Design and simulation of Automatic Transfer Switch with shutdown timing

using Programmable logic controller.

1
Omogoye, O.S, 2Ogundare. A.B. 3Ojo F.E.
1
Samelect2003@yahoo.com,2ayoadeogundare@yahoo.com,
3
doncyben40@yahoo.com
(1,2,3 Electrical and Electronic Engineering Department LASPOTECH)
ABSTRACT

This work is design and simulation of 63A, 3phase ATS incorporating a shutdown timer. Considering the
engineering education curriculum, tertiary institution is meant to provide an industrial based technology to the
students in order to be able to cope with the trend of industrial demand of advanced manufacturing technology.
To achieve this, it is important to provide students the adequate industrial instructions and also boost their
practical skill via improving on the already existing laboratory industrial resources.
General overview of ATS is briefly discussed; the design steps and implementation of the proposed work
includes, the use of electromagnetic relay, 63A contactor, circuit breaker, indicator lamp, selector switch,
voltage monitor, timer relay, terminal block, phase sequence device and a Programmable Logic Controller
(PLC) using Ladder logic for its programming.
The work is tested and the proposed set up is found effective, user friendly, improves reliability of power
supply, saves time, helps to improve students skill industrial-wise and can also be used in an industry for
commercial production of goods and services.

Keywords: Automatic Transfer Switch, Programmable Logic Controller, Ladder logic programming,
shut down timer.

1.0 INTRODUCTION
Automatic Transfer Switch monitors incoming voltage from the utility line. [1]
The operation of this ATS is based on proper functioning of its basic units. Incessant power outages paved way
for the use of ATS. An automatic transfer switch panel helps to automatically switch its load to any available
power source in the event of an interruption in the main AC supply. The incorporated shut down timing in this
work helps to use a preset timing for the use of alternative power supply. This is the main contribution of this
work to the already existing work done on ATS.

2.0 METHODOLOGY
The ATS (Automatic Transfer Switch) can be achieved using three control methods viz;
(i) Programmable Logic Controller (PLC)
(ii) Microcontroller
(iii) Relay Logic
2.1 Relay Logic: the sequence of the operation of the ATS control is done using set of described relay
operation. When the logical conditions are met, an output is triggered to carry out an operation. It is simple to
understand but without its disadvantages which includes;
i. Bulky wiring
ii. Delay in trouble shooting
iii. Overall reliability of the system is not so high as a failure of one component, could lead to failure of the
entire system.

ADVANTAGES OF RELAY LOGIC

i. Reduced cost of production
ii. The wiring and the control circuit is not difficult to achieve.
iii. The construction and installation is very easy.

2.2 MICRO CONTROLLER

Micro controller based control systems are quite faster in switching operations; however, they have a major
disadvantage of static programming (i.e. after a particular design has been made and there is need for
modification, the entire circuit will be changed).

Omogoye .O.S, Ogundare .A.B, Ojo .F.EPage 1

2.3 PROGRAMMABLE LOGIC CONTROLLER (PLC).
The PLC is most advanced of the three methods. A PLC offers variety of advantages which includes;
i. Faster processing time (scan time)
ii. Easy programming using ladder logic
iii. Compact size of control panels
Owing to the consideration of above brief discussion, a PLC approach is chosen for this work via the use of
relay logic in other to save cost, without interfering with the intelligence of the device .

2.4 OPERATION OF THE ATS USING A SHUT DOWN TIMER

The load considered during the operation of this work is 3phase load. Hence, there is need to maintain correct
voltage phase sequence. One must bear in mind that if the phase are connected wrongly, the phase sequence
device may not supply an output to the connected load.
If the supply from the mains fails and the generator start module is on automatic mode, the generator is
automatically started to supply the load. However, if the switch is turned to manual mode, the generator will not
come up. It is assumed that only a start signal is needed to activate the start sequence of the generator on the
condition that other starting conditions are met (oil level, fuel level in the tank of the generator, water, etc)

3.0 Design Calculation

Given the assumed load of 32Kw
P = 32 KW
V L = 415V
P.F = 0.8
For three phase circuit , P = 3 V L I L Cosθ
P 32 × 10 3
IL = = = 56.06 A
3V L I L Cosθ 3 × 415 × 0.8
56.04A rating does not exist, the nearest Amps value according to IEEE regulations are 50A and 63A.[3] So, it
is advisable to choose circuit breaker above the calculated value. This will help during future load expansion.

Omogoye .O.S, Ogundare .A.B, Ojo .F.EPage 2

3.1 Cable Selection Design Calculation
The cross sectional area for a maximum load current of 63A for a 3-phase AC is
cable.
VD ( MA ) × I L × Lenght
V ( Final voltage drop) = Where VD for 16mm 2 = 2.5mV /( A / m)
1000
I L = 56.04 A
l = 20m(assumed )
2.5 × 56.04 × 20
Final Voltage drop = = 2.802V
1000
According to IEEE regulation, the calculated final voltage is below the MPVD
( Multichannel Pr ogram min g Video Distributor ),
the cable selected is correct.

CONTROL CIRCUIT
P = VL I L cos θ (sin gle phase) where assumed load = 1500W
V = 220V
Cosθ = 0.8
P 1500
IL = = = 8.52 A
V cos θ 220 × 0.8
The selected cable for the control circuit is 1.5mm 2 according to IEEE regulation.

3.2 OPERATIONAL BLOCK DIAGRAM

Utility supply

Voltage Generator off

Load-utility
Isolator switch monitor/PHASE
Transfer delay timer
FAILURE

Off delay Generator

Siren Load-gen
switch
transfer

Generator Isolator Switch

Supply

Cut-Off Load Generator

Auto-shut
From generator Off-Delay
down elapse

Omogoye .O.S, Ogundare .A.B, Ojo .F.EPage 3

3.2 OPERATIONAL CONTROL DIAGRAM

230 VAC
SUPPLY FROM
GENERATOR
L
ACTIVATE
+24V SHUTDOWN
DC TIMER SEALING
ISOLATOR ISOLATOR CONTACT
SWITCH SWITCH
(UTILITY GENERATOR
TO SUPPLY) SUPPLY
PLC
X20

PHASE DEACTIVATE
FAILURE SHUTDOWN
/ TIMER
NC OF
SEQUEN
UTILITY
CE
CONTACTOR
DEVICE
K1
FROM
PLC TO PLC
Y7 X24

ALARM

FROM PLC
Y1

UTILITY GENERATOR
CONTAC CONTACTOR SHUTDOWN
TOR COIL/K2/Y2 TIMER COIL
COIL / T2
K1/Y1

0V N

GEN OFF SIGNAL

GEN OFF SIGNAL FROM SHUTDOWN MANUAL
FROM PLC Y21 CIRCUIT SWITCH
T4

TO
FROM GENERATOR GENERATOR
SWITCH SWITCH

TO START
START MODULE
GENERATOR
FROM PLC
X21

Fig ii. CONTROL DIAGRAM OF A 63A 3-PHASE ATS USING A PLC

Omogoye .O.S, Ogundare .A.B, Ojo .F.EPage 4

 STANDBY
UTILITY LINE SOURCE
L1 L1
L2 L2
L3
L3
N

SAFETY
INTERLOCK
K1
K2
UTILITY
GENERATOR
CONTACTOR
CONTACTOR

3-POLE
CIRCUIT 3-POLE
BREAKER CIRCUIT
BREAKER

L1 L2 L3
TO LOAD
BUS

Fig iii. Power diagram of a three phase 63A ATS using a PLC

Omogoye .O.S, Ogundare .A.B, Ojo .F.EPage 5

PLC PROGRAMME WRITTEN IN LADDER LOGIC USING MITSUBISHI FX-TRAINER

Programme was written with Mitsubishi fx trainer software

Omogoye .O.S, Ogundare .A.B, Ojo .F.EPage 6

3.4 SIMULATION OF ATS USING SHUTDOWN TIMER OPERATIONAL CONDITIONS

OUTPUT SIGNALS:
Y1 (GREEN LAMP) POWER UTILITY SUPPLY IS IN USE
Y3 (RED LAMP) GENERATOR OFF SIGNAL
Y4(GREEN LAMP) GENERATOR SUPPLY IS IN USE
Y5 (YELLOW LAMP) AUTO SHUT DOWN IS ACTIVE
Y7 (BUZZER) ALARM INDICATING SUDDEN RESTORATION OF UTILITY SUPPLY
INPUT SIGNALS:
X20 (PB1) START AUTO SHUT DOWN TIMER
X21 (PB2) STOP SHUT DOWN TIME
X24 (SW1) IF ‘ON’ UTILITY SUPPLY IS AVAILABLE
IF ‘OFF’ UTILITY SUPPLY IS UNAVAILABLE
CONDITION 1
WHEN THERE IS SUPPLY FROM POWER UTILITY AND THERE IS SUDDEN OUTAGE;
COMMANDS:
SW1 IS AT ‘OFF’ STATE
Y4 (GREEN) COMES UP SIGNIFYING THAT GENERATOR HAS BEEN ACTIVATED.
CONDITION 2
WHEN SUPPLY IS RESTORED
COMMANDS;
SW1 IS AT ‘ON’ STATE.
Y7 (BUZZER ALARM) COMES UP FOR 4SECS
Y1 (GREEN) COMES UP AFTER 4SEC TO SHOW THAT THE POWER FROM UTILITY HAS BEEN
RESTORED.
Y3 (RED) COMES UP FOR 4.5SECS INDICATING OFF SIGNAL TIME
CONDITION 3:
WHEN THE GENERATOR IS AT ‘ON STATE’ AND TIMED LETS SAY, T=10SEC
COMMANDS:
PUSH PB1(X20)
AMBER LIGHT Y5 COMES UP TO INDICATE THAT AUTO SHUT DOWN TIME HAS BEEN
ACTIVATED.
Y3 (RED) COMES UP FOR 4.5SEC INDICATING OFF SIGNAL
CONDITION 4:
AFTER SHUT DOWN, IF POWER IS RESTORED, CONDITION 2 REPEATS IT SELF IN THE SAME
SEQUENCE
CONDITION 5
IF GENERATOR IS ‘ON’, ‘TIMED’ AND POWER IS RESTORED SUDDENLY BEFORE THE SET TIME
ELAPSES.
COMMAND;
PUSH X24 (SW1) TO ‘OFF’ STATE, Y4 COMES UP
PUSH X20, Y5 COMES UP
PUSHX24(SW1) TO ‘ON’ STATE, Y5 GOES ‘OFF’
Y7 (BUZZER) IS ACTIVATED FOR 4SEC
Y1 IS ACTIVATED AFTER 4SEC AND
Y3 IS ACTIVATED FOR 4.5SEC TO SWITCH OF THE GENERATOR

4.0 RESULT
The shut down timing worked correctly for precise short down operational schedule .
5.0 CONCLUSION
The aim of the research work was achieved.

Reference
(1) www.Generatorjoe.net
(2) H.Ashour,’’ Automatic transfer switch(ATS) using programmable logic
controller(PLC)Mechatronics,2004,ICM’04,Proceedings of the IEEE international conference.
(3) Simons,Donald M;’’Cable geometry and calculation of current carrying capacity’’ American Institute
of Electrical Engineers, Journal ,Volume 42,pp525-539,1923(ISSN;03560-6449)

Omogoye .O.S, Ogundare .A.B, Ojo .F.EPage 7