GE ZTS Series, ZTSD Series Operation And Maintenance

GE Zenith Controls

e

ZTS/ZTSD Series Transfer Switches 40-4000 Amps

71R-3000

5/03

Operation and Maintenance Manual

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Authorized Service

For GE parts and service, call: 773 299-6600

Table of Contents

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Equipment Inspection and Storage . . . . . . . . . 1

Final Equipment Inspection . . . . . . . . . . . . . . . 1

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Power Connections . . . . . . . . . . . . . . . . . . . . . . 2

Engine Start Control Connections . . . . . . . . 2-3

Initial Energization . . . . . . . . . . . . . . . . . . . . 3-4

Control Connections . . . . . . . . . . . . . . . . . . . . 5

Entelli-Switch 250 Microprocessor Controller . . . . . 6

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

LCD & Keypad . . . . . . . . . . . . . . . . . . . . . . . . . 7

User Setting for Voltage & Frequency . . . . . . . 8

Accessory Group Packages. . . . . . . . . . . . . . . . . 9

Accessory Definitions . . . . . . . . . . . . . . . . . 10-13

How to Set the System Clock . . . . . . . . . . . . . 13

CDT One Event Timer Exerciser . . . . . . . . . . 14

CDP Clock Exerciser . . . . . . . . . . . . . . . . . . . 15

User Setup - CFG Menu . . . . . . . . . . . . . . . . . 16

User Setup - SET Menu . . . . . . . . . . . . . . . . . 17

User Setup - System Info . . . . . . . . . . . . . . . . 18

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

ATS Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Standard Transition . . . . . . . . . . . . . . . . . . . . 19

Delayed Transition . . . . . . . . . . . . . . . . . . . . . 19

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . 20

Standard Transition . . . . . . . . . . . . . . . . . . . . 20

Delayed Transition . . . . . . . . . . . . . . . . . . . . . 20

Page

Relay/Transformer (R/T Box) . . . . . . . . . . . . . . . 21

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Delayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Troubleshooting & Diagnostics . . . . . . . . . . . . . . . 24

Maintenance and Testing . . . . . . . . . . . . . . . . . . . . 25

Inspection and Cleaning . . . . . . . . . . . . . . . . 25

Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . 26

Standard Transition . . . . . . . . . . . . . . . . . . . . 26

40-200 Amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

225-400 Amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

600-1200 Amps . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1600-3000 Amps . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4000 Amps

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Delayed Transition . . . . . . . . . . . . . . . . . . . . . 31

40-400 Amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

600-1200 Amps . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

1600-3000 Amps . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4000 Amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

ZTSH/ZTSDH/ZTSDL/ZTSHL/ZTSDHL . . . . . . 35

Standard Control Panel Layout (SSRCP) . . . . 35

Panel Mount Control Relays . . . . . . . . . . . . . . 35

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . 36

Adjustments and Settings . . . . . . . . . . . . . . . . . . . . 37

Solid State Timers . . . . . . . . . . . . . . . . . . . . . . 37

Voltage/Frequency Sensor (VSFM) . . . . . . . . 37

Solid State Phase Relay . . . . . . . . . . . . . . . . . . 37

Introduction

GE Zenith Transfer Switches are used to provide a continuous source of power for lighting and other critical loads by auto

matically transferring from source 1 power to source 2 power in the event that source 1 voltage falls below preset limits.

Voltage sensing and system control is performed via a state-of-the-art microcontroller located on the cabinet door

. It is designed to give highly accurate control of the transfer switch system.

All GE Zenith transfer switches are designed for use on emergency or standby systems, and are rated for total system or motor loads. T

ransfer switches are UL Listed under Standard 1008 and CSA Certified under Standard C22.2 No. 178 and IEC Listed under Standard 947.

NOTES:

A protective device such as a molded case circuit breaker or fused disconnect switch MUST be installed on both sources of incoming power for circuit protection and as a disconnection device.

All references made within this manual about the term “S1” or “Source 1” relate to a Normal Power Source. All references made about the term “S2” or “Source 2” relate to an Emergency or Alternative Power Source.

Safety

DANGER

HAZARDOUS VOLTAGE

(Can Cause Severe Injury or Death)

Turn OFF all power before installation, adjustment, or removal of transfer switch or any of its components.

The safe operation of your switch is GE Zenith’s focus. The proper storage, installation, operation and maintenance will help increase the life of the switch.

CAUTION

Due to hazardous voltage and current, GE Zenith rec-

ommends that a

GE Zenith Certified technician or a

qualified electrician must perform the

installation and maintenance of the switch.

Equipment Inspection and Storage

Once you have received the transfer switch, inspect it for any damage. This includes damage to the enclosure, power panel, control panel and wiring harness. If any damage is found or suspected, file a claim as soon as possible with the carrier and notify the nearest

GE

Zenith representative.

Before installation, if it is necessary, store the transfer switch in a clean dr

y place, protected from dirt and water. Provide ample air circulation and heat, if necessary, to prevent condensation.

Storage Temperature

Operating T

emperature

(Ambient): Humidity

-30°C to

40-400

AMP

5% to 95% +75°C (-22°F to +167°F)

(molded shell)

-20°C to +65°C (-4°F to +149°F)

(non-con-

densing)

40-4000

AMP

(all other frame and panel types)

-20°C to +60°C (-4°F to +140°F)

Final Equipment Inspection

Prior to energizing the transfer switch:

1. Remove any debris incurred, with a vacuum, due to shipment or installation.

WARNING



Do not use a blower since debris may

become lodged in the electrical and

mechanical components and cause damage.

2. Verify that all cabled connections are correct and that phase rotation of both sources match.

3. Check engine start connections.

4. Verify the correct connection of all control wires.

5. Check settings of all timers and adjust as necessar

y.

6. Adjust any optional accessories as required.

7. Check the lug torque values of the power connections.

NOTE: Lug torque values are specified

in table 2 on pg.2.

8. Make sure that all covers and barriers are installed and properly fastened.

NOTE: Power panels ship from GE Zenith

in Source 1 Position.

Each GE Zenith transfer switch is factory wired and tested. A complete information package is furnished with each switch which includes:

a. Sequence of operation. b. Description and operation of

all accessories supplied.

c. Power panel connection diagram

and schematic.

d. Description and identification of

all customer field connections.

Installation of GE Zenith transfer switches includes:

a. Mounting the transfer switch cabinet. b. Connection of Source 1, Source 2,

and Load cables or bus bars.

c. Connection of external control

circuits as required.

Mounting

Adequate lifting means must be used to mount the transfer switch into place. The recommended method for moving the transfer switch using the lifting eyes, where supplied, and a spreader bar is illustrated in Figure 1. Enough room should be allowed to open the cabinet doors fully for inspection and servicing of the switch per NEC and local codes.

CAUTION

Before drilling conduit entry holes or any

accessory mounting holes, cover and protect

the switch and control panel to prevent dirt

and metal fragments from entering the mechanical and electrical components.

Failure to do so may result in

damage and malfunction of the switch.

GE Zenith Controls

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

1



Installation

DANGER

HAZARDOUS VOLTAGE

(Can Cause Severe Injury or Death)

Turn OFF all power before installation, adjustment, or removal of transfer switch or any of its components.

Power Connections

SPREADER BAR

GE Zenith transfer switches are supplied with UL listed

45°

solderless screw type terminals as standard for the

H

Source 1, Source 2 and Load power connections. Table 1 lists the number and sizes of cable lugs supplied as standard for each switch amp rating.

Connect the Source 1, Source 2, and Load conductors

LIFTING EYES

to the clearly marked terminals on the transfer switch. Remove sur

face oxides from cables by cleaning with a wire brush. Verify that all connections are correct before tightening the lugs. All cable lug connections must be tightened to the proper torque values as shown in Table 2.

NOTE

: Do not run cables or wiring behind

CABINET

D

front-connected transfer switches.

NOTE

: When lifting the switch using a spreader bar,

height H must be equal to half of distance D.

Figure 1

Power Connections: Screw Type Terminals for External Power Connections

Switch Size

(Amps)

Source 1, Source 2 & Load Terminals Neutral Bar (When Required)

Cable Per Pole Range of Wire Sizes No. of Cables Range of Wire Sizes

40 1 #8 AWG to 1/0 3 #8 AWG to 1/0

80 1 #8 AWG to 1/0 3 #8 AWG to 1/0 100 1 #8 AWG to 1/0 3 #8 AWG to 1/0 150 1 #8 AWG to 3/0 3 #8 AWG to 300 MCM

200, 225, 2500 1 #6 AWG to 250 MCM 3 #6 AWG to 300 MCM 260, 300*, 400

1

#4 AWG to 600 MCM 3 #4 AWG to 300 MCM

600 2 #2 AWG to 600 MCM 8 #2 AWG to 600 MCM

800, 1000, 1200 4 #2 AWG to 600 MCM 12 #2 AWG to 600 MCM

1600, 2000

2600, 3000, 4000

Line, Load and Neutral terminals are located in the rear of switch

and arranged for bus bar locations

Table 1

Engine Start Control Connections

Engine-start control wires connect to control terminals beside the Entelli-Switch 250. Engine start terminals are indicated by a schematic symbol (the symbol indicates the contact state for a de-energized normal source). Figure 2 shows the engine-start contacts.

Make all other necessary control connections to the control panel terminal blocks per the schematics supplied with the A

TS.

NOTE: All control wires (18-12 AWG) must be

torqued to 19 in/lbs.

Tightening Torque for Lugs

Socket Size

Across Flats

Torque

Lb. - In.

Lb. - Ft.

1/8 45

4

5/32

100

8

3/16 120

10

7/32

150

12

1/4

200 17

5/16 275

23

3/8

375

31

1/2

500 42

9/16

600 50

Table 2

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

GE Zenith Contr

ols 2



Installation

(cont’d)

DANGER

HAZARDOUS VOLTAGE

(Can Cause Severe Injury or Death)

Turn OFF all power before installation, adjustment, or removal of transfer switch or any of its components.

Engine Start Control Connections

The engine-start terminals are clearly identified by a label on the microcontroller backplate. In the case of manual transfer switches, or in other applications not requiring the microprocessor, clearly marked terminal blocks are provided in the upper left corner of the control panel for the engine start control wires.

Transfer Switch. Figure 5 (pg.5) shows location of engine start connections for Automatic Transfer Switch.

Terminals for field connections to the A3 Source 2 auxiliary contacts and the A4 Normal auxiliary contacts are also provided. These terminals are clearly marked and appear on the side of the power panel. On 400 amp metal frame units these terminals appear on the bracket above the operator handle.

E

Figure 2

Initial Energization

Before proceeding, refer to the information package supplied with the ATS and read and understand the information on all accessories provided.

1. Unlock the enclosure.

2. Open the enclosure.

3. Verify the correct system voltage.

NOTE: The equipment rating nameplate on

the transfer switch lists the voltage. See

Figure 3

.

4. Close Source 1 circuit. breaker.

NOTE:The controller will illuminate Source 1

Available LED if proper voltage is sensed.

5. Verify the phase to phase voltages at Source 1 line terminals.

6. Close Source 2 source circuit breaker.

7. Start the generator’s engine.

NOTE

: The controller will illuminate Source 2

Available LED when preset voltage and frequency levels are reached.

8. Verify the phase to phase voltages at Source 1 line terminals.

9. Verify that the phase rotation of Source 1 is the same as the phase rotation of Source 2.

10. Shut down the generator’s engine.

11. Place the starting control in the Automatic position.

12. Complete the visual inspection of the transfer switch.

13. Close the enclosure.

14. Lock the enclosure.

g

GE Zenith Controls

SERIAL NUMBER:

RATING: VOLTS -

HZ -

AMPS -

PHASE -

SYSTEM VOLTS:

MODEL NUMBER:

Figure 3

CAUTIONS

Certain accessories, per specific

schematics, can inhibit automatic transfer.

Engine Gen-Set could start when

engine control wires are attached.

GE Zenith Controls

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

3

4

5

6

1

P Relay

2

(Engine Start)

3

Contact rating is 10 Ampere at 120VAC or 28VDC Gold plated

Installation

(cont’d)

Initial Energization (cont’d)

After all options and accessories are checked and verified, follow these steps to set up the ATS. Refer to Entelli-Switch 250 display Figure 4. The annunciation LEDs illuminate to indicate (1) source availability, (2) ATS position, and (3) Entelli-Switch 250 control function (timing).

Entelli-Switch 250

S1 OK

21:56

MON 23 APR 2002

MORE TEST



Figure 4 – LCD and keypad

1. Unlock the enclosure.

2. Open the enclosure.

3. Place the Disconnect Switch in the Inhibit.

NOTE: This step is only performed if the

“DS” Option was purchased.

4. Close the external (up-stream) Source 1 circuit breaker.

NOTES

: Source 1 Available and Source 1

Position LED’s will illuminate.

If Source 1 Available LED does not illuminate, verify that Source 1 Voltage is above the preset restore value.

The Gen-Set will start and run while Source 2 stop Delay Timer is timing.

5. Close the External (up-stream) Source 2 line circuit breaker.

6. Start the engine generator in

MANUAL mode.

NOTE: When the voltage and frequency

reach preset values, the Source 2 Available LED will illuminate.

7. Verify the phase to phase voltages at Source 2 line terminals.

8. Verify that the phase rotation of Source 2 is the same as the phase rotation of Source 1.

9. Shut down the generator's engine. (Place in Automatic Mode.)

NOTE

: Source 2 Available LED

will turn off.

NOTE: The engine generator will continue

to run for the duration of Source 2 Stop Delay Timer.

10. Place the disconnect switch to ENABLE.

11. Complete the visual inspection of the transfer switch.

12. Close the enclosure.

13. Lock the enclosure.

WARNING

When performing a hi-pot or

dielectric test on the power section,

DISCONNECT

the control panel plugs from

the microprocessor to avoid potential damage.

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

GE Zenith Controls

4

Installation

(cont’d)

DANGER

HAZARDOUS VOLTAGE

(Can Cause Severe Injury or Death)

Turn OFF all power before installation, adjustment, or removal of transfer switch or any of its components.

Control Connections

Figure 5

Clock Program Backup Battery

Remove protective

Connections

Engine Start

strip to enable clock functions

Network Connector

Input/Output

Connectors

to I/O Modules

To R/T Box

To Power

Panel



A complete information package is furnished with each transfer switch including a complete connection diagram and schematic which details all necessary control circuit field connections.

The engine start control wires connect to the engine start relay terminals located to the left of the microprocessor

. Figure 5 shows the location

of these terminals.

The terminals are clearly identified by a label on the microcontroller backplate. In the case of manual trans

fer switches, or in other applications not requiring the microprocessor

, clearly marked terminal blocks are provided in the upper left corner of the control panel for the engine start control wires.

GE Zenith Controls

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

5

Entelli-Switch 250 Controller

Consists of two major assemblies:

I. The Micr

oprocessor contains the following:

A. Entelli-Switch 250 Board - Customer Input

and Output (I/O) for system inter

face. Located on the left hand side of the back of the unit (see figure 6)

1. I/O accessories that can be found here are: a. Engine start relay P output b. Pre-Signal to transfer T3, W3 and

UMD output (optional)

c. Transfer Inhibit Q3 and Q7 input

(optional) d. Remote test Q2 input (optional) e. Network interface ZNET

input/output (optional)

B. LCD and Keypad located on the exterior

of the door (see figure 7)

1. User accessibility to the following: a. LED indication of source

availability

b. LED indication of transfer

switch position

c. LCD screen indicates:

(1) timer count down (numeric) (2) event reporting (text)

d. Keypad provides user interface to:

[in conjunction with LCD screen]

(1) Setting sensors and timers (2) Configuring logic accessories

II. The R/T bo

x (relay transformer box) contains

the following: (see figure 6)

A. Relays which are required for controller output

to energize the transferring mechanism of the transfer switch at line voltage.

B. Transformers which drop line voltage

to control level for controller input.

Engine Start Relay P

I/O Interface

Board

Battery Strip

and

Access

Code Label

R/T Box

Entelli-Switch 250

Figure 6

Entelli-Switch 250

S1 OK

21:56

MON 23 APR 2002

MORE TEST



Figure 7

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

GE Zenith Controls

6

Entelli-Switch 250 Controller

(cont’d)

LCD & Keypad

These options are accessible through the LCD and keypad (see figure below). To become familiar with the options loaded into a particular unit, scrolling through the SET and CFG menu will show the descriptions of the options (see pages 16-17). These menus are the very same menus that are used to access the setting and/or configuration of these options. The SET (setting) menu is primarily used to show or change, time and voltage settings. The CFG menu is primarily used to turn an option on or off. When scrolling through these menus,

no changes can be made without entry of the access code. The factory set six-digit access code is located on a white label on the back of the unit (see figure 10 pgs. 16-18).

The Entelli-Switch 250 has many logic options. Each controller is downloaded with options at the time of manufacture. The collection of options that any one controller has is specified at the time of order placement. The following pages include all the options that can reside in the controller. Not all units include all options.



Figure 8

GE Zenith Controls

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

7

Source 1 LED (Green) indicates Source 1 is acceptable for use

Source 1 Position LED (Green) indicates Power Panel (ATS) is closed to Source 1 position

Source 2 Position LED (Red) indicates Power Panel (ATS) is closed to Source 2 position

Source 2 (Red) indicates Source 2 is acceptable for use

LCD Screen

Current Time, Day and Date of Display

Menus (MORE, CFG, TEST)

#1 or the word on the LCD above the key. The word above the key changes depending on which screen is being displayed.

S1 OK

01: 50

FRI 31 MAY 2003

MORE CFG TEST SET

Entelli-Switch 250

#2 or the word on the LCD above the key. The word above the key changes depending on which screen is being displayed.

* E *

#3 or the word on the LCD above the key. The word above the key changes depending on which screen is being displayed.

Exercise Event "Impending"

SET Menu

Keypad

#4 or the word on the LCD above the key. The word above the key changes depending on which screen is being displayed.



User Setting for Voltage & Frequency

Standard 3-Phase Sensing on 3 and 4 Pole Units

Source 1

Under Voltage "Restore"

Factory Default: 90% This adjustment determines the minimum acceptable voltage required to transfer to Source 1. Adjust via the SET menu. Range is 85% to 100% in 1% increments (see page 17). Once satisfied, the T timer will begin timing to transfer to Source 1.

Under Voltage "Fail"

Factory Default: 80% This adjustment determines the low voltage threshold. Adjust via the SET menu. Range is 75% to 98% in 1% increments (see page 17). "Fail" must be a minimum of 2 % below "Restore" setting. Once voltage falls below threshold, P timer begins timing to signal Source 2 Generator to start.

Under Frequency "Restore"

Factory Default: 95% This adjustment determines the minimum acceptable frequency required to transfer to Source 1. Adjust via the SET menu. Range is 90% to 100% in 1% increments (see page 17). Once satisfied, the T timer will begin timing to transfer to Source 1.

Under Frequency "Fail"

Factory Default: 90% This adjustment determines the low frequency threshold. Adjust via the SET menu. Range is 88% to 98% in 1% increments (see page 17). "Fail" must be a minimum of 2 % below "Restore" setting. Once satisfied, the T timer will begin timing to transfer to Source 1.

Over Frequency "Restore"

Factory Default: 102% This adjustment determines the minimum acceptable Over Frequency threshold at which the transfer switch is allowed to re-transfer to Source 1. Adjust via the SET menu. Range is 102% to 104% in 1% increments (see page 17). “Restore” must be a minimum of 1% below “Fail” setting.

Over Frequency "Fail"

Factory Default: 105% This adjustment determines the maximum acceptable Over Frequency

. Adjust via the SET menu. Range is 103% to 105% in 1% increments (see page 17).Once exceeded, the P timer begins timing to signal the generator to start.

Source 2

Under Voltage "Restore"

Factory Default: 90% This adjustment determines the minimum acceptable voltage required to transfer to Source 2. Adjust via the SET menu. Range is 85% to 100% in 1% increments (see page 17). Once satisfied, the W timer will begin timing to transfer to Source 2.

Under Voltage "Fail"

Factory Default: 80% This adjustment determines the low voltage threshold. Adjust via the SET menu. Range is 75% to 98% in 1% increments (see page 17). "Fail" must be a minimum of 2 % below "Restore" setting. Once voltage falls below threshold, T timer will be bypassed to expedite the transfer to Source 1.

Over Voltage "Fail"

Factory Default: 110% This adjustment determines the maximum acceptable Over V

oltage. Adjust via the SET menu. Range is 105% to 110% in 1% increments (see page 17). Once exceeded, the T timer will be bypassed to expedite the transfer to Source 1.

Over Voltage "Restore"

Factory Default: 105% This adjustment determines the minimum acceptable Over V

oltage threshold at which the transfer switch is allowed to transfer to Source 2. Adjust via the SET menu. Range is 103% to 105% in 1% increments (see page 17). “Restore” must be a minimum of 2% below “Fail” setting.

Under Frequency "Restore"

Factory Default: 95% This adjustment determines the minimum acceptable frequency required to transfer to Source 2. Adjust via the SET menu. Range is 90% to 100% in 1% increments (see page 17). Once satisfied, the W timer will begin timing to transfer to Source 2.

Under Frequency "Fail"

Factory Default: 90% This adjustment determines the low frequency threshold. Adjust via the SET menu. Range is 88% to 98% in 1% increments (see page 17). "Fail" must be a minimum of 2 % below "Restore" setting. Once satisfied, the W timer will begin timing to transfer to Source 2.

Over Frequency "Fail"

Factory Default: 105% This adjustment determines the maximum acceptable Over Frequency

. Adjust via the SET menu. Range is 103% to 105% in 1% increments (see page 17). Once exceeded, the T timer will be bypassed to expedite the transfer to Source 1.

Over Frequency "Restore"

Factory Default: 102% This adjustment determines the minimum acceptable Over Frequency threshold at which the transfer switch is allowed to re-transfer to Source 2. Adjust via the SET menu. Range is 102% to 104% in 1% increments (see page 17). “Restore” must be a minimum of 1% below “Fail” setting.

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

GE Zenith Controls 8

Accessory Group Packages

Table 3



Standard Accessory included in the group package. Optional Accessory not included but can be added to group package. Optional Accessory. Can not be used with accessory having the same symbol. N/A Denotes an Accessory with 2 circuits as a standard.

*

Delayed Transition Units Only.

Denotes an Accessory with 3 circuits as a standard.

**

Optional for 40-400 Amp

GE Zenith Controls

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

9

Accessories

6P A1 A1E A3 A4 Calibrate CDT CDP **DS *DT *DW E EL/P K/P L1 L2 L3 L4 *LN P1 Q2 Q3 Q7 R1-1 R1-3 R15 *R15D R16 R50 S5P S12P S13P T T3/W3 U UMD VI W YEN

STDS EXES

2 2

2

Group Packages CONS

SENS SPES PSGS

2 2

2

2 2

2

2 2

2

3 3

2

3



Accessory Definitions

6P

Test Switch, Momentary

6A

Test Switch, Maintained Auto/Momentary Test

6AP

Test Switch, Maintained/Momentary utilizing keypad

6B

Test Switch, Maintained - Auto / Momentary - Test, Key Operated

6C

Test Switch, Maintained - Auto / Maintained - Test, Key Operated

A1

Auxiliary Contact, operates on Source 1 line failure.

A1E

Auxiliary Contact, operates on Source 2 line failure.

A3

Auxiliary Contact: Closed in emergency (Source 2) Additional Available (10 max.) and need to be specified.

A4

Auxiliary Contact: Closed in normal (Source 1) Additional Available (10 max.) and need to be specified.

A62

Sequential Universal Motor Load Disconnect Circuit. Normally closed auxiliary contacts for motor loads. Open 0-60 seconds prior to transfer, after transfer, or both in either direction then re-close in timed sequence after transfer.

AB3

Auxiliary Contact: Closed in bypass emergency (Source 2) (S.P.D.T.) (Standard up to 400 Amp) Additional Available (10 max.) and need to be specified.

AB4

Auxiliary Contact: Closed in bypass normal (Source 1) (S.P.D.T.) (Standard up to 400 Amp) Additional Available (10 max.) and need to be specified.

B9

Battery charger connections.

Calibrate

While monitoring the actual Phase to Phase voltage levels and Frequency with a calibrated test equipment, the Phase to Phase voltage sensing and Frequency can be adjusted accordingly

. Calibration capabilities are available for Frequency and AB, BC, CA Phase to Phase voltage for both Sources. Adjust via SET menu (see page 18)

CDP

Clock Exerciser Load/ No Load: Allows the Generator to start and run unloaded or to simulate a power failure, start Generator and run under load. Can be configured by end user for 1, 7, 14, 28, 365 day cycle. (See page 16)

CDT

Load or NO-Load. One event exerciser with adjustable Engine exercise timer. Exercise duration can be set between 5 and 60 minutes in 1 minute increments. Can be configured to run every 1, 7, 14, or 28 days. Factory Default is 20minutes. When exerciser is impending, (*E*) appears in the upper right hand corner of LCD screen. See page 15 for instructions. Configured via CFG (see page 17). Set via SET menu (see page 18).

CTAP

Alarm Panel on transfer to Source 2 with Silence button.

DS

Disconnect Switch, Auto/Inhibit. Inhibits transfer in either direction when in inhibit. Allows automatic operation when in Auto. (40-400 Amps optional, 600-4000 Amps standard)

DT (Delayed Transition Only)

Time Delay from Neutral Switch position to Source 1 position. Adjustable 0-10 minutes in 1 second increments. Standard setting is 5 seconds Adjust via SET menu (see page 18)

DW (Delayed Transition Only)

Time Delay from Neutral Switch position to Source 2 position. Adjustable 0-10 minutes in 1 second increments. Standard setting is 5 seconds.Adjust via SET menu (see page 18)

E

Engine Start Contact

EL/P

Event Log: Sequentially Numbered Log

of 16 events that track date, time, reason and action taken

System Data:

Total Life Transfers (N2P) Days Powered Up Total Transfers to S2 Total S1 Failures Time S1 available in Hrs Time S2 available in Hrs. (N1P)

F

Fan contact, operates when generator is running.

HT

Heater and Thermostat

K

Frequency Meter, Door mount.

K/P

Frequency Indication for S1 and S2

L

LNP Center-off position LCD-Indicator Indicating LED lights:

L1 Indicates Switch in Source 2 position. L2 Indicates Switch in Source 1 position. L3 Indicates Source 1 available. L4 Indicates Source 2 available.

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

GE Zenith Controls 10



Accessory Definitions

(cont’d)

M1

Single Phase Amp Meter

M2

Three Phase Amp Meter

M80

3000 Digital Power Monitor

M82

5200 Digital Power Meter

M83A

EPM 5300 Digital Power Meter with Modbus Port

M83B

EPM 5350 Digital Power Meter with Ethernet Port

M84

7430 Digital Power Meter , Wye or Delta

M85A

EPM 9450 Digital Power Meter, Ethernet

M85B

EPM 9450 Digital Power Meter with Internal 56K Mod.

M86A

EPM 9650 Digital Power Meter, Wye or Delta, RS232 or RS485

M86B

EPM 9650 Digital Power Meter, Wye or Delta, RS232 or RS485

N1

Running Time Meter, Door mount

N2

Operation Counter, Door Mount

P1

Time Delay Source 2 Start. Adjustable 0-10 seconds. Standard setting is 3 seconds. Adjust via SET menu (see page 18)

P2

Time Delay S2 Start. Adjustable 1/6 to 300 seconds.

Q2

Remote Peak Shave or Area Protection Circuit. Energize Q2 to simulate Source 1 Line failure causing the Generator to start and transfer the load to Source 2. Should Emergency fail during this operation, Transfer Switch will retransfer back to Source 1.

Q3

Remote inhibit transfer to Source 2 circuit. Energize Q3 input to allow transfer to Source 2. To enable Q3 option, engage Q3 jumper.

Q7

Inhibit transfer to Source 1 circuit. Energize Q7 input to prevent transfer to Source 1.

R1-1/R1-3

Source 1 Over Voltage sensing for single and three phase systems. Source 1 Over Voltage "Fail" Factory Default: 110% This adjustment determines the maximum acceptable over voltage. Adjust via the SET menu. Range is 105% to 110% in 1% increments (see page 18). Once exceeded, the P timer begins timing to signal the Generator to start.

Source 1 Over Voltage "Restore" Factor

y Default: 105% This adjustment determines the minimum acceptable over Voltage threshold at which the Transfer Switch is allowed to automatically transfer to Source 1. Adjust via SET menu. Range is 103% to 108% in 1% increments. "Restore" must be a minimum of 2% below "Fail" setting (see page 18).

R15/R15D

Load Shed Should Source 2 become overloaded, a signal can be given to switch to the dead or Mid position.

R16

Phase Rotation Sensing Can be turned on or off via CFG menu (see page 17). Factory Default is on. This feature prevents Line Source to Line Source transfers from occurring between dissimilar phase sequences. This condition is primarily caused by an installation error

. Connections from Source 1 and Source 2 need be verified, compared, and corrected to remedy the inconsistent phase rotation between the sources. WARNING: Turning off this feature can cause severe damage to loads.

R26

Interruptable Power Rate Provisions. Allow transfer out of Source 1 position to Source 2 or dead Source 2. Alarm and Pre-Signal circuit included.

GE Zenith Controls

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

11



- - - -

Accessory Definitions

(cont’d)

R50

In Phase Monitor this feature restricts Live to Live Source Transfers to occur unless both Sources are within

7 electrical degrees or less of each other. (live Source to live Source transfers usually occur during transfer back to Source 1 or during Testing). R50 does not change the operation of the Automatic Transfer Switch in a power failure mode. After all timer functions have elapsed, the CHECKING FOR SOURCE SYNCHRO

-

NISM will be displayed as well as the direction of

transfer (S1-S2 for example denotes transfer from Source 1 to Source2). When synchronism is accomplished, transfer will take place.

Notes: - If S2 Frequency is less than S1 Fr

equency,

display will show a series of (- - - - -…..) symbols.

- If S2 Frequency is greater than S1 Frequency, display will show a series of (+++++…..) symbols.

- Each (-) or (+) symbol represents 10 electrical degr

ees out of phase. A maximum of 18 symbols

(180 electrical degrees) can be monitored.

- The number of (-) or (+) symbols decrease as the two sour

ces approach synchronism and increase as the two sources drift out of synchronism.

- If S1 and S2 Frequencies are identical, the display will show a series of alter

nating symbols (++++…) which also indicate the approximate out of phase degrees

In the event that the Sources do not come within 7 electrical degrees of each other within 60 seconds, the unit will display the message: SYNCH CHECKING and will allow the user to BYP

ASS. If the BYPASS button is pressed, the unit will display the message: WARNING MAY CAUSE DAMAGE TO THE LOAD. Pressing XFR will actually bypass the R50. Since R50 is a passive device, the length of time it takes to reach Synchronism is de

pendent on the frequency difference between the two Sources. Source 1 is usually a Utility and the frequency is not within the control of the consumer

. Source 2 needs to be adjusted to create an adequate difference in order for the transfer to happen a timely fashion.

Note: For optimum performance, Source 2

Generator should be adjusted a Maximum of 2 Her

tz above or below the Utility frequency, minimum of 0.1 Hertz. (58 to 59.9) or (60.1 to 62) Hertz. Adjustment of Generator to 60Her

tz could cause lengthy transfer delay

.

R50 Feature can be turned ON or OFF via CFG Menu (see page 17). Factory Default if OFF.

S5P

Auto / Semi Manual selector In "Auto" position, retransfer to Source 1 is automatic after the T timer has timed out. The T time delay is bypassed if Source 2 fails. In "Manual", retransfer to Source 1 is upon depression of BYPASS DELAY button YEN or if Source 2 fails.

S12P

Auto / Manual Selector In "Auto" position, the Automatic Transfer Switch functions automatically as specified with the Switch drawings. In "Manual" the Automatic Transfer Switch will transfer to either direction upon depression of Source 1 or Source 2 transfer buttons. Should Source 1 fail, the Generator (Source 2), will automatically start. Once transferred in Manual, the Switch maintains position selected even if selected power fails.

S13P

Transfer Commit. Configured via CFG menu. (see page 17) When this Feature is set to OFF: The transfer Switch is not committed to transfer unless the outage duration is longer than the timers that precede the transfer to Source 2 position. This assumes that the outage will be an isolated event. When this Feature is set to ON: The transfer Switch is committed to transfer to Source 2 position once the W timer has begun timing, even if Source 1 power returns before the transfer to Source 2. This is to ensure that the transfer takes place, because one outage may be followed by another.

S14

Test / Auto / Source 1 Selector, Door mount

SW1

Auto/Off/Start Engine control selector, Door mount (Keyed or non-keyed operation available)

SW2

Auto / Off Engine control selector, Door mount (Keyed or non-keyed operation available)

SW3

Source Priority Selector Switch, Door mount Allows selection of Source 1 or Source 2 to be the Prime Source. Transfer Switch will transfer to selected Prime Source if that Source is available. (Keyed or non-keyed operation available)

T

Time Delay (S1) Source 1 Stable Timer. To delay transfer to Source 1 (immediate retransfer on Source 2 failure). Adjustable 0-60 minutes in 1 second increments. Standard setting is 30 minutes. Adjust via SET menu (see page 18)

T3/W3

Elevator Pre-Signal Auxiliary Contacts: Open 0-60 seconds prior to transfer to either direction, re-closes after transfer.

U

(S2) Source 2 Stop Delay Timer. Allows Engine to run unloaded after switch retransfer to Source 1. Adjustable 0-60 minutes in 1 second increments. Standard setting is 5 minutes. Adjust via SET menu (see page 18)

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

GE Zenith Controls 12



VI

Accessory Definitions

(cont’d)

UMD

Universal Motor Load Disconnect Circuit: Auxiliary Contact opens 0-60 seconds prior to transfer in either direction, re-closes after transfer. Can be configured by end user for Pre-transfer, Post-transfer, or both.

Voltage Imbalance (Three Phase) For a three phase source, this feature monitors phase voltage ratios based on a selected range within a selected time window

. Should any phase fall below the selected lower window limit or exceed the selected higher window limit within the selected time frame, the controller initiates transfer to the other source.

Range: 5% to 20% of Nominal voltage, 10 to 30 seconds window

, user adjustable. Resolution: 1% Increments Minimum Differential: 2% between “Fail” and “Restore” settings. Factory default: 10% “Fail”, 8% “Restore”, 30 Seconds. See CFG Menu page 17 to configure ON or OFF. See SET Menu page 18 to set Percentage and time windows

W

Time Delay (S2) Source 2 Stable Timer. To delay transfer to Source 2. Adjustable 0-5 minutes in 1 second increments. Standard setting is 1 second. Adjust via SET menu (see page 18)

YEN

Bypass Timers Key utilizing Keypad. When applicable, the system prompts the user to press a button to bypass (T) or (W) Timers should the user so desires.

ZNET

Network Communications Interface Card

How to Set the System Clock

Set System Clock, time and date

· If the clock is not set, the display will show

SET SYSTEM CLOCK on the second line of the S1 OK screen.

· The S1 OK screen will show time (hours and

minutes) on the second line if the system clock has been set. (Date on third line)

Setting the System Clock

(Start from S1 OK screen)

1. Remove battery protective white plastic strip

near P relay. *

2. Press MORE then press SET.

3. Press MORE and scroll to SET SYSTEM CLOCK

using the MORE key.

4. Press SEL.

5. ENTER ACCESS CODE located on the white label

on the back of the controller.

6. Press SEL.

7. Use the up and down keys to change the hour value.

8. Press SAVE (this will enter this value and move

cursor to minutes).

9. Use the up and down keys to change the minutes.

10. Press SAVE (this will enter this value and move

cursor to month).

11. Use the up and down key up to change the month.

12. Press SA

VE (This will enter this value and complete

the clock setting).

13. Use the up and down keys to change the date.

14. Press SAVE (this will enter this value and move

cursor to year).

15. Use the up and down keys to change year.

16. Press SAVE (this will enter this value and

compete the clock setting).

17. To edit settings, press SEL and repeat steps 6-16.

18. If the setting is satisfactory, press MORE (unit then returns to the SET menu then press BACK, then ESC.)

* Replacement battery part #K-4100

Battery will last 5 years and provides power to retain clock function only (Controller functions without battery).

GE Zenith Controls

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

13



CDT One Event Timer Exerciser

Load or No-Load

One event Exerciser with adjustable Timer. Exercise duration can be set between 5 and 60 minutes in 1 minute increments. Can be configured to run every 1,7,14, or 28 days. Factory default is 20 minutes.

How to CONFIGURE (CFG) and Set (SET) the Timer Exerciser

1. Beginning from the S1 OK screen, press MORE then CFG.

2. Press MORE to scroll to

CONFIG TIMER

EXERCISER screen.

3. The third line of the CONFG TIMER EXERCISER will show either DAIL

Y, WEEKLY, 14 DAY, 28 DAY,

or OFF.

4. If the third line of the CONFG TIMER EXERCISER shows DAIL

Y, WEEKLY, 14 DAY, or 28 DAY as

desired, then proceed to step 10.

5. If the third line of the CONFG TIMER EXERCISER shows OFF or if another timer selection is desired, continue.

6. Press SEL

.

7. Enter ACCESS code located on white label on the back of the controller

.

8. Press UP or DOWN to select DAIL

Y, WEEKLY,

14 DAY, or 28 DAY as desired.

9. Press SA

VE.

10. Press MORE to scroll to

CONFG TIMER

EXERCISER (XFR) or (NO XFR).

11. Press Up or Down to select XFR (Load T

ransfer)

or NO XFR (No Load Transfer).

12. Press SA

VE.

13. Press MORE repeatedly to

BACK then S1 OK screen.

Set (SET) the Exerciser:

14. Beginning from the S1 OK screen, press MORE then SET.

15. Press MORE repeatedly until EXER S2 RUN TIME screen.

16. Press SEL

17. Enter ACCESS code located on white label on the back of the controller

.

18. Press SEL

19. Cursor is indicated as a line under character to be changed. Change values with up and down keys.

20. Press SA

VE when complete.

21. Press MORE repeatedly until

SET USER SETUP

then press BACK then ESC to the S1 OK screen.

How to Initiate CDT Exerciser and to start an exercise cycle every 1, 7, 14, or 28 days

From S1 screen

1) Press TEST

2) Press MORE

3) Press ST

ART TEST TIMER (to initiate Test).

• If the CDT Exerciser is Factory configured for a Load Exerciser

, the Controller will immediately start a load exercise. The controller will start the generator, transfer the load to Source 2 and remain in Source 2 for the duration set for EXER S2 RUN TIME in the SET menu. The controller will retransfer the load back to Source 1 after the S1 stable timer has timed out and run the generator unloaded for the duration of the S2 stop delay timer (Engine Cool Down Timer).

• If the CDT Exerciser is Factory configured for a No-Load Exerciser, the Controller will immediately start a No-load exercise. The controller will start the generator and run it unloaded for the duration of the S2 stop delay timer (Engine Cool Down Timer).

Exercise will be repeated at the same time as initiated on ever

y 1, 7, 14, or 28 days according to the selection

made in the Configure CFG menu.

How to Bypass (Cancel) an exercise during an exercise cycle

1) Press BPASS

2) Allow the controller to complete the Engine cool down cycle

If the CDT Exerciser is Factor

y configured for a No-Load Exerciser Or allow the controller to complete retransfer to Source 1 If the CDT Exerciser is Factory configured for a Load Exerciser

How to Bypass the next exercise event and Keep the rest of scheduled events unchanged

1) Press Test

2) Press MORE

3) Press BYP

ASS EXER

To re-institute the next exercise event back, press CANCL BPASS

How to initiate a new exercise start time

1) Press TEST

2) Press MORE

3) Press EXER CANCL

4) Press ST

ART TIMER TEST

How to check the next exercise event

1) From S1 OK screen, press MORE three times.

2) The unit will display the PLANT EXERCISER NEXT

event in DA

YS, HOURS, and MINUTES

3) Press ESC to S1 OK

Screen.

Notes:

- *E* appears in the upper right hand corner

of LCD screen when exercise is impending.

- For Load Exerciser, actual exercise period

(ATS in S2 position)= CDT (Exerciser) timing period +T (S1 stable Timer) timing period.

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

GE Zenith Controls 14

CDP Clock Exerciser

Load / No-Load Clock Exerciser

Allows the Generator to start and run unloaded or to simulate a power failure, start Generator and run under load. Can be configured by the end user for 1, 7, 14, 28, or 365 day cycles.

• A total of 7 independent No Load exercise periods (up to 10 hours each) can be programmed for each of the daily, weekly, 14-day, and 28-day exercisers.

• A total of 12 independent No Load exercise periods (up to 10 hours) can be programmed for the 365-day Exerciser

.

How to Configure (CFG) the Exerciser

1. Beginning from the S1 OK screen, press MORE then CFG.

2. Press MORE to scroll to

CONFIG CLOCK

EXERCISER screen.

3. The third line of the CONFG CLOCK EXERCISER will show either DAIL

Y, WEEKLY, 14 DAY, 28 DAY,

365 DAY or OFF.

4. If the third line of the CONFG CLOCK EXERCISER shows DAIL

Y, WEEKLY, 14 DAY, 28 DAY, or 365 DAY as desired, press MORE repeatedly to BACK. Press ESC then proceed to the SET menu to set the EXERCISER.

5. If the third line of the CONFG CLOCK EXERCISER shows OFF, continue.

6. Press SEL

.

7. Enter ACCESS code located on white label on the back of the controller

.

8. Press UP or DOWN to select DAIL

Y, WEEKLY,

14 DAY, 28 DAY, or 365 DAY as desired.

9. Press SA

VE.

10. Press MORE repeatedly to

BACK then ESC

to S1 OK screen.

How to set (SET) the DAILY Exerciser

1. Beginning from the S1 OK screen, press MORE

then SET.

2. Press MORE repeatedly until

SET EXERCISER

screen.

3. Press SEL

.

4. Enter ACCESS code located on white label on the back of the controller

.

5. Press SEL

6. Cursor is indicated as a line under character to be changed. Change values with up and down keys. Press SA

VE after each entry to save value and to

move to the next value to be changed.

7. Press BACK when complete.

8. Press MORE repeatedly until SET USER SETUP. Press BACK then ESC to the S1 OK screen.

How to Bypass (Cancel) an exercise during an exercise cycle

1) Press BPASS

2) Allow the controller to complete the Engine cool down cycle.

If the CD Exerciser is configured or Set for a No-Load Exercise. Or allow the controller to complete retransfer to Source 1. If the CD Exerciser is configured for a Load Exerciser

How to Bypass the next exercise event and Keep the rest of scheduled events unchanged

1) Press TEST

2) Press MORE

3) Press BYP

ASS EXER

To re-institute the next exercise event back, press CANCL BPASS

How to check the next exercise event

1) From S1 OK screen, press MORE three times.

2) The unit will display the PLANT EXERCISER NEXT event in

DAYS, HOURS, and MINUTES

3) Press ESC to S1 OK

Screen.

Notes:

• In the S1 OK screen, an (*E*) appears in the upper right hand corner of LCD screen when exercise is impending.

• For Load Exerciser, actual exercise period (A

TS in S2 position)= CDT (Exerciser)

timing period +T (S1 Stable Timer) timing period.

• A value greater than zero must be entered in the Exerciser duration field to be accepted as a valid exercise period.

• The Exercise cycle will be repeated on a regular basis as programmed and initiated in the SET menu depending on what Exerciser was configured (selected) in the

CFG menu.

Figure 9



GE Zenith Controls

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

15

Indicates # of Exercise Periods

Indicates type of Exerciser DAILY, WEEKLY, 14-DAY, 28-DAY or 365-DAY

Indicates Exerciser start: Time for DAILY Exerciser Time & Day for WEEKLY Exerciser Time, Date & Month for 14-DAY, 28-DAY and 365-DAY Exerciser (24 Hour System)

Cursor

EXERCISER 00:00

BACK

To previous field or to exit screen.

SET

^

Up and Down Use to change values.

v

NL #1

SAVE

To save value and to move cursor to next field to be changed.

Load No-Load (CDP) Exercise Indicator

Exercise duration for this event in hours and minutes up to 10 hours per event

Entelli-Switch 250 User Setup - CFG Menu



Turn options ON or OFF via keypad through the CFG menu

Enter six digit access code (The factory assigned six-digit access code is located on the back of the controller)

Network Communications (Option)

11

12

13

R1

Output

5

6

7

R1

Output

14

15

16

R2

Output

8

9

10

R2

Output

Contact Rating: 10A @ 277VAC or 30VDC

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

PROG 1 PROG 2 GRD (Input Sink) LS OUT NIA OUT ELEV. PRE. OUT ALARM OUT STE OUT

MOTOR DISC. OUT

TMS IN INHIB. > S1 INHIB. > S2 LS IN

1

2

3

4

5

6

7

8

9 10 11 12 13 14

+12V (Output Source) LN OUT L4 OUT L3 OUT L2 OUT L1 OUT YN IN YE IN TSNL IN Q2/TSL IN S12 IN S5 IN

11 12 13

5 6 7

14 15 16

8 9

10

R1

1 2

R2

3 4

Output Contacts

{ {

From J2/J4 Output

J4-3

414

13

12 11 10

9

123

567

8

J2-3 N.O. N.C.

To J2/J4 Input

Customer

Input

Voltage

{

WARNING

1 Controller inputs must be relay isolated.

2 Controller ouputs have limited source capability.

Use only GE Zenith - specified output modules.

Entelli-Switch 250

TM

Lithium Battery Exerciser Battery

Replacement - K-4100 (BR2032) Service Life - 10 Years

+

During normal operation

User Access Code Default - 121212

Product Information www.geindustrial.com

24-Hour Service (773) 299-6600

J4

*

J2

*

* Input and output availability

subject to factory configuration.

Figure 10

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

GE Zenith Controls

16

S1 OK

01: 50

FRI 31 MAY 2003

MORE TEST

1 VAB = ___ 2 VAB = ___

VBC = ___ VBC = ___ VCA = ___ VCA = ___

MORE CFG SET ESC

CONFIG

USER SETUP

MORE BACK

—TIMER EXERCISER (CDT) 1, 7, 14, 28 Day (pg. 10 & 14)

—CLOCK EXERCISER LOAD OR NO LOAD (CDP) 1, 7, 14, 28, 365 Day (pg. 10 & 15)

—TEST KEY (6) Maintained/Momentary (pg. 10)

—TRANSFER COMMIT (S13) ON/OFF (pg. 12)

—AUTO / MANUAL (S5 or S12) ON/OFF (pg. 12)

—IN-PHASE MONITOR (R50) ON/OFF (pg. 12)

—S1 OVER VOLTAGE (R1-1 or R1-3) ON/OFF (pg. 11)

—S1 UNDER FREQUENCY ON/OFF (pg. 8)

—S2 OVER VOLTAGE ON/OFF (pg. 8)

—S2 OVER FREQUENCY ON/OFF (pg. 8)

—PHASE IMBALANCE (VI) ON/OFF (pg. 13)

—PHASE ROTATION MATCH (R16) ON/OFF (pg.11)

—LOAD DISCONNECT TD (UMD) (pg.13)

—TRANSFER ALARM (CTAP) ON/OFF (pg.10)

—NETWORK (ZNET) ON/OFF (pg. 13)

Optional Accessories

Entelli-Switch 250 User Setup - SET Menu



Change adjustable values through the SET menu.

Enter six digit access code (The factory assigned six-digit access code is located on the back of the controller)

Figure 10

Network Communications (Option)

11

12

13

R1

Output

5

6

7

R1

Output

14

15

16

R2

Output

8

9

10

R2

Output

Contact Rating: 10A @ 277VAC or 30VDC

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

PROG 1 PROG 2 GRD (Input Sink) LS OUT NIA OUT ELEV. PRE. OUT ALARM OUT STE OUT

MOTOR DISC. OUT

TMS IN INHIB. > S1 INHIB. > S2 LS IN

1

2

3

4

5

6

7

8

9 10 11 12 13 14

+12V (Output Source) LN OUT L4 OUT L3 OUT L2 OUT L1 OUT YN IN YE IN TSNL IN Q2/TSL IN S12 IN S5 IN

11 12 13

5 6 7

14 15 16

8 9 10

1 2

3 4

Output Contacts

{ {

From J2/J4 Output

J4-3

414

13

12 11 10

9

123

567

8

J2-3 N.O. N.C.

To J2/J4 Input

Customer

Input

Voltage

{

WARNING

1 Controller inputs must be relay isolated.

2 Controller ouputs have limited source capability.

Use only GE Zenith - specified output modules.

Entelli-Switch 250

TM

Lithium Battery Exerciser Battery

Replacement - K-4100 (BR2032) Service Life - 10 Years

+

During normal operation

User Access Code Default - 121212

Product Information www.geindustrial.com

24-Hour Service (773) 299-6600

J4

*

J2

*

* Input and output availability

subject to factory configuration.

R1

R2

GE Zenith Controls

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

17

S1 OK

01: 50

FRI 31 MAY 2003

MORE TEST

1 VAB = ___ 2 VAB = ___

VBC = ___ VBC = ___ VCA = ___ VCA = ___

MORE CFG SET ESC

SET

USER SETUP

MORE BACK

—SET SYSTEM CLOCK (pg.13)

—DAYLIGHT SAVINGS ON/OFF

—CLOCK EXERCISER (CDP) (pg.10 & 15)

—EXER S2 RUNTIME (CDT) (pg.10 & 14)

—S1 UNDER VOLTAGE (pg.8) Fail Restore

—S1 UNDER FREQUENCY (pg.8) Fail Restore

—S1 OVER VOLTAGE (pg.11) Fail Restore

—S1 OVER FREQUENCY (pg.8) Fail Restore

—S2 UNDER VOLTAGE (pg.8) Fail Restore

—S2 UNDER FREQUENCY (pg.8) Fail Restore

—S2 OVER VOLTAGE (pg.8) Fail Restore

—S2 OVER FREQUENCY (pg.8) Fail Restore

—SET % PHASE IMBALANCE (VI) FAIL 5%, RESTORE 3% (pg.13)

—SET PHASE IMBALANCE (VI) TIME DELAY 30 seconds (pg.13)

—TIME DELAY S2 START (P1) (pg.11)

—TIME DELAY S2 STABLE (W) (pg.13)

—LOAD PRESIGNAL TD (T3/W3) (pg.12)

—LOAD DISCONNECT TD (UMD) (pg.13)

—ATS OPEN TIME TO S2 (DW) DELAY units only (pg.10)

—TIME DELAY S1 STABLE (T) (pg.12)

—ATS OPEN TIME TO S1 (DT) DELAY units only (pg.10)

—S2 STOP DELAY (U) (pg.12)

—CALIBRATE S1 (pg.10)

—CALIBRATE S2 (pg.10)

Optional Accessories

Entelli-Switch 250 User Setup - System Info



Figure 10

Network Communications (Option)

11

12

13

R1

Output

5

6

7

R1

Output

14

15

16

R2

Output

8

9

10

R2

Output

Contact Rating: 10A @ 277VAC or 30VDC

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

PROG 1 PROG 2 GRD (Input Sink) LS OUT NIA OUT ELEV. PRE. OUT ALARM OUT STE OUT

MOTOR DISC. OUT

TMS IN INHIB. > S1 INHIB. > S2 LS IN

1

2

3

4

5

6

7

8

9 10 11 12 13 14

+12V (Output Source) LN OUT L4 OUT L3 OUT L2 OUT L1 OUT YN IN YE IN TSNL IN Q2/TSL IN S12 IN S5 IN

11 12 13

5 6 7

14 15 16

8 9

10

R1

1 2

R2

3 4

Output Contacts

{ {

From J2/J4 Output

J4-3

414

13

12 11 10

9

123

567

8

J2-3 N.O. N.C.

To J2/J4 Input

Customer

Input

Voltage

{

WARNING

1 Controller inputs must be relay isolated.

2 Controller ouputs have limited source capability.

Use only GE Zenith - specified output modules.

Entelli-Switch 250

TM

Lithium Battery Exerciser Battery

Replacement - K-4100 (BR2032) Service Life - 10 Years

+

During normal operation

User Access Code Default - 121212

Product Information www.geindustrial.com

24-Hour Service (773) 299-6600

J4

*

J2

*

* Input and output availability

subject to factory configuration.

View System Data

Enter six digit access code (The factory assigned six-digit access code is located on the back of the controller)

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

GE Zenith Controls

18

S1 OK

01: 50

FRI 31 MAY 2003

MORE TEST

—PHASE TO PHASE VOLTAGE, S1 & S2

—FREQUENCY INDICATION FOR S1 & S2 (K/P) (pg.10)

—PLANT EXERCISER: Next Impending Exerciser (shows only if set)

—SYSTEM INFO:

Serial #: Unit Serial # Rev #: Software Revision #

Event Log:

Sequentially Numbered Log of 16 events that track date, time, reason and action taken

Data: Total Life Transfers (N2P)

Days Powered Up Total Transfers to S2 Total S1 Failures Time S1 available in Hrs Time S2 available in Hrs. (N1P)

—CHANGE USER ACCESS CODE



Testing

NOTICE

A periodic test of the transfer switch under load conditions is recommended to insure proper operation.

(See National Electric Code articles 700 and 701)

ATS Testing

Start generator and verify proper voltage, frequency and phase sequence (match to Source 1). Shut down gen set and place in Auto. Complete the visual inspection of the transfer switch, and close the cabinet door.

Initiate the test by pressing the TEST button on the LCD keypad. The controller will then prompt for your access code. After entering the code, three test options will appear— XFR LOAD, FAST TEST and NO XFR (See Figure 11).

• XFR LOAD test starts the generator and using

the current timer settings, transfers the load to Source 2.

• FAST TEST test presets timer values to a maximum

30 seconds during the test. After completion of the test, all timers are reset to their original values. (T3, W3, DT and DW remain)

• NO XFR test starts the generator but does not

transfer the load to the Source 2.

Press and hold the desired test option button until the switch transfers to Source 2 (load test) or until the generator has been run for the desired amount of time (no load test). Releasing the test button before W timer timeout will abort the test (Exception: when the transfer commit option, is configured “ON”).

To test lamps, press TEST then scroll through MORE, then press LAMP TEST. To cancel LAMP TEST press MORE.

Standard Transition

When the test is initiated, the controller initiates the Time Delay Source 2 Start Timer (Engine Start Timer "P") cycle. A manual CANCEL button is provided to cancel the test if desired. Upon completion of the (P) time delay, an Engine start Signal is sent to Source 2. When Source 2 voltage and frequency reach the preset "Restore" Values, the time delay to Source 2 Timer (W) begins its timing cycle to ensure voltage and frequency stabilization before transfer. A manual pushbutton BYPASS is provided to bypass the "W" time delay if desired. After the (W) time delay, the CCE relay energizes the CE solenoid to close the transfer switch in to Source

2. The SE limit switch activates to de-energize the CCE relay.

Restoration of Source 1 Power:

Deactivating the test switch initiates re-transfer to Source 1 sequence.The delay to Source 1 Timer (T) begins its timing cycle to ensure voltage and frequency stabilization before retransfer. A manual pushbutton BYPASS is provided to bypass the "T" time delay if desired. After the (T) time delay, the CCN relay energizes the CN solenoid to retransfer the switch to Source 1. The SN limit switch activates to de-energize the CCN relay.

Immediately after re-transfer, the S2 Stop Delay Timer (Delay to Engine Stop "U") begins its cycle to allow Source 2 Engine

SYSTEM TEST

FAST XFR NO

MORE TEST LOAD XFR

Figure 11

to run unloaded. A manual pushbutton BYPASS is provided to bypass the "U" time delay if desired. Upon completion of the (U) timing cycle, the controller sends an Engine stop signal.

Delayed Transition

Source 1 Power Failure:

When the test is initiated, the controller initiates the Time Delay Source 2 Start (Engine Start Timer "P") cycle. A manual CANCEL button is provided to cancel the test if desired Upon completion of the (P) time delay, an Engine start Signal is sent to Source 2. When Source 2 voltage and frequency reach the preset "Restore" values, the time delay to open Source 1 timer (W) begins its timing cycle to ensure voltage and frequency stabilization before re-transfer. A manual pushbutton BYPASS is provided to bypass the "W" time delay if desired. After the (W) time delay, the CCNO relay energizes the CNO solenoid to open the transfer switch out of Source 1 position. The time delay to Source 2 timer (DW) begins its timing cycle. After the (DW) time delay, the CCE relay energizes. The switch then completes transfer to Source 2 by energizing the CE solenoid. The SE limit switch activates to de-energize the CCE relay.

Restoration of Source 1 Power:

Deactivating the test switch initiates re-transfer to Source 1sequence.The delay to open Source 2 Timer (T) begins its timing cycle to ensure voltage and frequency stabilization before retransfer. A manual pushbutton BYPASS is provided to bypass the "T" time delay if desired. After the (T) time delay, the CCEO relay energizes the CEO solenoid to open the switch out of Source 2 position. The time delay to Source 1 timer (DT) begins its timing cycle. After the (DT) time delay, the CCN relay energizes the CN solenoid to complete re-transfer of the switch to Source 1. The SN limit switch activates to de-energize the CCN relay.

Immediately after re-transfer, the S2 Stop Delay Timer (Delay to Engine Stop "U") begins its cycle to allow Source 2 Engine to run unloaded. A manual pushbutton BYPASS is provided to bypass the "U" time delay if desired. Upon completion of the (U) timing cycle, the controller sends an Engine stop signal.

GE Zenith Controls

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

19

Entelli-Switch 250



Sequence of Operation

Standard Transition

Source 1 Power Failure:

When Source 1 voltage or frequency has fallen below the preset "Fail" values, the controller initiates the Time Delay Source 2 Start Timer (Engine Start Timer "P") cycle. Upon completion of the (P) time delay, an Engine start Signal is sent to Source 2. When Source 2 voltage and frequency reach the preset "Restore" Values, the time delay to Source 2 Timer (W) begins its timing cycle to ensure voltage and frequency stabilization before transfer. A manual pushbutton BYPASS is provid

ed to bypass the "W" time delay if desired. After the (W) time delay

, the CCE relay energizes the CE solenoid to close the transfer switch in to Source 2. The SE limit switch activates to de-energize the CCE relay.

Restoration of Source 1 Power:

When Source 1 power reach the preset "Restore" values, the controller initiates re-transfer to Source 1sequence.The delay to Source 1 Timer (T) begins its timing cycle to ensure voltage and frequency stabiliza

tion before retransfer. A manual pushbutton BYPASS is provided to bypass the "T" time delay if desired. After the (T) time delay

, the CCN relay energizes the CN solenoid to retransfer the switch to Source 1. The SN limit switch activates to de-energize the CCN relay.

Immediately after re-transfer, the S2 Stop Delay Timer (Delay to Engine Stop "U") begins its cycle to allow Source 2 Engine to run unloaded. A manual pushbutton BYPASS is provided to bypass the "U" time delay if desired. Upon completion of the (U) timing cycle, the controller sends an Engine stop signal.

Delayed Transition

Source 1 Power Failure:

When Source 1 voltage or frequency has fallen below the preset "Fail" values, the controller initiates the Time Delay Source 2 Start (Engine Start Timer "P") cycle. Upon completion of the (P) time delay, an Engine start Signal is sent to Source 2. When Source 2 voltage and frequency reach the preset "Restore" values, the time delay to open Source 1 timer (W) begins its timing cycle to ensure voltage and frequency stabiliza

tion before re-transfer. A manual pushbutton BYPASS is provided to bypass the "W" time delay if desired. After the (W) time delay

, the CCNO relay energizes the CNO solenoid to open the transfer switch out of Source 1 position. The time delay to Source 2 timer (DW) begins its timing cycle. After the (DW) time delay, the CCE relay energizes. The switch then completes transfer to Source 2 by energizing the CE solenoid. The SE limit switch activates to de-energize the CCE relay.

Restoration of Source 1 Power:

When Source 1 power reach the preset "Restore" values, the controller initiates re-transfer to Source 1 sequence.The delay to open Source 2 Timer (T) begins its timing cycle to ensure voltage and frequency stabi

lization before retransfer. A manual pushbutton BYPASS is provided to bypass the "T" time delay if desired. After the (T) time delay

, the CCEO relay energizes the CEO solenoid to open the switch out of Source 2 position. The time delay to Source 1 timer (DT) begins its timing cycle. After the (DT) time delay, the CCN relay ener

gizes the CN solenoid to complete re-transfer of the switch to Source 1. The SN limit switch activates to deenergize the CCN relay.

Immediately after re-transfer, the S2 Stop Delay Timer (Delay to Engine Stop "U") begins its cycle to allow Source 2 Engine to run unloaded. A manual pushbutton BYPASS is provided to bypass the "U" time delay if desired. Upon completion of the (U) timing cycle, the controller sends an Engine stop signal.

Table 4

Timer Designations as they appear in the SET menu

ATS Type P W DW T DT U

Standard Time Delay Time Delay Time Delay S2 Stop Transition S2 Start S2 Stable S1 Stable Delay

Delayed Time Delay Time Delay ATS Open Time Delay ATS Open S2 Stop Transition S2 Start S2 Stable Time to S2 S1 Stable Time to S1 Delay

Source 1 Transfer to Source 2 T

ransfer to Source 1 Engine

Source 1

Fails Cooldown

Returns

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

GE Zenith Controls 20



Relay/Transformer (R/T Box)

Standard Transition

Each Entelli-Switch 250 microprocessor based ATS controller requires a relay/transformer box to apply line voltage to the ATS operator via coil control relays. Also required is power for the Entelli-Switch 250 printed circuit board and an application of sensing voltage proportional to line voltage. This is accomplished by the relay trans

former box. This method of switching operator voltage and applying power and sensing voltage to the printed

1

2

(inside)

3

Figure 12

circuit board isolates the MX250 from the line voltage, further protecting the controller from harmful line tran

sients. Two versions of the R/T box exist depending on the type of A

TS (standard transition or delayed transition).

The following layout drawings of the R/T Box components (standard and delayed transition) include a bill of materials for replacement parts. Schematics are included to indicate proper wiring.

SEC.

PRI.

SEC.

PRI.

SEC.

PRI.

1

2

3

Figure 13

40-225 Amp Molded Power Section

40-3000 Amp - All Other Standard Types

Transformer Usage (see Figure 12)

Transformer Usage (see Figure 13)

R/T Box Primary 1 VA 25 VA

Assembly Voltage XFMR XFMR

Part No. at 50/60 Hz Part No. Part No.

57P-1015 120V K-3216 K-3224 57P-1016 208-220V K-3217 K-3225 57P-1017 230-240V K-3218 K-3226 57P-1018 277V K-3219 K-3227 57P-1019 380-400V K-3220 K-3228 57P-1020 416-440V K-3221 K-3229 57P-1021 460-480V K-3222 K-3230 57P-1022 575-600V K-3223 K-3231

R/T Box Primary 1 VA 25 VA

Assembly Voltage XFMR XFMR

Part No. at 50/60 Hz Part No. Part No.

50P-1026 120V K-3216 K-3224 50P-1027 208-220V K-3217 K-3225 50P-1028 230-240V K-3218 K-3226 50P-1029 277V K-3219 K-3227 50P-1030 380-400V K-3220 K-3228 50P-1031 416-440V K-3221 K-3229 50P-1032 460-480V K-3222 K-3230 50P-1033 575-600V K-3223 K-3231

Bill of Material

Item Part No. Description Qty

1 See Chart Transformer (1 VA) 2

2 See Chart Transformer (25 VA) 2

3 K-1274 Relay Flange Mounted 2

Item Part No. Description Qty

1 See Chart Transformer (25 VA) 2

2 See Chart Transformer (1 VA) 2

3 K-1260 Coil Control Relay (24V) 2

GE Zenith Controls

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

21



Relay/Transformer (R/T Box)

(cont’d)

Delayed Transition

SEC.

PRI.

1

2

3

Figure 14

Transformer Usage

Bill of Material

R/T Box Primary 1 VA 25 VA

Assembly Voltage XFMR XFMR

Part No. at 50/60 Hz Part No. Part No.

50P-1034 120V K-3216 K-3224 50P-1035 208-220V K-3217 K-3225 50P-1036 230-240V K-3218 K-3226 50P-1037 277V K-3219 K-3227 50P-1038 380-400V K-3220 K-3228 50P-1039 416-440V K-3221 K-3229 50P-1040 460-480V K-3222 K-3230 50P-1041 575-600V K-3223 K-3231

Item Part No. Description Qty

1 See Chart Transformer (25 VA) 2

2 See Chart Transformer (1 VA) 2

3 K-1260 Coil Control Relay (24V) 4

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

GE Zenith Controls

22

PRI.

SEC.



Relay/Transformer (R/T Box)

(cont’d)

Standard Transition R/T Box Schematic

Figure 15

Delayed Transition R/T Box Schematic

Figure 16

GE Zenith Controls

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

23

20

CCN

24V

21 22

XN1

10V

11 V

XN2

10V

CCE

24V

XE1

10V

30 31 32

XE2

10V

11 V

XN1 - SOURCE 1 CONTROL TRANSFORMER XN2 - SOURCE 1 3 PHASE SENSING TRANSFORMER XE1 - SOURCE 2 CONTROL TRANSFORMER XE2 - SOURCE 2 3 PHASE SENSING TRANSFORMER

SOURCE 2 24V OUTPUT

900

(18)

SOURCE 1 24V OUTPUT

800 907

3 PHASE SOURCE 2 SENSING (BLANK) (BLANK) GROUND

GND

CCE - COIL CONTROL RELAY (SOURCE 2)

901

CCN - COIL CONTROL RELAY (SOURCE 1)

801

COMMON

902 903 904 803 804 807

806 805 906 905

SINGLE PHASE SOURCE 2 SENSING

3-PHASE SOURCE 1 SENSING

SOURCE 1 CONTROL POWER

SOURCE 2 CONTROL POWER

(1)

J5

CCEO

CCN

24V

XN1

10V

20

11 V

21

XN2

10V

22

CCNO

CCE

24V

XE1

10V

32

31

30

XN1 - SOURCE1 CONTROL TRANSFORMER XN2 - SOURCE1 3 PHASE SENSING TRANSFORMER XE1 - SOURCE 2 CONTROL TRANSFORMER XE2 - SOURCE 2 3 PHASE SENSING TRANSFORMER

900

SOURCE 2 24V OUTPUT

(18)

800

SOURCE 1 24V OUTPUT

907

3 PHASE SOURCE 2 SENSING

808

CCEO - COIL CONTROL RELAY (OPEN SOURCE 2)

908

CCNO - COIL CONTROL RELAY (OPEN SOURCE 1) GROUND

901

CCE - COIL CONTROL RELAY (SOURCE 2)

801

CCN - COIL CONTROL RELAY (SOURCE 1)

902

COMMON

903 904 803 804 807 806 805 906 905

SINGLE PHASE SOURCE 2 SENSING

3-PHASE SOURCE 1 SENSING

SOURCE 1 CONTROL POWER

SOURCE 2 CONTROL POWER

(1)

J5

11 V

XE2

10V

GND



Troubleshooting and Diagnostics

DANGER

HAZARDOUS VOLTAGES CAN CAUSE SEVERE INJURY OR DEATH.

These charts may indicate problems that require authorized GE Zenith service personnel.

Hazardous voltages may exist on termination plugs other than those that go into the Entelli-Switch 250.

General Troubleshooting

The following troubleshooting guide is used to recognize, and determine basic faults. When using this guide, it will ask several questions about the condition of the switch. This guide will then list an order of the possible faults. You will then look at the first suspected fault to determine if it is the problem. If it is not a fault, you go to the

second suspected fault. If you go through all of the suspected faults, or the chart instructs you to, call a GE Zenith Representative for further assistance.

NOTE

: When you use the troubleshooting charts, the Annunciation column refers to the LED’s on the control panel.

Symptom Annunciation Possible Cause(s) Corrective Action

Engine does not START SOURCE 2

AVAILABLE LED off

Engine start wires not terminated properly

Check engine start connections

Generator is in OFF position

Investigate why Engine Control S

witch was turned off

Engine does not stop

LCD Display “TD Engine Cool Down

”

U timing cycle not complete Check U timer setting

SOURCE 1 POSITION, and SOURCE 1 and SOURCE 2 A

VAILABLE LEDs on,

but U timer has timed out

Engine start wires not terminated cor

rectly

Check Engine Start Connections

Generator in MANUAL Place generator in AUTO

ATS will not transfer to SOURCE 2

SOURCE 2 AVAILABLE LED of

f

SOURCE 2 voltage or frequency not within acceptable parameter

s

Check: Engine Start Connections, Generator

Breaker, Generator Output,

and Engine Control Switch

ZTG Series

None Power supply connector unplugged Plug in connector

LCD Display “S1 _ _ _ _ TD XFR S1>S2 T

ime Remaining _ _ _ _”

W timing cycle not complete Check WTimer setting

ATS will not transfer to SOURCE 1

LCD Display “ATS Open T

ime Remaining _ _ _ _”

DW timing cycle not complete Check DWT

imer setting

ZTGD Series

SOURCE 1 AVAILABLE LED of

f

SOURCE 1 voltage or frequency not within acceptable parameter

s

Check utility and utility breakers

None Power supply connector unplugged Plug in connector

LCD Display “Diagnostic Code 001”

Limit switch or RT box connector unplugged

Call Technical Services

LCD Display “S1 OK

T

ime Remaining _ _ _ _

Bypass”

T timing cycle not complete Check T T

imer setting

LCD Display “ATS Open T

ime Remaining _ _ _ _”

TD timing cycle not complete Check DT Timer setting

Table 5

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

GE Zenith Controls

24

Maintenance and Testing

CAUTION

Due to hazardous voltage and current, GE Zenith rec-

ommends that a

GE Zenith Certified technician or a

qualified electrician must perform the

installation and maintenance of the switch.

WARNING



Both power sources must be disconnected

before manual operation of the switch.

A preventive maintenance program will insure high reliability and long life for the transfer switch. The preventive maintenance program for the transfer switch should include the following items:

Inspection and Cleaning

The switch should be inspected for any accumulation of dust, dirt, or moisture, and should be cleaned by vacuuming or wiping with a dry cloth or soft brush. do not use a blower since debris may become lodged in the electrical and mechanical components and cause damage.

Remove the transfer switch barriers and check the condition of the contacts. Any surface deposits must be removed with a clean cloth (do not use emery cloth or a file). If the contacts are pitted or worn excessively, they should be replaced. A general inspection of mechanical integrity should be made to include loose, broken or badly worn parts.

Servicing

All worn or inoperative parts must be replaced using GE Zenith recommended replacement parts. Please refer to the Replacement Parts manual for specific part information and ordering procedures. Please contact the GE Zenith Technical Services Department for the Replacement Parts manual.

The operating mechanism of the transfer switch is lubricated with Lubriplate 105. The lubricant applied at the factory provides adequate lubrication for the lifetime of the switch. Should debris contaminate the mechanism, clean and apply additional Lubriplate.

GE Zenith can provide complete preventative maintenance services. Please contact the GE Zenith Technical Services Department for additional information.

CDT battery replacement - lithium batteries may last up to 10 years, however it is recommended that batter

y replacement be included in a 3-5 year service cycle. The battery maintains the exerceser memory only and does not otherwise affect the operation.

Testing

A manual operator handle is provided with the transfer switch for maintenance purposes only. Manual operation of the switch must be checked before it is operated electrically. Both power sources

must be disconnected before manual operation of the switch.

Insert the handle and operate the transfer switch between the Source 1 and Source 2 positions. The transfer switch should operate smoothly without binding. Return the switch to Source 1 position, remove the handle, and return it to the holder provided.

After completing the inspection, cleaning and servicing of the transfer switch, reinstall the switch cover, and close and lock the cabinet door. Reclose the circuit breakers feeding the utility and generator sources to the switch.

Initiate the electrical transfer test by activating the TS test switch. P timer will time out and the microcontroller will send an engine start signal. When the W time has elapsed, the switch will complete its transfer by closing into Source 2.

Deactivating the test switch will start retransfer to Source 1. The switch will complete its retransfer to Source 1 after the time delay of the T timer. The U engine overrun timer allows the engine generator to run unloaded for a preset cool down period.

NOTE: A periodic test of the transfer switch

under load conditions is recommended to insure proper operation. (See National Electric Code articles 700 and 701).

WARNING

When performing a hi-pot or dielectric test

on the power section,

DISCONNECT the

contr

ol panel plugs from the microprocessor

to avoid potential damage.

GE Zenith Controls

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

25

Replacement Parts

Standard Transition — 40 to 200 Amps

TAG DESCRIPTION

CN/CE Solenoid

Solenoid Plunger and Link

SCN/SCE Coil Cutout Switch

SCN/SCE

Coil Cutout Switch

BR Rectifier

Figure 17

VOLTAGE 40 TO 200 AMPS

120

K-2207

208

K-2208

220

K-2208

240

K-2228

277

K-2211

380/416

K-2212

440/480

K-2209

575/600

K-2213

ALL 57P-1030

120-480V L-3078

600V L-4027

ALL PS-5076

A3/A4 Auxiliary Contacts

L

-3078

26

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

GE Zenith Controls



BR

CN/CE

SCN/SCE



Replacement Parts (cont’d)

Standard Transition - 225 to 400 Amps

Figure 18

ge

d

g

n

s

*

00

N

g

S

1

S

1

S

1

N

e Size

CM

Co

s

0

5B

0

6B

E

Solenoid

6

0

8B

0

9B

E

Co

es

8

4

s

er

6

GE Zenith Controls

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

27

BR

CN/CE

T1 T2 T3 TN

N1 N2 N3 NN

SN A4

SE A3

Ta

N 1,2,3 E 1,2,3 T 1,2,3

CN/C

SN/S

A3/A

Descriptio

Cable Connection Lu

Wir

il Cutout Switch

Auxiliary Contact

Rectifi

E1 E2 E3 EN

Recommende

as Spare

225, 250

-270

il Volt

12

208/22

380/41

440/48

575/60

Stock Numbers by Ampera

260, 300

-270

#4-600 M

K-224

-

K-224

L-307

PS-507

4

-270

#4-600 M

Replacement Parts (cont’d)

Standard Transition — 600 to 1200 Amps



Figure 19

TAG DESCRIPTION

STOCK NUMBERS BY AMPERAGE

600 800 1000 1200

N 1,2,3, N

E 1,2,3, N T 1,2,3, N

Cable Connection Lug

S1393F

(2)

S1392F

(4)

S1392F

(4)

S1392F

(4) Wire Size #2-600 MCM #2-600 MCM #2-600 MCM #2-600 MCM Stationary Contact Assembly Kit Consult Factory Arc Grid Assembly Kit 23P-1366 Movable Contact Assembly Kit Consult Factory

CN/CE Main Operating Coils Coil Volts Poles

120 2 K-2090F K-2073F K-2073F

K-2073F

240

2 K-2092F K-2070F K-2070F

K-2070F 3 K-2078F K-2070F K-2070F K-2070F 4 K-2091F K-2074F K-2074F K-2074F

208 3,4 K-2091F K-2074F K-2074F K-2074F

575/600 3,4 K-2095 K-2155 K-2155 K-2155

480

3 K-2080F K-2071F K-2071F K-2071F 4 K-2079F K-2071F K-2071F K-2071F

416 3 K-2080F K-2071F K-2071F K-2071F SN CCN Cut-out Switch 23P-1333 SE CCE Cut-out Switch 23P-1327 23P-1452 A3 Emergency Position Aux Contact (Qty 1) 23p-1327 (Qty 2) 23p-1328 (Qty 3) 23p-1334 (Qty 4) 23p-1336 A4 Normal Position Aux Contact (Qty 1) 23p-1333 (Qty 2) 23p-1334 (Qty 3) 23p-1328 (Qty 4) 23p-1330 DS Disconnect Switch Operator L-4009; ; Contact Block L-1020

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

GE Zenith Controls

28

ARC GRID

NN

N1

N2

N3

CN

A4

SN

A4 A3

DS

A3 SE

CE

EN

STATIONARY CONTACT

E1

E2

MOVABLE CONTACT

E3

(ARC GRID REMOVED FOR CLARITY)



Replacement Parts (cont’d)

Standard Transition — 1600 to 3000 Amps

Figure 20

TAG DESCRIPTION

STOCK NUMBERS BY AMPERAGE

1600 2000 3000

N 1,2,3, N

E 1,2,3, N T 1,2,3, N

Cable Connection Lug

S1126F (2)

Optional

S1126F (2)

Optional

S1126F (2)

Optional Wire Size (8) #2-600 MCM (8) #2-600 MCM (8) #2-600 MCM Stationary Contact Assembly Kit 23P-1594 23P-1594 23P-1594 Arc Grid Assembly Kit 23P-1171 23P-1171 23P-1171 Movable Contact Assembly Kit 23P-1400 23P-1400 23P-1400

CN/CE Main Operating Coils Coil Volts Poles

120 2 SPO SPO SPO

240

2,3 K-2123F K-2123F K-2123F

4 K-2127F K-2127F K-2127F

208

3 K-2125F K-2125F K-2125F 4 K-2128F K-2128F K-2128F

575/600

3 K-2153F K-2153F K-2153F 4 K-2154F K-2154F K-2154F

480

3 K-2120F K-2120F K-2120F 4 K-2130F K-2130F K-2130F

416 3 K-2126F K-2126F K-2126F SN CCN Cut-out Switch 23P-1352 SE CCE Cut-out Switch 23P-1356 A3 Emergency Position Aux Contact (Qty 1) 23p-1356 (Qty 2) 23p-1357 (Qty 3) 23p-1353 (Qty 4) 23p-1355 A4 Normal Position Aux Contact (Qty 1) 23p-1352 (Qty 2) 23p-1353 (Qty 3) 23p-1357 (Qty 4) 23p-1359 DS Disconnect Switch Operator L-4009; ; Contact Block L-1020

RN, RE Rectifier 23P-1473 (Up to 240V); 23P-1582 (Up to 600V)

GE Zenith Controls

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

29

ARCH GRID ASSEMBLY

NN

A4

CN

SN

RN

DS

RE

A3 SE

CE

EN

STATIONARY CONTACT (ARCH GRID REMOVED FOR CLARITY)

N1

E1

N2

E2

MOVEABLE CONTACT

N3

E3



Replacement Parts (cont’d)

Standard Transition — 4000 Amps

Figure 21

TAG DESCRIPTION

STOCK NUMBERS

N 1,2,3, N E 1,2,3, N

Cable Connection Lug

S1511F (3)

Optional

T 1,2,3, N

Wire Size

(12) #2-600 MCM Stationary Contact Assembly Kit 23P-1655 Arc Grid Assembly Kit

23P-1171

Movable Contact Assembly Kit 23P-1640

CN/CE

Main Operating Coils

Coil Volts Poles

240

3 K-2219 4 K-2219

208

3 K-2226 4 K-2226

575/600

3 K-2221 4 K-2221

480

3 K-2218 4 K-2218

416 3 K-2220

SN CCN Cut-out Switch 23P-1352

SE CCE Cut-out Switch 23P-1356 A3 Emergency Position Aux Contact (Qty 1) 23p-1356 (Qty 2) 23p-1357 (Qty 3) 23p-1353 (Qty 4) 23p-1355 A4 Normal Position Aux Contact (Qty 1) 23p-1352 (Qty 2) 23p-1353 (Qty 3) 23p-1357 (Qty 4) 23p-1359

DS Disconnect Switch Operator L-4009; ; Contact Block L-1020

RN, RE Rectifier 23P-1473 (Up to 240V); 23P-1582 (Up to 600V)

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

GE Zenith Controls

30

ARC GRID ASSEMBLY

CN

CE

N1

E1

MOVABLE CONTACT

N2

E2

N3

E3

NN

CN

RN

RE

CE

EN

STATIONARY CONTACT

Replacement Parts

(cont’d)

Delayed Transition - 40 to 400 Amps

4

40-80 Amps

Figure 22

100-400 Amps

Figure 23

g

n

d

s

ge

80

00

N

g

S-2515

S

1

N

e

/0

CM

Co

s

SECO

Y

0

5B

58

6

0

6B

58

7

5

58

8

E

Solenoid

0

8B

58

9

0

9B

58

0

K

9B

58P

0

al

54

p

8

4

s

8

O

Co

ch

1

)

6

er

52

GE Zenith Controls

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

31



BR

(RN/RE)

CN/CE

T1 T2 T3 TN

E1 E2 E3 EN

N1 N2 N3 NN

SNO

SN/A

SE/A3

SEO

Ta

N 1,2,3 E 1,2,3 T 1,2,3

CN/C

A3/A

SNO/SE

Descriptio

Cable Connection Lu

Wire Siz

Handle-Manu

Handle-Gri

Auxiliary Contact

il Cutout Swit

Rectifier (>380V

Rectifi

Recommende

as Spare

il Volt

12

208/24

380/41

440/48

575/60

Stock Numbers by Ampera

40-

#8 MCM-3

K-224

-

K-224

-224

E30

L-307

E352

PS-507

PS-51

100-4

-270

#4-600 M

NDAR

P-110

P-111

-111

Replacement Parts

(cont’d)

Delayed Transition - 600 to 1200 Amps

ge

g

n

d

s

p

6

0

,3

N

e

S-1383F

(2)

2

t

1

t

358

t

9

e Contact

0

O

Co

er

)

O

ch

)

O

ch

)

3

t

536

t

535

S Disconnect S

ch

0

O

s

w

.

s

e

Co

C

e

600

0

3

0

3

5

8

3

8

,4

6

80 3 3 480

3

58

0

3

80

,4

58

6

3

6

3

y

000

00

(4)

2

336

6

334

335

8

0

57

F

Figure 24



ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

GE Zenith Controls

32

Ta

NL 1,2 EL 1,2

1,2

NN, EN, T

RN/RN RE/RE

SN/SN SE/SE A

D

CN/CN CE/CE

Volt

24

120/20

4 277/48 240/41

Descriptio

Cable Connection Lug, CU Wir

Stationary Contact Assembly Ki Arc Grid Assembly Ki Movable Contact Assembly Ki Movabl

il Rectifi

Limit Swit Limit Swit Emergency Position Auxiliary Contac Normal Position Auxiliary Contac

wit

Main Operator Solenoid

Wir

il VD

24 20

4 41

Recommende

as Spare

Pol

3

Stock Numbers by Ampera

00-80

500MCM-

23P-147 23P-1 23P-146 23P-147

23P-1473 (Up to 240 VAC 23P-1582 (Up to 600 VAC

23P-1535(L); 23P-1533(R 23P-1536(L); 23P-1534(R

23P-1 23P-1

Operator: L-4009; Contact Block: L-102

See Chart Belo

Solenoid Part No

K-214 K-214 K-21 K-21

Consult Factor

1

-12

2-1392

600MCM-

26P-1 23P-136 26P-1 26P-1

00-120

-

K-21 K-21

Replacement Parts

(cont’d)

Delayed Transition - 1600 to 3000 Amps

D

Y

3

/

O

E

/

CT

O

Figure 25

RY

CT

g

ecommended

n

s

600 2000

3000

,3

(2)

,3

l

,3

2

N

t

X

Y

Z

t

1

t

0

4

O

s

w

O

a

.

s

e

Co

C

e

0 120

O.

0

3

0

,3

51

0

3

0

3

51

8

3 208

,4

51

51 480

3

80

3

0

5

3

0

3

.

0

3 480

,4

0

51

6

3

6

3

y

t

,2

y

0

2

y

1

,4

y

2

,4

y

3

GE Zenith Controls

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

33



CN

N

ARC GRI

N

ASSEMBL

N

E

Ta

N1,2 E1,2 T1,2 NLN,EL

CN/CN CE/CE

Volt

12

120/24

24

120/20

57 277/48 120/24 240/41

SN/SNO-1 SE/SEO-1, SN/SNO-3 SE/SEO-3

CE

E

MOVABL

NTA

STATIONA

NTA

Descriptio

Cable Connection Lug, CU Wire Optiona

Stationary Contact Assembly Ki Arc Grid Assembly Ki Movable Contact Assembly Ki

Main Operator Solenoid

Voltage System

Wir

Switch Bracket Assembl Switch Bracket Assembl Switch Bracket Assembl Switch Bracket Assembl

il VD

24 24

4

575/60

24 41

Operating Coil Hardware Ki

R

as Spare

23P-4134

23P-117 23P-140

Pol

2

3

K-21 K-21 K-21 K-216

K-216 K-21

23P-154 23P-154 23P-154 23P-154

Stock Numbers by Amperage

1

.P.

S.P.O

S-1126F

8) 600MCM-

23P-4134

23P-117 23P-140

See Chart Belo

Solenoid P

.P.O. K-21 K-21 K-21 K-216

S.P.O. S.P.O K-216 K-21

Consult Factor

23P-154 23P-154 23P-154 23P-154

23P-4134

23P-117 23P-134

rt No

.P. K-21 K-21 K-21 K-216

K-216 K-21

23P-154 23P-154 23P-154 23P-154



Replacement Parts (cont’d)

Delayed Transition — 4000 Amps

Figure 26

TAG DESCRIPTION

STOCK NUMBERS

N 1,2,3, N E 1,2,3, N

Cable Connection Lug

S1511F (3)

Optional

T 1,2,3, N

Wire Size

(12) #2-600 MCM Stationary Contact Assembly Kit 23P-1655 Arc Grid Assembly Kit

23P-1171

Movable Contact Assembly Kit 23P-1640

CN/CE

Main Operating Coils

Coil Volts Poles

240

3 K-2215 4 K-2215

208

3 K-2227 4 K-2227

575/600

3 K-2217 4 K-2217

480

3 K-2214 4 K-2214

416 3 SPO

SN/SNO CCN Cut-out Switch 23P-1568

SE/SEO CCE Cut-out Switch 23P-1569

A3 Emergency Position Aux Contact (Qty 1) 23p-1356 (Qty 2) 23p-1357 (Qty 3) 23p-1353 (Qty 4) 23p-1355 A4 Normal Position Aux Contact (Qty 1) 23p-1352 (Qty 2) 23p-1353 (Qty 3) 23p-1357 (Qty 4) 23p-1359

DS Disconnect Switch Operator L-4009; ; Contact Block L-1020

RN, RNO, RE, REO

Rectifier 23P-1473 (Up to 240V); 23P-1582 (Up to 600V)

ZTS / ZTSD Operation and Maintenance Manual (71R-3000)

GE Zenith Controls

34

ARC GRID ASSEMBLY

CN

CE

N1

E1

MOVABLE CONTACT

N2

E2

N3

E3

NN

EN

STATIONARY CONTACT

CN

RN

RE

CE



ZTSH/ZTSDH/ZTSDL/ZTSHL/ZTSDHL

Standard Control Panel Layout (SSRCP)

Figure 27

JUMPER

CONNECTS

POINTS

REMOVE WHEN

ACCESSORIES USED

J1 23, 23A B1 J2 23A, 23B B2 J3 23B, 23C B3 J4 23C, 23Z JIN, TS, C/D J5 23Z, 27 T, YN J6 25, 25Z T3, R4 J7 28, 28Z S1, C, C/D J8 28Z, 29 P1 & U

J9 33A, 33Y ER1, 2, 3, J1E J10 33Z, 37 W J11 35, 35Z R4, W3

Panel Mount Control Relays

Figure 28

TAG

DESCRIPTION

L1

L2

ATS Source 2 (EMER) Position Indicator A

TS Source 1 (NORMAL) Position Indicator

Lens Source 1 (NORMAL) Lens Source 2 (EMER) Bulb Socket Source 2 (EMER) Bulb Source 1 (NORMAL) Bulb

TS Test Switch

Operator

, Momentary Contact Block N.C. Contact Mounting Base

GE Zenith Controls

ZTS/ZTSD/ZTSH/ZTSDH/ZTSDL/ZTSHL/ZTSDHL Operation and Maintenance Manual (71R-3000)

35

P1

B1

T

U

B2 B3

VFSM

CR

XN

XE

RT

JUMPERS

J1 J2 J3 J4 J5 J6 J7 J8 J9 J10 J11

SPARE

P1

B3

T

U

W

ATS

L2

NORMAL

SOURCE 1

L1

EMER

SOURCE 2

VFSM

PRESS TO TEST

B2

RT

HOLD UNTIL

TRANSFER

TS

B1

XN XE

CR

CE1

CN1



Sequence of Operation

The information package supplied with the transfer switch includes a schematic diagram and description of operation of all accessories provided.

The sequence for load transfer to Source 2 begins automatically when any phase of Source 1 falls below the preset “fail” or dropout point and this undervoltage failure condition is detected by the solid state phase relays B1, B2, B3.

The phase relays drop out, de-energizing Source 1 control relay CR, and engine start timer P1 begins its timing cycle. The P1 time delay is provided to override momentar

y outages and to prevent nuisance starting of the engine generator. If Source 1 voltage returns above the “restore” or pickup setting of the phase relays, the P1 timing cycle is reset to zero by the re-energization of the CR relay.

If Source 1 voltage does not return before the P1 time delay is completed, the P1 timer drops out and sends a starting signal to the engine generator

. Source 2 voltage and frequency sensing relay VFSM monitors the voltage and frequency of Source 2. When both the voltage and the frequency of Source 2 reach the preset “restore” or pickup points, the VFSM relay initiates the transfer to Source 2 and timer W begins its timing cycle. The W timer provides an adjustable transfer delay to Source 2 as required.

When the W time delay is completed, Source 2 control relay R

T energizes and picks up the power relay, CE1 or CCE. The power relay connects voltage from Source 2 to the Source 2 switch operating circuit causing the switch to transfer its main contacts to Source 2. The switch is mechanically locked in Source 2 position. The power relay and Source 2 operator are de-ener

gized when the SE limit switch is activated by the operator

. The SN limit switch is deactivated at the same time, readying Source 1 control circuit for retransfer when Source 1 is restored.

The sequence for retransfer to Source 1 begins automatically when the voltage on all phases of Source 1 reach the preset “restore” or pickup point and this condition is detected by the solid state phase relays.

When Source 1 restores, the solid state phase relays B1, B2, B3 pick up and initiate retransfer of the switch to Source 1 by energizing timer T and beginning its timing cycle. The T timer provides an adjustable delay to ensure that Source 1 has stabilized before reconnection to the load. If Source 1 fails before the T time delay is completed, the phase relays drop out and the T timing cycle is reset to zero.

When the T time delay is completed, Source 1 control relay CR energizes and picks up the power relay

, CN1 or CNN. The power relay connects voltage from Source 1 to Source 1 switch operating circuit causing the retransfer of the main switch contacts to Source 1. The switch is mechanically locked in Source 1. The power relay and Source 1 operator are de-energized when the SN limit switch is activated by the operator. The SN limit switch also energizes the engine over-run timer U and begins its timing cycle. The timer provides a period of time for the engine generator to run without load and cool down before shutdown. After the U time delay is completed, the P1 timer is energized and the engine generator is shutdown.

36

ZTS/ZTSD/ZTSH/ZTSDH/ZTSDL/ZTSHL/ZTSDHL Operation and Maintenance Manual (71R-3000)

GE Zenith Controls

Adjustments and Settings

Solid State Timers

Solid state timers are adjustable from 0.1 second to 100 hours. The red timing indicator in the upper left corner flashes as the timer progresses through the timing cycle. When the timing cycle is completed, the indicator remains illuminated. A flathead screwdriver is required to change the setting, as shown in Figure 30.

The time unit is selected by turning the rotary switch at the lower right of the timer

. Four selections are available: “Seconds”, “Minutes”, “Hours”, “10 Hours”. The time unit selected is displayed in the window below the time setting dial.

The time range is selected by turning the rotary switch at the lower left of the timer

. Four ranges are available: “0-0.5”, “0-1.0”, “0-5.0”, “0-10.0”. The dial digits appear in the windows around the time setting knob.

Figure 29



CAUTION

Do NOT change the setting while the timer is energized. Timer malfunction or damage may occur.

The factory setting of the solid state timers used in the Zenith standard package are shown in Table 4.

Timer

Factory Setting

T 30 minutes U 5 minutes

W 1 second

Table 4

Voltage/Frequency Sensor (VFSM)

The “restore” or pickup point may be adjusted by rotating the adjustment screw as shown in Figure 31. Counter-clockwise rotation increases the pickup voltage.

“Restore”/Pickup Voltage (at 100% Frequency)

Adjustable: 80% to 95% Factor

y Set: 90%

“Restore”/Pickup Frequency

Adjustable: 80% to 100%

Figure 30

Factory Set: 95%

Solid State Phase Relay (ARSM)

The “restore” or pickup and “fail” or dropout points may be adjusted by using the following procedure. Use of a variable voltage supply (Variac) is required. The relay is illustrated in Figure 32.

1. Turn the “restore” or pickup adjustment fully clockwise.

2. Turn the “fail” or dropout adjustment fully counter-clockwise.

3. Set Variac to the desired “restore” or pickup voltage.

4. Rotate the “restore” or pickup adjustment counterclockwise very slowly until the relay picks up. The LED will illuminate.

5. Set Variac to the desired “fail” or dropout voltage.

6. Rotate the “fail” or dropout adjustment clockwise very slowly until the relay drops out. The LED will go out.

7. Verify the setting by raising the voltage until the relay restores or picks up and lowering the voltage until the relay fails or drops out.

“Restore”/Pickup Voltage: 75% to 115% of Nominal Factory Set: 90% of Nominal

“Fail”/Dropout Voltage: 55% to 105% of Nominal Factory Set: 80% of Nominal

Figure 31

GE Zenith Controls

ZTS/ZTSD/ZTSH/ZTSDH/ZTSDL/ZTSHL/ZTSDHL Operation and Maintenance Manual (71R-3000)

37

g

GE Zenith Controls

A Product of GE Industrial Systems General Electric Company

830 West 40

th

Street, Chicago, IL 60609 USA

773 299-6600

, Fax: 773 247-7805

www.geindustrial.com

GE ZTS Series, ZTSD Series Operation And Maintenance

Specifications and Main Features

Frequently Asked Questions

User Manual

Safety

Installation

Entelli-Switch 250 Controller

Accessory Group Packages

Accessory Definitions

USER SETUP

Testing

Sequence of Operation

Relay/Transformer (R/T Box)

Troubleshooting and Diagnostics

Maintenance and Testing

Replacement Parts

Sequence of Operation

Adjustments and Settings