ATS CONTROLLER FOR GENERATOR
An ATS controller is an electronic module capable of transferring the LOAD from a "PRIMARY" source of electric energy to a "SECONDARY" source. The "PRIMARY" source is considered the UTILITY POWER source.
In other words, the ATS controller automatically tries to connect the "PRIMARY" source first. You can override the automatic control and manually choose the "SECONDARY" source. The ATS controller is the key component of your ATS panel.
ATS CONTROLLER PRICE
199€
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HOW TO BUILD ATS PANELS E-BOOK 4,90€
Based on our 34-year experience in making ATS panels for standby generators, this short handbook "IS a MUST" for the hands of an ATS panel maker.
DIGITAL PURCHASE OF THE E-BOOK WITH IMMEDIATE DOWNLOAD
E-BOOK CONTENT
1.0 CONTACTORS CHANGEOVER
2.0 MOTORISED CHANGEOVER
3.0 ATS PANEL SPECIFICATIONS
4.0 ATS CONTROLLER ADVANTAGES IN SHORT
5.0 POPULAR ATS PANEL TABLE SIZES
6.0 ATS PANEL WIRING DIAGRAM
7.0 INSTALLING THE ATS CONTROLLER
8.0 MAKING THE ATS PANEL BACKPLANE
9.0 INSTALLING CONTACTORS AND CTs
10.0 AUXILIARY CIRCUIT BREAKERS AND TERMINAL BLOCKS
11.0 INSTALLING THE INTERFACE BOARD AND B.C.
12.0 COMMENCING THE ATS PANEL WIRING
12.1 WIRING THE GENERATOR’S CIRCUITS
12.2 WIRING THE MAINS’ CIRCUITS
12.3 WIRING THE KG DRIVING CIRCUITS
12.4 WIRING THE KM DRIVING CIRCUITS
12.5 CONNECTING THE BATTERY CHARGER
12.6 MAINS VOLTAGE MEASUREMENT CONNECTION
12.7 GENERATOR VOLTAGE MEASUREMENT CONNECTION
12.8 CURRENT MEASUREMENTS
12.9 THE CONTACTOR OUTPUTS
13.0 BATTERY AND CHARGER ALTERNATOR
14.0 INTERFACING THE ENGINE
15.0 THE MANDATORY CHECK-LIST BEFORE TESTING
16.0 ELECTRICAL ATS PANEL TESTING PROCEDURES
17.0 APPLICATION NOTE: DUAL GENERATOR
18.0 APPLICATION NOTE: DUAL LOAD
19.0 A FINAL OVERVIEW AND CONCLUSIONS
FORGET TOYS WITH LCD
MOVE TO MILITARY-GRADE -30°C/+70°C DISPLAY
HOW TO PROGRAM THE ATS CONTROLLER
In this video, you can see how simple programming parameters are. The ATS controller is delivered with defaults that meet all general-purpose applications. You can adapt the controller to your miscellaneous needs.
The Be242 ATS controller features over 50 adjustable settings, including various Input/Output options. In other words, you can adapt the controller to old-fashioned or second-hand engines. You do not need external tools for programming. The installation manual includes a full description.
ATS PANEL MANUAL MODE OF OPERATION DEMO
The Be242 is user-friendly. All functions are intuitive. High-luminosity indicators guide you through each step in activating a contactor or starting and stopping the generator after (or not) a cooling-down time.
The membrane push buttons are rated for an industrial environment and designed to last decades.
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BUILD YOUR OWN ATS PANEL
A traditional ATS controller needs as many meters of cables, many connections and accessories. The Be242 controller is made of two parts. You will change the way you make ATS panels. On the backplane, you install the interface relay board. It will be easy to connect the engine auxiliary circuits. You will benefit from the following features
FUEL SOLENOID RELAY
STOP SOLENOID RELAY
START SOLENOID RELAY
2 CONFIGURABLE RELAYS
2 CONFIGURABLE DIGITAL INPUTS
3-PHASE 600V INPUT GENERATOR
3-PHASE 600V INPUT UTILITY POWER
8Amp KM DRIVE RELAY
8Amp KM DRIVE RELAY
3X5Amp CT INPUTS
2xfuses FOR THE COILS
BELT ALTERNATOR I/O MONITOR
OVER 100 ADJUSTABLE SETTINGS
We design state-of-the-art ATS CONTROLLERS so you can make professional products.
YOU SAVE METERS OF CABLE
You will exponentially increase the reliability of the panel by providing a rational aspect.
FORGET ABOUT SQUARE HOLES AND DANGEROUS TOOLS
To install the ATS controller on the front of the cabinet, you must cut out a round hole and four 4,5mm diameter holes. This job only takes 10 minutes.
MAKE A SIMPLE ROUND HOLE!
Protects the whole border with suitable paint. This prevents rust in the long term.
NO EXTRA RELAYS NEEDED
HOW TO MAKE ATS PANELS WEB TUTORIAL
MAKE COMPACT AND COST-EFFECTIVE ATS PANELS
HOW TO MAKE ATS PANELS WEB TUTORIAL
20 mm-THICK ATS CONTROLLER
You will fix the controller on the door of the ATS panel by making 4 holes. You will make a round hole for the interconnection cable we supplied. No square hole is required. It is a 5-minute job. The BE242 controller will benefit from the metal door plate shielding effect.
THAT SEEMS INCREDIBLE, BUT BERNINI DESIGN STARTED MANUFACTURING ATS CONTROLLERS IN 1984
We know what it is about. Thousands of controllers made in 1990 are fully functional. But most incredible is that we can manufacture in 2025 the items manufactured in 1984. All equipment is fully interchangeable pin-to-pin. Incredible but true!
IN THE PICTURE, THE FIRST COMPACT AT THE WORLD: THE AMT910
ATS CONTROLLER INSTALLATION MANUAL
Thanks to the ATS cable, you can no longer wire connections to the rear door panel.
The relay board includes auxiliary relays and short-circuit-proof components. To make a professional Automatic Transfer Switch panel, you only require a metal or plastic cabinet, a battery charger, current transformers, and contactors. You can choose the best solution by using the configurable INPUT-OUTPUT options.
Despite its square shape, the BE242 controller needs only a round hole for the interconnection cable and emergency switch.
THE ATS CONTROLLER RELAY INTERFACE BOARD
The controller on the front door features an ATS interface cable. This is connected to the Relay Interface Board. The Be242RB module features all removable connectors needed to interface with the engine, the generator, the mains, and miscellaneous input-output lines.
The label on the top of the module indicates all functions. The board is supplied from the engine's battery via automotive blade terminals. The following sections will explain all the details.
INTERFACE BOARD DIMENSIONS
This ATS controller board interface features a metallic cover. Electric noise generated by the changeover will not affect the accuracy of the electrical measurements.
This ATS controller extension board includes 7 relays committed to driving the engine auxiliary circuits and the changeover coils.
The board features electronic fuses and glass fuses to protect the coils of the changeover. The installation of this board drastically reduces the component count of your bill of materials. Not to mention the time you save assembling this item. The total weight is about 500 grams.
ATS CONTROLLER INPUTS
The ATS controller interfaces with all kinds of switches. The Be242RB offer 3 fully configurable inputs. For each input, you can choose one of the 28 options. By default, input 3 is configured to "REMOTE ENGINE TEST INPUT".
In the same way, input 2 is configured as "REMOTE LOCK INPUT", while input 4 is configured as "MAINS SIMULATED INPUT". All inputs are protected against overvoltages, AC voltage up to 50v, and reverse polarity.
ATS CONTROLLER OUTPUTS
The ATS controller DC outputs feature short-circuit-proof relays. The outputs are designed for driving automotive relays. The total current delivered by the outputs may not exceed 4amp. Over this current, the ATS controller triggers the output short-circuit protection.
The OUTPUT 1 is programmed by default as "ALARM OUTPUT". You can connect a sound alarm. The OUTPUT 2 is programmed by default as "PREGLOW". You may install a pilot relay to start a diesel engine. THE ATS CONTROLLER INSTALLATION MANUAL lists over 50 available options.
VOLTAGE MEASUREMENTS
The ATS controller directly interfaces with GENERATORS and UTILITY POWER LINES up to 600vac. The fuses indicated in the picture are mandatory. These fuses (or a circuit breaker as an option) protect the wires in case of a direct short-circuit.
You will find more details about contactors or motorized switches driving in our tutorial:
CURRENT MEASUREMENTS
We always recommend installing CURRENT TRANSFORMERS of a suitable size. You will have a precise measurement of the current that flows in your LOAD, and you can set warnings and shutdowns in case of an OVERLOAD.
The ATS controller interfaces with current transformers from 50/5a up to 1000/5a
THERE ARE TWO BASIC CONFIGURATIONS: CONTACTOR-BASED AND MOTORIZED-BASED
ATS CONTROLLER DIAGRAM
The "SECONDARY SOURCE" or "EMERGENCY SOURCE" is usually a diesel generator. The ATS panel connects the LOAD via the KG. This is possible only when the "PRIMARY SOURCE" (in this case, the "UTILITY POWER") is isolated using the KM. The KM auxiliary contacts are closed when the KM is open. In this way, the ATS controller supplies the KG coil. When switching the LOAD to the "PRIMARY SOURCE", the Be242 add a programmable DEAD-TIME. This will avoid sparks over voltages. and over currents when the LOAD is highly inductive. This is the case with big electric motors. In other words, before energising a heavy LOAD, the Be242 controller waits for a while. Set the dead time between two and ten seconds.
CLICK ON DIAGRAM, OPEN HD EXPLANATION
UTILITY POWER-LOAD The utility power is connected to the LOAD via the KM contactor. This output energises the KM contactor. The KG closes its auxiliary contact when it is open. In this way, the neutral line supplies the KM coil. The relay output that drives the KM output features normally closed contacts. By doing so, the ATS controller gives priority to UTILITY POWER in case the ATS controller is damaged or without a supply. The user will not suffer unexpected power failures if the UTILITY POWER is healthy. The ATS controller energises the KM output only in the "TRUE UTILITY POWER FAILURE" event. This prevents the panel from supplying the LOAD with improper electrical parameters. Once the KM is open, the auxiliary contacts KM will close. This action will enable the KG to connect the load to the generator.
THE MOTORISED SWITCH-BASED DIAGRAM
The motorized changeover consists of a switch with three positions: "primary source," "OFF," and "secondary source." An electric motor drives the switch to move in each position.
The motorized changeover has several advantages. Firstly, it can manage big currents if compared with a contactor-changeover. Secondly, it does not require power to hold the position. Thirdly, it is a cheap and safe solution for high-power switching.
ATS CONTROLLER CONTROLS TWO SEPARATE LOADS
Install the ATS controller to supply two separate loads from a single generator. The generator connects to the load affected by the power outage. This application is typical in private houses. Two houses' power outages can be resolved by investing in a single generator. You must make two ATS panels of a suitable size.
ATS CONTROLLER IN A DUAL GENERATOR SYSTEM
The following wiring diagram presents the basic connections of a dual-generator ATS controller configuration. With Be242 you can connect two generators as an emergency standby to one single load. The BREAK-BEFORE-MAKE configuration is mandatory for the protection of the load. In case of a prolonged outage, you can set up ENGINE 1 as a master. In case of starting failure, the second engine will start. The generator will supply the load. You are required to include the ATS controllers and transfer switches in the same cabinet.
SETTING UP THE ATS CONTROLLER
The Be242 is user-friendly. The installation manual will help you install the panel. The ATS controller features default settings for a 400V 3-phase system. You can program the ATS controller on-site in a few minutes. You can arrange a dual-set configuration or dual-load configuration. The ATS controller accepts single or three-phase voltage for the utility power and generator. You can choose single-phase or three-phase configurations. To drive the motor of the transfer switch, connect the KM and KG outputs as indicated in the wiring diagram. The battery supplies the ATS controller's electronic circuits. You can use the ATS controller for up to 1000kVA electrical systems.
ATS CONTROLLER OFF-MODE OF OPERATION
Push the button [OFF] of the ATS controller to enter the OFF mode. The OFF mode clears the fault alarms and allows you to read or program parameters.
The Display and LEDS are turned off, and a dot on the display will blink slowly. Push one of the pushbuttons on the front panel to energise the display.
MANUAL MODE: STARTING THE ENGINE
The MANUAL mode allows manual control of the engine and circuit breakers. Push the [MAN] push button to select the MANUAL mode. Push the [START] push button of the ATS controller until the engine starts; the display indicates the message [. . . .] during the starting attempts or [! ! ! !] if preheat has been programmed.
When the engine is running, the green LED turns on.
To stop the engine, push the [STOP] push button of the ATS controller until the [StOP] message appears on the display. If the engine has already stopped, it is possible to reset the STOP sequence by pressing the [STOP] push button.
MANUAL CHANGEOVER
Select MANUAL mode. Start the engine, and wait for a voltage. Push the [ I ] (KG) push button of the ATS controller to close the Generator circuit breaker.
To transfer the Load to "UTILITY POWER", push the [I] (KM) push button (the [KG] will open). Push the [O] push button to open a Contactor. In manual mode, the CHANGEOVER timer lasts one second.
ATS CONTROLLER AUTO MODE OF OPERATION
Push the [AUTO] push button of the ATS controller until the green LED illuminates. The engine starts when the Be242 detects a power outage. The Contactor of the "PRIMARY SOURCE" (KM) opens after the BREAKER timing. After the warm-up time, if the voltage and frequency are within the settings, the circuit breaker of the "SECONDARY SOURCE" (KG) will close.
If the UTILITY POWER is restored, the KG will open. The KM will close following a programmed changeover timing. The Engine will stop after cooling downtime. If the engine shuts down, the KM closes independently of the "UTILITY POWER" status if the [P.48] is [ON] (NFPA-110 mode), otherwise, the KM will close only if the UTILITY POWER is within programmed settings. In AUTO mode, the BE242 will periodically test the engine. You must set parameters [P.41] and [P.42]. During this test, the AUTO mode green LED will continue to blink. The Be242 controller starts and stops the engine according to programmed inputs.
ATS CONTROLLER TEST MODE OF OPERATION
Push the [TEST] push button of the ATS controller until the green LED illuminates. The Be242 ATS controller starts the engine and transfers the load to the Generator if [P.17] is [on]. Select the AUTO or OFF mode to stop the engine. If you push the [STOP] push button when the ATS controller is in AUTO or TEST, the [Er.09] will energise. To clear the alarm, select the OFF mode.
ATS CONTROLLER SPECIFICATIONS
DC Supply: 5.5/30Vdc, 50/150mA
Protection: 500mA thermal fuse
Dimensions: 194 X 146 X 205
Panel Cut-out: Round 60mm
Operating temperature: -30 to +70 deg C
Humidity range: 8% up to 90%
Weight: 300 grams
Meets ECC 89/336, 89/392, 73/23, 93/68, IEC 68-2-6
Certification: CE
Display: 4 digits solid state
LED Indicators for all functions
12 Silver-Membrane-Type 100.000 actions life
Over 60 programmable adjustable settings
THE ATS CONTROLLER RELAY BOARD INTERFACE
Supply Voltage: 5.5-30Vdc, 50-150mA
Protection: internal 3A thermal fuse
Dimensions: 210 X 150 X 80 (mm)
Installation: DIN-RAIL
Temperature: -30 deg C up to +70 deg C.
Humidity: 5% up to 90%
Weight: 600 grams
Metts ECC 89/336, 89/392, 73/23, 93/68.
Certification: CE
DC Relay Outputs: 3A 30VDC.
AC Relay Outputs: 8Amp 250V AC
Output Fuses: 2Amp
Connectors: removable terminal blocks
Operating Vac: up to 600Vac
Overvoltage Voltage: 2KVac
CTs: up to 1000/5Aac
BERNINI DESIGN SRL
ITALY Industrial Park
46035 OSTIGLIA
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