This attention t unexpected malfunctions. Mechanical and/or electrical tests should be performed as described in this section.
The frequency of subsequent testing should be base mendations of the Genset manufactur to check the electrical operation of the switch.
WARNING
HIGH VOLTAGES ASSOCIATED WITH OPERATIONAL TRANSFER SWITCH EQUIPMENT PRESENT A SHOCK HAZARD THAT CAN CAUSE SEVERE PERSONAL INJURY OR DEATH. USE EXTREME CAUTION TO AVOID TOUCHING ELECTRICAL CONNECTIONS WHENEVER INSPECTING OR TESTING THE EQUIPMENT.
IN ADDITION, IMPROPER OPERATION OF THE GENERATOR SET
NTS A HAZARD THAT CAN CAUSE SEVERE PERSONAL
PRESE INJURY OR DEATH. OBSERVE ALL SAFETY PRECAUTIONS IN YOUR GENERATOR SET OPERATIONS AND INSTALLATION MANUALS.
6.1.1 Mechanical and/or Electrical Testing
NOTICE
SINCE FEATURE 4 (TIME DELAY ENGINE COOL-OFF), AS DESCRIBED IN SECTION 3, IS A STANDARD FEATURE, AN ENGINE START SIGNAL WILL BE PRESENT FOR A PERIOD OF TIME WHEN THE S WI TCH IS FI RS T ENER GI ZE D. THE PE RIOD OF T IM E IS EQ UA L TO THE TIMER SETTING. TO AVOID STARTING THE ENGINE DUR­ING THIS TIME PERIOD, TURN THE GENERATOR CONTROLS TO
E OFF POSITION.
TH
Energize the ATS equipment as described in Sections 6.1.2 through 6.1.6. Insure that all safety precautions are taken and that all WARNINGS and CAUTIONS are observed.
6.1.2 No Voltage Steps
With no voltage available on either power source, proceed as fol­lows.
Step 1: The
Step 2: Ensure that the
Step 3: Check
6.1.3 Connecting the Power Sources
Step 1: Close the Source 1 power source upstream protection
Step 2: Connect the engine sta
Step 3: With the emer
generator engine start controls should be in the OFF
position to prevent an undesired start.
ATS has been set to the proper applied
system voltage (See Section 4.7).
all ATS loads to ensure that they are ready to be
energized.
device.
rt battery cable.
gency generator in the OFF position, close the Source 2 power source upstream protective device, assuming such a device used.
o detail will help avoid
d on recom-
er. Use the test pushbutton
For more information visit: www.generac.com IB01602078E
40-400A (480/600Vac) ATC-300+ 3-Postion Contactor Based Transfer Switch
Instruction Booklet
Effective: September 2011 Page 23
NOTICE
AT THIS POINT, AND PRIOR TO MAKING ANY ATTEMPT TO ENER­GIZE THE ATS EQUIPMENT, THE ENGINE-DRIVEN GENERATOR SHOULD BE OPERATED. IF NECESSARY, THE VOLTAGE REGULA­TOR ON THE GENERATOR SHOULD BE ADJUSTED ACCORDING TO THE MANUFACTUR MENT WILL RESPOND ONLY TO THE RATED VOLTAGE AND FRE­QUENCY PROGRAMMED INTO THE CONTROLLER.
Step 4: Close any generator engine-start controls opened as a
Step 5: Where required, use an accurate voltmeter to check
result of actions taken in Step 1, Section 6.1.2.
phase-to-phase and phase-to-neutral voltages present at the transfer switch Source 1, Source 2, and/or load ter­minals.
6.1.4 Operational Checks
Step 1: Check to ensure that Source 1 switching device is in the
Step 2: Initiate an automatic trans
Note:The ATC-300+ Logic Controller provides the capability to set the
Engine Test function to:
The factory default is set to 0 - No Load Engine Test:
Step 3: Initiate an automatic transfer operation back to the
CLOSED position. This should have been done in Section
6.1.3, Step 1.
1 to the Source 2 power source by pressing the <Engine Test> pushbutton two times.
0. No Load Engine Test;
1. Load Engine Test; or
2. Disabled.
1. Load Engine Test
a. After the Time Delay Engine Starting (TDES) has timed out,
b. The transfer switch will transfer to the Source 2 power
Source 1 power source by pressing the <Engine Test> pushbutton one time.
1. After the Time Delay Emergency to Normal timer (TDEN) has timed out, t back to the Source 1 power source.
2. The Time Delay for Engine Cool-Off (TDEC - Feature 4) will allow the eng after transfer to the Source 1 power source is com­pleted.
6.1.5 Alternate Tests
1. Alternate operational tests may be possible depending upon the options provided with any given ATS. Refer to the sche­matic diagram provided with the ATS equipment, along with the spec provided.
ER’S RECOMMENDATIONS. THE ATS EQUIP-
fer operation from the Source
the engine should start, run, and build up to normal voltage and frequency.
source after the Time Delay Normal to Emergency (TDNE) times out.
he transfer switch will transfer
ine to run unloaded for a preset time
ification nameplate, to determine the exact options
WARNING
DO NOT ATTEMPT TO MANUALLY OPERATE THE ATS WITH THE SOURCE 1 POWER SOURCE CONNECTED AND AVAILABLE.
DO NOT ATTEMPT TO MANUALLY OPERATE THE ATS WITH THE
URCE 2 POWER SOURCE CONNECTED AND AVAILABLE.
SO
6.2 Problem Solving
WARNING
HAZARDOUS VOLTAGES IN AND AROUND ATS EQUIPMENT DUR­ING THE PROBLEM SOLVING PROCESS CAN CAUSE SEVERE PER­SONAL INJURY AND/OR DEATH. AVOID CONTACT WITH ANY VOLTAGE SOURCE WHILE PROBLEM SOLVING.
WARNING
ONLY PROPERLY TRAINED PERSONNEL, FAMILIAR WITH THE ATS EQUIPMENT AND ITS ASSOCIATED EQUIPMENT, SHOULD BE PER­MITTED TO PERFORM THE PROBLEM SOLVING FUNCTION. IF AN
DIVIDUAL IS NOT QUALIFIED TO PERFORM THE PROBLEM SOLV-
IN ING FUNCTION, THE INDIVIDUAL SHOULD NOT ATTEMPT ANY OF THESE PROCEDURES
A basic problem-solving effort is the first step to take prior to calling for assistance. Frequently, the effort will successfully address most problems encountered. The problem solving proce­dure is presented in the Troubleshooting Guide (Table 3, Section 7 of ATC 300 Controller Instruction Booklet IB01602009E). R with the ATS equipment and the system in which it is applied should attempt these problem solving procedures.
If a problem persists after having completed the problem solving
ocedure, contact a Generac representative for further assis-
pr tance. When calling for assistance, the following is the minimum information r
1. Style number of ATS, if applicable;
2. Catalog number of ATS;
3. Actual location of the ATS (type of facility, address, etc.);
4. Company name and name and position of individual repre­senting company;
5. Basic description of the situation as it exists; and
6. Any results of the problem solving steps taken and/or read­ings taken.
equired to properly address the need:
.
emember, only qualified individuals familiar
IB01602078E For more information visit: www.generac.com
Instruction Booklet
Page 24 Effective: September 2011
40-400A (480/600Vac) ATC-300+ 3-Postion
Contactor Based Transfer Switch
Section 7: Adjustments
7.1 General
Refer to I.B. 01602009E, supplied with the ATS for ATC-300+ Controller adjustments and programming.
Section 8: Maintenance
8.1 Introduction
WARNING
HIGH VOLTAGES ARE PRESENT IN AND AROUND ATS EQUIPMENT. BEFORE INSPECTING OR MAINTAINING THIS EQUIPMENT, DISCON­NECT THE LINE POWER FROM, THEN LOCK OUT, IF POSSIBLE, THE
T HIGHEST DISCONNECT DEVICE. FAILURE TO FOLLOW THIS
NEX PROCEDURE COULD CAUSE SEVERE PERSONAL INJURY AND/OR DEATH.
In general, ATS switch equipment is designed to be relatively maintenance free under normal usage. However, because of the variability of application conditions and the importance placed on dependable operation by this type of equipment, inspection and maintenance checks should be made on a regularly scheduled basis. Since equipment maintenance will consist mainly of keep­ing the equipment clean, the f depend to a large extent on the cleanliness of the equipment’s surroundings. If a significant amount of dust or foreign matter is present, a more frequent maintenance schedule should be fol­lowed.
It is suggested that visual inspections of the equipment be made
egular basis, not just during scheduled periods. Always be
on a r alert for an accumulation of dirt in and around the structure; loose parts; and/or hardware, cracks, and/or discoloration to insulation; and damaged or discolored components.
requency of maintenance will
8.2 Procedures
A suggested maintenance procedure is outlined in Table 5.
Table 5. Periodic Maintenance Procedures
STEP ACTION
a. Make the ATS equipment safe for inspection and/or maintenance. Disconnect the line power from equipment being serviced by opening the next highest disconnect device. Make
b. Inspect the structure area for safety hazards or potential maintenance problems. Inspect the area, especially where switching device is installed, for any safety hazards, including personnel
c. Inspect the power contactor for dust, dirt, soot, grease, moisture, or corrosion. Remove dust, dirt, soot, grease, moisture, and corrosion contamination from the surface of the switching device
d. Check for material integrity, uneven wear, discoloration, or loose hardware. Severe material cracking will require replacement and loose hardware will need to be tightened.
e. Check the terminals and connectors for looseness or signs of overheating. Overheating will show as discoloration, melting, or blistering of the conductor insulation.
f. Contact Inspection Procedure Carefully remove the arc chute clips using needle nose pliers. Remove the arc chutes to inspect the contacts.
g. Exercise the power contactor if it is not often exercised while in operation.
This will permit a “wiping” action by the contacts.
h. Return the ATS equipment to service. Make certain all barriers are in place and doors closed. Reapply secondary and primary power.
certain that any accessory control power is switched off by disconnecting all control plugs.
safety and fire hazards. Exposure to certain chemical vapors can cause deterioration of electrical connections.
Inspect for accumulated dirt, loose hardware, or physical damage.
Examine the primary insulation for evidence of cracking or overheating. Overheating will show as discoloration, melting, or blistering of conductor insulation, or as pitting or melting of conductor surfaces due to arcing.
Inspect the secondary control connections for damage and the control wiring for insulation integrity.
using a dry soft lint-free cloth, dry soft bristle brush, and vacuum cleaner. Do not blow debris into the power contactor. If contamination is found, look for the source and fix the problem.
Connections that do not have signs of looseness or overheating should not be disturbed.
Contact Generac if the contacts have excessive wear. Reinstall the arc chutes and arc chute clips, making sure the ends of the clips are fully seated in the grooves on the barriers.
If the power contactor is used for frequent switching during normal operation, this step can be disregarded.
For more information visit: www.generac.com IB01602078E
40-400A (480/600Vac) ATC-300+ 3-Postion Contactor Based Transfer Switch
SECTION 9: RENEWAL PARTS GUIDE
Instruction Booklet
Effective: September 2011 Page 25
9.1 General
Refer to Figure 19 for assistance with selecting and ordering selected ATS renewal parts. For more information, please see Renewal Parts Publication (RP01603002E).
Example: To order
ATC3C3X30400WRU transfer switch, order Catalog
Number as shown in Figure 19, below.
the ATC-300+ Controller for an
ATC-300+ Controller - 3 Position Contactor type (In-Phase) - CAT#8160A00G27
Transformer Pack 400A, 2-Pole, 3-Pole, 4-Pole - Cat# 68C8229G02
Contactors (400A) 400A, 480VAC, 2-Pole - Cat# 69C2990G01
Wire Harness (400A Contactor)
Lugs (400A Contactor) Up to 400A - Cat# AB-750-4
100W Space Heater Domestic Switch, up to 600VAC - Cat# 8160A41G54
Figure 19. Typical ATC-300+ Controlled Contactor Based ATS.
IB01602078E For more information visit: www.generac.com
400A, 480VAC, 3-Pole - Cat# 69C2990G02 400A, 480VAC, 4-Pole - Cat# 69C2990G03
200A, 600VAC, 2-Pole - Cat# 69C2990G01 200A, 600VAC, 3-Pole - Cat# 69C2990G02 200A, 600VAC, 4-Pole - Cat# 69C2990G03
AG Switch, up to 240VAC, 2-Pole - Cat# 68C8189G05 + 68C8189G06 AG Switch, up to 240VAC, 3-Pole, 1-Phase - Cat# 68C8189G05 + 68C8189G09 AG Switch, up to 240VAC, 3-Pole, 3-Phase - Cat# 68C8189G05 + 68C8189G07 AG Switch, up to 240VAC, 4-Pole - Cat# 68C8189G05 + 68C8189G08
Domestic Switch, up to 600VAC, 2-Pole - Cat# 69D8301G02 + 68C8189G35 Domestic Switch, up to 600VAC, 3-Pole - Cat# 69D8301G02 + 68C8189G35 Domestic Switch, up to 600VAC, 4-Pole - Cat# 69D8301G02 + 68C8189G35
Instruction Booklet
ase
ase
Page 26 Effective: September 2011
Section 10: ATC-300+ Controlled ATS Quick Start Instructions
WARNING
THESE QUICK START INSTRUCTIONS ARE NOT A COMPLETE SOURCE OF INFORMATION ON THE ATC-300+ CONTROLLED ATS EQUIPMENT. INSTALLATION SHOULD NOT BE STARTED UNTIL THE ENTIRE INSTRUCTION BOOK HAS BEEN REVIEWED AND UNDERSTOOD. FAILURE TO FOLLOW THE FULL INSTRUCTIONS CAN RESULT IN DEATH, SEVERE PERSONAL INJURY, OR PROP­ERTY DAMAGE.
WARNING
THESE QUICK START INSTRUCTIONS ARE PROVIDED FOR USE ONLY BY TECHNICIANS HIGHLY FAMILIAR AND EXPERIENCED WITH ATC-300+ CONTROLLED ATS EQUIPMENT INSTALLATION, SET UP, AND TESTING. IT IS STRONGLY SUGGESTED THAT THE FULL INSTRUCTIONS BE FOLLOWED FOR ALL INSTALLATIONS, SET UP, AND TESTING.
40-400A (480/600Vac) ATC-300+ 3-Postion
Contactor Based Transfer Switch
Electrical
Unit Status
ATC-300
Available
Source 1
Connected
Load
Available
Connected
Source 2
Help
Step
Engine
Lamp
Test
Enter
Test
Alarm
Bypass
Reset
TDNE / TDEN
Step 1: Mount the ATS on a flat rigid surface (Figure 20). Shim if
necessary.
Figure 20. Mounting Details.
Step 2: Install the powe
r cables. Cables must be sized and installed per National Electrical Code, refer to NFPA70. The cables must be sized within the specified cable size range on the side of the cable connectors.
Connect the cables and torque to the correct value indi­cated on the label on the door in the following order:
1.Load Cables* (T1, T2, T3);
2.Source 1 or Utility Supply (N1, N2, N3); and
3.Source 2 or Generator Supply (E1, E2, E3).
For 4 pole transfer switches, connect the load cables
(TN), Sour
ce 1 or utility supply (NN), and Source 2 or generator supply (EN). Refer to Figure 21 for the location of all parts discussed in this document.
*Load cables MUST be connected and torqued BEFORE
installing the SUP
PLY cables (Figures 21).
Shim if Necessary
For more information visit: www.generac.com IB01602078E
NEUTRAL
CONNECTION
TRANSFER
MECHANISM
LOAD LUGS
EMERGENCY LUGS
NORMAL LUGS
LOGIC PANEL
VOLTAGE SELECTION AND TRANSFORMER PANEL
GROUND
CONNECTION
40-400A (480/600Vac) ATC-300+ 3-Postion Contactor Based Transfer Switch
Instruction Booklet
Effective: September 2011 Page 27
Figure 21. 400A, 3-Pole, ATS Interior Components.
IB01602078E For more information visit: www.generac.com
Instruction Booklet
123
4
5678
9
10
11 12 13
14
123
4
5678
9
10
11 12 13
14
123
4
5678
9
10123
4
5678
9
10
J5
J7
J2
J1
J4
7
6
5
4
3
4
J3
Phase C
Phase B Phase A
Source 1
Phase C
Phase B Phase A
Source 1
Phase C
Phase B Phase A
Source 2
Phase C
Phase B Phase A
Source 2
S1 - Line S1 - Neut
S2 - Line
Control
Power
S2 - Neut
Clk
In
Out
5V
Gnd
Programming
Port
K1 - (Com)
K1 - (NO)
K2 - (Com)
K2 - (NO)
Pretransfer - (Com)
Pretransfer - (NO)
Pretransfer - (NC)
Alarm - (Com)
Alarm - (NO)
Alarm - (NC)
Ear th Ground
Gen Start - (Com)
Gen Start - (NO)
Output Relays
+32 VDC
Source 1 Closed
+32 VDC
Source 2 Closed
+32 VDC
Lockout
+32 VDC
Go To Source 2
+32 VDC
Monitor Mode
Control Inputs
8.0 in.
6.5 in.
3
4
1
2
7
8
5
6
Output Relays
Control Inputs
J8
K4 NO K4 C om
K3 NO K3 Com
2
1
Rx
Tx
Emergency Inhibit
Manual Re-Transfer
J10
3
4
2 1
RS485 Termination
RS-485 MODBUS
A
B
Com
SHD
1
ON
S2 Close
S1 Close
S2
Open
S1
Open
TERMINALS 13 & 14
ATC-300+ Controller - 2 Position Contactor type (In-Phase) - CAT#8160A00G27
ATC-300+ Controller - 3 Position Contactor type (TDN) - CAT#8160A00G28
Page 28 Effective: September 2011
40-400A (480/600Vac) ATC-300+ 3-Postion
Contactor Based Transfer Switch
Step 3: Turn the generator OFF at the generator control panel.
This will prevent unexpected activation of the generator.
Step 4: Connect the Engine Generator Start wires to terminals
13 and 14 on the J-5 connector on the ATC-300+ Con-
ct is CLOSED whenever
troller (Figure 22). This conta
the engine generator is needed, and should be connected to a generator controller. NEVER connect directly to a starter solenoid or ignition system. See the Genset man­ufacturer instruction leaflet for recommended wire sizes and location procedur
es.
Figure 22. Engine Generator Control Connection.
Step 5: Apply
Utility (Source 1) power. If the switch is properly applied for the system voltage ordered, the display should work and the Source 1 Available white LED should light (Figure 23). Using a voltmeter, check for proper system voltage on Source 1 and load terminals. Check all phases on a 3-phase switch. Voltage measure­ments should be taken phase to phase and phase to neu­tral.
For more information visit: www.generac.com IB01602078E
40-400A (480/600Vac) ATC-300+ 3-Postion Contactor Based Transfer Switch
Unit Status
ATC-300
Available
Source 1
Source 2
Available
Connected
Load
Connected
Instruction Booklet
Effective: September 2011 Page 29
Engine
Tes t
Help
Lamp
Tes t
TDNE / TDEN
Bypass
Step
Enter
Alarm
Reset
Figure 23. ATC-300+ Logic (Utility Supplying Load).
Step 6: To view the setpoints, press the <Step/Enter> pushbut-
ton and enter the Password.
Note: The factory default Password is 0300. Once all installation and
testing is complete, the Password should be changed by authorized personnel to a unique Password for the equipment.
After entering the password, press the <Step/Enter> pushbutton until the VIEW SETPOINTS menu appears. Select YES. Press the <Step/Enter> pushbutton to scroll through the setpoints (Figures 24 through 26 and Table 6).
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Instruction Booklet
Page 30 Effective: September 2011
Utility - Generator Transfer Switch
Source 1 is available
Source 1 is powering the load
Source 1 becomes unavailable
(or Engine Test, Plant Exercise, Go To Emergency)
40-400A (480/600Vac) ATC-300+ 3-Postion
Contactor Based Transfer Switch
Close Source 1
(Energize K1)
No
Is Source 1
Available?
TDES timer times out
Send "Engine Start" signal
(Energize Gen Start relay)
Is Source 2
Available?
Ye s
TDNE timer times out
Sends pretransfer signal
TPRE timer times out
(If Source 1 is Available)
Open Source 1
(Energize K2)
Close Source 2
(Energize K2)
No
Ye s
TDEN timer times out
Sends pretransfer signal
TPRE timer times out
Open Source 2
(Energize K1)
Close Source 1
(Energize K1)
Source 1 is powering the load
TDEC timer times out
Remove "Engine Start" signal
(De-energize Gen Start relay)
Source 2 is powering the load
Figure 24. Utility - Generator Transfer Switch.
For more information visit: www.generac.com IB01602078E
Dual Utility Transfer Switch
Source 1 is available
Close Source 1
(Energize K1)
Source 1 is powering the load
Source 1 becomes unavailable
(or Go To Emergency)
Is Source 2
Available?
TDNE timer times out
Open Source 1
(Energize K2)
Close Source 2
(Energize K2)
Source 2 is powering the load
Is Source 1
Available?
TDEN timer times out
Ye s
No
No
Ye s
Open Source 2
(Energize K1)
Close Source 1
(Energize K1)
Source 1 is powering the load
Sends pretransfer signal
TPRE timer times out
(If Source 1 is Available)
Sends pretransfer signal
TPRE timer times out
40-400A (480/600Vac) ATC-300+ 3-Postion Contactor Based Transfer Switch
Instruction Booklet
Effective: September 2011 Page 31
Figure 25. Dual Utility Transfer Switch.
IB01602078E For more information visit: www.generac.com
Instruction Booklet
Page 32 Effective: September 2011
Table 6. Setpoint Possibilities
40-400A (480/600Vac) ATC-300+ 3-Postion
Contactor Based Transfer Switch
SETPOINT SETPOINT UNITS DESCRIPTION RANGE FACTORY
New Password Four Digits Set New Password 0000 to 9999 0300
TDES Minutes: Seconds Time Delay Engine Start 0 to 120 seconds 0:03
TDNE Minutes: Seconds Time Delay Normal to Emergency 0 to 1800 seconds 0:00
TDEN Minutes: Seconds Time Delay Emergency to Normal 0 to 1800 seconds 5:00
TDEC Minutes: Seconds Time Delay Engine Cool-off 0 to 1800 seconds 5:00
NOM FREQ Hertz Nominal Frequency 50 or 60 Hz As ordered
NOM VOLTS Volts Nominal Voltage 120 to 600 volts As ordered
S1 UV DROP Volts Source 1 Undervoltage Dropout Range:
S2 UV DROP Volts Source 2 Undervoltage Dropout Range:
S1 UV PICK Volts Source 1 Undervoltage Pickup Range:
S2 UV PICK Volts Source 2 Undervoltage Pickup Range:
S1 OV DROP Volts Source 1 Overvoltage Dropout Range:
S2 OV DROP Volts Source 2 Overvoltage Dropout Range:
S1 OV PICK Volts Source 1 Overvoltage Pickup Range:
S2 OV PICK Volts Source 2 Overvoltage Pickup Range:
S1 UF DROP Hertz Source 1 Underfrequency Dropout Range:
S2 UF DROP Hertz Source 2 Underfrequency Dropout Range:
S1 UF PICK Hertz Source 1 Underfrequency Pickup Range:
S2 UF PICK Hertz Source 2 Underfrequency Pickup Range:
S1 OF DROP Hertz Source 1 Overfrequency Dropout Range:
S2 OF DROP Hertz Source 2 Overfrequency Dropout Range:
S1 OF PICK Hertz Source 1 Overfrequency Pickup Range:
S2 OF PICK Hertz Source 2 Overfrequency Pickup Range:
TDN Minutes: Seconds Time Delay Neutral 0 to 120 seconds 0:00
BAUD RATE Modbus Baud Rate 9600 or 19200 9600
ADDRESS Modbus Address 1 to 247 1
PLANT EXER Days Plant Exerciser Programming OFF, DAILY, 7-DAY, 14-DAY or 28 DAY OFF
PE LOAD XFR Plant Exerciser Load Transfer 0 or 1 (1 = yes) 0
Contactor Style ATS (2-position/3-position)
Contactor Style ATS (2-position/3-position)
Contactor Style ATS (2-position/3-position)
Contactor Style ATS (2-position/3-position)
Contactor Style ATS (2-position/3-position)
Contactor Style ATS (2-position/3-position)
Contactor Style ATS (2-position/3-position)
Contactor Style ATS (2-position/3-position)
Contactor Style ATS (2-position/3-position)
Contactor Style ATS (2-position/3-position)
Contactor Style ATS (2-position/3-position)
Contactor Style ATS (2-position/3-position)
Contactor Style ATS (2-position/3-position)
Contactor Style ATS (2-position/3-position)
Contactor Style ATS (2-position/3-position)
Contactor Style ATS (2-position/3-position)
78 to 97% of Nominal System Voltage
78 to 97% of Nominal System Voltage
(Dropout +2%) to 99% of Nominal System Voltage
(Dropout +2%) to 99% of Nominal System Voltage
105 to 110% of Nominal System Voltage
105 to 110% of Nominal System Voltage
103% to (Dropout -2%) of Nominal System Voltage
103% to (Dropout -2%) of Nominal System Voltage
90 to 97% of Nominal System Frequency
90 to 97% of Nominal System Frequency
(Dropout +1 Hz) to 99% of Nominal System Frequency
(Dropout +1 Hz) to 99% of Nominal System Frequency
103 to 105% of Nominal System Frequency
103 to 105% of Nominal System Frequency
101% to (Dropout -1 Hz) of Nominal System Frequency
101% to (Dropout -1 Hz) of Nominal System Frequency
85%
85%
90%
90%
110%
110%
105%
105%
90%
90%
95%
95%
105%
105%
102%
102%
DEFAULT
For more information visit: www.generac.com IB01602078E
40-400A (480/600Vac) ATC-300+ 3-Postion Contactor Based Transfer Switch
Table 6. Setpoint Possibilities (cont’)
Instruction Booklet
Effective: September 2011 Page 33
SETPOINT SETPOINT UNIT S DESCRIPTION RANGE FACTORY
PE DAY Days Plant Exerciser Day of the Week 1 SUN, 2 MON, 3 TUE, 4 WED, 5 THU, 6 FRI or 7 SAT
PE HOUR Hours Plant Exerciser Hour 0 to 23 0
PE MINUTE Minutes Plant Exerciser Minute 0 to 59 0
TEST MODE Test Mode 0, 1 or 2 (0 = No Load Engine Test, 1 = Load Engine Test, 2 =
TER Hours: Minutes Engine run test time 0 min to 600 min 5:00
TPRE Minutes: Seconds Pretransfer delay timer 0 sec to 120 sec 0:00
PHASES Three phase or single phase 1 or 3 AS ORDERED
VOLT UNBAL Volts Voltage Unbalanced 0 or 1 (1 = Enabled) 1
UNBAL DROP % Percent Percent for Unbalanced Voltage Dropout 5 to 20% of Phase to Phase Voltage Unbalance 20%
UNBAL PICK % Percent Percent for Unbalanced Voltage Pickup Dropout minus (UNBAL DROP % -2) to 3% 10%
UNBAL DELAY Seconds Unbalanced Delay Timer 10 to 30 0:20
TDEF Seconds Time Delay Emergency Fail Timer 0 sec to 6 sec 6
IN-PHASE Hertz In-Phase Transition 0 or 1 (1=Enabled) 1
IP FREQ DIFF Hertz In-phase Transition Frequency Difference 0.0 Hz to 3.0 Hz 1.0
SYNC TIME Minutes In-phase Transition Synchronization Timer 1 min to 60 min 5
PHASE REV Phase Reversal OFF, ABC, or CBA OFF
DST ADJUST Day Light Savings 0 or 1 (1=Enabled) 1
MAN RETRAN Manual Retransfer 0 or 1 (1=Enabled) 0
LANGUAGE Selected Language English, French, or Spanish English
CHANGE TIME/DATE? Set Time and Date
Hours Set Hour 0 to 23 Eastern Standard
MINUTES Set Minute 0 to 59 Eastern Standard
WEEKDAY Set Weekday SUN, MON, TUE, WED, THU, FRI or SAT Eastern Standard
MONTH Set Month JAN or 01 Eastern Standard
DAY Set Day 1 to 31 Eastern Standard
YEAR Set Year Current Year Eastern Standard
RESET SYSTEM COUNTERS?
RESET ALL? Resets all System Counters Yes or No No
RESET ENGINE RUN?
RESET S1 CONN
RESET S2 CONN
RESET S1 AVAIL
RESET S2 AVAIL
RESET LOAD ENERG
RESET TRANSFERS
SAVE SETPOINTS?
Hours Resets ENGINE RUN Counter 0 to 9999 XXXX
Hours Resets S1 CONN Counter 0 to 9999 XXXX
Hours Resets S2 CONN Counter 0 to 9999 XXXX
Hours Resets S1 AVAIL Counter 0 to 9999 XXXX
Hours Resets S2 AVAIL Counter 0 to 9999 XXXX
Hours Resets LOAD ENERG Counter 0 to 9999 XXXX
Cycles (Counts) Resets TRANSFERS Counter 0 to 9999 XXXX
Save Changed Setpoints Yes or No Yes
Disabled)
Yes or No No
DEFAULT
0
Time
Time
Time
Time
Time
Time
See tables in the appendix for Voltage and Frequency Pickup and Dropout settings.
IB01602078E For more information visit: www.generac.com
Instruction Booklet
ATC-300
Source 1
Source 2
Available
Available
Connected
Connected
Load
Unit Status
Alarm Reset
Engine
Test
Lamp
Test
Help
Step
Enter
Bypass
TDNE / TDEN
ALARM RESET
DECREASE
ENTER
INCREASE
STEP
BYPASS
TDNE/TDEN
LAMP TEST
ENGINE
TEST
HELP
Page 34 Effective: September 2011
40-400A (480/600Vac) ATC-300+ 3-Postion Contactor Based Transfer Switch
Step 7: To change or add a setpoint, select Yes when the
“Change Setpoints” message appears on the screen. Use the <Step/Enter> pushbutton to step through the setpoints.
Use the <Increase> and <Decrease> pushbuttons to change the setpoint.
When finished scrolling through and changing the desired
tpoints, answer Yes when the “Save Setpoints?” ques-
se tion appears on the screen. The display will return to the
fault screen.
de
WARNING
THE GENERATOR SHOULD BE MANUALLY STARTED AND THE OUTPUT CHECKED AND VERIFIED BEFORE PROCEEDING TO STEP
8. IF IMPROPER VOLTAGE/FREQUENCY IS APPLIED TO THE LOAD, THE ATS MAY BE DAMAGED.
Step 8: Manually start the engine generator at the generator con-
Step 9: Initiate a Load Te
troller. Check that the generator is running and the
ce 2 Available amber LED is lit. Press the <Step/
Sour
Enter> pushbutton, step through the phase voltages, frequency, and message display. If the source message indicates that the source is Good, shut down the genera­tor and place the Genset controller in the Auto-operating position. If
the message indicates a problem with the source, the setpoints should be reviewed and the genera­tor checked for proper voltage and frequency output.
st from the front panel of the ATC­300+ (Figure 28). This may be done by setting the engine test setpoint to:
1 Load Test
then saving the setpoints. Once the engine test setpoint has been cha
nged and saved, press the <Engine Test> pushbutton twice. The generator should start, the ATS should transfer and run on the generator for the set test interval, then proceed to a TDEN countdown and return to Source 1. While the ATS is connected to Source 2, use a voltmeter to check for correct system voltage on the load terminals of the ATS. Check all phases on a 3­phase system. Voltage measurements should be taken phase to phase and phase to neutral. A load test will cause a momentary power outage during transfer.
Figure 26. ATC-300+ Pushbuttons.
For more information visit: www.generac.com IB01602078E
ATC-300
Source 1
Source 2
Available
Available
Connected
Connected
Load
Unit Status
Alarm Reset
Engine
Test
Lamp
Test
Help
Step
Enter
Bypass
TDNE / TDEN
40-400A (480/600Vac) ATC-300+ 3-Postion Contactor Based Transfer Switch
Instruction Booklet
Effective: September 2011 Page 35
Figure 27. ATC-300+ Logic.
Step 10: ATC3 Controlled ATS Power Failure Test - Initiate a
Load Test by simulating an actual power failure.
1. This should be done by opening the upstream ker or fused disconnect switch.
brea
2. The generator should start and the ATS should transfer
to Source 2.
3. After transfer, close the upstream breaker, or close the Source
1 Control Circuit Fused Disconnect. The TDEN timer should begin counting, and, when com­plete, the ATS should transfer to Source 1. The TDEC should
time out and shut the Source 2 power
unit down.
NOTICE
WHILE PERFORMING TESTING, IF AN UNDESIRED OR UNDOCU­MENTED RESULT OCCURS, CONTACT YOUR GENERAC REPRESEN­TATIVE.
IB01602078E For more information visit: www.genarac.com
Instruction Booklet
Page 36 Effective: September 2011
Appendix A: Pickup / Dropout Tables
UNDERVOLTAGE PICKUP / DROPOUT TABLE
PERCENTAGE VOLTAGE
120 208 220 240 380 415 480 600
97 116 202 213 233 369 403 466 582
96 115 200 211 230 365 398 461 576
95 114 198 209 228 361 394 456 570
94 113 196 207 226 357 390 451 564
93 112 193 205 223 353 386 446 558
92 110 191 202 221 350 382 442 552
91 109 189 200 218 346 378 437 546
90 108 187 198 216 342 374 432 540 Pickup
89 107 185 196 214 338 369 427 534
88 106 183 194 211 334 365 422 528
87 104 181 191 209 331 361 418 522
86 103 179 189 206 327 357 413 516
85 102 177 187 204 323 353 408 510 Dropout
84 101 175 185 202 319 349 403 504
83 100 173 183 199 315 344 398 498
82 98 171 180 197 312 340 394 492
81 97 168 178 194 308 336 389 486
80 96 166 176 192 304 332 384 480
79 95 164 174 190 300 328 379 474
78 94 162 172 187 296 324 374 468
77 92 160 169 185 293 320 370 462
76 91 158 167 182 289 315 365 456
75 90 156 165 180 285 311 360 450
74 89 154 163 178 281 307 355 444
73 88 152 161 175 277 303 350 438
72 86 150 158 173 274 299 346 432
71 85 148 156 170 270 295 341 426
70 84 146 154 168 266 291 336 420
69 83 144 152 166 262 286 331 414
68 82 141 150 163 258 282 326 408
67 80 139 147 161 255 278 322 402
66 79 137 145 158 251 274 317 396
65 78 135 143 156 247 270 312 390
64 77 133 141 154 243 266 307 384
63 76 131 139 151 239 261 302
62 74 129 136 149 236 257 298 372
61 73 127 134 146 232 253 293 366
60 72 125 132 144 228 249 288 360
59 71 123 130 142 224 245 283 354
58 70 121 128 139 220 241 278 348
57 68 119 125 137 217 237 274 342
56 67 116 123 134 213 232 269 336
55 66 114 121 132 209 228 264 330
54 65 112 119 130 205 224 259 324
53 64 110 117 127 201 220 254 318
52 62 108 114 125 198 216 250 312
51 61 106 112 122 194 212 245 306
50 60 104 110 120 190 208 240 300
40-400A (480/600Vac) ATC-300+ 3-Postion
Contactor Based Transfer Switch
378
For more information visit: www.generac.com IB01602078E
40-400A (480/600Vac) ATC-300+ 3-Postion Contactor Based Transfer Switch
OVERVOLTAGE PICKUP / DROPOUT TABLE
PERCENTAGE VOLTAGE
120 208 220 240 380 415 480 600
120 144 250 264 288 456 498 576 720
119 143 248 262 286 452 494 571 714
118 142 245 260 283 448 490 566 708
117 140 243 257 281 445 486 562 702
116 139 241 255 278 441 481 557 696
115 138 239 253 276 437 477 552 690
114 137 237 251 274 433 473 547 684
113 136 235 249 271 429 469 542 678
112 134 233 246 269 426 465 538 672
111 133 231 244 266 422 461 533 666
110 132 229 242 264 418 457 528 660 Dropout
109 131 227 240 262 414 452 523 654
108 130 225 238 259 410 448 518 648
107 128 223 235 257 407 444 514 642
106 127 220 233 254 403 440 509 636
105 126 218 231 252 399 436 504 630 Pickup
Instruction Booklet
Effective: September 2011 Page 37
UNDERFREQUENCY PICKUP / DROPOUT TABLE
PERCENTAGE FREQUENCY
50 60
97 49 58
96 48 58
95 48 57 Pickup
94 47 56
93 47 56
92 46 55
91 46 55
90 45 54 Dropout
OVERFREQUENCY P ICKUP / DROPOUT T ABLE
PERCENTAGE FREQUENCY
50 60
110 55 66
109 55 65
108 54 65
107 54 64
106 53 64
105 53 63 Dropout
10
4 52 62
103 52 62
102 51 61 Pickup
IB01602078E For more information visit: www.generac.com
Instruction Booklet
Page 38 Effective: September 2011
Notes:
40-400A (480/600Vac) ATC-300+ 3-Postion
Contactor Based Transfer Switch
For more information visit: www.generac.com IB01602078E
40-400A (480/600Vac) ATC-300+ 3-Postion Contactor Based Transfer Switch
Notes:
Instruction Booklet
Effective: September 2011 Page 39
IB01602078E For more information visit: www.generac.com
Instruction Booklet
Generac Power Systems, Inc. S45 W29290 Hwy. 59 Waukasha, WI 53189 1-888-GENERAC (1-888-436-3722)
generac.com
Page 40 Effective: September 2011
40-400A (480/600Vac) ATC-300+ 3-Postion
Contactor Based Transfer Switch
This instruction booklet is published solely for information pur­poses and should not be considered a
ll-inclusive. If further infor-
mation is required, you should consult Generac.
Sale of the product(s) shown in this literature is subject to terms and conditions outlined in appropriate Generac selling policies or other contractual agr
eements between the parties. This literature is not intended to and does not enlarge or add to any such con­tract. The sole source governing the rights and r
emedies of any purchaser of this equipment is the contract between the pur­chaser and Generac.
NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WAR­RANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MER­CHANTABILITY, OR WARRANTIES
ARISING FROM COURSE OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS AND DESCRIPTIONS CONTAINED HEREIN.
In no event will Generac be responsible t
o the purchaser or user in contract, in tort (including negligence), strict liability or other­wise for any special, indirect, incidental or consequential damage or loss whatsoeve
r, including but not limited to damage or loss of use of equipment, plant or power system, cost of capital, loss of power, additional expenses in the use of existing power facilities, or claims against the purchaser or user by its customers resulting from the use of the information, recommendations and descrip­tion contained herein.
CSA is a registered trademark of the Canadian Standards Associ­ation. National Electrical Code and NEC ar
e registered trademarks of the National Fire Protection Association, Quincy, Mass. NEMA is the registered trademark and service mark of the National Elec­trical Manufacturers Association.
Uniform Building Code (UBC) is a trademark of the International Conference of Building Officials (ICBO). UL is a federally registered trademark of the Underwriters Laboratories Inc.
© 2011 Generac Power Systems, Inc. All Rights Reserved Printed in USA
Publication No. IB01602078E/TBG00610 September 2011
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