GE Industrial Solutions ZBTSD User Manual

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GE Digital Energy

Power Quality

Zenith

ZBTS/ZBTSD Series

Bypass Isolation Transfer Switches 100-4000 Amps

Operation & Maintenance Manual

Page

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

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Connections . . . . . . . . . . . . . . . . . . . . . . .

Engine Start Control Connections . . . . . . . . .

12-3

Initial Energization . . . . . . . . . . . . . . . . . . . . .

13-4

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

Entelli-Switch 250 Microprocessor Controller . . . . .

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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Installation

Table 2

Tightening Torque for Lugs

Socket Size

Across Flats

Torque

Lb. - In.

Lb. - Ft.

1/8

100

5/32

120

3/16

150

7/32

200

1/4

275

5/16

375

3/8

500

1/2

600

9/16

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)

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 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 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.

CABINET

LIFTING EYES

SPREADER BAR

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

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

Interconnect plug plate

RNH

P Relay

(Engine Start)

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

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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

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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

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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

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MORE TEST

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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

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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”

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

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Accessory Definitions

Test Switch, Momentary

Test Switch, Maintained Auto/Momentary Test

6AP

Test Switch, Maintained/Momentary utilizing keypad

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

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

Auxiliary Contact, operates on Source 1 line failure.

A1E

Auxiliary Contact, operates on Source 2 line failure.

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

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.

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.

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)

(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)

(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)

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)

Fan contact, operates when generator is running.

Heater and Thermostat

Frequency Meter, Door mount.

K/P

Frequency Indication for S1 and S2

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.

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Accessory Definitions

(cont’d)

Single Phase Amp Meter

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

Running Time Meter, Door mount

Operation Counter, Door Mount

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

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

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.

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

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” Factory 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.

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ZBTS / ZBTSD Operation & Maintenance Manual

Accessory Definitions

(cont’d)

R50

In Phase Monitor this feature restricts Live to Live Source Transfers to occur unless both Sources are within 7 electri-

cal 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 SYNCHRONISM 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 Frequency,

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 degrees out of phase. A maximum of 18 symbols (180 electrical degrees) can be monitored.

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

- - - -

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 BYPASS. 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 dependent 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 Hertz 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 60Hertz 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)

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.

(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)

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ZBTS / ZBTSD Operation & Maintenance Manual

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

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 SAVE (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).

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ZBTS / ZBTSD Operation & Maintenance Manual

Load / 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 DAILY, WEEKLY, 14 DAY, 28 DAY, or OFF.

4. If the third line of the CONFG TIMER EXERCISER shows DAILY, 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 DAILY, WEEKLY, 14 DAY, or 28 DAY as desired.

9. Press SAVE.

10. Press MORE to scroll to CONFG TIMER EXERCISER (XFR) or (NO XFR).

11. Press Up or Down to select XFR (Load Transfer) or NO XFR (No Load Transfer).

12. Press SAVE.

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 SAVE 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 START 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 every 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 Factory 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 BYPASS 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 START 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 DAYS, 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.

CDT One Event Timer Exerciser

SET EXERCISER 00:00

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

Indicates # of Exercise Periods

BACK ^ v SAVE

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)

To previous field or to exit screen.

Up and Down Use to change values.

Cursor

NL#1

Load No-Load (CDP) Exercise Indicator

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

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ZBTS / ZBTSD Operation & Maintenance Manual

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 DAILY, WEEKLY, 14 DAY, 28 DAY, 365 DAY or OFF.

4. If the third line of the CONFG CLOCK EXERCISER shows DAILY, 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 DAILY, WEEKLY, 14 DAY, 28 DAY, or 365 DAY as desired.

9. Press SAVE.

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 SAVE 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 BYPASS 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 (ATS 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 10

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ZBTS / ZBTSD Operation & Maintenance Manual

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)

Figure 11

Engine Start Relay (De-Energized)

Network Communications (Option)

1 2

3 4 5 6 7 8

9 10 11 12 13 14 15 16

PROG 1 PROG 2 GRD (Input Sink)

NIA OUT ELEV. PRE. OUT ALARM OUT

MOTOR DISC. OUT

INHIB.>S1 INHIB.>S2

Input and output availability subject to factory configuration.

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

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

Entelli-Switch MX250

(-)

A1 (+)

RELAY

14 11 12

Customer

Input

Voltage

COM J2-3

N.O N.C

J2/J4

Inputs

WARNING

Controller Inputs must be relay Isolated.

Controller Outputs have Limited Source Capacity. Use only GE Zenith-specified Output Modules.

11 14

A1 (+)

21 24 22

A2 (-)

Output

Contacts

R1 Output

Contact Rating: 10A @ 250 VAC or 30 VDC

2 3

4 5

2421121411

LS OUT

STE OUT

TMS IN

LS IN

S5 IN

2008

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ZBTS / ZBTSD Operation & Maintenance Manual

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 11

Engine Start Relay (De-Energized)

Network Communications (Option)

1 2

3 4 5 6 7 8

9 10 11 12 13 14 15 16

PROG 1 PROG 2 GRD (Input Sink)

NIA OUT ELEV. PRE. OUT ALARM OUT

MOTOR DISC. OUT

INHIB.>S1 INHIB.>S2

Input and output availability subject to factory configuration.

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

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

Entelli-Switch MX250

(-)

A1 (+)

RELAY

14 11 12

Customer

Input

Voltage

COM

J2-3

N.O N.C

J2/J4

Inputs

WARNING

Controller Inputs must be relay Isolated.

Controller Outputs have Limited Source Capacity. Use only GE Zenith-specified Output Modules.

11 14

A1 (+)

21 24 22

A2 (-)

Output

Contacts

R1 Output

Contact Rating: 10A @ 250 VAC or 30 VDC

2 3

4 5

2421121411

LS OUT

STE OUT

TMS IN

LS IN

S5 IN

2008

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ZBTS / ZBTSD Operation & Maintenance Manual

Entelli-Switch 250 User Setup - System Info

View System Data

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

Figure 11

Engine Start Relay (De-Energized)

Network Communications (Option)

1 2

3 4 5 6 7 8

9 10 11 12 13 14 15 16

PROG 1 PROG 2 GRD (Input Sink)

NIA OUT ELEV. PRE. OUT ALARM OUT

MOTOR DISC. OUT

INHIB.>S1 INHIB.>S2

Input and output availability subject to factory configuration.

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

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

Entelli-Switch MX250

(-)

A1 (+)

RELAY

14 11 12

Customer

Input

Voltage

COM J2-3

N.O N.C

J2/J4

Inputs

WARNING

Controller Inputs must be relay Isolated.

Controller Outputs have Limited Source Capacity. Use only GE Zenith-specified Output Modules.

11 14

A1 (+)

21 24 22

A2 (-)

Output

Contacts

R1 Output

Contact Rating: 10A @ 250 VAC or 30 VDC

2 3

4 5

2421121411

LS OUT

STE OUT

TMS IN

LS IN

S5 IN

2008

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ZBTS / ZBTSD Operation & Maintenance Manual

Testing

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 12).

• 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 MX controller initiates a transfer signal through the SCR-E to operate the main transfer operator. The load is now transferred to Source 2 line. The transfer switch is mechanically locked. SN limit switch awaits the next operation to Source 1.

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 MX controller initiates a transfer signal through the SCR-N to operate the main transfer operator. The load is now transferred to Source 1 line. The transfer switch is mechanically locked. SE limit switch awaits the next operation to Source 2.

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 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 retransfer. A manual pushbutton BYPASS is provided to bypass the “W” time delay if desired. After the (W) time delay, the MX controller initiates a transfer signal through the SCR-NO to operate the main transfer operator. The load is now transferred to the Open position. The time delay to Source 2 timer (DW) begins its timing cycle. After the (DW) time delay, the MX controller initiates a transfer signal through the SCR-E to operate the main transfer operator. The load is now transferred to Source 2 line. The transfer switch is mechanically locked. SN limit switch awaits the next operation to Source 1.

Restoration of Source 1 Power:

Deactivating the test switch initiates re-transfer to Source 1 sequence. 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 MX controller initiates a transfer signal through the SCR-EO to operate the main transfer operator. The load is now transferred to the Open position. The time delay to Source 1 timer (DT) begins its timing cycle. After the (DT) time delay, the MX controller initiates a transfer signal through the SCR-N to operate the main transfer operator. The load is now transferred to Source 1 line. The transfer switch is mechanically locked. SE limit switch awaits the next operation to Source 2.

SYSTEM TEST

FAST XFR NO

MORE TEST LOAD XFR

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

(See National Electric Code articles 700 and 701)

NOTICE

Figure 12

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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 provided to bypass the “W” time delay if desired. After the (W) time delay, the MX controller initiates a transfer signal through the SCR-E to operate the main transfer operator. The load is now transferred to Source 2 line. The transfer switch is mechanically locked. SN limit switch awaits the next operation to Source 1.

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 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 MX controller initiates a transfer signal through the SCR-N to operate the main transfer operator. The load is now transferred to Source 1 line. The transfer switch is mechanically locked. SE limit switch awaits the next operation to Source 2.

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 stabilization before re-transfer. A manual pushbutton BYPASS is provided to bypass the “W” time delay if desired. After the (W) time delay, the MX controller initiates a transfer signal through the SCR-NO to operate the main transfer operator. The load is now transferred to the Open position. The time delay to Source 2 timer (DW) begins its timing cycle. After the (DW) time delay, the MX controller initiates a transfer signal through the SCR-E to operate the main transfer operator. The load is now transferred to Source 2 line. The transfer switch is mechanically locked. SN limit switch awaits the next operation to Source 1.

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 stabilization before retransfer. A manual pushbutton BYPASS is provided to bypass the “T” time delay if desired. After the (T) time delay, the MX controller initiates a transfer signal through the SCR-EO to operate the main transfer operator. The load is now transferred to the Open position. The time delay to Source 1 timer (DT) begins its timing cycle. After the (DT) time delay, the MX controller initiates a transfer signal through the SCR-N to operate the main transfer operator. The load is now transferred to Source 1 line. The transfer switch is mechanically locked. SE limit switch awaits the next operation to Source 2.

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

Source 1

Transfer to Source 1 Engine

Fails

Returns

Cooldown

Table 4

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ZBTS / ZBTSD Operation & Maintenance Manual

Sequence of Operation

(cont’d)

Bypass-Isolation Operation

An automatic transfer switch equipped with a bypassisolation switch provides the ability to withdraw the ATS for testing and/or maintenance purposes without interrupting the served load.

Operation of the unit is quick and convenient requiring only one operator and less than one minute to complete. Instructions are mounted on the front of each isolation switch door along with a mimic panel providing indication of power source availability and ATS/bypass switch positions.

The bypass switch is normally open on both sources with the ATS feeding the system load. During operation, the bypass is closed paralleling the ATS contacts which then allows withdrawal of the ATS to the “TEST” or “ISOLATE” positions. Mechanical and electrical interlocks are included to prevent cross-servicing or bypassing to a dead source.

In the “TEST” position, the ATS is disconnected from the load (now fed through the bypass) but control power is present to allow complete operational testing through the control panel of the transfer switch

In the “ISOLATE” position, the ATS is completely withdrawn and may be removed from the enclosure for maintenance if desired.

After the isolation operation, if the bypass is closed on Source 1 and if this source fails, an auxiliary contact on the bypass control will automatically start the enginegenerator set. When the second source is available, the manual handle of the bypass may be operated to transfer the load to the available source. Interlocks prevent both this transfer, if the ATS is in the circuit and connected to the opposite source or reconnection of the ATS unless the positions match.

Figure 13 Figure 14

While the bypass switch is out of the AUTO

position/mode, the ATS is INHIBITED from

automatic operation. Make certain the ATS is left

in automatic after completion of any service.

WARNING

BYPASS

SOURCE 1

AVAILABLE

BYPASS

SOURCE 1

BYPASS

SOURCE 2

SOURCE 1

AVAILABLE

SOURCE 2

AVAILABLE

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ZBTS / ZBTSD Operation & Maintenance Manual

Sequence of Operation

(cont’d)

100-400 AMP

1) Automatic

a) Manually operated Bypass Switch contacts

(BN/BE) are open and ATS is supplying load.

b) Disconnect Switch (DS) is in Auto.

2) To Bypass ATS

a) Open bottom cabinet door and turn DS to Inhibit. b) Position manual bypass handle (MBH) to same

power source as ATS.

3) To Test ATS

a) Bypass per above instructions. b) Move ATS location handle (ALH) to Test location. c) Turn DS to Auto. d) Test Switch (TS) on bottom cabinet door

will allow electrical operation of ATS.

4) To Isolate ATS

a) Bypass per above instructions. b) Move ALH to Isolate location.

5) To Remove ATS

a) Bypass and isolate per above instructions. b) Move ALH to Release location. c) Disconnect multipin plugs. d) Lift ATS out of drawer.

6) To Reconnect ATS

a) Place ATS into drawer slots (front rollers first). b) Turn DS to Inhibit. c) Manually position ATS into same source

as Bypass Switch.

d) Reconnect multipin plugs and external

connections to ATS. e) Push ATS inward to engage carriage. f) Move ALH to Test location (as indicated by light). g) Turn DS to Auto and use TS to electrically

operate ATS. h) Turn DS to Inhibit. i) Move ALH to Auto location. j) Turn DS to Auto and open Bypass with MBH. k) 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 Source 1. Sequence is the same for Bypass Source 2.

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.

Figure 15

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ZBTS / ZBTSD Operation & Maintenance Manual

600-1200 AMP

1) Automatic

a) Manually operated Bypass Switch contacts

(BN/BE) are open and ATS is supplying load. b) Disconnect Switch (DS) is in Auto.

2) To Bypass ATS

a) Open bottom cabinet door and turn DS to Inhibit. b) Turn Bypass Selector Switch (BSS) to same power

source as ATS c) Position manual bypass handle (MBH) upward.

3) To Test ATS

a) Bypass per above instructions. b) Rotate crank mechanism counter-clockwise until

ATS test light is illuminated. c) Turn DS to Auto. d) Test Switch (TS) on bottom cabinet door will allow

electrical operation of ATS.

4) To Isolate ATS

a) Bypass per above instructions. b) Rotate cank mechanism counter-clockwise

until ATS Isolated light is illuminated.

5) To Remove ATS

a) Bypass and isolate per above instructions. b) Disconnect multipin plugs and external

connections to ATS. c) Rotate four power panel latches to vertical

position, slide ATS forward and lock mechanism

in place. d) ATS can now be removed from cabinet.

6) To Reconnect ATS

a) Place ATS in slide mechanism. b) Unlock slide mechanism. Slide ATS over power

panel latches and rotate latches to horizontal

position. c) Turn DS to Inhibit. d) Manually position ATS into same source

as Bypass Switch. e) Reconnect multipin plugs and external

connections to ATS. f) Rotate crank mechanism clockwise until

ATS Test light is illuminated. g) Turn DS to Auto and use TS to electrically

operate ATS. h) Turn DS to Inhibit. i) Move ALH to Auto location. j) Turn DS to Auto and open Bypass with MBH. k) 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 Source 1. Sequence is the same for Bypass Source 2.

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 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.

Sequence of Operation

(cont’d)

Figure 15

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ZBTS / ZBTSD Operation & Maintenance Manual

1600-4000 AMP

1) Automatic

a) Manually operated Bypass Switch contacts

(BN/BE) are open and ATS is supplying load.

b) Disconnect Switch (DS) is in Auto.

2) To Bypass ATS

a) Open bottom cabinet door and turn DS to Inhibit. b) Turn Bypass Selector Switch (BSS) to same power

source as ATS

c) Position manual bypass handle (MBH) upward.

3) To Test ATS

a) Bypass per above instructions. b) Rotate crank mechanism counter-clockwise until

ATS test light is illuminated. c) Turn DS to Auto. d) Test Switch (TS) on bottom cabinet door will allow

electrical operation of ATS.

4) To Isolate ATS

a) Bypass per above instructions. b) Rotate crank mechanism counter-clockwise

until ATS Isolated light is illuminated.

5) To Remove ATS

a) Bypass and isolate per above instructions. b) Disconnect multipin plugs and external

connections to ATS. c) Slide four corner latches of ATS to innermost

position. d) ATS can now be removed from cabinet.

6) To Reconnect ATS

a) Roll cart back into cabinet. b) Slide four corner latches of ATS to outermost

position. c) Turn DS to Inhibit. d) Manually position ATS into same source

as Bypass Switch. e) Reconnect multipin plugs and external

connections to ATS. f) Rotate crank mechanism clockwise until

ATS Test light is illuminated. g) Turn DS to Auto and use TS to electrically

operate ATS. h) Turn DS to Inhibit. i) Rotate crank mechanism clockwise until ATS

location pointer is aligned with Auto mark

on location indicator. (ATS must be in same

source as Bypass.) j) Turn DS to Auto and open Bypass with MBH. k) 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 Source 1. Sequence is the same for Bypass Source 2.

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.

Sequence of Operation

(cont’d)

Figure 15

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ZBTS / ZBTSD Operation & Maintenance Manual

1600-3000 AMP Horizontal Bypass

1) Automatic

a) Manually operated Bypass Switch contacts

(BN/BE) are open and ATS is supplying load.

b) Disconnect Switch (DS) is in Auto.

2) To Bypass ATS

a) Turn DS to Inhibit. “Open bottom cabinet door” removed. b) Open Bypass Isolation Access panel c) Turn Bypass Selector Switch (BSS) to same power

source as ATS

d) Position Manual Bypass Handle (MBH) upward

3) To Test ATS

a) Bypass per above instructions. b) Rotate crank mechanism counter-clockwise until

ATS test light is illuminated. c) Turn DS to Auto. d) Test Switch (TS) on microprocessor controller will

allow electrical operation of ATS.

4) To Isolate ATS

a) Bypass per above instructions. b) Rotate crank mechanism counter-clockwise

until ATS Isolated light is illuminated.

5) To Remove ATS

a) Bypass and isolate per above instructions. b) Open Automatic Transfer Switch access panel. c) Slide four corner latches of ATS to innermost

position. d) ATS can now be removed from cabinet.

6) To Reconnect ATS

a) Roll cart back into cabinet. b) Slide four corner latches of ATS to outermost

position. c) Turn DS to Inhibit. d) Manually position ATS into same source

as Bypass Switch. e) Close Automatic Transfer Switch access panel. f) Rotate crank mechanism clockwise until

ATS Test light is illuminated. g) Turn DS to Auto and use TS to electrically

operate ATS. h) Turn DS to Inhibit. i) Rotate crank mechanism clockwise until ATS

location pointer is aligned with Auto mark

on location indicator. (ATS must be in same

source as Bypass.) j) Turn DS to Auto and open Bypass with MBH. k) 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 Source 1. Sequence is the same for Bypass Source 2.

4. When ATS is in Test or Isolate, Bypass Switch is a manual transfer switch to either available source (indicated on light panel).

Legend

1. BP - Bypass switch (indicated by contacts BN/BE) is a three position switch.

2. ATS - Automatic Transfer Switch.

Sequence of Operation

(cont’d)

Figure 16

SOURCE 1

ATS

LOAD SOURCE 2

FIG. 1 BP IS OPEN WITH ATS IN SOURCE 1

SOURCE 1

ATS

LOAD SOURCE 2

FIG. 2 BP IN SOURCE 1 WITH ATS IN SOURCE 1

SOURCE 1

ATS

LOAD SOURCE 2

FIG. 3 BP IN SOURCE 1 WITH ATS IN TEST (LOAD CONNECTIONS ARE OPEN)

SOURCE 1

ATS

LOAD SOURCE 2

FIG. 4 BP IN SOURCE 1 WITH ATS ISOLATED

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ZBTS / ZBTSD Operation & Maintenance Manual

Standard and Delay Transition

Each Entelli-Switch 250 microprocessor based ATS controller requires Controls Power Supply (CPS) to apply line voltage to the ATS operator via SCRs. 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 Controls Power Supply (CPS). This method of switching operator voltage and applying power and sensing voltage to the printed circuit board isolates the MX250 from the line voltage, further protecting the controller from harmful line transients.

Controls Power Supply (CPS)

Primary CPS CPS Voltage Assembly Board

at 50/60 Hz Part No. No.

120V 50P-1224 50P-1200 208-220V 50P-1225 50P-1201 230-240V 50P-1226 50P-1202

277V 50P-1227 50P-1203 380-400V 50P-1228 50P-1204 416-440V 50P-1229 50P-1205 460-480V 50P-1230 50P-1206 575-600V 50P-1231 50P-1207

Figure 17

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ZBTS / ZBTSD Operation & Maintenance Manual

Figure 18

Figure 19

Standard Transition CPS Schematic

Delayed Transition CPS Schematic

Controls Power Supply (CPS)

(cont’d)

20 21 22

31 32

20 21 22

XN1 XN2

24V 10V 11V 10V

800

902

804

803

C.V.

SCR-N

801

805

806

804

807

C.V.

SCR-E

900

30 31

XE1

24V 10V 11V

902

904

903

905

906

XE2

904

XN1 -

SOURCE 1 CONTROL TRANSFORMER

XN2 -

SOURCE 1 3 PHASE SENSING TRANSFORMER

XE1 -

SOURCE 2 CONTROL TRANSFORMER

XE2 - SOURCE 2 3 PHASE SENSING TRANSFORMER

907

900

SOURCE 2 24V OUTPUT

(18)

800

SOURCE 1 24V OUTPUT

907

3 PHASE SOURCE 2

808

(BLANK)

908

(BLANK)

GND

GROUND

901

C.V. SCR-E CONTROL VOLTAGE (SOURCE

801

C.V. SCR-N CONTROL VOLTAGE (SOURCE

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)

XN1 -

SOURCE 1 CONTROL TRANSFORMER

XN2 -

SOURCE 1 3 PHASE SENSING TRANSFORMER

907

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

C.V. SCR-EO CONTROL VOLTAGE (OPEN SOURCE

908

GND

C.V. SCR-NO CONTROL VOLTAGE (OPEN SOURCE

GROUND

901

C.V. SCR-E CONTROL VOLTAGE (SOURCE 2)

801

C.V. SCR-N CONTROL VOLTAGE (SOURCE 1)

902

COMMON

903 904 803 804 807 806 805 906 905

(1)

SINGLE PHASE SOURCE 2 SENSING

3-PHASE SOURCE 1 SENSING

SOURCE 1 CONTROL POWER

SOURCE 2 CONTROL POWER

XN1 XN2

C.V.

SCR-EO

800

902

803

805

806

804

C.V.

SCR-N

801

808

804

807

SCR-NO

900

C.V.

908

C.V.

SCR-E

XE1

24V 10V 11V 10V24V 10V 11V 10V

902

903

904

908

901

905

906

XE2

904

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ZBTS / ZBTSD Operation & Maintenance Manual

Troubleshooting and Diagnostics

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

Engine does not stop

LCD Display “TD Engine Cool Down”

SOURCE 1 POSITION, and SOURCE 1 and SOURCE 2 AVAILABLE LEDs on, but U timer has timed out

U timing cycle not complete

Engine start wires not terminated correctly

Generator in MANUAL

Check U timer setting

Check Engine Start Connections

Place generator in AUTO

ATS will not transfer to SOURCE 2

SOURCE 2 AVAILABLE LED off

None

SOURCE 2 voltage or frequency not within acceptable parameters

Power supply connector unplugged

Check: Engine Start Connections, Generator Breaker, Generator Output, and Engine Control Switch

Plug in connector

ATS will not transfer to SOURCE 1

SOURCE 1 AVAILABLE LED off

None

SOURCE 1 voltage or frequency not within acceptable parameters

Power supply connector unplugged

Check utility and utility breakers

Plug in connector

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.

Generator is in OFF position

Investigate why Engine Control Switch was turned off

LCD Display “S1 _ _ _ _ TD XFR S1>S2 Time Remaining _ _ _ _”

W timing cycle not complete Check W Timer setting

LCD Display “Diagnostic Code 001”

LCD Display “S1 OK

Time Remaining _ _ _ _

Bypass”

Limit switch or RT box connector unplugged

T timing cycle not complete

Call Technical Services

Check TTimer setting

LCD Display “ATS Open Time Remaining _ _ _ _”

DW timing cycle not complete Check DWTimer setting

LCD Display “ATS Open Time Remaining _ _ _ _”

TD timing cycle not complete Check DT Timer setting

NOTE: When you use the troubleshooting charts,

the Annunciation column refers to the LED’s on the control panel.

Table 5

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.

DANGER

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ZBTS / ZBTSD Operation & Maintenance Manual

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:

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 battery 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).

CAUTION

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.

WARNING

Both power sources must be disconnected

before manual operation of the switch.

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.

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ZBTS / ZBTSD Operation & Maintenance Manual

ZBTSH / ZBTSDH

Standard Control Panel Layout (SSRCP)

Panel Mount Control Relays

SPARE

J1 J2 J3 J4 J5 J6 J7 J8 J9 J10 J11

JUMPERS

B2 B3

VFSM

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, Y N 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

VFSM

CE1

CN1

XN XE

TAG

DESCRIPTION

ATS Source 2 (EMER) Position Indicator ATS 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

Figure 20

Figure 21

ATS

NORMAL

SOURCE 1

EMER

SOURCE 2

PRESS TO TEST

HOLD UNTIL

TRANSFER

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ZBTS / ZBTSD Operation and Maintenance Manual

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 momentary 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 RT 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-energized 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.

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ZBTS / ZBTSD Operation and Maintenance Manual

CAUTION

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 22.

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

Timer

T U

30 minutes

5 minutes

1 second

Table 4

Figure 23

Factory Setting

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

Voltage/Frequency Sensor (VFSM)

The “restore” or pickup point may be adjusted by rotating the adjustment screw as shown in Figure 23. Counter-clockwise rotation increases the pickup voltage.

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

Adjustable: 80% to 95% Factory Set: 90%

“Restore”/Pickup Frequency

Adjustable: 80% to 100% 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 24.

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 24

Figure 22

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ZBTS / ZBTSD Operation and Maintenance Manual

71R-4000B (11/08)

GE Digital Energy – Power Quality

830

W 40th Street, Chicago, IL 60609 USA

800 637 1738 www.gedigitalenergy.com/ats

Information subject to change without notice. Please verify all details with

GE.

Extensive Customer Service and Support

Supported by a worldwide network of factory-trained Authorized Service Centers, our Technical Service Representatives can provide you with ﬁeld service, equipment parts and preventive maintenance.

Because emergency power systems are required to operate under the most adverse circumstances, site personnel may be called upon at any time to make decisions regarding the operation of the system, therefore training of these personnel is critical to the future of any installation.

GE oﬀers a variety of training options including on-site classes for project

personnel, factory instruction on your equipment prior to shipment and service schools covering transfer switches and switchgear systems.

Product Overview

When you purchase emergency power equipment, reliability and quality are a necessity.

GE is committed to providing the highest level of quality

demanded by the industry. Our complete product line will allow you to specify a total power management system while maintaining overall compatibility and the most comprehensive warranty in the industry.

Commitment to the Customer

All team members at GE are aware of the critical situations in which our products are called upon to perform. With that understanding comes an obligation beyond merely fulﬁlling an order or turning out a product. Serving that obligation is our mission at

GE.

GE’s team works with you from the first phone call through completed

start-up. Then, working hand in hand with the consulting engineer, the contractor and the facility owner/operator, we’ll ensure that the system fulfills both current and future needs.

“Commitment to our customer” has been

GE’s driving force for more than

100 years in the power control industry. This same sense of purpose and responsibility will continue as we address future power control challenges.

GE Industrial Solutions ZBTSD User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual