How to build ATS panels

WHAT IS AN ATS PANEL?WHAT IS AN ATS PANEL OVERVIEW


Are you looking for ATS panels in the range 15 up to 160kVA?

ATS PANELS PRICE LIST


Are you looking for AMF panels in the range of 15 up to 160kVA?

AMF PANELS PRICE LIST


HOW DO YOU MAKE AN ATS PANEL USING AN ATS CONTROLLER?

HOW DO YOU MAKE AN ATS PANEL?CIRCUIT BREAKERS INPUT CONNECTIONS

The controller has to sense the voltage of the utility power (mains) and a generator. You have to provide power to the contactors coils as well. It is quite dangerous to connect these loads to a high-power source. Utility power can be able to supply hundreds of amperes. For this reason, it is mandatory to put a circuit breaker that limits the current. This will prevent major damage in case of a short circuit. We consider that 10 Amps are more than enough for this application. Follow the indication of the picture. Turning OFF the circuit breakers allows you to maintain the parts without risk easily.

ATS-PANEL-MAINS-AND-UTILITY-CONNECTIONS

Connect Phases L1-L2-L3-N from the ‘generator’ terminal block to the entrance of the circuit breaker on the left side. Do the same connections for the circuit breaker on the right side by connecting the R-S-T-N terminal blocks. We recommend to use 1,5 square mm flexible stranded copper cable. See the above picture.


VOLTAGE MEASUREMENT CONNECTIONS

With this task, you will connect the voltage measurement circuits. You can see in RED colour the three cables for the generator voltage measurements (5-6-7). The three YELLOW cables provide voltage measurements of utility power (mains) (1-2-3).

ats panel VOLTAgE-MEASUREMENTS WIRINGS

We recommend to use 1,5 square mm flexible stranded copper cable. See the picture below.


BATTERY CHARGER AND CURRENT TRANSFORMER

With this task, you will connect the current transformers to the BE242RB inputs. The end side of the common cable must be grounded. In this step, you are also required to connect the phase ‘2’ and neutral ‘4’ to supply the battery charger.

BATTERY CHARGER CONNECTIONS

We recommend using a 1,5 square mm flexible stranded copper cable. See the following picture.


WIRING THE KG CONTACTOR AUXILIARY CIRCUITS OF AN ATS PANEL

You are required to wire the coil of the KG (terminals A1 & A2 on the left side) and the electrical interlock contacts of the KM (utility power contactor). Follow the wiring diagram and the below picture. According to the wiring diagram, the KG will only energize if the KM is OFF. The OFF position of the KM will hold closed the interlock auxiliary contact in a way that lets the KG coil energize. If the KM, for any reason, is in the ON position, the auxiliary contact, being in the open state, will not allow KG to energize. In blue color the connection to the neutral terminal of the generator via the circuit breaker.

COILS-OF-THE-CONTACTORS


WIRING THE KM CONTACTOR AUXILIARY CIRCUITS OF AN ATS PANEL

You are required to wire the coil of the KM (terminals A1 & A2 on the right side) and the electrical interlock contacts of the KG (GENERATOR power contactor on the left side). Follow the wiring diagram and the below picture. According to the wiring diagram, the KM will only energize if the KG is OFF. The OFF position of the KG will hold closed the interlock auxiliary contact in a way that lets the KM coil energize.

COILS-OF-THE-CONTACTORSIf the KG, for any reason, is in the ON position, the auxiliary contact, being in open condition, will not allow KM to energize. In blue color the connection to MAINS neutral terminal via the circuit break


ATS PANEL WIRING THE CONTACTORS

This is the most critical part of the job. Particular skills are required to connect the wires of big size. You have to follow the recommendations and instructions of the contactor manufacturer. This will avoid overheating of the connection points. You have to use the recommended force to guarantee good contact especially when high currents are involved (in this case the nominal current is about 110Amps). Connect phases ‘L1’-’L2’-’L3’-‘N’,connect phases ‘R’-‘S’-‘T’-‘N’

CONTACTORS-OUTPUT-CONNECTIONS

In choosing the size of the cables consider the table on page 7. According to the table, a 60kVA panel require a 25 sqmm size. This size will allow a continuous current of about 100 amps. For terminal blocks, the better choice is to use a 35 sqmm size.


WIRING THE CONTACTORS OUTPUT

This is the most critical part of the job. Particular skills are required in connecting the wires of big size. You have to follow the recommendations and instructions of the contactor manufacturer. This will avoid connections overheating. Currents over 100 Amps may circulate in these wires. Use the recommended force to guarantee good contacts. Connect phases ‘L1’-’L2’-’L3’-‘N’ together with the phases ‘R’-‘S’-‘T’-‘N’ Each output phase must enter the proper current transformer before connecting the terminal blocks. The neutral wire must be directly connected to the terminal block.

DRILLING THE DOOR OF THE PANEL

The main advantage of using the BE242 controller is time-saving. The BE242 is the only AMF ATS controller of square size that requires a round hole. This means that you can make the hole using a circular saw. You are required to download the template. Double-check the dimensions reported on the drawing. This is particularly important if you are not sure that your printer can print in 1:1 ratio. Choose the correct position for the template [1] over the panel [5]. Use a paper tape to fix and hold the template. Make a round hole between 56mm to 64mm. This will be the main hole for the BE242 controller.

ROUND HOLE ON THE DOOR

Make four holes [3] of about 4,5mm. These holes will allow you to fix the controller on the panel by using 4 nuts 4MA. You can additionally make a 22mm hole [4] if you need to install an emergency stop button. See the picture.


The quality of your panel & final checklist

Very well done. You are supposed to finish your panel. Your work is not over yet. We recommend that you print the following checklist. Check carefully, step by step, each item. This is a general guide. You can integrate it based on your experience.

1) The controller is very well fixed on the front door. Make sure the nuts are tight. The surface of the panel is clean.

2) Ensure that the nuts for the front door grounding and panel structure are tight.

3) The backplane that supports the hardware is normally held in place by 4 bolts M6. Make sure you have a spacer between it and the panel frame. Being the bolts soldered, if you apply too much force, without a washer spacer, you can de-solder the bolts.

4) Verify that all screws of the terminal blocks, fuse holders, CTs, circuit breakers, and auxiliary contacts are properly tight.

5) Verify that there are no strands exposed on each cable termination. You could get arcing or overheating.

6) Check if the bolts, or screws, on the contactors, are tight according to the contactor specifications.

7) When using multipolar connectors check the holding screws: must be tight.

8) The emergency switch on the front door must be carefully verified. If necessary use thread locker adhesive to avoid rotation of the switch.

9) Verify the size of the fuses. Put a proper label indicating the value. Add spare fuses for the user.

10) Check the free mechanical movement of the contactors. Check the mechanical interlock. You must not be able to activate both contactors. The mechanical interlock will allow only one contactor at a time.

11) Hold the panel in a vertical position. Hit gently the panel with a rubber mallet. Check for vibration and collect various dirty remains (iron filings, copper remains and so on) on the bottom of the panel. Use a powerful vacuum cleaner. Make sure there are no extra items (screws, loose terminals, tools, pieces of wire and so on)

12) Verify the presence of the labels indicating Mains, Generator, Load, Phases, Electric Danger and so on.

13) Put inside the door an adhesive sheet that illustrates the schematics and the nominal panel data. This may help an electrician in case of service.

14) Mechanically check the closure of the door. If your panel is over IP42, check the gasket.

15) Proceed with electric test. The contactors, when activated, should not emit noise. The presence of noise could be caused by iron filing pollution on the body of the contactors.

16) Make sure the ATS controller's settings match the size of the current transformers.

17) Remove all connections after testing. Tight the bolt again without forgetting the washers (this is in case connections are directly made on the contactors)

18) Do not forget to put on a small box, or envelope, the spare Panel Fasteners. It will be important for the user.

19) Close the door of the panel. You can proceed with the final packaging.


PURCHASE THE ATS CONTROLLER OR AMF CONTROLLER SUITABLE FOR YOUR APPLICATION

The BE242 ATS Controller is the best option for saving money and time when building ATS panels. It contains a universal relay interface board. You can connect any type of engine and generator.

THE BE242 ATS CONTROLLER

When it comes to automatic mains failure panels, use the BeK2 AMF controller..

THE BEK2 AMF CONTROLLER


BERNINI DESIGN SRL

GENERATOR CONTROLLER MANUFACTURER

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46035 OSTIGLIA

BERNINI@BERNINI-DESIGN.COM

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