GE STS-400-25-4, STS-400-40-3, STS-400-25-3, STS-400-40-4, STS-400-63-4 Installation And Operating Manual
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GE Consumer & Industrial
Digital Energy™
INSTALLATION and
OPERATING MANUAL
Digital Energy™ STS-400-25/40/63/100-3/4
Static Transfer Switch
400V-25/40/63/100A-3/4-pole
GE Digital Energy™
General Electric Company Telephone +41 (0)91 / 850 51 51
CH - 6595 Riazzino (Locarno) Fax +41 (0)91 / 850 51 44
Switzerland Website www.gedigitalenergy.com
STS
GE imagination at work
Ver 1.1 - GB
Digital Energy™ Static Transfer Switch
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INSTALLATION AND OPERATING MANUAL
Digital Energy STS-400-25/40/60/100 Static Transfer Switch
LX-DOC File: OPM_STS_400_25A_100_1GB_V011
Manual version 1.1 June 2004
INSTALLATION and
OPERATING MANUAL
Digital Energy™ STS-400-25/40/63/100-3/4
Static Transfer Switch
400V-25/40/63/100A-3/4-pole
Preface
We thank you for selecting a General Electric Digital Energy™ STS Series Static Transfer Switch and
recommend that you read these instructions carefully before installation and start-up of the device.
The instructions in this manual are for:
the 3-phase 3-pole models STS-400-25-3, STS-400-40-3, STS-400-63-3 and STS-400-100-3;
the 3-phase 4-pole models STS-400-25-4, STS-400-40-4 and STS-400-63-4.
Please keep this manual in a safe place for future reference and carefully read the important safety instructions
in chapter 1 before installation of this device.
© 2004 by GE Consumer & Industrial
All rights reserved.
The information contained in this publication is intended solely for the purposes indicated.
The present publication and any other documentation supplied with the Static Transfer Switch system is not to be reproduced, either in part
or in its entirety, without the prior written consent of GE.
The illustrations and plans describing the equipment are intended as general reference only and are not necessarily complete in every
detail.
The content of this publication may be subject to modification without prior notice.
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CONTENTS
1 IMPORTANT SAFETY INSTRUCTIONS ..................................................................3
1.1 Save these instructions
1.2 Safety warnings and symbols
1.3 General
1.4 Intended use
1.5 Transport, storage, unpacking
1.6 Installation
1.7 Electrical connection
1.8 Operation
1.9 Fire regulations
1.10 Standards applied and conformity
2 INTRODUCTION .......................................................................................................8
2.1 Warranty
2.2 Description
2.3 Application
2.4 Fuses and TVSS circuits
3 INSTALLATION ........................................................................................................16
3.1 Transport
3.2 Unpacking
3.3 Location
3.4 Installation
3.5 Connection
3.6 Starting up
4 OPERATION ............................................................................................................21
4.1 Operation mode settings
4.1.1 Preferred source selection
4.1.2 Automatic retransferring
4.1.3 Manual operation
4.1.4 Reset button
4.2 Manual bypass operation
4.2.1 Bypassing load to primary source
4.2.2 Return from primary bypass mode to STS operation
4.2.3 Bypassing load to secondary source
4.2.4 Return from secondary bypass mode to STS operation
4.3 Service
4.3.1 STS operation test
4.3.2 Main fuse exchange procedure
4.3.3 TVSS fuse exchange procedure
4.3.4 Trouble shooting
4.4 Parameter settings (dip switches)
4.5 Default dip switch settings
4.6 Terminals
4.6.1 Relay communication terminal block
4.6.2 Communication Interface Module CI-M1
4.6.3 High current terminal
4.7 Fuse selection
5 SPECIFICATIONS ...................................................................................................43
5.1 Technical data
5.2 Dimensions
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1 - Important Safety Instructions
1.1 Save these instructions
This manual contains important instructions that should be followed during erection, installation, use
and maintenance of the Static Transfer Switch. Before attempting to erect, install and use of the
device, carefully read this manual. Keep this manual next to the device for future references
Full understanding of and compliance with the safety instructions and warnings
contained in this manual are
THE ONLY CONDITION
to avoid any dangerous situation during erection, installation, operation and
maintenance work, and to preserve the maximum reliability of the system.
In the event of equipment failures or special problems it is not permitted to take unauthorised remedial
action. In such cases the responsible GE technical service department must be contacted and the
GE refuses any responsibility in case of non-observance, unauthorized alterations or improper use of
While every care has been taken to ensure the completeness and accuracy of this manual, GE accepts
This document shall not be copied nor reproduced without the permission of GE.
Due to technical improvements, some of the information contained in this manual may be changed
1.2 Safety warnings and symbols
Safety warnings
The text of this manual contains warnings to avoid risk to persons and to avoid damages to the UPS
The non-observance of the warnings reminding hazardous situations could result in human injury and
required information obtained.
the delivered device.
no responsibility or liability for any loss or damage resulting from the use of the information contained in
this document
without notice
system and the supplied critical loads. Do not proceed beyond these warnings if you do not fully
understand and/or are not able to meet the mentioned conditions.
equipment damage. Please pay attention to the meaning of the following warnings and symbols.
WARNING !
Refers to procedures or operations which, when not correctly performed,
could cause personal injury or serious damage to the system
NOTE
Warns the user about important operations or procedures described in this
manual
Safety Symbols
CAUTION
The product may be in danger: when procedures or operations are not
correctly performed, damage to the product may be the result.
DANGER OF PARTS ELECTRICALLY LIVE
Related to all situations with potentially hazardous voltage
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1.3 General
DANGER!
RISK OF ELECTRIC SHOCK.
When the STS operates, some of its parts are necessarily under a hazardous
voltage.
Do not remove the cover; there are no user serviceable parts inside.
There may be danger, loss of life or personal injury if warnings are not strictly
observed.
CAUTION
There may be damage to the equipment if procedures and practices are not
strictly observed and followed.
NOTE
Do not attempt to service the STS unless you have had proper training. Refer
all maintenance and servicing to properly qualified, skilled and competent
service personnel.
Properly qualified, skilled and competent service personnel are persons who:
• Are familiar with the erection, installation and operation of the equipment and the system that is
being installed.
• Are capable of performing switching operations according to safety technology standards and
entitled and authorized to switch the equipment on and off and to isolate from the voltage.
• Are instructed according to the standards of safety technology in the care and use of safety
equipment.
• Are trained to immediate rescue measures (first aid).
• Have completed instructions with appropriate confirmation of GE.
1.4 Intended use
• A Static Transfer Switch (STS) is designed to transfer power supply between independent AC power
sources, thus protecting the connected load from power supply interruptions. It protects automatic
systems for power industry, power supply systems for petrochemical industry, computer and
telecommunication centers, automatic and security systems of ‘intelligent’ buildings as well as other
equipment that is highly sensitive for power supply interruptions.
• The STS is intended to be operated by technically qualified personnel.
Technically qualified personnel are persons who (because of their training, experience, and position
as well as their knowledge of appropriate standards, regulations, health and safety requirements and
working conditions) are authorised to be responsible for the safety of the equipment, at all times whilst
carrying out their normal duties and are therefore aware of, and can report, possible hazards (observe
IEC 364, DIN VDE 0105 and national wiring regulations and accident prevention rules).
• The technical data as well as information concerning connecting requirements can be found on the
rating label and in this document and shall be strictly observed.
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1.5 Transport, storage, unpacking
• The STS should be transported in a container truck with shock protection against moves during
transport. The STS should be belted to the wall of the container.
• Any special treatment during storage of the STS is not needed.
• Move the STS in its original package to the final destination room.
• Check for sufficient floor and elevator loading capacity.
• Immediately after unpacking carefully check the integrity of the equipment. In case you note
recognizable damage, do not connect any voltage to the STS, do not put the STS into operation, but
contact the nearest Service Centre.
1.6 Installation
The following instructions are provided for the personal safety of operators and also for the protection
of the described product and connected equipment.
• Observe the prescribed accident prevention and safety rules for the specific application.
• When installing the STS strictly observe all information on technical data and operating conditions.
Comply with all warnings, and strictly follow the procedures and practices as described in this manual.
• This STS is intended to be used in a controlled indoor environment and free of conductive
contaminants and protected against animal intrusion.
• Check for sufficient floor loading capacity.
• Avoid placing the unit in direct sunlight or near heat sources.
• It is important that the unit has adequate ventilation. Maintain air movement around and through the
unit. Do not block the air vents.
• The unit must be placed in a sufficiently ventilated area; the ambient temperature should not exceed
40°C (104°F).
• Do not install the STS in an excessively humid environment or near water, relative humidity should not
exceed 90% at 20°C (68°F).
• Avoid spilling liquids or dropping any foreign object into the STS.
• Emergency stop devices must be provided for all applications. An emergency stop must inhibit any
further uncontrolled operation.
• The electric connections must be covered.
• Earth connection must be checked for safe function after assembly.
• Countermeasures should be taken to avoid accidental turning on of previously switched off systems
through either a control vault or a third party (e.g. key switches).
• Do not touch electronic components. They may be electrostatic sensitive and are for that reason easily
damaged due to improper handling.
• To avoid potential health risks, electrical components should not be mechanically damaged or
destroyed.
• Isolate from mains and battery before installation or dismantling work, as well as for fuse changes or
post installation modifications.
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1.7 Electrical connection
• All electrical connections are to be realized by properly qualified, skilled and competent service
personnel only.
• When working on live STS, be sure to comply with the applicable national accident prevention rules.
• Before putting into operation make sure that the rated voltage for the unit corresponds to the local
supply voltage.
1.8 Operation
• These instructions cover normal operation in the automatic as well as in manual modes. Special
operating conditions, such as short circuit tests, input supplies, etc., are not covered in this document.
These operating modes require comprehensive knowledge of the overall system and should be carried
out by properly qualified, skilled and competent service personnel only. Refer to section 1.3 for further
details.
• Operators shall make sure that the system is ready for operation and that all cabinet doors are properly
closed before switching it on.
• Warning signs are placed on all cabinet doors to warn of excessive voltage (over 50 V) in the control
cabinets, but also of voltages in the power section and enormous short circuit currents. These signs
supply a warning not to open the doors during operation.
DANGER ! High Voltage!
Only qualified personnel may carry out work or manipulation of the device.
• Operators are prohibited from performing any work inside the control cabinets.
• Service and maintenance will not be covered in this document.
1.9 Fire regulations
WARNING
Should a fire break out inside the system, a fire extinguisher with CO2 or
halogen must be used. Do not inhale vapors.
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1.10 Standards applied and conformity
European Standards
Standard
EN 60950
EN 50178 (project)
IEC 600076
IEC 60146-1-2
IEC 60529
IEC 60617
EN 50082-2
DIN 41773 Part 1
Safety of information technology equipment, including electrical
business equipment
Equipment of Power Plants with electronic resources
Power transformers
General requirements and line commutated converters
Degrees of protection provided by enclosures (IP codes)
Graphical symbols and diagrams
EMC Requirements
Static power converters, semiconductor rectifiers equipment with IU
characteristics for charging of Lead Acid batteries - guideline
The standards mentioned above fulfil the
Description
requirements for CE marking.
The product mentioned in this manual conforms to the relevant requirements to the appropriate EU
Directive, i.e. that this product meets all relevant EU Directives and that it can be sold inside the
European Union without national commercial hindrances.
Relevant EU Directives for GE are called EMC- and Low Voltage Directives:
• EU Directive on Electromagnetic Compatibility 89/336/EU, in version 92/31/EU, 93/68/EU
• EU Directive on Electrical Equipment designed for use within certain Voltage Limits (Low
Voltage Directive) 73/23/EU, in version 93/68/EU
The directives themselves define only on a modest scale what's to do and refer to the harmonised
Standards. One of the EU harmonised product standards is applicable for rectifier systems. According
to this standard GE fulfils the basic requirements.
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2 - Introduction
2.1 Warranty
GE Digital Energy, operating through its authorized agents, warrants that the standard products will be free of
defects in materials and workmanship for a period of 24 months after the date of invoice, or such other period
as may be specified.
NOTE
This warranty does not cover failures of the product which result from incorrect
installation, misuse, alterations by persons other than authorized agents, or abnormal
operating conditions
2.2 Description
Static Transfer Switches type STS-400-XX-3/4 (four 3-pole models STS-400-25/40/63/100-3 and three 4-pole
models STS-400-25/40/63-4) are designed for switching between two alternative electrical power sources
without interruption of the power supplied to the load. The neutral wires in the 3-pole STS type are connected
together, whereas the neutral wires in the 4-pole type are being switched the same way as the phase wires.
The static transfer switch (STS) is connected to two sources of electrical power with terminals called X01
PRIMARY SOURCE and X02 SECONDARY SOURCE. The rated voltage of both sources is 400V AC phaseto-phase and the frequency is 50Hz. Depending on the current settings and the state of the system, one of the
two sources (either the PRIMARY SOURCE or the SECONDARY SOURCE) is “connected” to the output
terminal called X03 STS OUTPUT. Possible methods for transferring the load from one source to other are
explained in chapter 4.
Figure 1. Electrical diagram of Static Transfer Switch (STS) with manual bypasses
Each single line on the diagram represents three wires inside the 3-pole STS and four wires inside the 4-pole
STS.
PRIMARY SOURCE, SECONDARY SOURCE and STS OUTPUT connections consist of five wires each
including Protective Earth (PE).
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Five switches (figure 3) are set from the front panel without need for taking out the panel. These switches are
equipped with a mechanical interlock that prevents against short circuit between both supplying sources. Each
of them may be set manually into one of two positions: either “ON” or “OFF”. The device operates in STS mode
if the switches are set as in table 1.
Table 1
K1 STS
PRIMARY BYPASS
OFF
K2 STS
SECONDARY BYPASS
K3 STS
OUTPUT
K4 STS
PRIMARY SOURCE
K5 STS
SECONDARY SOURCE
OFF
ON
ON
ON
In normal mode of operation, the process of transferring the supply from one input to the other one is performed
automatically. The start up procedure is described in chapter 3, operation is explained in chapter 4.
The device is equipped with a mechanical interlock plate that prevents against unintentional short circuit during
manipulation with high current switches. The interlock plate is being moved aside during manipulation and may
be set in three positions: SECONDARY BYPASS, NORMAL MODE and PRIMARY BYPASS. The interlock
plate is equipped with a knurled nut that is screwed after a change of plate position. In that way the interlock
plate positions are locked with the knurled nut to prevent unintentional move of the plate.
Figure 2. STS front
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OFF
ON
MAIN AND AUXILARY FUSES
K4 STS
PRIMARY SOURCE
RELAY COMMUNICA TION
TERMINAL BLOCK
Figure 3. STS with opened door
SW1SW2SW3SW4SW5SW6SW8SW7
K1 STS
PRIMARY
BYPASS
XO1
PRIMARY SOURCE
K3 STS
OUTPUT
NORMAL
MODE
XO3
OUTPUT
K5 STS
SECONDARY SOURCE
PRIMARYSECONDARY
BYPASSBYPASS
K2 STS
SECONDARY
BYPASS
XO2
SECONDARY SOURCE
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K4 STS
PRIMARY SOURCE
K1 STS
PRIMARY
BYPASS
N
1
X10 X11
1
14
14
L1 L2 L3
X01
Figure 4.a. High current terminals location for all types excluding STS-400-100-3
K3 STS
OUTPUT
PRIMARYSECONDARY
BYPASSBYPASS
NORMAL
MODE
L1 L2 L3
X03
(cover removed)
K5 STS
SECONDARY SOURCE
K2 STS
SECONDARY
BYPASS
PE PE PE
PE
N
PE
L1 L2 L3
X02
N
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K4 STS
PRIMARY SOURCE
K1 STS
PRIMARY
BYPASS
1
1
14
X10 X11
14
L1 L2
X01
N
L3
Figure 4 b. High current terminals location for STS-400-100-3
K3 STS
OUTPUT
NORMAL
MODE
L1 L2
(cover removed)
X03
K5 STS
SECONDARY SOURCE
PRIMARYSECONDARY
BYPASSBYPASS
N
L3
K2 STS
SECONDARY
BYPASS
PE PE PE
PE
PE
L1 L2
X02
N
L3
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O1
Primary Source
Fuses
KO1 KO2
K4 STS
PRIMARY SOURCE
Figure 5 a. Fuses and TVSS location (without STS-400-100-3)
Fuse burn
indication for
primary source
fuses
KO3
O3
K3 STS
OUTPUT
Output
Fuses
Fuse burn
indication for
output fuses
K5 STS
SECONDARY SOURCE
O2
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O1
Primary Source Fuses
KO1
K4 STS
PRIMARY SOURCE
Figure 5b. Fuses and TVSS location for STS-400-100-3
Fuse burn
indication for
primary source
fuses
KO3
O3
K3 STS
OUTPUT
Output
Fuses
Fuse burn
indication for
output fuses
KO2
K5 STS
SECONDARY SOURCE
O2
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