Users Guide

Clipper
ATS/AMF

Automatic Transfer Switch Automatic Generator Controller

Microlink Computer LLC P.O. Box 117726, Dubai (U.A.E.)

Clipper ATS/AMF Automatic Generator Controller Users Guide.

Index
S.No. -01-02-03-04-05Features Introduction Name and Function of Control Panel Buttons Name and Function of Control Panel Indicators Installation
Generator Side Wiring RJ45 Connector pinout configurations

Contents

Page 02 04 05 06 07 07 07 08 08 09 09 10 11 12 13 13 14 15 15

-06-

Electrical Wiring
Summary of Electrical wiring types

-07-

Wiring diagrams Figure1. Single phase Grid-Single phase generator.

Figure2. 3Phase Grid-Single phase generator Figure3. 3Phase Grid-Single phase generator Figure4a. 3Phase Grid-3phase generator Figure4b. 3Phase Grid-3phase generator Change-over switch

-08-

Customizing through setup procedure

Getting into setup Setup messages

Page 2

Clipper ATS/AMF Automatic Generator Controller Users Guide.

Features
Automatically starts power generator upon Utility/Grid power failure and stops when Grid power resumes, without user intervention. No need for Manual Change over switches. Clipper SF series ATS will control the automatic Load Change-over from Grid to Generator and viceversa. Simple and Easy installation. Uses in-expensive CAT5 cable to connect to generator. Uses RJ45 connector on Clipper ATS system, provides neat and easy connection. Option for controlling the Generator Manually from the control panel itself with the help of buttons on Control panel. Models available from 2KVa until 300KVa single fuel power generators. Control panel can be mounted anywhere near or far from the Power cabinets. User can place control panel inside the building or house or office and the remaining system near the Power cabinet. Both sides will be connected via in-expensive single UTP5 cable with RJ45 standard Networking connectors. User can set all necessary delay time with the help of on-board 20x2 character alphanumeric LCD display and buttons on the control panel. This makes Clipper ATS system suitable for almost all types of single fuel generators. User can configure all sort of parameters such as, Delay to start the generator, Delay before Load put-onto Generator, Delay before Load put

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Clipper ATS/AMF Automatic Generator Controller Users Guide. onto Utility/Grid power when power resumes, Maximum, number of tries system should attempt in order to start the generator etc. Built-in the system non-volatile flash memory to keep user setting intact even during power failure or disconnected the unit from the generator for relocation or for maintenance. User data will be intact without power for at least 10 years. Revocable Factory default settings offers safe landing if user made mistakes during the setup. Manual mode offers option to make system idle in case if Auto start for generator is not needed. Such as if house or office might be empty or closed. This can be achieved by simply pressing the Manual button on control panel. No need to turn the ATS system OFF. High end micro-controller based design offers a very high degree of safety and made the complete operation easily configurable and controllable even by a normal user without having too deep technical knowledge. Thanks to latest technology implementation, the Clipper ATS system is relatively much lower in cost in comparison with traditional relay based limited-function bulky and expensive ATS panels.

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Clipper ATS/AMF Automatic Generator Controller Users Guide.

Introduction
Clipper ATS Model No.SF25, SF50, SF75, SF100, SF200, SF300, SF600, SF1200, SF2000 & SF3000 are fully automatic generator Control Unit. It is designed to control Single fuel such as Natural Gas or Diesel power generators. Clipper ATS SF series is not suitable for any generator that needs to pull choke as the design does not offer any mechanism for pulling the choke, which is required in most Petrol or dual fuel generators. Clipper ATS SF series can be used in Auto or Manual mode. Upon power ON Auto mode is selected by default. User can change the mode of operation to Manual by just pressing Manual button on control panel. In Auto mode, Clipper ATS does not require user intervention. It automatically turns ON the generator upon Utility/Grid power failure. And will turns the generator OFF when utility/Grid power resumes. This also includes automatic Load switch from Utility power to Generator and from Generator to Utility/Grid power; thus eliminating the need of any external change-over switch. In Manual mode Clipper ATS observes all the events such as Utility/Grid power failure, the status of Generator and Transfer relay/contactors etc. It will show the status of all events on LCD display, but it does not act upon any event by itself; rather it will wait for user to command the system by pressing appropriate button on front panel. i.e. Generator ON/OFF button, Generator START motor ON/OFF button, Load transfer change-over button. There are five push buttons and 7 LED indicators on the control panel. Each Push button has dual function. Table1 and Table 2 shows the description of each one.

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Clipper ATS/AMF Automatic Generator Controller Users Guide.

S/No.
-1-

Name
Manual/Setup

Function description
Upon pressing this button, system will go into Manual mode, if it was in Auto mode or will come back to Auto mode if Manual mode was selected. Manual LED will turns ON to show the system is in Manual mode. Setup will be called if the manual button is pressed by user for over 5 seconds. Please refer to General Operation section of this manual for more details about Setup. Error LED will turn ON and system will go into Error mode if power generator could not be started by the Clipper ATS due to some problem with generator. Error status can be removed by pressing this button. This button works in Auto mode as well as in Manual mode. This button will be used to increase the values of user selectable parameters if SETUP mode is selected. Upon pressing this button Power LOAD (such as house or office power load) can be switched forth and back, from Utility/Grid to Generator if Grid power is lost, or from Generator to Utility/Grid upon Grid power resumed. Load will be put onto generator if Transfer relay is ON which will be indicated by transfer LED is ON. Please note that this button does not function in Auto mode. This button will move the setup menu one step UP if SETUP mode was selected. Upon pressing this button generator self-start motor will try to start the generator. Generator motor will be powered-up as long as this button is pressed by user. Generator start motor will stop if user un-press this button. Please note that this button will not function in Auto mode. This button will not work if Generator Switch is not in ON position. This button will not function in Auto mode. This button will move the setup menu one step Down if SETUP mode was selected. This button will turn the generator switch ON or OFF. Switch LED indicates the switch is ON if LED is ON. Please note that this button will not function in Auto mode. User values will be decreased by 1 upon pressing this button, while SETUP mode is selected. Page 6

-2-

Error/INC

-3-

Transfer/Menu UP

-4-

START/Menu Down

Switch/Dec

Clipper ATS/AMF Automatic Generator Controller Users Guide. Table1. Name and function of Control Panel buttons.

S/No.
-1-

Name
Manual

Description

If ON, shows Clipper ATS is in Manual Mode, if OFF means Clipper ATS system is in Auto mode. -2Error If ON, shows Clipper ATS system could not start the generator due to some problem at generator side. If OFF, means no Error has been reported while generator start procedure. -3Transfer If ON, shows Load is switched onto Generator. If OFF means load is on Utility/Grid supply. -4Start Turns ON while generator self start motor is powered ON and generator is trying to start. -5Switch If ON, shows generator switch is in ON position, if OFF means generator switch is in OFF position. -6Grid Power Turns ON if Utility/Grid power is present. -7Genset Power Turns ON while Generator Power is detected. Table2. Name and function of Control Panel LED indicators.

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Clipper ATS/AMF Automatic Generator Controller Users Guide.

Installation
Installation of Clipper ATS/AMF is straight forward. However to further simplify we divide it into 3 major areas. 123Generator Side wiring. Electrical Wiring. Customizing through setup procedure.

Generator side wiring. Generator will be connected to the Clipper ATS power board via UTP5 8 core cable with the help of RJ45 8pin networking connector. Since the UTP5 cable has 8 core cable, however Clipper ATS system requires only 4 connecting wires, therefore, we used two wires in parallel in place of one. This offers further strength to the signal and DC power thus allow longer distance between generator and Power distribution cabinet. Please refer to table3 for RJ45 connections on power board side. Pin Number 1&8 2&7 3&6 Cable color (recommened) Orange & Orng+white Blue & Blue+white Brown & Brwn+white Description Carry +12V supply to be used by Clipper ATS as its power source. Ground connection used by Clipper ATS as its power ground. Carry self start motor signal from ATS to generator Connected point at Generator Connected to Battery +12V positive terminal Connected to Battery minus terminal. Connected to round solenoid positive terminal which is fixed on top of self-start motor. Connected to joint wire between start winding and generator keyswitch.

4&5

This will be used to ground the starting winding in order to stop the generator. Table3. RJ45 connector and UTP5 cable connections

Green & Grn+ white

User should get RJ45 connector crimped with UTP5 cable on one side with the above recommended color codes. On the other side of the cable, remove the UTP5 outer jacket for around 2 to 3 feet length and connect them firmly to the generator Page 8

Clipper ATS/AMF Automatic Generator Controller Users Guide. locations described in Table3. We suggest you to wrap the connection with electrical insulation tape and later tie them with cable tie wherever it is required and suitable. Please do not connect the RJ45 connector to the Power board at this time. Wait for this until all other electrical connections has been finalized. After you have done this, your first step of installation is completed. Electrical Wiring: Electrical wiring is a vast topic and may differ for different models of Clipper ATS. For Clipper ATS Model SF25 it is relatively straight forward. Model SF25 is designed for single phase generators rated up to 2.5kvA. This model is designed for cost effective single phase implementation of ATS and AMF function for simple house-hold application. It uses built-in SPDT hi-power relay for switching the load between Utility/Grid supply and Generator output power. This saves money and offers affordable ATS solution for low-cost generators. Please refer to Figure1 to understand electric wiring connections for the model SF25. Other higher models of SF series such as SF50 to SF300 uses external multi-terminal Contactors for switching the power. Using contactors allows the higher power loads to be switched when Utility/Grid supply fails and resumes. The electrical wiring of the higher models requires good understanding for Electricity. It is not recommended to install this portion for a regular user rather we highly recommend to hire some professional to carry out the job for them. There could be 4 possible electrical wiring combinations to connect Clipper SF series ATS system. Please refer to Table4 to summarize all 4 wiring combinations. S/No. Utility/Grid Phases Generator Phases Typical Application Utility/Grid Generator External Typical Application No. Phases Phases Contactor capacity used -1Single phase Single phase No Up to 2.5KVA -23 Phase Single phase No Upto 2.5KVA on L1 -33 Phase Single phase Yes From 2KVA to 30KVA -43 Phase 3 Phase Yes From 10KVA to 300KVA Table4. Summary of Electrical wiring types.

Illustrative Figure Figure1 Figure2 Figure3 Figure4

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Clipper ATS/AMF Automatic Generator Controller Users Guide.

To Genset AC input to ATS Power board L

OUTPUT connection From Power board of ATS L

To Grid AC input to ATS Power board

Generator Output Supply

N N

L1

L1

single phase 3way High Power, Change-over Switch (102) L1 N

Output to LOAD Load can not Exceed 10Amp limit.

Figure1. Single phase Grid-Single phase generator. In Figure1 wiring layout, no external high power contactor is used, therefore the load will be on to the relay installed on ATS power board. That relay can only with-stand with 2.5KVa load maximum. Therefore regardless of supply limit from Electric company, total LOAD should not exceed from 2.5kva maximum. Safety circuit breakers are not shown in the schematic and can be implemented according to the specific requirements. In this wiring scheme only high power single phase selector switch can be installed.

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Electric Company Supply

Clipper ATS/AMF Automatic Generator Controller Users Guide.

To Genset AC input to ATS Power board L

OUTPUT connection From Power board of ATS L

To Grid AC input to ATS Power board

3Phase sensing Module

Generator Output Supply

N N L3 L2 L1 L1

single phase 3way High Power, Change-over Switch (102) L3 L2 L1 N

Output to LOAD Load on L1 can not Exceed 10Amp limit.

Figure2. 3Phase Grid-Single phase generator. This wiring can be used for the following Loads Load on L1 = Maximum 2.5KVa. Load on L2 and L3 = Maximum available supply load. In Figure2 wiring layout, no external high power contactor is used, therefore all load on L1 will be on to the relay installed on ATS power board. That relay can only with-stand with 2.5KVa load maximum. Therefore Load on L1 should not exceed from 2.5kva maximum. However, L2 & L3 are directly supplied to the Load therefore L2 & L3 can be loaded with any capacity of Load which is supplied by the Electric company. Safety circuit breakers are not shown in the schematic and can be implemented according to the specific requirements. In this wiring scheme only high power single phase selector switch can be installed.

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Electric Company Supply

Clipper ATS/AMF Automatic Generator Controller Users Guide.

0 = OUTPUT connection From Power board of ATS, Load Output will be controlled by ATS. To Genset AC input to ATS Power board L N 1= Connected to Generator output Permenantly 1 0 2 Very low power selector switch (102) 1Amp will do. 2 = Left open to Select Utility/Grid AC Permenantly. To Grid AC input to ATS Power board L N 3Phase sensing Module

RELAY DPDT

Generator Output Supply

N L3 L2 L1 L1

Contactor 3PST+1NC

L1

L2

L3 COIL

NC1

NC1

COIL L3

L2

L1

T1

T2 T3

NC2

NC2

T3 T2

T1

L3

L2

L1

Contactor 3PST+1NC

Output to LOAD

Figure3. 3Phase Grid-Single phase generator. From 2KVA to30KVA Wiring diagram. Safety circuit breakers are not shown in the schematic and can be implemented according to the specific requirements. Please notice L!,L2 and L3 are shorted together at Generator side contactors inputs. For using high power selector switch please refer to figure 4a.

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Electric Company Supply

Clipper ATS/AMF Automatic Generator Controller Users Guide.

OUTPUT connection From Power PCB of ATS

RELAY DPDT

Generator Output Supply

N L3 L2 L1 L3 L2 L1

Contactor 3PST+1NC

L1

L2

L3 COIL

NC1

NC1

COIL L3

L2

L1

T1

T2 T3

NC2

NC2

T3 T2

T1

3phase 3way Change-over Switch (102) L3 L2 L1 N

Output to LOAD

Figure4a. 3Phase Grid-3phase generator. From 10KVA to300KVA Wiring diagram. Safety circuit breakers are not shown in the schematic and can be implemented according to specific requirements. Please note the high power 3phase selector switch implementation to by-pass the ATS. In the case of emergencies ATS can be by-pass by implementing Selector switch. Selector switch can be installed in all other wirings shown from Figure1 to Figure4. Selector switch can be a high power 3 phase switch or can be small, very low power. Both work in the same manner as far as ATS by-pass is concern. In high power selector switch implementation, all power to the LOAD will be supplied through selector switch itself. ATS as well as Magnetic contactors do not take part in supplying the power to the LOAD. Whereas in low-power Selector switch implementation, ATS is by passed, but all power to the LOAD will be supplied through magnetic contactors.

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Contactor 3PST+1NC

Electric Company Supply

Clipper ATS/AMF Automatic Generator Controller Users Guide.

0 = OUTPUT connection From Power board of ATS, Load Output will be controlled by ATS. To Genset AC input to ATS Power board L 1= Connected to Generator output Permenantly 1 0 2 Very low power selector switch (102) 1Amp will do. 2 = Left open to Select Utility/Grid AC Permenantly. To Grid AC input to ATS Power board L N 3Phase sensing Module

3Phase sensing Module

RELAY DPDT

Generator Output Supply

N L3 L2 L1 L3 L2 L1
Electric Company Supply

Contactor 3PST+1NC

L1

L2

L3 COIL

NC1

NC1

COIL L3

L2

L1

T1

T2 T3

NC2

NC2

T3 T2

T1

L3

L2

L1

Contactor 3PST+1NC

Output to LOAD

Figure4b. 3Phase Grid-3phase generator. From 10KVA to300KVA Wiring diagram. Safety circuit breakers are not shown in the schematic and can be implemented according to specific requirements. The schematic in Figure4b is same as in Figure4a, but in figure4b selector switch used isa single phase very low power one.

Change-over switches shown in schematics are optional and are not included with the Clipper ATS systems package. System can work without any problem even if change-over switches are not installed. However they might be recommended if ATS by-passing is required. This will offer the possibility to Manually switch the LOAD to the Generator or to Utility/Grid supply in the event of any problem with ATS or its related other items or wiring. Page 14

Clipper ATS/AMF Automatic Generator Controller Users Guide.

Customizing through setup procedure

. Every generator brand and model might behave different from each other while starting and loading. Therefore ATS should be configured with appropriate procedure and delays for every event during starting procedure and during Loading. Traditional Electrical ATS are mostly designed based upon static timer-driven relays. To setup and configure such ATS requires experience and a lot of patient as it takes a lot of time. Mostly timers used in those traditional ATS are dependent upon variable analog settings through a round knob. Therefore they could not be adjusted easily and accurately. To setup such Traditional ATS we need to call a professional which costs extra time and money. Clipper SF series ATS offers great flexibility to customize it for many different brands of generators with different operating behavior. Clipper SF series ATS are equipped with a powerful setup program where user can customize it according to specified generators requirements. Clipper SF series ATS has 5 button control panel and a 20x2 character LCD alphanumeric display with backlit. User can easily setup all different types of parameters and delays using the setup routine which guides the user through a step by step menu. In the following section you will be shown an step by step tutorial for setting up custom parameters.

Getting into setup:

1To enter into setup mode, press Manual/Setup button for 5 seconds. As soon as 5 seconds completed, the following message will show on the LCD display. 'Press > to restore' ' factory settings'

Please note that if you remove the finger from the Manual/Setup button before 5 seconds and before the above message appears on LCD display, system will go into Manual mode which will be shown by Lighting up the Manual LED indicator. Should this happen, you will have to come out from the Manual mode by briefly pressing the Manual/Setup button again, Manual LED will turn OFF. Now start over from section 1 again. Page 15

Clipper ATS/AMF Automatic Generator Controller Users Guide. Upon appearing 1st menu item, which gives the option to restore factory defaults, if user press Right Arrow key > all settings will be reset to its original factory default settings. This facilitate to re-start from fresh. If reset to factory default option is not needed, please press down arrow key in order to proceed the next setup item. Note: Exiting from setup is possible at any moment. If needed, press Manual/Setup button and system will come out from Setup mode into Auto mode after Saving user entered parameters if entered any. All possible setup messages and other details are shown in table5 Message sequence -1Message text appear on LCD Press > to restore factory settings GENSET START DELAY Enter Seconds --Application Remove all user settings and recall original settings. After power outage, delay before genera-tor starts. After power comes back, delay before load put-on to Grid After generator is started, delay befo-re load puton to generator How many times system will try to start the generator before error is generated Generator free running time before turn it OFF Duration the start motor will be turned ON for starting the generator Self explanatory Possible values NA Default value NA

-2-

1~255 seconds

01 second

-3-

BACK to GRID DELAY Enter Seconds ---

1~255 seconds

30 seconds

-4-

Loading GENSET DELAY Enter Seconds ---

1~255 seconds

30 seconds

-5-

GENSET START TRIES Enter No. of Try ---

1~10 times

5 times

-6-

GENSET COOLING TIME Enter Seconds --Time for 1st Try Enter Seconds ---

1~255 seconds 1~255 seconds

15 seconds 10 seconds

-7-

-8-

Delay before 2nd Try Enter Seconds ---

1~255 seconds

5 seconds

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Clipper ATS/AMF Automatic Generator Controller Users Guide. -9Time for 2nd Try Enter Seconds --Duration the start motor will be turned ON for starting the generator Self explanatory Duration the start motor will be turned ON for starting the generator Self explanatory Duration the start motor will be turned ON for starting the generator Self explanatory Duration the start motor will be turned ON for starting the generator Self explanatory Duration the start motor will be turned ON for starting the generator Self explanatory Duration the start motor will be turned ON for starting the generator Self explanatory Duration the start motor will be turned ON for starting the generator Page 17 1~255 seconds 10 seconds

-10-11-

Delay before 3rd Try Enter Seconds --Time for 3rd Try Enter Seconds ---

1~255 seconds 1~255 seconds

5 seconds 10 seconds

-12-13-

Delay before 4th Try Enter Seconds --Time for 4th Try Enter Seconds ---

1~255 seconds 1~255 seconds

5 seconds 10 seconds

-14-15-

Delay before 5th Try Enter Seconds --Time for 5th Try Enter Seconds ---

1~255 seconds 1~255 seconds

5 seconds 10 seconds

-16-17-

Delay before 6th Try Enter Seconds --Time for 6th Try Enter Seconds ---

1~255 seconds 1~255 seconds

5 seconds 10 seconds

-18-19-

Delay before7th Try Enter Seconds --Time for 7th Try Enter Seconds ---

1~255 seconds 1~255 seconds

5 seconds 10 seconds

-20-21-

Delay before 8th Try Enter Seconds --Time for 8th Try Enter Seconds ---

1~255 seconds 1~255 seconds

5 seconds 10 seconds

Clipper ATS/AMF Automatic Generator Controller Users Guide. -22-23Delay before 9th Try Enter Seconds --Time for 9th Try Enter Seconds --Self explanatory Duration the start motor will be turned ON for starting the generator Self explanatory Duration the start motor will be turned ON for starting the generator 1~255 seconds 1~255 seconds 5 seconds 10 seconds

-24-25-

Delay before 10th Try Enter Seconds --Time for 10th Try Enter Seconds ---

1~255 seconds 1~255 seconds

5 seconds 10 seconds

Table5. Setup messages. To come out from setup at any point, press Manual/Setup button briefly, all settings will be saved in permanent memory and system will come out from setup mode. To increase the value press > key, to decrease the value press < key. To move between the menus, press Up or Down key. When you reach at the last menu item, pressing Down key will roll-over to the first menu item. If menu is at the first menu item, pressing Up key will roll-under to the last menu item. Note: Restore Factory default menu item will appear only once. When user first enter in to the setup menu. Once it is skipped to the next menu item, Restore factory default option will not appear again within the same setup session. Even menu roll-over will not show it again. However, Factory Default Setting can be activated by going out from the setup by pressing setup key, then again re-enter into setup mode by pressing Manual/Setup key for 5 seconds.

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