STS-30 Owner`s Manual
Contents
1. T1 LINE L COMMON T2 NEUTRAL N COMMON T3 LINE L1 NO NORMALLY OPEN T4 NEUTRAL N1 NO NORMALLY OPEN T5 LINE L2 NC NORMALLY CLOSED T6 NEUTRAL N2 NC NORMALLY CLOSED T7 INPUT FOR RELAY COIL T8 INPUT FOR RELAY COIL INPUT FROM ELECTRIC UTILITY SHORE ER CORD OR GENERATOR POWER CORD OR TO NORMALLY OPEN NO CONTACT TERMINALS T3 T4 aes EXISITING ON BOARD CONVERTER 1 2 3 a 5 Fig 4 30 A System for alternate source inverter Let BRANCH CIRCUITS CONVERTER TO BATTERY SECTION 3 a Feed the 3 core cable from the electric utility shore power cord the generator through the 34 cable clamp that has been provided 4 Fig1 Connect the three cores as follows Fig 4 The black core to the black piece of wire connected to the NO Line L1 contact terminal T3 Use the twist on type of wire nut provided for splicing the ends The white core to the white piece of wire connected to the NO Neutral N1 contact terminal T4 Use the twist on type of wire nut provided for splicing the ends The green grounding core to one of the spare grounding studs Use an appropriate insulated ring or spade lug for making this connection b Feed the 3 core cable for output to the main breaker panel by using a convenient knockout cable clamp 3 4 or 1 for the cable entry Cable clamp has not been provided for thi2. Weight STS 30 120 VAC 60 Hz 30A NEMAS 20R Duplex Receptacle 20A max 16A continuous Fused at 20A for 1 and 34 25 msec 20 sec 5 sec Yes With DIP switch SW1 e Delay enabled OFF 1 This is the default factory setting e Delay disabled ON 0 40 C 32 F to 104 F in 8 4 x 9 0 x 3 2 mm 213 4 x 228 6 x 81 3 Ibs 4 4 kgs 2 0 appropriate plug termination A 15A cord with NEMAS 15P plug has been provided for convenience of connection to an inverter generator with continuous current of up to 12A For full 30 A capacity replace this cord with 30 A rated cord and NOTE Specifications are subject to change without notice 14 SAMLEX AMERICA INC SECTION 6 2 YEAR LIMITED WARRANTY STS 30 Transfer Switch manufactured by Samlex America Inc the Warrantor is warranted to be free from defects in workmanship and materials under normal use and service The warranty period is 2 years for the United States and Canada and is in effect from the date of purchase by the user the Purchaser Warranty outside of the United States and Canada is limited to 6 months For a warranty claim the Purchaser should contact the place of purchase to obtain a Return Authoriza tion Number The defective part or unit should be returned at the Purchaser s expense to the author ized location A written statement describing the nature of the defect the date of pur chase the place of
3. and if the converter is not disconnected from the panel it will result in a battery to inverter to converter to battery loop that will quickly drain the batteries In case the external battery charger is not being used the converter may be re wired to the NEMA5 20R Duplex receptacle 3 Fig 1 As these receptacles are connected to the NO contact terminals T3 and T4 the converter will always be powered from the electric utility shore power cord the generator In case the current drawn by the converter is gt 16A continuous the converter should be wired to a separate circuit connected to the NO contact terminals T3 and T4 through a fuse applicable to the input current of the converter f Incase the primary power source is electric utility shore power cord the time delay of 20 sec has to be disabled by setting the internal DIP Switch SW1 Figs 2 4 to ON position In case the primary source is generator the internal DIP Switch SW1 Fig 2 4 should be retained in the preset off condition 1 SAMLEX AMERICA INC 9 SECTION 3 TESTING OF THE OPERATION FIG 4 Read and Follow ALL Safety Instructions BEFORE Testing the Operation a Plug in the power cord As the time delay has been disabled As explained above if the primary source is electric utility shore power cord the time delay should be disa bled by changing the position of the DIP Switch SW1 to ON position the relay coil will energize as soon as the power cord is plug
4. counter cabinets below closet compartments inside the bed pedestal or cabinets overhead cabinets under floor storage compartments accessed from the vehicle exterior etc The chosen location must be accessible after installation is complete to facilitate future servicing CABLE ENTRY AND EXITS A number of 34 and 1 knockouts have been provided on all the sides 7 Fig 2 for ease of routing the input and output cables Choose a knockout that will facilitate installa tion and service within the selected mounting area Use 3 4 or 1 cable clamps as neces sary to clamp the cables entering and exiting the box MOUNTING Mount the unit with screws through holes in the bottom of the unit The unit should be screwed to a solid surface firmly enough to hold its weight during vehicle operation MAKING ELECTRICAL CONNECTIONS Attach an 8 gauge earth ground wire to the transfer switch chassis ground lug 6 Fig 2 4 studs with serrated lock washers and nuts have been provided on the inner bottom of the case to make grounding connections from the inner side N The color code for 120 VAC wiring is as follows e The Grounding wire is bare or green e The Neutral wire is white e The Line wire is black w A 3 4 cable clamp has been provided 4 Fig 1 Additional 34 and 1 knockouts have been pro vided for convenience Please ensure that a cable clamp is used for the cable entries 4 For making firm co
5. purchase and the Purchaser s name address and telephone number should also be included If upon the Warrantor s examination the defect proves to be the result of defective material or workmanship the equipment will be repaired or replaced at the Warran tor s option without charge and returned to the Purchaser at the Warrantor s expense Contiguous US and Canada only No refund of the purchase price will be granted to the Purchaser unless the Warrantor is unable to remedy the defect after having a reasonable number of opportunities to do so Warranty service shall be performed only by the Warrantor Any attempt to remedy the defect by anyone other than the Warrantor shall render this warranty void There shall be no warranty for defects or damages caused by faulty installation or hook up abuse or misuse of the equipment including exposure to excessive heat salt or fresh water spray or water immersion No other express warranty is hereby given and there are no warranties which extend beyond those described herein This warranty is expressly in lieu of any other expressed or implied warranties including any implied warranty of merchantability fitness for the ordinary purposes for which such goods are used or fitness for a particular purpose or any other obligations on the part of the Warrantor or its employees and representatives There shall be no responsibility or liability whatsoever on the part of the Warrantor or its employee
6. A samlexpower Transfer ES Pease read this H manua Switch Manual operating your 30 Am ps transfer switch STS 30 OWNER S MANUAL SECTION 1 HEFOG CUO Mit occ oi iers eas ot zareauncs E nna 3 SECTION 2 General information ccccceceececescessceseesecsessessseeeerseseens 5 SECTION 3 VSAM AIO Graat a r 6 SECTION 4 THOUBICSMOOUO GO oisinnean A EE EE 12 SECTION 5 Specifica ONS sasinen aee E 14 SECTION 6 Wealramty asacewiensdancevenl auaenaeaddeenin dings 15 DETAILED PRODUCT INFORMATION For a complete user manual including specifications application notes installation instructions trouble shooting and more please visit the web page for this product on samlexamerica com Product page can be found using the search by model field 2 SAMLEX AMERICA INC SECTION 1 FUNCTION OF A TRANSFER SWITCH In case of failure of the main AC power source like the electric utility power it is desir able to switch the critical AC loads to a standby back up AC power source like a genera tor or an inverter The switching action should ensure that only one AC power source is connected to the AC loads at any one time and that the electric utility power and the generator inverter output power are never connected in parallel but remain isolated The electrical loads cannot be connected in parallel with the generator inverter and electric utility power at the same time This will cause the following damage and safety h
7. CB1 T5 T6 T3 T4 R1 T7 T8 T1 T2 R41 Transfer relay coil T1 Line L Common T2 Neutral N Common 7T3 Line L1 NO Normally open contact of transfer relay T4 Neutral N1 NO Normally open contact of transfer relay T5 Line L2 NC Normally closed contact of transfer relay T6 Neutral N2 NC Normally closed contact of transfer relay T7 input for relay coil T8 input for relay coil SW1 DIP Switch for enabling disabling time delay for transfer to generator OFF Delay of 20 25 sec ON No delay LED1 Green LED On when transfer relay coil R1 is energized PCB1 Printed Circuit Board for transfer relay control Fig 2 Internal layout of contacts of the transfer relay and the PCB for relay control FEATURES Can be configured for generator power cord connection or inverter alternate source connection Multiple 34 and 1 knockouts 7 Fig 1 have been provided on all the sides for ease of routing the input and output cables Consists of heavy duty 110 VDC Double Pole Double Throw DPDT relay for switching both the Line and Neutral R1 Fig 2 SAMLEX AMERICA INC 5 SECTION 3 Internal DIP Switch SW1 Fig 2 for enabling or disabling delayed transfer to generator Internal LED LED1 Fig 2 for indicating energized condition of the transfer relay coil R1 Fig 2 and for diagnostics OPERATION OF THE TRANSFER RELAY PLEASE SEE FI
8. CONTACT TERMINALS T3 T4 MAIN BRANCH CIRCUITS BREAKER PANEL Fig 5 Typical Generator Power Cord 10 SAMLEX AMERICA INC SECTION 3 a Connect the Shore Power Cord leads to the Normally Closed NC contacts T 5 and T 6 of the Transfer Relay The pre wired 15 A cord 1 Fig1 and NEMAS5 15 plug 2 Fig 1 can be used for 15 A service If it is required to be connected to a 30 A service this cord should be replaced with a 30 A cord b Connect the generator leads to the Normally Open NO contacts T3 and T4 of the Transfer Relay If convenient use the knockout and the 34 cable clamp provided marked Shore 4 Fig 1 Otherwise use any other convenient knockout with cor responding cable clamp c Connect the Breaker Panel to the Common Contacts T1 and T2 of the Transfer Relay d The time delay circuit should be energized The DIP switch SW1 Fig 2 should be in the off position marked 1 TESTING OF THE OPERATION FIG 5 Read and Follow ALL Safety Instructions BEFORE Testing the Operation a Plug in the power cord If the main panel circuit breakers are switched on the RV load should operate normally Unplug the power cord b Start the generator There is a pre programmed 20 to 25 second delay in the transfer switch The delay is designed to allow the generator a brief warm up period When the delay completes its cycle the switch should engage and the RV load should oper ate normally An audible cli
9. G 2 Relay R1 is a Double Pole Double Throw DPDT relay and is used to switch power from one source to the other The relay coil is energized as soon as 110 VDC is fed to terminals T7 and T8 When the relay coil is de energized the common contact terminals T1 and T2 are connected to the Normally Closed NC contact terminals T5 and T6 respectively When the relay coil is energized the common contact terminals T1 and T2 switch over to the Normally Open NO contact terminals T4 and T5 The relay coil operates at 110 VDC This voltage is generated and controlled by the cir cuitry located on PCB1 120 VAC is tapped from contact terminals T3 and T4 is rectified and made available to the relay coil terminals T7 and T8 through a time delay circuit DIP Switch SW1 located on the PCB1 is used to enable or disable the time delay circuit When the Time Delay Circuit is enabled SW1 in OFF position 1 This is the factory default preset position 110 VDC control signal for energizing the relay coil is delayed by around 20 to 25 sec from the time 120 VAC is made available at the NO contact ter minals T3 and T4 When the time delay circuit is disabled DIP Switch in ON position the 110 VDC control signal for energizing the relay coil is made available to terminals T7 and T8 as soon as 120 VAC is made available at the NO terminals T3 and T4 As soon as the 110 VDC control signal is fed to the relay coil to terminals T7 and T8 the green LED 1 lights up in
10. To disable the time delay the DIP Switch SW1 should be set to ON position When time delay is disabled the transfer will be instantaneous 12 SAMLEX AMERICA INC SECTION 4 FAILED TIME DELAY CIRCUIT It is possible for a voltage spike etc to cause the time delay module to fail if this hap pens the switch will no longer transfer If the AC input to the control board PCB1 is available and the LED does not light after 20 to 25 seconds the time delay function in the module has failed and the module will be required to be replaced To verify this try setting the time delay switch on the PCB1 to disabled position ON the switch should transfer with no delay Note that this position will allow emergency operation until the module can be replaced however there will not be a 20 25 second delay for generator start up All repairs should begin by unplugging and replacing PCB1 for relay control first However if the LED1 is on and the switch is not working then PCB1 for relay con trol is functioning properly and the switch has other problems such as a failed relay and the entire switch will be required to be replaced SAMLEX AMERICA INC 13 SECTION 5 Model Input output voltage Input output current Battery charger receptacle Knockouts Maximum operating time of the relay Delay time for generator warm up Enabling disabling of delay time Operating temperature Dimensions W X D X H with max protrusions
11. ads requiring relatively small amounts of power The 120 VAC system powers larger loads like microwave ovens hot water heaters washer dryer coffee machines hair dryers space heaters heating and air conditioning HVAC and convenience outlets that supply power to audio video and entertainment systems The domestic refrigerator is common ly supplied by both the 12 VDC and the 120 VAC system and sometimes alternatively by propane Inverters are also used to provide AC power for dry camping where AC shore power is not available or in cases where gensets are not permitted due to noise restrictions Typically the inverter only supplies AC devices that are the highest priority such as microwave entertainment and convenience outlets It is not practical to run loads like hot water heaters and HVAC systems from inverters that are ultimately powered from batteries SAMLEX AMERICA INC 3 SECTION 1 Introduction Frequently the total AC power requirement of all the system loads exceeds the camp ground RV park s power inlet and consequently requires the genset to power the entire system Thus there may be 3 types of AC power sources Transfer switches are used to config ure switching of the AC power sources so that the priority of the AC sources is Electric utility power Genset generator Inverter SIZING OF TRANSFER SWITCH Determining which circuits you will require during a power outage is the first step in selecting t
12. atures for the pre wired configu ration are given below The primary AC power will be the electric utility power also called the Shore Pow er Cord or Cord in RVs or a generator This is connected to the Normally Open Contacts T3 and T4 A NEMA 20R Duplex Receptacle 3 Fig 1 has been provided on the side of the unit for ease of connecting the NEMA5 15P or NEMAS5 20P plug of a battery charger The back up power will be provided from an inverter A 15 A power cord 1 Fig 1 with a 15 A NEMAS5 15P plug 2 Fig 1 has been provided This allows very con venient connection to the 15 A NEMAS5 15R receptacle provided on the inverter The maximum power of the back up inverter should be less than 1800 VA as the maximum capacity of the cord provided for the inverter connection is only 15 A Preset Configuration Detailed Information Please see Fig 1 2 and 4 NEMAS 20R DUPLEX RECEPTACLE BATTERY CHARGER on o sm LED1 BATTERY SIDE FUSE FOR CHARGER BATTERY SIDE FUSE FOR INVERTER a BATTERY INVERTER INPUT FROM INVERTER TO NORMALLY CLOSED NC CONTACT TERMINALS T5 T6 8 SAMLEX AMERICA INC OUTPUT TO AC BREAKER PANEL DISCONNECT THE CONVERTER TERMINALS
13. azards The electric utility line voltage is normally stepped down by a transformer before entering the home RV park campground The transformer will work in reverse when voltage is sent through it in the opposite direction and will step up the voltage fed back into it If the electric utility power is interrupted say the feeder section upstream is switched off by workers for repairs the generator inverter will feed voltage back into the electric utility power lines this voltage will be stepped up by the transformer and will electrocute the workers that come into contact with the utility lines If the electric utility power and the generator inverter are alive at the same time the electric utility power will be fed back into the generator inverter and the gen erator inverter will get damaged There is also a potential of fire APPLICATION OF TRANSFER SWITCH IN HOMES By installing a transfer switch at your breaker box and connecting a generator inverter to the transfer switch you can run selected circuits for appliances such as a furnace well pump sump pump refrigerator television computer printer or lighting circuit during a power outage depending on the capacity of your generator inverter APPLICATION OF TRANSFER SWITCH IN RECREATIONAL VEHICLES RVS RVs have both a 12 VDC house or domestic system and a 120 VAC system The DC system commonly provides power for area lighting stereo water pumping and other lo
14. ck should sound as the switch engages c Shut down the generator As the generator winds down the switch should disengage without chatter or cycling An audible click should sound as the switch disengages d Plug in the power cord Start the generator After the pre programmed delay the switch should transfer power automatically from the power cord to the generator Lis ten for the audible click as the switch transfers Green LED1 will be lighted indicating that the relay has energized Shut down the generator and unplug the power cord SAMLEX AMERICA INC 11 SECTION 4 LOW VOLTAGE Low voltage is harmful to most appliances Relay based transfer switches are also af fected by low voltage if the voltage level drops lower than the holding voltage of the coil the relay contacts will chatter Sustained contact chattering may cause damage GENERAL LOW VOLTAGE Low voltage can be caused by low voltage conditions such as in an RV park with inadequate wiring for crowded camper conditions where everyone s electricity suffers brownout In this case a voltmeter will be helpful and will show a low voltage read ing from the park receptacle even before the RV is plugged in When you experience general low voltage conditions remember that brownouts can be harmful to most appliances A better alternative might be to utilize the generator until park voltage conditions improve LOCALIZED LOW VOLTAGE Low voltage conditions can be caus
15. dicating that the relay coil has energized The delay of around 20 to 25 sec is required when the AC load is transferred to the gen erator The generator should never be started on load Also the generator takes around 20 to 25 sec to stabilize in voltage and frequency SAFETY INSTRUCTIONS Connections for stand by backup power to a building RV system using the transfer switch must be made by a qualified electrician and must comply with all applicable laws and electrical codes Before starting installation disconnect all live sources or power Make sure that the generator is off the external shore power cord is unplugged and the inverter if any is shut off The unit is not weather proof and should be mounted in a cool dry and protected environment To prevent exposure to foreign contaminants do not mount the transfer switch in an engine compartment under kitchen sink drains or water pipes within the battery compartment or in any compartment designed for storage of flammable liquids such as gasoline 6 SAMLEX AMERICA INC SECTION 3 MOUNTING LOCATION The unit can be installed near the power cord entry of the RV or near the location of the generator output on the line side of the main distribution panel or it can be installed on the load side of the panel between the main panel and a sub panel al lowing switching for either the entire electrical load or only designated circuits Typical locations include under
16. ed by specific situations such as an additional cord which is too long and too small for the load Do not attempt to extend the RV power cord by using a 16 gauge 100 foot extension cord or any cord not rated for an RV size load A localized low voltage condition will result when a load is turned on which is larger than that which the cord is designed for As soon as the RV tries to draw more current than the amount for which the cord is rated the voltage will fall within the length of the cord and the RV will experience low voltage This is especially noticeable during inrush current situations such as an air conditioner start up TIME DELAY FOR GENERATOR As already explained earlier once a generator is started it should not be loaded im mediately The time delay is necessary during generator start up so that the generator does not have to start under load the delay is not necessary for electric utility power Shore Power Cord or inverter Therefore in transfer switch operation where the Transfer Switch is controlling an AC source other than a generator the time delay should be disabled and DIP Switch SW1 should be set to ON position This will allow instantane ous switching Another time for disabling the delay is during diagnostic and troubleshooting efforts if disabling the delay causes the switch to work when it otherwise won t then the time delay circuit has malfunctioned and the control board PCB1 will be required to be replaced
17. ged in The green LED1 will light up indicating that the relay has energized If the main panel circuit breakers are switched on the RV loads should operate normally The external battery charger will start charging the batteries b Switch on the inverter The inverter will be in standby condition c Unplug the power cord The relay will immediately de energize and the AC loads will be transferred to the inverter INSTALLATION BETWEEN POWER CORD AND GENERATOR FIG 5 This configuration is used in RV application when it is desired to switch between the shore power cord and the onboard generator When the load demand in the RV is more than the capacity of the Shore Power Cord the breaker capacity of the RV Park Camp Ground the on board generator is required to be started In this case the AC loads should transfer to the generator as soon as the generator is started and is ready to take on the load after a delay of around 20 to 25 sec on ai PCB1 TERMINALS T1 LINE L COMMON T2 NEUTRAL N COMMON T3 LINE L1 NO NORMALLY OPEN T4 NEUTRAL N1 NO NORMALLY OPEN T5 LINE L2 NC NORMALLY CLOSED T6 NEUTRAL N2 NC NORMALLY CLOSED T7 INPUT FOR RELAY COIL T8 INPUT FOR RELAY COIL INPUT FROM SHORE POWER CORD OUTPUT TO a TO NORMALLY CLOSED NC AC BREAKER INPUT FROM GENERATOR CONTACT TERMINALS T5 T6 PANEL TO NORMALLY OPEN NO
18. he proper backup generator inverter and the transfer switch Since most home appliances operate intermittently a 3000 watt generator inverter and a 30 A Transfer Switch can provide adequate power to circuits for the most common appli ances such as furnace lights refrigerator freezer microwave oven and TV If your home has a deep well pump with up to 1 HP motor a 5000 watt generator and 50 A Transfer Switch will be required to provide the starting capacity for the pump Larger wattage units can be selected for simultaneous starting and operation of multi ple appliances TRANSFER SWITCH STS 30 Transfer Switch STS is designed for single phase operating voltage of 120 VAC 60 Hz and can handle input output current of up to 30 A or an Apparent Power of 3600 VA Apparent Power Volts X Amps In this case 120 V X 30 3600 VA It consists of a Transfer Relay Fig 2 R1 and a Relay Control PCB Fig 2 PCB1 for controlling the operation of the Transfer Relay 15A power cord for connection to inverter 15A NEMA5 15P North American plug NEMA 20R Duplex receptacle for battery charger 34 cable clamp for shore power cord generator cord Cable clamp for inverter power cord Grounding lug Spare knockouts for 34 cable clamp Additional 34 amp 1 knockouts are provided on the two other sides not shown Fig 1 External view and layout 4 SAMLEX AMERICA INC SECTION 2 General Information sw LED1 P
19. nnections to the terminals T1 to T6 Fig 2 of the Transfer Relay R1 Fig 2 please crimp appropriate size of insulated ring spade lugs on the ends of the conductors of the cables 5 Connect the grounding conductors green bare wire of the cables to the spare grounding studs marked L 6 Two or more conductors can be spliced together using the appropriate size of twist on type of cone shaped plastic insulated wire nut connector also called Marrette See Fig 3 The connec tor twists over the wires to make a tight connection around the wires A square cut spring inside provides tension on the wires to hold them secure As you tighten the wire connector the spring draws tighter around the wires Fig 3 Twist on type of wire nut connector To splice the wire leads using the wire nut connector hold the bare ends of the wires parallel to each other so that the wire tips are even then secure with the wire nut Use the proper size nut Manually tighten nuts as tightly as possible Verify that all connections are tightened SAMLEX AMERICA INC 7 SECTION 3 INSTALLATION CONFIGURATIONS Preset Configuration General This Transfer Switch has been especially pre wired for ease of connections for setting up a backup power UPS Un interruptible Power Supply system comprising of an Inverter a battery charger and batteries A backup power system UPS can be used in on grid off grid and RV applications General overview and fe
20. s and representatives for injury to any persons or damage to person or persons or damage to property or loss of income or profit or any other consequential or resulting damage which may be claimed to have been incurred through the use or sale of the equipment including any possible failure of malfunction of the equipment or part thereof The Warrantor assumes no liability for incidental or consequential dam ages of any kind Samlex America Inc the Warrantor www samlexamerica com SAMLEX AMERICA INC 15 Contact Information Toll Free Numbers Ph 800 561 5885 Fax 888 814 5210 Local Numbers Ph 604 525 3836 Fax 604 525 5221 Website www samlexamerica com USA Shipping Warehouse Kent WA Canadian Shipping Warehouse Delta BC Email purchase orders to orders samlexamerica com samlexamerica
21. s connection and has to be provided by the user Connect the 3 cores as follows Fig 4 The black core to the common Line L contact terminal T1 and the white core to the common Neutral N contact terminal T2 Use appropriate insulated ring fork lugs at the bare end of the wires for firm contact The green grounding core to one of the spare grounding studs Use an appropriate ring or spade lug for making this connection c Plug the NEMAS 15 plug 2 Fig 1 of the inverter power cord 1 Fig 1 to the output of the inverter Fig 4 Please ensure that the inverter is switched off and the battery input connection to the inverter is disconnected d Plug the external battery charger to one of the receptacles of the NEMA 20R Duplex receptacle 3 Fig 1 Fig 4 Please ensure that the AC input current of the battery charger is less than 16A continuous as the receptacle is internally fused at 20A max In case the current drawn by the external battery charger is gt 16A continuous the charger should be wired to a separate circuit connected to the NO contact terminals T3 and T4 through a fuse applicable to the input current of the charger e Incase the Transfer Switch is being used in an RV application the built in converter of the RV should be disconnected from the AC Breaker Panel Fig 4 This is necessary because when the electric utility shore power cord the generator fails is removed the panel will be fed by the inverter
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