OPERATION AND MAINTENANCE MANUAL
ZBTSCTH SERIES POWER PANEL
100 - 4000 AMPS
46R-7000D
Rev 8/97
INTRODUCTION
Zenith Bypass-Isolation Closed Transition Transfer Switches provide
Zenith’s most comprehensive load power protection during standard
operation, maintenance and testing procedures.
Closed Transition Transfer Switches parallel two available sources of
power during test procedures to enable transfer without interrupting power
to the load (make-before-break). Paralleling of the two sources occurs
within a predefined window of synchronization and the initial source is then
disconnected. If the primary source falls below preset voltage limits and the
second source is available, the transfer switch defaults to open transition
(break-before-make) mode. In this mode, the transfer switch uses the
power from the available source to open the switch from the “dead source”
first, before closing the switch into the second source. When in the BypassIsolation mode, the switch acts as a manual transfer switch, enabling
testing, repair and even removal of the automatic transfer switch.
All Zenith transfer switches are designed for use on emergency or
standby systems, and are rated for total system or motor loads.
Transfer switches are UL Listed under Standard 1008 and CSA
Certified under Standard C22.2 No. 178.
This manual provides information on the installation, operation, and
maintenance of the switch. In addition, a complete information package is
supplied with each transfer switch which details the features and
accessories provided on that switch. The information package and the
instruction manual should be kept in a readily accessible location to
provide complete reference information on this critically important piece of
equipment.
TABLE OF CONTENTS
Section I INSTALLATION
1. Requirements
2. Equipment Inspection and Storage
3. Mounting
4. Power Connections
5. Control Connections
6. Final Equipment Inspection
7. Functional Test
Section II OPERATION AND FEATURES
1. Sequence Of Operation
2. Bypass-Isolation Switch Operation
3. Zenith Standard Package
4. Zenith Optional Accessories
Section III MAINTENANCE AND TESTING
1. Inspection and Cleaning
2. Servicing
3. Testing
4. Troubleshooting
5. Emergency Service Procedure/Extended Parallel Time
2
2
2
2
3
4
5
5
6
6
8
11
11
12
12
12
12
13
14
Section IV ADJUSTMENTS AND SETTINGS
1. Paralleling Relay Settings
2. Solid State Timers
3. Voltage/Frequency Sensor (VFSM)
4. Solid State Phase Relay (ARSM)
5. Paralleling Window Under-Overvoltage Sensing Relay
6. Electronic Time Switch Z2000-2A
Appendix A TYPICAL SCHEMATIC DIAGRAMS
1. 100-400 Amps
2. 600-3000 Amps
3. Alarm Circuit Schematic
4. Three-Phase Control Sensing Schematic
5. Bypass Control Circuit
Appendix B REPLACEMENT PARTS
1. Power Panel — 100-400 Amps
2. Power Panel — 600-1200 Amps
3. Power Panel — 1600-3000 Amps
4. Bypass Subpanel
5. Control Panel Layout and Parts List
6. Cabinet Door Pilot Devices
16
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16
17
17
17
19
19
20
21
21
22
23
23
23
24
24
28
31
SECTION I - 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.
Each 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 Zenith transfer switches includes:
a. Mounting the transfer switch cabinet.
b. Connection of all Normal, Emergency,
and Load cables or bus bars.
c. Connection of external control circuits
as required.
1. REQUIREMENTS
DANGER
Closed transition transfer switches typically
require momentary paralleling of utility and
generator sources. The customer should
obtain approval from their utility before using
a closed transition transfer switch.
Before installation, it is necessary to store the
transfer switch in a clean dry place, protected
from dirt and water. Provide ample air circulation
and heat, if necessary, to prevent condensation.
Storage Temperature:
-30 C to + 65 C (-22 F to +149 F)
Operating Temperature (Ambient):
-20 C to +75 C (-4 F to +167 F) [40-260 Amps]
-20 C to +40 C (-4 F to +104 F)[400-3000 Amps]
Humidity:
5% to 95% (non-condensing)
3. 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 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.
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.
H
45°
SPREADER BAR
The following requirements must be met to use a
closed transition transfer switch:
a. Isochronous governor with a frequency
range of 60 ± 0.2 Hz.
b. Shunt trip breaker on the genset with
a response time not exceeding 50
milliseconds.
2. EQUIPMENT INSPECTION AND
STORAGE
Immediately inspect the transfer switch when
received to detect any damage which may have
occurred during transit. If damage is found or
suspected, file claims as soon as possible with
the carrier and notify the nearest Zenith
representative.
ZBTSCTH Operation and Maintenance Manual (46R-7000)2 Zenith Controls, Inc.
LIFTING EYES
CABINET
D
Figure 1
NOTICE
When lifting the switch using a spreader bar,
height H must be equal to half of distance D.
SECTION I - INSTALLATION (Continued)
4. POWER CONNECTIONS
Zenith transfer switches are supplied with UL
listed solderless screw type terminals as
standard for the Normal, Emergency, and Load
power connections. Table 1 lists the number and
sizes of the cable lugs supplied as standard for
each switch amp rating.
Connect the Normal, Emergency, and Load
conductors to the clearly marked terminals on
the transfer switch. Remove surface 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.
Do not run cables or wiring behind frontconnected transfer switches.
In cases where the Normal, Emergency, and
Load connections are made to a rear connected
bus bar, a compression washer, flat washer, and
a minimum grade 5 bolt must be used and
torqued to the values in Table 3.
Screw Type Terminals for External Power Connections
Switch Size
(Amps)
100 1 #14 to 1/0 AWG 3 #14 to 1/0 AWG
150 1 #8 to 3/0 AWG 3 #6 AWG to 300 MCM
225 1 #6 AWG to 250 MCM 3 #6 AWG to 300 MCM
260 1 #6 AWG to 350 MCM 3 #6 AWG to 300 MCM
Normal, Emergency & Load Terminals Fully Rated Neutral Bar (When Required)
Cable Per Pole Range of Wire Sizes Number of Cables Number of Cables
400 1 #4 AWG to 600 MCM 4 #6 AWG to 300 MCM
600 2 #2 AWG to 600 MCM 8 #2 AWG to 600 MCM
800
1000
1200
1600
2000
3000
4000
Line and load terminals are located in
rear and arranged for bus bar
connection.
4 #2 AWG to 600 MCM 12 #2 AWG to 600 MCM
12 3/0 AWG to 750 MCM
Table 1
Tightening Torque for Lugs
Socket Size Torque
Across Flats 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
Tightening Torque for Bus Bars
Bolt Size Torque Bolt (Grade 5)
Lb.-In. Lb.-Ft.
1/4-20 72 6
5/16-18 132 11
3/8-16 300 25
1/2-13 720 60
Table 3
Table 2
ZBTSCTH Operation and Maintenance Manual (46R-7000)Zenith Controls, Inc. 3
SECTION I - INSTALLATION (Continued)
5. CONTROL CONNECTIONS
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
terminals specified in the upper right corner of
the bypass cabinet. Terminals for field
connections to the A3 Emergency auxiliary
contacts and the A4 Normal auxiliary contacts
are also provided. These terminals are clearly
marked and appear on the left side of the ATS
power panel. Figure 2 below shows the location
of these terminals.
Make all other necessary external control
connections to the appropriate terminal blocks
located on the control panel. Insure that all
connections are tightened to the torque
specified in Table 4.
Control Wire Connections
Wire Size (AWG) Torque Lb.-In.
18-16 19
14-8 19
6-4 36
Table 4
Figure 2
ZBTSCTH Operation and Maintenance Manual (46R-7000)4 Zenith Controls, Inc.
SECTION I - INSTALLATION (Continued)
!
6. FINAL EQUIPMENT INSPECTION
Prior to energizing the transfer switch:
a. Remove any debris incurred due to
shipment or installation. DO NOT use a
blower since debris may become lodged in
the electrical and mechanical components
and cause damage. Use of a vacuum is
recommended.
b. Verify that all cabled connections are
correct and that phase rotation of both
sources match.
c. Check engine start connections and verify
the correct connection of all control wires.
d. Check settings of all timers and adjust as
necessary. Also adjust any optional
accessories as required. [See MX200
manual (50R-2000) for instructions on
timer and option adjustments.]
e. Check the integrity of power connections
by verifying actual lug torque values as
specified in this manual.
f. Make sure that all covers and barriers are
installed and properly fastened.
7. FUNCTIONAL TEST
pick up and the LED indicator will illuminate.
Check the phase to phase voltages at the
Emergency line terminals. Also, verify that the
phase rotation of the Emergency source is the
same as the phase rotation of the Normal
source.
After the sources have been verified, shut down
the engine generator, and put the starting control
in the automatic position. Complete the visual
inspection of the transfer switch, and close and
lock the cabinet door.
Initiate the electrical transfer test by activating
the test switch (TS). This de-energizes the
engine start relay. The transfer switch closes into
Emergency only after the sync-check relay
ensures the proper phase relationship of both
sources. After the transfer switch closes into
Emergency, the SE limit switch becomes
activated to de-energize the CCE relay and
energize the CCNO relay. This opens the
transfer switch out of Normal. When the transfer
switch has opened out of Normal, the SNO-2
limit switch activates to de-energize the CCNO
relay. The transfer switch has now closed into
Emergency power without interrupting the load.
The functional testing of the transfer switch
consists of electrical tests described in this
section. Before proceeding, refer to the
information package supplied with the transfer
switch. Read and understand all instructions and
review the operation of all accessories provided.
Before starting the operation test, check the
equipment rating nameplate on the transfer
switch to verify the correct system voltage. An
example of the equipment rating nameplate is
shown in Figure 3.
Figure 3
To begin the test, close the Normal source circuit
breaker. Phase relays B1, B2, and B3 will pick
up and the LED indicators will illuminate. Verify
the phase to phase voltages at the Normal line
terminals.
Next, close the Emergency source breaker and
start the engine generator. The VFSM relay will
ZBTSCTH Operation and Maintenance Manual (46R-7000)Zenith Controls, Inc. 5
Turning the TS to AUTO initiates re-transfer to
Normal. The transfer switch closes into Normal
only after the sync-check relay ensures the
proper phase relationship of both sources. After
the transfer switch closes into Normal, the SN
limit switch becomes activated (de-activated in
400 Amp units) to de-energize the CCN relay and
energize the CCEO relay; the transfer switch
opens out of Emergency. Then the SEO-2 limit
switch activates to de-energize the CCEO relay.
The transfer switch has now closed back into
Normal power without interrupting the load.
The transfer switch defaults to an open transition
transfer when the Normal source fails. Closed
transition transfer is not possible with one source
available. Open transition transfer for testing can
be selected via the transition mode selector
switch. (For a description of the Open Transition
sequence of operation, refer to Section II Operation and Features, page 6.)
A 24 VDC circuit is supplied to control the alarm
and warning indicators. To ensure continuous
power to this circuit, a constant 24 VDC can be
supplied by the customer from the engine start
battery.
NOTICE
A periodic test of the transfer switch under
load conditions is recommended to insure
proper operation.
SECTION II - OPERATION AND FEATURES
1. SEQUENCE OF OPERATION
Figure 4 is a typical schematic diagram of a
Zenith closed transition transfer switch. The
information supplied with the transfer switch
includes a schematic diagram and description of
operation of all accessories provided.
Transfer of the load to the Emergency source
begins automatically when any phase of the
Normal source falls below the preset dropout
point and this undervoltage failure condition is
detected by solid state phase relays B1, B2, B3.
The phase relays drop out, de-energizing the
Normal control relays CR & CR2, and engine
start timer P1 begins its timing cycle. The P1 time
delay is provided to override momentary outages
and to prevent nuisance starting of the engine
generator. If the Normal source voltage returns
above the phase relays’ pickup setting, the P1
timing cycle is reset to zero by re-energizing the
CR relay.
If the normal source 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. An Emergency voltage and
frequency sensing relay (VFSM) monitors the
voltage and frequency of the Emergency source.
When both the voltage and the frequency of the
Emergency source reach the preset pickup
points, the VFSM relay initiates transfer to the
Emergency source and timer W begins it timing
cycle. The W timer provides an adjustable
transfer delay to the Emergency source as
required.
When the W time is completed, the Emergency
control relay RT energizes and picks up the
CCNO relay. The CNO solenoid is then
energized to open the transfer switch from
normal position to neutral position. The switch
remains in the neutral position for the duration of
the DW time delay. After the DW time delay is
completed, the CCE relay energizes the CE
solenoid to close the transfer switch into the
emergency source. The SE limit switch activates
to de-energize the CCE relay.
The sequence for retransfer to the Normal
source begins automatically when the voltage on
all phases of the Normal source reach the preset
pickup point and this condition is detected by the
solid state phase relays, B1, B2, B3.
When the Normal source restores and if the
transition mode selector switch is in CT (Closed
Transition), the transfer switch will return to the
Normal source in a make-before-break sequence
(this is described in the Testing section of this
manual).
If the transition mode selector switch is in OT
(Open Transition), the transfer switch will return
to the normal source in a break-before-make
sequence. When the Normal source restores, the
solid state phase relays, B1, B2, B3 pick up and
switching to the Normal source is initiated by
energizing timer T, beginning its timer cycle. The
T timer provides an adjustable delay to insure
that the Normal source has stabilized before
reconnection to the load. If the Normal source
fails before the T time delay completes, the
phase relays drop out and the T timing cycle is
reset to zero.
When the T time delay is completed, the Normal
control relay CR energizes and picks up the
power relay CCEO. This energizes the CEO
solenoid opening the transfer switch out of the
emergency source. The SEO-1 limit switch
activates to energize the DT time delay and
de-energize the CCEO relay. After the DT time
delay is completed, the CCN relay energizes the
CN solenoid to retransfer the switch into the
normal source. The SN limit switch activates to
de-energize the CCN relay. The SN limit switch
also energizes the engine over-run timer U and
begins its timing cycle. This 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
isenergizedand the enginegeneratoris shutdown.
NOTES:
1. The transition mode selector switch on the
front door enables the user to operate the
unit in Open Transition mode, if so desired.
2. When in Closed Transition mode, if the
transfer switch does not open the first source
within 100 milliseconds, an alarm will sound,
the transfer switch will open the last source it
closed in to and will lock out the control
circuit from any transfer operation. After the
condition has been corrected the control
circuit should be reset by turning the Failed
to Open Lockout Reset switch to the right.
3. The controls will provide a signal to shunt trip
the generator breaker if the transfer switch
remains closed into both sources for more
than 325 ms. The load will then be fed by the
utility source. The maximum time that the
two sources would be parallel, under these
conditions, is less than 0.5 sec. Before
operating the closed transition transfer
switch the condition must be corrected and
the shunt trip reset. Refer to the procedure
for servicing the switch after shunt tripping
occurs. The shunt trip reset switch is
provided on the front door. Alarm and lights
on the front door provide indication of failure
conditions.
ZBTSCTH Operation and Maintenance Manual (46R-7000)6 Zenith Controls, Inc.
SECTION II - OPERATION AND FEATURES (Continued)
Figure 4
ZBTSCTH Operation and Maintenance Manual (46R-7000)Zenith Controls, Inc. 7
SECTION II - OPERATION AND FEATURES (Continued)
2. BYPASS-ISOLATION OPERATION - 100-400 AMP
a. Automatic
1) Manually operated bypass switch contacts (BN/BE) are
open and ATS is supplying load.
2) Disconnect Switch (DS) is in Auto.
b. To Bypass ATS
1) Open bottom cabinet door and turn DS to Inhibit.
2) Position Manual Bypass Handle (MBH) to same power
source as ATS.
c. To Test ATS
1) Bypass per above instructions.
2) Move ATS Location Handle (ALH) to Test location.
3) Turn DS to Auto.
4) Test Switch (TS) on bottom cabinet door will allow
electrical operation of ATS.
d. To Isolate ATS
1) Bypass per above instructions.
2) Move ALH to Isolate location.
e. To Remove ATS
1) Bypass and isolate per above instructions.
2) Move ALH to Release location.
3) Disconnect multipin plugs.
4) Lift ATS out of drawer.
f. To Reconnect ATS
1) Place ATS into drawer slots (front rollers first).
2) Turn DS to Inhibit.
3) Manually position ATS into same source as bypass switch.
4) Reconnect multipin plugs and external connections to ATS.
5) Push ATS inward to engage carriage.
6) Move ALH to Test location (as indicated by light).
7) Turn DS to Auto and use TS to electrically operate ATS.
8) Turn DS to Inhibit.
9) Move ALH to Auto location.
10)Turn DS to Auto and open bypass with MBH.
11) ATS is now fully automatic.
Notes:
1. DS in Inhibit will prevent ATS
electrical operation.
2. Do not use excessive force on
mechanical handles.
3. Figures depict Bypass Normal.
Sequence is the same for
Bypass Emergency.
4. When ATS is in Test or Isolate,
bypass switch is manual;
transfer switch to either
available source (indicated on
light panel).
5. To operate bypass switch when
ATS is in Test or Isolate,
position MBH to available
power source.
Legend:
1. BP - bypass switch
(indicated by contacts
BN/BE) is a three position
switch.
2. ATS -Automatic Transfer
Switch.
ZBTSCTH Operation and Maintenance Manual (46R-7000)8 Zenith Controls, Inc.
SECTION II - OPERATION AND FEATURES (Continued)
3. BYPASS-ISOLATION OPERATION - 600-1200 AMP
a. Automatic
1) Manually operated bypass switch contacts (BN/BE) are
open and ATS is supplying load.
2) Disconnect Switch (DS) is in Auto.
b. To Bypass ATS
1) Open bottom cabinet door and turn DS to Inhibit.
2) Turn Bypass Selector Switch (BSS) to same power source
as ATS.
3) Move the Manual Bypass Handle (MBH) upward.
c. To Test ATS
1) Bypass per above instructions.
2) Rotate crank mechanism counterclockwise until ATS Test
light is illuminated.
3) Turn DS to Auto.
4) Test Switch (TS) on bottom cabinet door will allow electrical
operation of ATS.
d. To Isolate ATS
1) Bypass per above instructions.
2) Rotate crank mechanism counterclockwise until ATS
Isolated light is illuminated.
e. To Remove ATS
1) Bypass and isolate per above instructions.
2) Disconnect multipin plugs and external connections to ATS.
3) Rotate four power panel latches to vertical position, slide
ATS forward and lock mechanism in place.
4) ATS can now be removed from cabinet.
f. To Reconnect ATS
1) Place ATS in slide mechanism.
2) Unlock slide mechanism. Slide ATS over power panel
latches and rotate latches to horizontal position.
3) Turn DS to Inhibit.
4) Manually position ATS into same source as bypass switch.
5) Reconnect multipin plugs and external connections to ATS.
6) Rotate crank mechanismclockwiseuntilATS Test light is
illuminated.
7) Turn DS to Auto and use TS to electrically operate ATS.
8) Turn DS to Inhibit.
9) Move ALH to Auto location.
10)Turn DS to Auto and open bypass with MBH.
11) ATS is now fully automatic.
Notes:
1. DS in Inhibit will prevent ATS
electrical operation.
2. Do not use excessive force on
mechanical handles.
3. Figures depict Bypass Normal.
Sequence is the same for
Bypass Emergency.
4. When ATS is in Test or Isolate,
bypass switch is manual transfer
switch to either available source
(indicated on light panel).
5. To operate bypass switch when
ATS is in Test or Isolate:
a) Move MBH downward (to open
open Bypass Contacts BN/BE).
b) Turn BSS to opposite power
source.
c) Move MBH upward to close
into selected power source.
Legend:
1. BP - Bypass Switch
(indicated by contacts
BN/BE) is a three posi
tion switch.
2. ATS - Automatic Transfer
Switch.
ZBTSCTH Operation and Maintenance Manual (46R-7000)Zenith Controls, Inc. 9
SECTION II - OPERATION AND FEATURES (Continued)
4. BYPASS-ISOLATION OPERATION - 1600-4000 AMP
a. Automatic
1) Manually operated bypass switch contacts (BN/BE) are
open and ATS is supplying load.
2) Disconnect Switch (DS) is in Auto.
b. To Bypass ATS
1) Open bottom cabinet door and turn DS to Inhibit.
2) Turn Bypass Selector Switch (BSS) to same power source
as ATS.
3) Move the Manual Bypass Handle (MBH) upward.
c. To Test ATS
1) Bypass per above instructions.
2) Rotate crank mechanism counterclockwise until ATS Test
light is illuminated.
3) Turn DS to Auto.
4) Test Switch (TS) on bottom cabinet door will allow electrical
operation of ATS.
d. To Isolate ATS
1) Bypass per above instructions.
2) Rotate crank mechanism counterclockwise until ATS
Isolated light is illuminated.
e. To Remove ATS
1) Bypass and isolate per above instructions.
2) Disconnect multipin plugs and external connections to ATS.
3) Slide four corner latches of ATS to innermost position.
4) ATS can now be removed from cabinet.
f. To Reconnect ATS
1) Roll cart back into cabinet.
2) Slide four corner latches of ATS to outermost position.
3) Turn DS to Inhibit.
4) Manually position ATS into same source as bypass switch.
5) Reconnect multipin plugs and external connections to ATS.
6) Rotate crank mechanism clockwise until ATS Test light is
illuminated.
7) Turn DS to Auto and use TS to electrically operate ATS.
8) Turn DS to Inhibit.
9) Rotate crank mechanism clockwise until ATS location
pointer is aligned with Auto mark on location indicator
(ATS must be in same source as bypass).
10) Turn DS to Auto and open bypass with MBH.
11) ATS is now fully automatic.
Notes:
1. DS in Inhibit will prevent ATS
electrical operation.
2. DO NOT use excessive force
on mechanical handles.
3. Figures depict Bypass Normal.
Sequence is the same for
Bypass Emergency.
4. When ATS is in Test or Isolate,
bypass switch is a manual
transfer switch to either available
source (indicated on light panel).
5. To operate bypass switch when
ATS is in Test or Isolate:
a) Move MBH downward (to
open Bypass Contacts
BN/BE)
b) Turn BSS to opposite power
source.
c) Move MBH upward to close
into selected power source.
Legend:
1. BP - Bypass Switch
(indicated by contacts
BN/BE) is a three position
switch.
2. ATS - Automatic Transfer
Switch.
ZBTSCTH Operation and Maintenance Manual (46R-7000)10 Zenith Controls, Inc.
SECTION II - OPERATION AND FEATURES (Continued)
5. ZENITH STANDARD PACKAGE
The Zenith Closed Transition Switch comes with
the following standard features:
A3 Auxiliary contact closes when the switch is
in the Emergency position.
A4 Auxiliary contact closes when the switch is
in the Normal position.
DT Adjustable time delay before closing into
Normal source from open position (Open
Transition Mode only).
DW Adjustable time delay before closing into
Emergency source from open position
(Open Transition Mode only).
E Engine start contact closes to start the
engine generator when the Normal source
fails. 1 N.O., 1 N.C. contact.
P1 Solid state adjustable timer with range from
0.5 to 6.0 seconds. The contact closes to
start the engine generator.
T Adjustable time delay to transfer out of
Emergency source and into open position
after Normal source is restored.
6. ZENITH OPTIONAL
ACCESSORIES
Many control accessories are available to meet
specific and special requirements. Your
drawings indicate which accessories were
ordered with your switch.
U Adjustable time delay for engine cool down
after engine generator is signaled to shut
down.
W Adjustable time delay to transfer out of
Normal source and into open position after
Normal source failure.
ZBTSCTH Operation and Maintenance Manual (46R-7000)Zenith Controls, Inc. 11
SECTION III - MAINTENANCE AND TESTING
!
!
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:
1. INSPECTION AND CLEANING
DANGER
HAZARDOUS VOLTAGE
(Can Cause Severe Injury or Death)
Turn OFF all power before installation,
adjustment, or removal of transfer switch or
Before doing any work on the transfer switch,
de-energize all sources of power. 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.
2. SERVICING
All worn or inoperative parts must be replaced
using Zenith recommended replacement parts.
Appendix B at the back of this manual includes
replacement part information for typical power
and control panel configurations. When ordering
parts provide the model number or serial number
from the transfer switch rating nameplate.
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.
3. TESTING
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. This de-energizes the engine
start relay. The transfer switch closes into
Emergency only after the sync-check relay
ensures the proper phase relationship of both
sources. After the transfer switch closes into
Emergency, the SE limit switch becomes
activated to de-energize the CCE relay and
energize the CCNO relay. This opens the
transfer switch out of Normal. When the transfer
switch has opened out of Normal, the SNO-2
limit switch activates to de-energize the CCNO
relay. The transfer switch has now closed into
emergency power without interrupting the load.
Turning the TS to AUTO initiates re-transfer to
Normal. The transfer switch closes into Normal,
only after the sync-check relay ensures the
proper phase relationship of both sources. After
the transfer switch closes into Normal, the SN
limit switch becomes activated to de-energize the
CCN relay and energize the CCEO relay; the
transfer switch opens out of Emergency. Then
the SEO-2 limit switch activates to de-energize
the CCEO relay. The transfer switch has now
closed back into normal power without
interrupting the load.
The transfer switch defaults to an open transition
transfer when the Normal source fails. Closed
transition transfer is not possible with one source
available. Open transition transfer for testing can
be selected via the transition mode selector
switch.
A 24 VDC circuit is supplied to control the alarm
and warning indicators. To insure continuous
power to this circuit, a constant 24 VDC can be
supplied by the customer from the engine start
battery.
NOTICE
A periodic test of the transfer switch under
load conditions is recommended to insure
proper operation.
ZBTSCTH Operation and Maintenance Manual (46R-7000)12 Zenith Controls, Inc.
SECTION III - MAINTENANCE AND TESTING (Continued)
4. TROUBLESHOOTING
Before beginning any troubleshooting activity, refer to the information package supplied with the transfer
switch and review the description and operation of all accessories supplied. Also refer to Section II of this
manual, Operation and Features.
CONDITION ITEMS TO BE CHECKED
a. Engine-Generator Does Not Start
when Normal source fails or Test
Switch (TS) is activated.
b. Does Not Transfer To Emergency
after generator starts.
c. Does Not Retransfer To Normal
when Normal source restores or
Test Switch (TS) is deactivated.
d. Engine-Generator Does Not
Shutdown
Normal.
after retransfer to
1) Verify the setting of the time delay P1.
2) Make sure timer P1 drops out and the engine-start
contact closes after time delay is completed.
3) Make sure the starting battery is charged and
connected to the engine-generator.
4) Generator controls in Automatic mode.
5) Verify wiring of the engine-start contact If the generator
does not start, contact the generator dealer.
1) If in Closed Transition Mode:
a) Verify that the phase angle difference between
Normal and Emergency is < 5° (@ 0.1 Hz f).
b) Verify that the frequency difference between
Normal and Emergency is < 0.2 Hz (0.1 Hz is
recommended). Also verify that the frequency
difference is not 0 Hz.
c) Verify that the voltage difference between Normal
and Emergency is < ±5% of nominal.
d) Verify that the phase sequence is the same for
Normal and Emergency.
2) Emergency source breaker should be closed.
3) Emergency source voltage and frequency should meet
the preset pickup values of the VFSM relay.
4) Make sure Emergency control relay RT picks up after
time delay W.
1) If in Closed Transition Mode:
a) Verify that the phase angle difference between
Normal and Emergency is < 5° (@ 0.1 Hz f).
b) Verify that the frequency difference between
Normal and Emergency is < 0.2 Hz (0.1 Hz is
recommended). Also verify that the frequency
difference is not 0 Hz.
c) Verify that the voltage difference between Normal
and Emergency is < ±5% of Nominal.
d) Verify that the phase sequence is the same for
Normal and Emergency.
2) Normal source voltage should meet the preset pickup
value of the phase relays.
3) Make sure Normal control relay CR picks up after time
delay T.
4) Verify the circuit connections from the power relay, CN1
or CCN, to the Normal switch operating circuit.
5) Verify the circuit connections from the power relay, CE1
or CCE, to the Emergency switch operating circuit.
1) Verify the setting of engine overrun time delay U.
2) Make sure timer P1 picks up and the engine-start
contact has opened.
3) Generator controls in Automatic mode.
4) Verify wiring of the engine-start contact.
ZBTSCTH Operation and Maintenance Manual (46R-7000)Zenith Controls, Inc. 13
SECTION III - MAINTENANCE AND TESTING (Continued)
5. EMERGENCY SERVICE
PROCEDURE FOR EXTENDED
PARALLEL TIME
a. Auto Location:
Removal of closed transition transfer switch
after Emergency breaker shunt trip.
1) Disconnect all power sources from
bypass-isolation transfer switch.
2) Open the bottom cabinet door and turn
the Disconnect Switch (DS) to the OFF
position.
3) Remove the service access cover on
the left hand side of the transfer switch.
4) The manual operator and the manual
handle will now be exposed. Insert the
handle into the Emergency side manual
operator. Open the Emergency side
contacts.
5) Close bottom cabinet door.
6) Energize Normal power.
7) Close the bypass contacts (BN) as
described in Section II of this manual.
8) Isolate the transfer switch as described
in Section II.
9) Remove the transfer switch from the
bypass-isolation transfer switch as
indicated on the bypass instruction label
to inspect and repair.
10)Re-install the transfer switch after
maintenance with contacts closed to the
same source as the bypass switch. Reinstall the manual handle in its holder
and the service access cover on the left
side of the transfer switch.
11)Re-connect the transfer switch to AUTO,
as described in Section II.
b. Auto Location:
Removal of the closed transition transfer
switch if Normal and Emergency contacts
remain open.
1) Turn the BSS to an available source.
Close the bypass switch into the
available source as described in
Section II of this manual.
2) Turn the DS to INHIBIT. Remove the
transfer switch service access cover.
Close the transfer switch into the same
source as the bypass switch. (Incorrect
sequencing is prevented by the
interlocks while the transfer switch is in
AUTO only.)
3) Remove the transfer switch from the
bypass-isolation transfer switch as
indicated in Section II to inspect and
repair.
c. Test Location:
Removal of the closed transition transfer
switch if both Normal and Emergency
contacts remain open.
1) Close the bypass switch contacts (BN)
as indicated on the bypass instruction
label on the cabinet door.
2) Disconnect all power sources from
bypass-isolation closed transition
transfer switch.
3) Open bottom cabinet door. Turn the
Disconnect Switch (DS) to the OFF
position.
4) Remove the service access cover on
the left side of the transfer switch.
5) The manual operator and the manual
handle will not be exposed. Insert the
handle into the Normal side and close
the Normal contacts.
6) Close the bottom cabinet door.
7) Energize Normal power.
8) Remove the automatic transfer switch
from the bypass-isolation transfer switch
as indicated in Section II.
9) Re-install the transfer switch after
maintenance with contacts closed to the
same source as the bypass switch. Reinstall the manual handle in its holder
and the service ccess cover on the left
side of the transfer switch.
10)Re-connect the transfer switch to AUTO,
as indicated in Section II.
ZBTSCTH Operation and Maintenance Manual (46R-7000)14 Zenith Controls, Inc.
SECTION III - MAINTENANCE AND TESTING (Continued)
Model Number
Serial Number
Date Shipped
Start-Up Date
Drawings Supplied
FIELD NOTES
Test And Maintenance Notes
Date
Tested Observations Notes
ZBTSCTH Operation and Maintenance Manual (46R-7000)Zenith Controls, Inc. 15
SECTION IV - ADJUSTMENTS AND SETTINGS (Continued)
!
1. PARALLELING RELAY SETTINGS
25, 27/59N & 27/59E are factory set to allow
paralleling of the sources only when these
conditions have been met:
a. Phase Angle Differences < 5° (@ 0.1 Hz f)
b. Frequency Difference < 0.2 Hz
c. Voltage Difference < ±5% Nominal
NOTES:
1. This system requires an isochronous
governor with an operating frequency of
60 ± 0.2 Hz.
2. Requires a shunt trip breaker on generator set
with a response time not exceeding 50 ms.
2. 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 5 below.
CAUTION
Do NOT change the setting while the timer is
energized. Timer malfunction or damage may
The factory setting of the solid state timers used
in the Zenith standard package are shown in
Table 5 below.
Timer Factory Setting
T
U
W
DT
DW
ST
PART
OLC
ETT
Table 5
30 minutes
5 minutes
1 second
5 seconds
5 seconds
1 second
0.002 sec,
0.275 sec.
0.420 sec.
3. VOLTAGE/FREQUENCY SENSOR
(VFSM)
Figure 5
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.
The pickup point may be adjusted by rotating the
adjustment screw as shown in Figure 6 below.
Counter-clockwise rotation increases the pickup
voltage.
Figure 6
Pickup Voltage (at 100% Frequency)
Adjustable: 80% to 95%
Factory Set: 90%
Pickup Frequency
Adjustable: 80% to 100%
Factory Set: 95%
ZBTSCTH Operation and Maintenance Manual (46R-7000)16 Zenith Controls, Inc.
SECTION IV - ADJUSTMENTS AND SETTINGS (Continued)
4. SOLID STATE PHASE RELAY
(ARSM)
The pickup and 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 7 below.
Figure 8
a. Turn both DIFF adjustments fully counter-
clockwise.
b. Undervoltage sensing - Use lowest phase to
phase relationship on Variac to set the relay.
Set Variac voltage to desired undervoltage
setting. Turn undervoltage SET adjustment
fully clockwise, then slowly counterclockwise
until the LED illuminates.
c. Overvoltage sensing - Use the highest phase
to phase voltage relationship on Variac to set
the relay. Set Variac voltage to desired
overvoltage. Turn overvoltage SET adjustment
fully clockwise, then counterclockwise until
LED illuminates.
Figure 7
a. Turn the pickup adjustment fully clockwise.
b. Turn the dropout adjustment fully counter-
clockwise.
c. Set Variac to the desired pickup voltage.
d. Rotate the pickup adjustment counterclock-
wise very slowly until the relay picks up. The
LED will illuminate.
e. Set Variac to the desired dropout voltage.
f. Rotate the dropout adjustment clockwise very
slowly until the relay drops out. The LED will
go out.
g. Verify the setting by raising the voltage until
the relay picks up and lowering the voltage
until the relay drops out.
Pickup Voltage: 75% to 115% of Nominal
Factory Set: 90% of Nominal
Dropout Voltage: 55% to 105% of Nominal
Factory Set: 80% of Nominal
5. PARALLELING WINDOW UNDER-
OVERVOLTAGE SENSING RELAY
Undervoltage: 75-100% of 120V
Factory Set: 95%
Overvoltage: 100-125% of 120V
Factory Set: 105%
6.ELECTRONIC TIME SWITCH
Z2000-2A
This time switch is used for the C/D option. Time
switch Z2000-1A is used for the C option.
a. Setting Time and Day:
Press and hold “ ” button during the Following
adjustments:
1) Press “d” to set day pointer to correct day:
1 = Monday...7 = Sunday
2) Press “h” to set the hour. The time of day is
expressed in 24-hour military time:
04:00 = 4 a.m.....20:00 = 8 p.m.
3) Press “m” to set minutes
4) Release “ ” button. Clock is running
The pickup and 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 8.
ZBTSCTH Operation and Maintenance Manual (46R-7000)Zenith Controls, Inc. 17
SECTION IV - ADJUSTMENTS AND SETTINGS (Continued)
c. Program Review and Change:
Press Prog button to recall and review the C1
and“C2 On/Off times. An E is displayed if all 24
positions are used or if the next available position
is not filled.To change or clear a program, press
Prog button to find the program to be changed or
cleared. Change by pressing d, h or m buttons as
required. Clear the entire program by
simultaneously pressing “h” and “m”. Press “ ”
to return to the clock run mode.
d. Program Override:
Figure 9
b. Programming:
Twenty-four total ON or OFF settings are
available on one, several, or all days of the week.
1) Press Prog button. The blank program entry
fieldwillappearwith twoflashingpoints: “__:__”
2) Press either C1 or C2 depending on which
channel you wish to program.
3) Next, select either On or Off by pressing
C1 or C2 which toggles the On/Off mode.
4) You will now see the pointer flashing above
1 for Monday. To lock in Monday, press Prog.
If you want to enter further days, press d then
Prog to lock them in. Solid pointers must be
displayed over each day that the switching
command is required.
5) Once the days are selected, press h button
to enter the desired hour and press m to
enter the desired minutes. To enter the
program into the time switch, press Prog.
When the programming is complete, press
“ ” to return the clock run mode. If the “ ”
button is not depressed, it will switch to the
clock run mode after 60 seconds.
Each On/Off state can be manually changed by
pressing C1 or C2. The next counteracting
program cancels the manual override and
resumes previous programming.
To continuously override automatic programming,
press m and C1 or C2. The continuous override
On/Off stat is preceded by a black dot on the
display. To cancel, press m and C1 or C2 until the
dot disappears.
The automatic program can be continuously
overridden up to 47 days by pressing and
holding h while pressing C1 or C2 until the
display shows the number of days desired.
Starting the following day at “0:00”, the display
will show a “0:00”, both C1 and C2 off, and an H
in the lower right hand corner.
ZBTSCTH Operation and Maintenance Manual (46R-7000)18 Zenith Controls, Inc.
APPENDIX A - TYPICAL SCHEMATIC DIAGRAMS
1. 100-400 AMPS
ZBTSCTH Operation and Maintenance Manual (46R-7000)Zenith Controls, Inc. 19
APPENDIX A - TYPICAL SCHEMATIC DIAGRAMS (Continued)
2. 600-3000 AMPS
ZBTSCTH Operation and Maintenance Manual (46R-7000)20 Zenith Controls, Inc.
APPENDIX A - TYPICAL SCHEMATIC DIAGRAMS (Continued)
3. ALARM CIRCUIT SCHEMATIC
4. 3φ CONTROL SENSING SCHEMATIC
ZBTSCTH Operation and Maintenance Manual (46R-7000)Zenith Controls, Inc. 21
APPENDIX A - TYPICAL SCHEMATIC DIAGRAMS (Continued)
5. BYPASS CONTROL CIRCUIT
a. 100-400 Amp
b. 600-3000 Amp
ZBTSCTH Operation and Maintenance Manual (46R-7000)22 Zenith Controls, Inc.
APPENDIX B - REPLACEMENT PARTS
!
NOTICE
Model number and serial number of switch must be included with all orders for replacement parts.
Specify line voltages, drawing numbers and date of installation. When ordering parts not shown on
the parts list, refer to this part by its legend description in the wiring diagrams.
1. POWER PANEL 100-400 AMPS
2. POWER PANEL 600-1200 AMPS
ZBTSCTH Operation and Maintenance Manual (46R-7000)Zenith Controls, Inc. 23
APPENDIX B - REPLACEMENT PARTS (Continued)
3. POWER PANEL 1600-3000 AMPS
5. BYPASS SUBPANEL4. POWER PANEL 4000 AMPS
ZBTSCTH Operation and Maintenance Manual (46R-7000)24 Zenith Controls, Inc.
APPENDIX B - REPLACEMENT PARTS (Continued)
Power Panel Replacement Parts List 100-400 Amps
Tag Description 100A 150A 225A 260A 400A
NL1,2,3
EL1,2,3 Cable Connection Lug, PS-4418 PS-4418 PS-4418 S-1422 S-1422
T1,2,3 CU Wire
NLN, ELN, TN
Bypass Contact Assembly (Movable and Stationary)
N1,2,3 Normal 46P-1104A 46P-1104B 46P-1104C 46P-1104D 46P-1104E
N (Sw. Neutral Normal) 46P-1105A 46P-1105B 46P-1105C 46P-1105D 46P-1105E
E1,2,3 Emergency 46P-1106A 46P-1106B 46P-1106C 46P-1106D 46P-1106E
E (Sw. Neutral Emergency) 46P-1107A 46P-1107B 46P-1107C 46P-1107D 46P-1107E
ATS Contact Assembly (Movable and Stationary)
NL1,2,3 Normal 46P-1100A 46P-1100B 46P-1100C 46P-1100D 46P-1100E
N (Sw. Neutral Normal) 46P-1101A 46P-1101B 46P-1101C 46P-1101D 46P-1101E
EL1,2,3 Emergency 46P-1102A 46P-1102B 46P-1102C 46P-1102D 46P-1102E
N (Sw. Neutral Emergency) 46P-1103A 46P-1103B 46P-1103C 46P-1103D 46P-1103E
Arc Grid Assy. 46P-1099
Voltage Part No.
120/240 K-3061
Bypass Step-Down 208/416 K-3063
XBN, XBE Transformer 220/440 K-3064
Secondary 24V 240/480 K-3062
380 K-3067
575 K-3065
600 K-3066
Main ATS Operating Coils
No. Volts Ph Wire Coil Volts Poles Part No.
-1 120 1 2 120 2 K-2178
-2 120/240 1 3 240 2, 3
-3 240 3 3 240 3 K-2189
-38 120/240 3 4 240 3, 4
CN/O & CE/O -4 120/208 3 4 208 3, 4 K-2177
-5 480 3 3 480 3 K-2176
-6 575/600 3 3 575/600 3 SPO
-7 277/480 3 4 480 3, 4 K-2176
-9 240/416 3 4 416 3, 4 SPO
-91 220/380 3 4 380 3, 4 K-2188
SN/SEO
SE/SEO
A3
A4
SCN/O & SCE/O CN/O & CE/O Limit Switches L-3079
AA
AE1,2
PLS1,2
AI
AT1,2
AB3/ABE
AB4/ABN
NA4
EA3
BTE
BTN
TSE
BLL
ALL
DS ATS Solenoid Disconnect Switch:
BPS
TRS
Normal Position Limit Switch
Emergency Position Limit Switch
ATS Emergency Position Switch
ATS Normal Position Switch
ATS Auto Location Switch
ATS Isolate/Remove Location Switch
Position Lever Switch
ATS Isolate Location Switch
ATS Test Location Switch
Bypass Emergency Position Switch
Bypass Normal Position Switch
Normal TRS Limit Switch
Emergency TRS Limit Switch
Bypass Emergency Position Switch
Bypass Normal Position Switch
ATS Engaged Switch
Bypass Lock Location Switch
ATS Lock Location Switch
Operator 2-Position Maintain L-4018
Contact Block N.C. (3) L-1029
Contact Block N.O. (2) L-1028
Contact Block Mounting Plate PS-3473
Bypass Interlock Solenoid
Transfer Release Solenoid
L-3002
L-3071
L-3070
L-5021
L-3054
K-2180
ZBTSCTH Operation and Maintenance Manual (46R-7000)Zenith Controls, Inc. 25
APPENDIX B - REPLACEMENT PARTS (Continued)
Power Panel Replacement Parts List 600-1200 Amps
Tag Description 600A 800A 1000A 1200A
N 1,2,3,N Normal Connections CU/AL Cable Lugs S-2119
(2) 600MCM-2
E 1,2,3,N Emergency Connections CU/AL Cable Lugs S-1393F
(2) 600MCM-2
T 1,2,3,N Load Connections CU/AL Cable Lugs S-1393F
(2) 600MCM-2
STAT (BP) Stationary Contact Assembly Bypass 26P-1144 26P-1126 26P-1126 26P-1126
STAT (ATS) Stationary Contact Assembly ATS 26P-1144 26P-1126 26P-1126 26P-1126
ARC Arc Grid Assembly Kit 23P-1366
MOV Movable Contact Assembly 23P-1157 23P-1125 26P-1125 26P-1125
Movable Contact (Switched Neutral) 23P-1157 26P-1231 26P-1231 26P-1231
Voltage Part No.
120/240 K-3061
Bypass Step-Down 208/416 K-3063
XBN, XBE Transformer 25VA, 220/440 K-3064
Secondary 24V 240/480 K-3062
380 K-3067
575 K-3065
600 K-3066
Main ATS Operating Coils
Voltage Systems
No. Volts Ph Wire Coil Volts Poles Part No.
-1 120 1 2 120 2 SPO
-2 120/2401 3 240 2 SPO
S-2131
(3) 600MCM-2
S-1391F
(3) 600MCM-2
S-1391F
(3) 600MCM-2
S-2132
(4) 600MCM-2
S-1392F
(4) 600MCM-2
S-1392F
(4) 600MCM-2
S-2132
(4) 600MCM-2
S-1392F
(4) 600MCM-2
S-1392F
(4) 600MCM-2
CN/CNO 3
CE/CEO -3 240 3 3 240 3 K-2146 K-2147
-4 120/2083 4 208 3, 4
-5 480 3 3 480 3 K-2158 K-2157
-7 277/4803 4 480 3, 4
-9 240/4163 4 416 3, 4 SPO
SN/SNO-1,2
SN/SNO-3,4
SE/SEO-1,2
SE/SEO-3,4
A3 ATS Emergency Position Switch L-5021
A4 ATS Normal Position Switch
AA
AT
ACU/ACD
AI
AE
AB3
AB4
ASE
ASN
DS
CBE
CBN
CBC Crank Mechanism Solenoid K-2159
RN/RNO
RE/REO
ATS Normal Position Coil
Cutout Switch DPDT
ATS Emergency Position Coil
Cutout Switch DPDT
Limit Switch, DPDT Roller Actuator
ATS Auto Location Switch
ATS Test Location Switch
Crank Limit Switches
ATS Isolate Location
Engine Start Transfer
Limit Switch, DPDT Lever Actuator
Bypass Emergency Position Switch
Bypass Normal Position Switch
BSS Emergency Position Switch
BSS Normal Position Switch
ATS Solenoid Disconnect Switch
Operator 2-Position Maintain L-4009
Contact Block N.C. (3) L-1020
Contact Block N.O. (2) L-1024
Emergency Interlock Solenoid
Normal Interlock Solenoid
Coil Rectifiers 23P-1473
23P-1533
23P-1535
23P-1534
23P-1536
L-3052
L-3054, L-3052
L-3054
L-3052
L-3052
L-5021
K-2192
ZBTSCTH Operation and Maintenance Manual (46R-7000)26 Zenith Controls, Inc.
APPENDIX B - REPLACEMENT PARTS (Continued)
Power Panel Replacement Parts List 1600-4000 Amps
Tag Description 1600/2000A 3000A 4000A
NL1,2,3
EL1,2,3
XBN, XBE Transformer 25VA, 220/440 K-3064
CN/O & CE/O -5 480 3 3 480 3 K-2160 K-2218
Cable Connection at Rear S-1302F(2)
Optional T1,2,3
(8) 600MCM-2
Stationary Contact Assembly Bypass and ATS S-2308 S-2343 23P-1655
Arc Grid Assembly Kit 23P-1171
Movable Contact Assembly 23P-1400 23P-1344 23P-1640
Movable Contact 23P-1399 23P-1338 SPO
Voltage Part No.
120/240 K-3061
Bypass Step-Down 208/416 K-3063
Secondary 24V 240/480 K-3062
380 K-3067
575 K-3065
600 K-3066
Main ATS Operating Coils
Voltage Systems
No. Volts Ph Wire Coil Volts Poles Part No.
-1 120 1 2 120 2 SPO
120/24
-2
-3 240 3 3 240 3
120/20
-4
-6 575 3 3 600 3 SPO
277/48
-7
120/24
-8
240/41
-9
1 3 240 2, 3
0
K-2151 K-2219
3 4 208 3, 4
8
3 4 480 3, 4 K-2160 K-2218
0
2 4 240 4 K-2151 K-2219
0
3 4 416 3, 4 Consult Zenith Factory K-2220
6
SN/SNO Limit Switch 23P-1540
SE/SEO Limit Switch 23P-1541
A3 ATS Emergency Position Switch 23P-1543
A4 ATS Normal Position Switch 23P-1542
AA
AT
AI
AE
AB3
AB4
DS ATS Solenoid Disconnect Switch:
CBE
CBN
CBC Crank Enable Solenoid K-2159R
CH Crank Handle Limit Switch L-3052
RN/RNO
RE/REO
ATS Auto Location Switch
ATS Test Location Switch
ATS Isolate Location Switch
Limit Switch DPDT, Roller Actuator
Engine Start Transfer L-3052
Limit Switch DPDT, Lever Actuator
Bypass Emergency Position Switch
Bypass Normal Position Switch
Operator 2-Position Maintain
Contact Block N.C. (1)
Contact Block N.O. (2)
Emergency Interlock Solenoid
Normal Interlock Solenoid
Coil Rectifiers 23P-1473
L-3071
L-5021
L-4018
L-1020
L-1024
K-2192
23P-1582 (480VAC)
ZBTSCTH Operation and Maintenance Manual (46R-7000)Zenith Controls, Inc. 27
APPENDIX B - REPLACEMENT PARTS (Continued)
5. CONTROL PANEL LAYOUT AND PARTS LIST
28 Zenith Controls, Inc.ZBTSCTH Operation and Maintenance Manual (46R-7000)
APPENDIX B - REPLACEMENT PARTS (Continued)
Closed Transition Transfer Switch Control Panel Parts List
Tag Description Voltage Part No.
CR2 Normal Control Relay 120 VAC K-1204
DT Transfer Delay Timer Neutral to Normal 120 VAC K-1230
DTR Normal Transfer Latch Relay 120 VAC K-1204
DW Transfer Delay Timer Neutral to Emergency 120 VAC K-1230
DWR Emergency Transfer Latch Relay 120 VAC K-1204
EFOAR Relay, Emergency Fail to Open Alarm 24 VDC K-1242
EFOR Emergency Fail to Open Latching Relay 120 VDC K-1240
ETT Emergency Trip Timer 120 VAC K-1230
LTCS Latch Test Cycle Start 120 VAC K-1204
NFOAR Relay, Normal Fail to Open Alarm 24 VDC K-1242
NFOR Normal Fail to Open Latching Relay 120 VDC K-1240
OLC Open Last Close 120 VAC K-1230
PAR Power Available Relay 120 VAC K-1204
PART Power Available Timer 120 VAC K-1249
PT1,2,3,4 Potential Transformers 120 /480 VAC K-3094
120/240 VAC K-3095
120/208 VAC K-3096
RAI Normal Available Relay 120 VAC K-1204
RAE Emergency Available Relay 120 VAC K-1204
RTCS Relay Test Cycle Start 240 VAC K-1256
SCL Sync Check Latch Relay 120 VAC K-1204
ST Sync Timer 120 VAC K-1230
STR Shunt Trip Relay 120 VDC K-1240
XNE Normal/Emergency Control Transformers 24/120 VAC K-3061
SSRCP Control Panel Standard Items Parts List
Tag Description Voltage Part No.
XN, XE Control Transformer 208 VAC K-3070
240/480 VAC K-3071
B1,2,3 Solid State Phase Relay 208/240 VAC K-1186
480 VAC K-1188
VFSM Voltage Frequency Sensor 120 VAC K-1192
CR Control Relay 120 VAC K-1204
RT Bypass T Relay 120 VAC K-1204
J1-J11 Jumpers - PS-5067
T Time Delay to Normal, Timer Solid State 120 VAC (Adjustable .1
second to 9990 hours)
U Engine Cool Down, Timer Solid State 120 VAC (Adjustable .1
second to 9990 hours)
W Time Delay to Emergency, Timer Solid State 120 VAC (Adjustable .1
second to 9990 hours)
P1 Time Delay Engine Start, Timer 120 VAC (Adjustable
.5 to 6 seconds)
ZBTSCTH Operation and Maintenance Manual (46R-7000)Zenith Controls, Inc. 29
K-1230
K-1230
K-1230
K-1201
APPENDIX B - REPLACEMENT PARTS (Continued)
Closed Transition Transfer Switch Control Panel (Standard Items)
Tag Description Voltage Part No.
25 Sync Check Relay 120 VAC K-1234
47N Phase Sequencing, Normal 120 VAC K-1246
47E Phase Sequencing, Emergency 120 VAC K-1246
27/59E Over/Undervoltage, Emergency 120 VAC K-1269
27/59N Over/Undervoltage, Normal 120 VAC K-1269
AS Alarm Silence Relays 24 VDC K-1242
CCN Power Relay for CN Solenoid 120 VAC K-1120 400-1200A
K-1257 1600-3000A
CCNO Power Relay for CNO Solenoid 120 VAC K-1120
CCE Power Relay for CE Solenoid 120 VAC K-1120 400-1200A
K-1257 1600-3000A
CCEO Power Relay for CEO Solenoid 120 VAC K-1120
Bypass Control Panel Parts List
Tag Description Part No.
BR-1,2,3 Bridge Rectifier PS-5076
RNH Normal Voltage Relay K-1218
R1 Resistor, RNH, 30 ohm PS-4056
R2 Resistor, LDS, 120 ohm PS-4057
D1 Diode PS-4812
C Capacitor RNH PS-4058
ATR Auxiliary Test Relay K-1218
30 Zenith Controls, Inc.ZBTSCTH Operation and Maintenance Manual (46R-7000)
APPENDIX B - REPLACEMENT PARTS (Continued)
6. CABINET DOOR PILOT DEVICES
BYPASS-ISOLATION CLOSED TRANSITION
TRANSFER SWITCH CONTROLS
ZBTSCTH Operation and Maintenance Manual (46R-7000)Zenith Controls, Inc. 31
APPENDIX B - REPLACEMENT PARTS (Continued)
Controls and Indicating Lights Parts List
Controls Part No.
Description Operator Switch Mounting Base
Transition Mode Selector L-3081 L-1028 (4)
L-1029 (2)
Test Switch L-3081 L-1029
Failed to Open Lock Out Reset L-4020 L-1028 PS-3473
Shunt Trip Reset L-4020 L-1028
Alarm Silence Push Button (ASPB) L-1025 L-1028
L-1029
Alarm Y780001
Indicating Lights (Upper Door) Part No.
Description Color Socket Bulb Lens
Normal Available Green PS-5048
Emergency Available Red PS-5047
Bypass Normal Location Green PS-5048
Bypass Emergency Location Red PS-5046 Y500005 PS-5047
ATS Test Position Amber PS-5049
ATS Isolate Position Amber PS-5049
ATS Inhibit Red PS-5047
ATS Disconnect Switch “Off” Red PS-5047
Indicating Lights (Lower Door) Part Numbers
Description Color Socket Bulb Lens
Normal Available Green PS-5048
Emergency Available Red PS-5046 PS-5105 PS-5047
Normal Closed Green PS-5048
Emergency Closed Red PS-5054 PS-5047
Sync Light White Y500005 PS-5051
Fail To Sync Light Red PS-5105
Normal Failed To Open Red PS-5046 Y500005
Emergency Failed To Open Red Y500005 PS-5047
Shunt Trip Light Red PS-1272
Alarm Silence (ASL) Red Y500005
32 Zenith Controls, Inc.ZBTSCTH Operation and Maintenance Manual (46R-7000)
830 West 40th Street
Chicago, IL 60609 USA
Phone: 773 247-6400
Fax: 773 247-7805
E-Mail: zenith@zenithcontrols.com
www.zenithcontrols.com
© 1997 Zenith Controls, Inc.
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