GE Industrial Solutions ZBTSD User Manual
GE Digital Energy
Power Quality
Zenith
ZBTS/ZBTSD Series
Bypass Isolation Transfer Switches
100-4000 Amps
Operation & Maintenance Manual
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
Equipment Inspection and Storage . . . . . . . . . .
11
Final Equipment Inspection . . . . . . . . . . . . . . .
11
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
Power Connections . . . . . . . . . . . . . . . . . . . . . . .
12
Engine Start Control Connections . . . . . . . . .
12-3
Initial Energization . . . . . . . . . . . . . . . . . . . . .
13-4
Control Connections . . . . . . . . . . . . . . . . . . . . . 5
Entelli-Switch 250 Microprocessor Controller . . . . .
16
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
LCD & Keypad . . . . . . . . . . . . . . . . . . . . . . . . . .
17
User Setting for Voltage & Frequency . . . . . . .
1 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
119
ATS Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . .
119
Standard Transition . . . . . . . . . . . . . . . . . . . . . 19
Delayed Transition . . . . . . . . . . . . . . . . . . . . . . 19
Page
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . 20
Standard Transition . . . . . . . . . . . . . . . . . . . . .
120
Delayed Transition . . . . . . . . . . . . . . . . . . . . . . 20
Bypass-Isolation Operation . . . . . . . . . . . . . . . 21
100-400 Amps . . . . . . . . . . . . . . . . . . . . . . . . . .
122
600-1200 Amps . . . . . . . . . . . . . . . . . . . . . . . . .
123
1600-4000 Amps . . . . . . . . . . . . . . . . . . . . . . . .
1 24
1600-3000 Amps, Horizontal Bypass . . . . . . . .
1 25
Controls Power Supply (CPS) . . . . . . . . . . . . . . . . . 26
Schematics, Standard & Delay . . . . . . . . . . . . .
127
Troubleshooting & Diagnostics . . . . . . . . . . . . . . . . 28
Maintenance and Testing . . . . . . . . . . . . . . . . . . . . . 29
Inspection and Cleaning . . . . . . . . . . . . . . . . . 29
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
129
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
129
ZBTSH/ZBTSDH . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Standard Control Panel Layout (SSRCP) . . . . 30
Panel Mount Control Relays . . . . . . . . . . . . . .
130
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . 31
Adjustments and Settings . . . . . . . . . . . . . . . . . . . . . 32
Solid State Timers . . . . . . . . . . . . . . . . . . . . . . .
132
Voltage/Frequency Sensor (VSFM) . . . . . . . . .
132
Solid State Phase Relay . . . . . . . . . . . . . . . . . . .
132
Table of Contents
Authorized Service
For GE parts and service, call: 773 299-6600
Introduction
GE Zenith Transfer Switches are used to provide a continuous
source of power for lighting and other critical loads by automatically 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 stateof-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. Transfer 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.
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Safety
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.
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.
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 dry place, protected from dirt and water.
Provide ample air circulation and heat, if necessary, to
prevent condensation.
5% to 95%
(non-condensing)
-30°C to
+75°C
(-22°F to
+167°F)
40-400
AMP
(molded shell)
-20°C to +65°C
(-4°F to +149°F)
40-4000
AMP
(all other frame
and panel types)
-20°C to +60°C
(-4°F to +140°F)
Operating
Storage Temperature
Temperature (Ambient): Humidity
Final Equipment Inspection
Prior to energizing the transfer switch:
1. Remove any debris incurred, with a vacuum,
due to shipment or installation.
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 necessary.
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.
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.
Due to hazardous voltage and current, GE Zenith
recommends that a
GE Zenith Certified technician
or a qualified electrician must perform the
installation and maintenance of the switch.
Do not use a blower since debris may
become lodged in the electrical and
mechanical components and cause damage.
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.
DANGER
CAUTION
WARNING
CAUTION
2
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Installation
Table 2
Tightening Torque for Lugs
Socket Size
Across Flats
Torque
Lb. - In.
Lb. - Ft.
45
1/8
4
100
5/32
8
120
3/16
10
150
7/32
12
200
1/4
17
275
5/16
23
375
3/8
31
500
1/2
42
600
9/16
50
Power Connections
GE Zenith transfer switches are supplied with UL listed
solderless screw type terminals as standard for the 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
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.
NOTE: Do not run cables or wiring behind
front-connected transfer switches.
Table 1
Power Connections: Screw Type Terminals for External Power Connections
Switch Size
(Amps)
40
80
100
150
200, 225, 2500
260, 300*, 400
600
800, 1000, 1200
Source 1, Source 2 & Load Terminals
1 #8 AWG to 1/0
Cable Per Pole Range of Wire Sizes
1 #8 AWG to 1/0
1 #8 AWG to 1/0
1 #8 AWG to 3/0
1 #6 AWG to 250 MCM
1 #4 AWG to 600 MCM
2 #2 AWG to 600 MCM
4 #2 AWG to 600 MCM
Neutral Bar (When Required)
3 #8 AWG to 1/0
No. of Cables Range of Wire Sizes
3 #8 AWG to 1/0
3 #8 AWG to 1/0
3 #8 AWG to 300 MCM
3 #6 AWG to 300 MCM
3 #4 AWG to 300 MCM
8 #2 AWG to 600 MCM
12 #2 AWG to 600 MCM
1600, 2000
2600, 300 0, 4000
Line, Load and Neutral terminals are located in the rear of switch
and arranged for bus bar locations
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 ATS.
NOTE: All control wires (18-12 AWG) must be
torqued to 19 in/lbs.
D
CABINET
LIFTING EYES
SPREADER BAR
H
45°
Figure 1
NOTE: When lifting the switch using a spreader bar,
height H must be equal to half of distance D.
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.
DANGER
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Installation
(cont’d)
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.
Figure 2 shows location of engine start connections for
Bypass Isolation Transfer Switch. Figure 6 (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 Source 1 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.
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 4
.
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 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.14. Lock the enclosure.
Figure 2
E
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.
DANGER
Figure 3A –
Horizontal
Bypass/Isolation
Transfer Switch
Customer
Connections
Figure 3 (Typical)
XBN
XBE
4
1
Interconnect plug plate
RNH
5
6
P Relay
2
(Engine Start)
3
Contact rating is
10 Ampere at 120VAC
or 28VDC Gold plated
Interlock Logic
Assembly
ATR
A4-1
A4-1
A4-2
A4-2
A3-1
A3-1
A3-2
A3-2
A4B-1
A4B-1
A3B-1
A3B-1
Input/Output
option relays.
Control Power Supply
Auxiliary contact
connections.
E11
E12
E12A
E13
Engine Start
Connections
4
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Installation
(cont’d)
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.
Figure 5 – LCD and keypad
After all options and accessories are checked and verified,
follow these steps to set up the ATS. Refer to Entelli-Switch
250 display Figure 5. The annunciation LEDs illuminate to
indicate (1) source availability, (2) ATS position, and (3)
Entelli-Switch 250 control function (timing).
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.
When performing a hi-pot or
dielectric test on the power section,
DISCONNECT the control panel plugs from
the microprocessor to avoid potential damage.
S1 OK
21:56
MON 23 APR 2008
MORE TEST
WARNING
Figure 4
SERIAL NUMBER:
RATING
: VOLTS -
AMPS -
SYSTEM VOLTS:
MODEL NUMBER:
HZ -
PHASE -
GE Zenith Controls
Certain accessories, per specific
schematics, can inhibit automatic transfer.
Engine Gen-Set could start when
engine control wires are attached.
Initial Energization
(cont’d)
CAUTION
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Installation
(cont’d)
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 6 shows the location of these terminals.
To R/T Box
To Power Panel
Input/Output
Connectors
to I/O Modules
Engine Start
Connections
Clock Program
Backup Battery
Remove protective strip to
enable clock functions
Network Connector
Control Connections
The 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.
Figure 6
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.
DANGER
6
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ZBTS / ZBTSD Operation & Maintenance Manual
Entelli-Switch 250 Controller
Entelli-Switch 250 Controller
Consists of two major assemblies:
I. The Microprocessor contains the following:
A. Entelli-Switch 250 Board - Customer Input and
Output (I/O) for system interface. Located on the
left hand side of the back of the unit (see figure 7)
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 8)
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 Controls Power Supply (CPS)
Contains transformers which drop line voltage
to control level for controller input and SCR
inputs (see figure 7).
Figure 7
Figure 8
I/O Interface
CPS
Engine Start Relay P
Battery Strip
and
Access
Code Label
Entelli-Switch 250
Board
S1 OK
21:56
MON 23 APR 2008
MORE TEST
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ZBTS / ZBTSD Operation & Maintenance Manual
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 sixdigit access code is located on a white label on the back
of the unit (see figure 11 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.
Entelli-Switch 250Entelli-Switch 250
S1 OK
01: 50
WED 31 MAY 2008
Source 2 (Red)
indicates Source 2
is acceptable for use
Source 1 LED (Green)
indicates Source 1 is
acceptable for use
Exercise Event
“Impending”
SET Menu
MORE CFG TEST SET
#1 or the word on the LCD
above the key. The word above
the key changes depending on
which screen is being displayed.
#2 or the word on the LCD
above the key. The word above
the key changes depending on
which screen is being displayed.
#3 or the word on the LCD
above the key. The word above
the key changes depending on
which screen is being displayed.
#4 or the word on the LCD
above the key. The word above
the key changes depending on
which screen is being displayed.
Current Time,
Day and
Date of Display
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
Menus (more, cfg, test)
Keypad
* E *
LCD Screen
Figure 9
8
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ZBTS / ZBTSD Operation & Maintenance Manual
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%, (5 seconds minimum)
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 Voltage. 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 Voltage 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%, (5 seconds minimum)
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.
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Accessory Group Packages
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.
Denotes an Accessory with 3 circuits as a standard.
Table 3
*
Delayed Transition Units Only.
**
Optional for 40-400 Amp
2
2
3
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