Champion Automatic Transfer Switch with aXis Controller™ Module

Introduction

Congratulations on your purchase of a Champion Power Equipment (CPE) product. CPE designs, builds, and supports all products to strict specifications and guidelines. With proper product knowledge, safe use, and regular maintenance, this product should provide years of satisfying service.

This manual contains information accurate at the time of publication, but CPE reserves the right to change, alter, or improve the product and document without prior notice. CPE values safety and product quality. It is important to thoroughly review this manual and other product materials to be fully aware of assembly, operation, dangers, and maintenance before use. Ensure all operators are familiar with proper safety and operation procedures. Exercise common sense and caution to prevent accidents, property damage, or injury.

When contacting CPE for parts or service, provide the complete model and serial numbers of your product. Record this information below:

CPE TECHNICAL SUPPORT TEAM: 1-877-338-0999

MODEL NUMBER: 102006, 102007, 102008, 102009, 102010

SERIAL NUMBER:

DATE OF PURCHASE:

PURCHASE LOCATION:

Safety Definitions

Safety symbols attract attention to potential dangers. They and their explanations require careful attention. Safety warnings do not eliminate danger themselves and are not substitutes for proper accident prevention measures.

⚠️ DANGER: Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

❗ WARNING: Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

⚠️ CAUTION: Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

ℹ️ NOTICE: Indicates information considered important, but not hazard-related (e.g., messages relating to property damage).

Important Safety Instructions

❗ WARNING: Cancer and Reproductive Harm - www.P65Warnings.ca.gov

Instructions for Champion Automatic Transfer Switch with aXis Controller™ Module

This Automatic Transfer Switch (ATS) with aXis Controller™ Module is NOT for "DO-IT-YOURSELF" INSTALLATION. It must be installed by a qualified electrician familiar with all applicable electrical and building codes.

This manual is for familiarizing servicing dealers/installers with the design, application, installation, and servicing of the equipment. Read and comply with all instructions. Keep this manual with the switch.

CPE reserves the right to change literature and products without notice. The manufacturer cannot anticipate every possible hazard. Warnings, tags, and decals are not all-inclusive. Follow recommended procedures and codes for safety.

Many accidents result from failing to follow basic rules. Before installing, operating, or servicing, read the SAFETY RULES carefully. Refer to NFPA 70, NFPA 70E, UL 1008, and UL 67 for safe use and installation standards. Always comply with local, state, and national codes.

Before Installation

❗ WARNING: Per OSHA 3120 Publication, "lockout/tagout" refers to procedures to safeguard individuals from unexpected energization or hazardous energy release during installation, service, or maintenance.

⚠️ DANGER: Ensure utility power and all backup sources are turned OFF and locked out before starting. Failure to do so could result in serious injury or death. Automatic start generators will start upon utility power loss unless locked OFF. Consult the generator operator manual to ensure ATS CONTROL and ENGINE CONTROL modules are in the OFF position.

CAUTION: Consult your Local municipal, State, and National electrical codes for proper mandatory wiring methods.

Safety Labels

These labels warn of potential hazards. Read them carefully. If a label is damaged, contact Technical Support for replacement.

• Label 1: Alternate Power Source Available - Standby Generator On Premises. (Also in French and Spanish).
• Label 2: Caution. Overcurrent device. This switch will not transfer if an overcurrent device opens due to a fault. (Also in French and Spanish).
• Label 3: Danger. Electrocution shock hazard. Warning. More than one live circuit. Disconnect all sources of supply before servicing. (Also in French and Spanish).

Safety Symbols

Study and learn the meaning of these symbols for safer operation:

• ? Read Installation Manual.
• ? Ground. Consult with a local electrician.
• ⚡ Electric Shock. Improper connections can create a hazard.

Controls and Features

Read this manual before installing. Familiarize yourself with the location and function of controls and features. Save for future reference.

Champion Automatic Transfer Switch with aXis Controller™ Module

Diagram Description: A diagram shows the internal components of the ATS with numbered labels. Key components include:

• 1. aXis Controller
• 2. Antenna
• 3. Generator L1 and L2 Terminals
• 4. Battery Charger Fuse Block
• 5. Two Wire Sensing Fuse Block (for non-Champion HSB)
• 6. Ground Bar
• 7. Neutral Bar
• 8. Neutral to Ground Bonding Wire
• 9. Load L1 and L2 Terminals
• 10. Utility L1 and L2 Terminals
• 11. Mounting Holes
• 12. Front Cover
• 13. Dead Front
• 14. Utility Access Panel (if applicable)

Unpacking

1. Handle components with care to avoid damage.
2. Allow the ATS to acclimate to room temperature for at least 24 hours before unpacking to prevent condensation.
3. Use a wet/dry vacuum or dry cloth to remove dirt and packing material. Do not use compressed air.
4. Retain the manual for future reference.

Tools Required:

• 5/16 in. Hex Wrench
• 1/4 in. Flat Screwdriver

Not Included:

• Mounting Hardware
• Line Voltage Wire
• Conduit
• Fittings

Location and Mounting

Install the ATS as close as possible to the utility meter socket. Wires will run between the ATS and the main distribution panel. Mount the ATS vertically to a rigid supporting structure. Ensure all mounting points are level; use washers behind mounting holes if necessary. Recommended fasteners are 1/4" lag screws. Always follow local code.

Dimensions: Approximately 24 inches (609.5 mm) height, 16 inches (406.4 mm) width.

Electrical Grommet(s)

Grommets can be used in any enclosure knockout for NEMA 1 (indoor) installations. For NEMA 3R (outdoor) installations, grommets can only be used in bottom enclosure knockouts.

Installation Wiring for ATS Utility Socket

WARNING: Installation should be performed by a licensed electrician or qualified individual. Ensure utility power and backup sources are turned OFF and locked out (lockout/tagout) before proceeding. Automatic start generators may activate upon utility power loss.

CAUTION: Consult local, state, and national electrical codes for mandatory wiring methods.

Conductor sizes must be adequate for the maximum current. Installation must comply with all applicable codes, standards, and regulations. Ensure conductors are properly supported, insulated, and protected by approved conduit. Remove surface oxides from cable ends before connecting. All power cables must enter through enclosure knockouts.

1. Determine conduit path from inside to outside. Drill pilot hole and then appropriate sized hole through wall sheathing and siding.
2. Route conduit along joists and studs. Secure to HSB generator. Apply silicone caulk around the conduit hole on both sides.
3. Mount the ATS near the Utility meter socket.

Wiring the ATS

NOTICE: US ATS model shown. For Canadian installation, refer to ATS Installation Manual.

The aXis ATS uses Power Line Communication (PLC) for automatic startup and shutdown of the aXis HSB. L1 and L2 power wires between the ATS and HSB facilitate communication. No additional communication wires are needed beyond power and battery charger wires.

1. Have authorized utility personnel pull the utility meter.
2. Remove ATS door and dead front.
3. Connect Utility (L1-L2) to ATS Utility side breaker (Torque: 275 in-lbs).
4. Connect Utility Neutral (N) to Neutral lug (Torque: 275 in-lbs).
5. Connect Earth Ground (G) to GROUND bar. Note: GROUND and NEUTRAL are bonded in this panel.
6. Connect Generator L1-L2 to Generator side breaker (Torque: 45-50 in-lbs).
7. Connect Generator Neutral (N) to neutral bar (Torque: 275 in-lbs).
8. Connect Generator Ground (G) to ground bar (Torque: 35-45 in-lbs).
9. Connect Load bars L1 and L2 to distribution panel (Torque: 275 in-lbs).
10. Pull NEUTRAL and GROUND from ATS to distribution panel.

CAUTION: Remove bond from distribution panel if installed.

Battery Charger Wiring

The aXis Controller™ HSB includes a 24V battery charger powered by 120V AC from the ATS's bottom left fuse block.

1. Run two wires from the ATS to the HSB for the battery charger circuit (120V AC, 1 amp max). Wire size must be appropriate. Wiring can share conduit with other power wires. Battery charger wire must have insulation rating >= 264VAC, be suitable for outdoor installation, and meet local codes/NFPA 70.
2. ATS Connections: L1 to bottom terminal of fuse block; Neutral to neutral block.
3. HSB Connection: L1 and N connect to terminals near L1, L2, N, G connection points. Refer to HSB manual for details.

Utility Sensing Fuse Block

This fuse block is typically not used. It is for connecting the Champion aXis ATS to a non-Champion HSB that monitors utility voltage for generator control. The voltage between the fuses is 240V AC. Do not use this block for battery charging.

Low Voltage Control Relays

The aXis Controller™ ATS has two low voltage relays, AC1 and AC2, for managing loads like air conditioners. These are located on the aXis control board.

Connecting to AC1 and AC2: Route low voltage wiring into the ATS using code-appropriate conduit and fittings. Connect to pin 1 and pin 2 of AC1 or AC2. Pin 3 of AC2 is used only when wiring to a non-aXis Controller™ HSB, where it acts as a two-wire start signal, and AC2 cannot manage a load.

Settings on the aXis Controller™ Module

Configure the control board settings for your generator and installation.

Generator Wattage Setting:

Set the two circular pots on the control board to match your generator's maximum power output. The left pot is for the 10's value, the right for the 1's value. Do not exceed the generator rating. If the rating falls between settings, choose the next lower value (e.g., 12,500W generator: set to 12,000W).

NOTICE: All DIP switches are ON by default, except switch #9 which is OFF.

DIP Switch Settings:

• Switch 1 (Load Module 1 Lockout): ON = Managed (lowest priority, turns off first). OFF = Stays off during HSB power.
• Switch 2 (Load Module 2 Lockout): ON = Managed. OFF = Stays off during HSB power.
• Switch 3 (Load Module 3 Lockout): ON = Managed. OFF = Stays off during HSB power.
• Switch 4 (Load Module 4 Lockout): ON = Managed (highest priority, turns off last). OFF = Stays off during HSB power.
• Switch 5 (Frequency Protection): ON = Loads off below 58 Hz. OFF = Loads off below 57 Hz.
• Switch 6 (Spare): Not used. Position does not matter.
• Switch 7 (Power Management): ON = ATS manages home load. OFF = Power management disabled.
• Switch 8 (PLC vs. Two Wire Communication): ON = ATS controls HSB via PLC (preferred, requires aXis HSB). OFF = ATS controls HSB via AC2 Relay (AC2 cannot manage load; pins 1 & 3 of AC2 used for HSB start signal).
• Switch 9 (Test HSB with Load): ON = Test with load. OFF = Test without load.
• Switch 10 (Master/Slave): ON = Primary or only ATS (most common). OFF = Controlled by another aXis ATS (for multi-ATS installations).
• Switch 11 (Exercise Test): ON = Scheduled exercise tests enabled. OFF = Exercise tests disabled.
• Switch 12 (Time delay for HSB to accept load): ON = 45 seconds. OFF = 7 seconds.

Installation Steps:

1. Have authorized utility personnel reconnect the meter.
2. Verify voltage at utility circuit breaker.
3. Turn on utility circuit breaker.
4. The ATS aXis Controller™ module will boot up (approx. 6 minutes).
5. Home should be fully powered.

WIFI Setup Method

Connect to the ATS WiFi network using a WiFi-enabled device.

1. Use a WiFi-enabled device (laptop, smartphone, tablet) near the ATS.
2. Search for and connect to the network named "Champion XXXX" (where XXXX are the last four digits of the serial number). The password is on a decal on the ATS dead front.
3. Open a web browser. The Champion aXis Controller™ Home Standby Generator Settings Page should load automatically or by refreshing/navigating to any website. If the device stays connected to the internet, turn off mobile data and ensure no other networks are connected. Note: The Champion WiFi is a direct connection and does not access the internet.
4. On the Settings Page, set the date and time using the dropdowns or the "USE THIS DEVICE'S DATE & TIME" button. Confirm and save.
5. Set the HSB exercise frequency and schedule. Confirm and save.
6. Wireless network settings are typically not adjusted and should retain default values.
7. The time, date, and exercise information are now set. You can close the browser or proceed to view ATS & HSB Status.

ATS & HSB Status Using WIFI

View real-time status information for the ATS and HSB.

1. Connect to the "Champion HSB" WiFi network as described in the WIFI Setup Method.
2. On the Home Standby Generator Settings page, locate and click the ? icon at the bottom right.
3. The ATS and HSB status page displays live data for voltage, frequency, current, etc., for both utility and HSB power. There are three tabs: ATS, GEN, and LMM, for viewing status of the Transfer Switch, Generator, and Load Management Modules, respectively.
4. When finished, close the browser and disconnect from the WiFi.

Connecting the Load Management Systems

Instructions for connecting aXis Controller™ Load Management Modules (LMM) using Power Line Carrier (PLC) communication are found in the LMM's installation instructions.

Teaching System

This procedure teaches the ATS which loads are attached. It is required if LMMs are installed or if AC1/AC2 are used to manage loads.

1. Turn the ATS UTILITY circuit breaker OFF. The generator will start automatically.
2. Confirm managed loads are operating.
3. Press and hold the "LEARN" button for 8 seconds. The ATS will shut off managed loads one by one until all are OFF, flashing LEDs to indicate the process.
4. Once learned, LMM units return to normal operation.
5. Configuration is saved and not affected by power outages.
6. Turn the UTILITY circuit breaker ON. The ATS will transfer load back to utility, and the generator will cool down and shut off.
7. Repeat if LMM units are added or removed.

Full System Check

Perform a complete system test.

1. Open the Utility breaker for a full system test, then close it after confirming all systems are working.
2. After the Utility breaker opens, the engine will start automatically.
3. The aXis ATS control panel will reboot on Generator power and control switching relays.
4. The home will be powered by the Generator. LMMs will become active after 5 minutes if installed.
5. Close the Utility breaker.
6. The system is now fully functional.
7. Replace the dead front by sliding it up into the cabinet, securing it with the included nut and stud.
8. Replace the door and secure with hardware. Locking the door is recommended.
9. Return to HSB and verify the controller is in "AUTO" mode. Confirm icons indicate Utility power is active, Utility side relay is closed, and home is receiving power.
10. Close and lock HSB hoods. Return keys to the customer.

NEMA Enclosure Types:

• NEMA 1: For indoor installations only.
• NEMA 3R: Weatherproof enclosure for exterior installations (required by code). Has knockouts on the bottom and side. Requires watertight connections and fasteners/grommets when installed outside. Can also be used indoors.

Specifications

Technical Specifications

• 22kAIC, no short-time current rating.
• Suitable for use in accordance with National Electrical Code, NFPA 70.
• Suitable for control of motors, electrical discharge lamps, tungsten filament lamps, and electrical heating equipment, provided load ratings do not exceed switch rating (tungsten load <= 30% of switch rating).
• Continuous load not to exceed 80% of switch rating.
• Line voltage wiring: Copper (Cu) or Aluminum (AL), min 60°C, min AWG 1 - max AWG 000, torque to 250 in-lb.
• Signal or Com Wiring: Cu only, min AWG 22 - max AWG 12, torque to 28-32 in-oz.
• All connection lugs are rated AL9CU - 90°C.
• NEMA 3R: Weatherproof enclosure for exterior installations. Requires watertight connections and fasteners/grommets. Can also be used indoors.

Warranty

Each Champion transfer switch or accessory is guaranteed against mechanical or electrical failure due to manufacturing defects for 24 months from shipment. The manufacturer's responsibility is limited to repair or replacement. Guarantee is void for improper installation, misuse, alteration, abuse, or unauthorized repair. No warranty is made for fitness for a user's particular application. This warranty is in lieu of all other warranties. This warranty provides specific legal rights, which may vary by state or province.

Warranty Qualifications:

Register product at championpowerequipment.com/register within 10 days of purchase, providing proof of purchase.

Repair/Replacement Warranty:

Two years (parts and labor) from original purchase date for residential use; 180 days for commercial/industrial use. Purchaser is responsible for transportation charges for warranty service. Applies only to the original purchaser.

Do Not Return The Unit To The Place Of Purchase:

Contact CPE Technical Service for troubleshooting. If unresolved, CPE will authorize evaluation, repair, or replacement. Keep case number for reference. Unauthorized repairs are not covered.

Warranty Exclusions:

• Normal Wear
• Installation, Use, and Maintenance issues (misuse, neglect, accidents, abuse, overloading, modification, improper connection).
• Cosmetic defects (paint, decals).
• Wear items (filters, o-rings).
• Accessory parts (storage covers).
• Acts of God or force majeure events.
• Use of non-Champion Power Equipment parts.

Limits of Implied Warranty and Consequential Damage:

Champion Power Equipment disclaims liability for loss of time, use, freight, or incidental/consequential claims. This warranty is exclusive and limits liability to the product cost.

Contact Information:

Address: Champion Power Equipment, Inc., 12039 Smith Ave., Santa Fe Springs, CA 90670 USA

Website: www.championpowerequipment.com

Customer Service: Toll Free: 1-877-338-0999, info@championpowerequipment.com, Fax: 1-562-236-9429

Technical Service: Toll Free: 1-877-338-0999, tech@championpowerequipment.com, 24/7 Tech Support: 1-562-204-1188