GE Industrial Solutions ZTSH User Manual
43R-1000E
1/99
OPERATION AND MAINTENANCE MANUAL
AUTOMATIC TRANSFER SWITCH
ZTSH SERIES
30-4000 AMPS
ISO 9001
Page
Introduction ............................................................................................................................................................................................1
Installation ................................................................................................................................................................................................2
Equipment Inspection and Storage......................................................................................................................2
Mounting ......................................................................................................................................................................................2
Power Connections..............................................................................................................................................................3
Control Connections ..........................................................................................................................................................3
Final Equipment Inspection........................................................................................................................................4
Functional Test ........................................................................................................................................................................6
Operation and Features
................................................................................................................................................................7
Sequence of Operation
.................................................................................................................................................. 7
Zenith Module 9 Accessory Package..................................................................................................................8
Zenith Optional Accessories ......................................................................................................................................9
Maintenance and Testing..........................................................................................................................................................10
Inspection and Cleaning ..............................................................................................................................................10
Servicing......................................................................................................................................................................................10
Testing ..........................................................................................................................................................................................10
Troubleshooting ..................................................................................................................................................................12
Adjustments and Settings ........................................................................................................................................................10
Solid State Timers..............................................................................................................................................................10
Voltage/Frequency Sensor VFSM ......................................................................................................................10
Solid State Phase Relays..............................................................................................................................................10
Electronic Exercise Clock Z1000-1A ..............................................................................................................12
Electronic Exercise Clock Z2000-2A ..............................................................................................................12
Appendix A—Typical Schematic Diagrams ............................................................................................................12
40 to 150 Amp, Series 2, ZTSH Switches ....................................................................................................12
40 to 260 Amp Switches ..............................................................................................................................................12
400 Amp Switches..............................................................................................................................................................12
600 to 1200 Amp Switches ........................................................................................................................................12
1600 to 4000 Amp Switches......................................................................................................................................12
Appendix B—Replacement Parts ....................................................................................................................................12
Power Panel 40 to 150 Amp, Series 2, ZTSH Switches ..................................................................12
Power Panel 40 to 260 Amp Switches..............................................................................................................12
Power Panel 400 Amp Switches ............................................................................................................................12
Power Panel 600 to 1200 Amp Switches........................................................................................................12
Power Panel 1600 to 3000 Amp Switches ....................................................................................................12
Power Panel 4000 Amp Switches ........................................................................................................................12
Standard Control Panel SSRCP............................................................................................................................12
Optional Control Panel ................................................................................................................................................12
Cabinet Door Pivot Devices ....................................................................................................................................12
Table of Contents
Zenith Transfer Switches are used to provide a continuous source of power for lighting and
other critical loads by automatically transferring from the normal source of power to an emergency source of power in the event that the normal source voltage falls below preset limits.
All Zenith transfer switches are designed for use on emergency or standby systems, and
are rated for total system or motor loads. Transfer switches are UL Listed under Standard
1008 and CSA Certified under Standard C22.2 No. 178.
This manual provides information on the installation, operation and maintenance of the
switch. In addition, a complete information package is supplied with each transfer switch
which details the features and accessories provided on that switch. The information package and the instruction manual should be kept in a readily accessible location to provide
complete reference information on this critically important piece of equipment.
Introduction
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ZTSH Operation and Maintenance Manual (43R-1000)
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ZTSH Operation and Maintenance Manual (43R-1000)
Each Zenith transfer switch is factory wired and tested. A complete information package
is furnished with each switch which includes:
a. Sequence of operation.
b. Description and operation of all accessories supplied.
c. Power panel connection diagram and schematic.
d. Description and identification of all customer field connections.
Installation of Zenith transfer switches includes:
a. Mounting the transfer switch cabinet.
b. Connection of all Normal, Emergency, and Load cables or bus bars.
c. Connection of external control circuits as required.
Equipment Inspection and Storage
Immediately inspect the transfer switch when received to detect any damage which may have
occurred during transit. If damage is found or suspected, file claims as soon as possible with
the carrier and notify the nearest Zenith representative.
Before installation, it is necessary to store the transfer switch in a clean dry place, protected from
dirt and water. Provide ample air circulation and heat, if necessary, to prevent condensation.
Storage Temperature: -30° C to + 85° C (-22° F to +185° F)
Operating Temperature (Ambient): -20° C to +75° C (-4° F to +167° F) [30-260 Amps]
-20° C to +40° C (-4° F to +140° F) [400-800 Amps]
Humidity: 5% to 95% (non-condensing)
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.
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.
Installation
DANGER
HAZARDOUS VOLTAGE
(Can Cause Severe Injury or Death)
Turn OFF all power before installation, adjustment, or removal of transfer switch or any of its components.
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D
CABINET
LIFTING EYES
SPREADER BAR
H
45°
Figure 1
NOTICE
When lifting the switch using a spreader bar, height H must be equal to half of distance D.
Installation (cont’d)
Table 2
Tightening Torque for Lugs
Socket Size
Across Flats
Torque
Lb. - In. Lb. - Ft.
451/8 4
1005/32 8
1203/16 10
1507/32 12
2001/4 17
2755/16 23
3753/8 31
5001/2 42
6009/16 50
Table 3
Tightening Torque for Bus Bars
Bolt Size
Torque Bolt (Grade 5)
Lb. - In. Lb. - Ft.
721/4-20 6
1325/16-18 11
3003/8-16 25
7201/2-13 60
Power Connections
Zenith transfer switches are supplied with
UL listed solderless screw type terminals
as standard for the Normal, Emergency and
Load power connections. Table 1 lists the
number and sizes of cable lugs supplied
as standard for each switch amp rating.
Connect the Normal, Emergency, and Load
conductors to the clearly marked terminals
on the transfer switch. Remove surface
oxides from cables by cleaning with a wire
brush. Verify that all connections are correct before tightening the lugs. All cable
lug connections must be tightened to the
proper torque values as shown in Table 2.
Do not run cables or wiring behind frontconnected transfer switches.
In cases where the Normal, Emergency and
Load connections are made to a rear connected bus bar, a compression washer, flat
washer, and a minimum grade 5 bolt must
be used and torqued to the values in Table 3.
Control Connections
A complete information package is furnished with each
transfer switch including a complete connection diagram
and schematic which details all necessary control circuit
field connections.
The engine start control wires connect to the terminals
specified in the upper left corner of the control panel.
Figure 2 shows the location of these terminals on the standard SSRCP printed circuit board mounted on the steel
backplate. These terminals are clearly identified by a preprinted label attached to the steel control panel. In the
case of manual transfer switches, or in other applications
not requiring the standard control panel, clearly marked
terminal blocks are provided in the upper left corner of
the control panel for the engine start control wires.
Terminals for field connections to the A3 Emergency auxiliary contacts and the A4 Normal auxiliary contacts are also
provided. These terminals are clearly marked and appear on
the side of the power panel. On 400 amp units these terminals
appear on the disconnect switch bracket above the operator
handle, and are marked as illustrated in Figure 3.
Figure 2
ENGINE
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ZTSH Operation and Maintenance Manual (43R-1000)
Installation (cont’d)
Figure 3
Table 1
Screw Type Terminals for External Power Connections
Switch Size
(Amps)
40
80
100
150
225
260
400
600
800
Normal, Emergency & Load Terminals
1 #8 to 2 AWG
Cable Per Pole Range of Wire Sizes
1000
1200
1600
2000
3000
4000
1 #8 to 1/0 AWG
1 #8 to 1/0 AWG
1 #8 to 3/0 AWG
1 #6 AWG to 250 MCM
1 #6 AWG to 350 MCM
1 #4 AWG to 600 MCM
2 #2 AWG to 600 MCM
4 #2 AWG to 600 MCM
Fully Rated Neutral Bar (When Required)
3 #8 to 1/0 AWG
No. of Cables Range of Wire Sizes
3 #8 to 1/0 AWG
3 #8 to 1/0 AWG
3 #6 AWG to 300 MCM
3 #6 AWG to 300 MCM
3 #6 AWG to 300 MCM
4 #2 AWG to 600 MCM
8 #2 AWG to 600 MCM
12 #2 AWG to 600 MCM
4 #2 AWG to 600 MCM 12 #2 AWG to 600 MCM
4 #2 AWG to 600 MCM 12 #2 AWG to 600 MCM
Line and load terminals are located
in rear and arranged for bus bar
connection.
12
12
12
12
3/0 AWG to 750 MCM
3/0 AWG to 750 MCM
3/0 AWG to 750 MCM
3/0 AWG to 750 MCM
A3-2
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Make all other necessary external control connections to the appropriate terminal blocks located
on the control panel. Insure that all connections
are tightened to the torque specified in Figure 4.
Final Equipment Inspection
Prior to energizing the transfer switch:
a. Remove any debris incurred due to shipment or installation.
DO NOT use a blower
since debris may become lodged in the electrical and mechanical components and
cause damage. Use of a vacuum is recommended.
b. Verify that all cabled connections are correct and that phase rotation of both
sources match.
c. Check engine start connections and verify the correct connection of all control wires.
d. Check settings of all timers and adjust as necessary. Also adjust any optional acces-
sories as required.
e. Check the integrity of power connections by verifying actual lug torque values as
specified in this manual.
f. Make sure that all covers and barriers are installed and properly fastened.
Functional Test
The functional testing of the transfer switch consists of manual and electrical tests described
in this section. Before proceeding, refer to the information package supplied with the transfer
switch. Read and understand all instructions and review the operation of all accessories provided.
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 Normal and Emergency positions.
The transfer switch should operate smoothly without binding. Return the switch to the
Normal position, remove the handle, and return it to the holder provided.
Before starting the electrical operation test,
check the equipment rating nameplate on the
transfer switch to verify the correct system
voltage. An example of the equipment rating
nameplate is shown in Figure 5.
First, close the Normal source circuit breaker.
The phase relays B1, B2, and B3 will pick up
and the LED indicators will be illuminated.
Verify the phase to phase voltages at the
Normal line terminals.
Installation (cont’d)
Figure 4
Control Wire Connections
Wire Size (AWG)
18-16
14-8
6-4
Torque Lb. - In.
19
19
36
Figure 5
SERIAL NUMBER:
RATING: VOLTS -
AMPS SYSTEM VOLTS:
MODEL NUMBER:
HZ -
PHASE -
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ZTSH Operation and Maintenance Manual (43R-1000)
Next, close the Emergency source breaker and start the engine generator. The VFSM relay
will pick up and the LED indicator will be illuminated. Check the phase to phase voltages at
the Emergency line terminals. Also, verify that the phase rotation of the Emergency source is
the same as the phase rotation of the Normal source.
After the sources have been verified, shut down the engine generator, and put the starting
control in the automatic position. Complete the visual inspection of the transfer switch,
and close and lock the cabinet door.
Initiate the electrical transfer test by activating the TS test switch. The CR control relay will
drop out and the P1 engine start timer will start its timing cycle.
After the P1 timer has completed its timing cycle, the engine start contact will close and signal
the engine generator to start. The VFSM relay will energize. The switch will transfer to the
Emergency source after the time delay of the W timer.
Deactivating the test switch will start retransfer to the Normal source. The switch will retransfer to the Normal source after the time delay of the T timer. The U engine over-run timer allows
the engine generator to run unloaded for a preset cool down time period.
Installation (cont’d)
NOTICE
A periodic test of the transfer switch under load conditions is recommended to insure proper operation.
(See National Electric Code articles 700 and 701).
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Sequence of Operation
Figure 6 is a typical schematic diagram of a Zenith transfer switch with a Module 9 accessory
package. 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 the Emergency source begins automatically when any
phase of the Normal source falls below the preset dropout point and this undervoltage
failure condition is detected by the solid state phase relays B1, B2, B3.
The phase relays drop out, de-energizing the normal 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 the Normal source voltage returns above the pickup setting of the phase relays, the P1 timing cycle is reset to zero by the re-energization of the CR relay.
If the normal source voltage does not return before the P1 time delay is completed, the P1 timer
drops out and sends a starting signal to the engine generator. An emergency voltage and frequency sensing relay VFSM monitors the voltage and frequency of the Emergency source. When
both the voltage and the frequency of the Emergency source reach the preset pickup points,
the VFSM relay initiates the transfer to the Emergency source and timer W begins its timing
cycle. The W timer provides an adjustable transfer delay to the Emergency source as required.
When the W time delay is completed, the Emergency control relay RT energizes and picks
up the power relay, CE1 or CCE. The power relay connects voltage from the Emergency
source to the Emergency switch operating circuit caaausing the switch to transfer its main
contacts to the Emergency source. The switch is mechanically locked in the Emergency
position. The power relay and Emergency 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 the Normal control circuit for retransfer when the Normal source is restored.
The sequence for retransfer to the Normal source begins automatically when the voltage
on all phases of the Normal source reach the preset pickup point and this condition is
detected by the solid state phase relays.
When the Normal source restores, the solid state phase relays B1, B2, B3 pick up and initiate
retransfer of the switch to the Normal source by energizing timer T and beginning its timing
cycle. The T timer provides an adjustable delay to ensure that the Normal source has stabilized
before reconnection to the load. If the Normal source 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, the Normal control relay CR energizes and picks up the
power relay, CN1 or CNN. The power relay connects voltage from the normal source to the
Normal switch operating circuit causing the retransfer of the main switch contacts to the
normal source. The switch is mechanically locked in the Normal position. The power relay and
the Normal 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 timefor the engine generator to run without load and cooldown
before shutdown. After the U time delay is completed, the P1 timer is energized and the
engine generator is shutdown.
Operation and Features
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N3
T3
N2
T2
N1
T1
NN
TN
E3
E2
E1
EN
22
21
20
32
31
30
16
15
20B121 22
CCN
323130
E1,2,3,N - EMERGENCY LINE
T1,2,3,N - LOAD
N1,2,3,N - NORMAL LINE
SWITCHED NEUTRAL OR
SOLID NEUTRAL IF REQUIRED
CR
CR
T
B1 B2 B3
CR
C
NC
NO
U
P1
CCN
23
23A 23B 23C
23Z
28
26
28Z
29
J1
J2
J3
J4
J7
CCN - POWER RELAY, ENERGIZES TRANSFER
TO NORMAL SOLENOID
W
RT
W - TIME DELAY TO EMERGENCY
RT - EMERGENCY CONTROL RELAY
CCE - POWER RELAY, ENERGIZE
VFSM- EMERGENCY VOLTAGE AND
FREQUENCY SENSING RELAY
VFSM
L2
27
RT
J5
T
U
25Z
P1
ENGINE START CONTACT FROM P1
LEGEND
WIRE CONNECTION
WIRE ON MAIN TERMINAL BLOCK
WIRE ON DISCONNECT PLUG
OPTIONAL ACCESSORY
A4
NORMAL
SN
A3
EMERGENCY
MECHANICALLY ACTUATED
NORMAL AND EMERGENCY
POSITION CONTACTS A3 & A4
B2
B3
CE - TRANSFER TO EMERGENCY SOLENOID
CN -TRANSFER TO NORMAL SOLENOID
DS - DISCONNECT SWITCH FOR SERVICE
XN - NORMAL CONTROL TRANSFORMER
XE - EMERGENCY CONTROL TRANSFORMER
UNDER VOLTAGE RELAYS
COM
TS
YN
J8
J6
J9
CR
33Z
37
W
RT
J10
2524
C
NC
NO
CCE
36
L1
35Z
SE
J11
3534
33Y
VFSM
33A
33
RT
38
RT
CR
12A
13
11
12
T - TIME DELAY ON RETRANSFER
CR - CONTROL RELAY
YN - PUSH BUTTON TO BYPASS T
L2 - NORMAL POSITION LIGHT
U - ENGINE OVER-RUN TIMER
P1 - TIME DELAY TO ENGINE START
SN - MECHANICALLY ACTUATED CONTACTS
(NORMAL POSITION)
SE - MECHANICALLY ACTUATED CONTACTS
(EMERGENCY POSITION)
L1 - EMERGENCY POSITION LIGHT
CN
206209
CCE
CE
306307
DS
NOTE - ZTSH SHOWN IN NORMAL POSITION WITH NO POWER AVAILABLE
NN EN
14
Figure 6
Typical Schematic Diagram
Operation and Features (cont’d)
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ZTSH Operation and Maintenance Manual (43R-1000)
Zenith Module 9 Accessory Package
The Zenith Module 9 Accessory package includes nine of the commonly specified accessories.
These accessories are:
A Auxiliary Contacts:
A3 Closed when switch is in emergency position
L Indicating LED Pilot Lights:
L1 Indicates switch in emergency position
L2 Indicates switch in normal position
P1 Time Delay - Engine Start: Adjustable 0.5 to 6 seconds
T200 Time Delay on Retransfer to Normal: To delay retransfer to normal source (immediate
retransfer on generator set failure); standard setting 30 minutes, adjustable 0-60 minutes.
T100 Time Delay on Retransfer to Normal: To delay retransfer to normal source (immedi-
ate retransfer on generator set failure); standard setting 30 min., adjustable 0-30 min.
T3/W3Time Delays - Presignal for Auxiliary Control: Prior to transfer between two live
sources in either direction, provides an adjustable (factory set at 20 second) presignal contact closure
U200 Time Delay for Engine Cooldown: Allows engine to run unloaded after switch
retransfers to normal. Standard setting 5 min., adjustable 0-60 minutes.
U100 Time Delay for Engine Cooldown: Allows engine to run unloaded after switch
retransfer to normal; standard setting 5 min., adjustable 0-5 min.
W200 Time Delay on Transfer to Emergency: To delay transfer to emergency after nor-
mal source failure; standard setting 1 sec., adjustable 0-5 minutes.
W100 Time Delay on Transfer to Emergency: To delay transfer to emergency after verifying
emergency source available; standard setting 1 sec., adjustable 0-15 sec.
Operation and Features (cont’d)
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ZTSH Operation and Maintenance Manual (43R-1000)
Operation and Features (cont’d)
Zenith Optional Accessories
Many control accessories are available to meet specific requirements. Some of the more
commonly specified accessories are:
A Auxiliary Contacts:
A6 Deenergizes external motor control circuit5 seconds (adjustable) prior to
transfer in either direction.
C Plant Exerciser (no load): Automatically starts the generator to run unloaded at
selected intervals
C/D Plant Exerciser (Load/no load): Allows the generator to start and run unloaded
or to simulate a power failure, start generator and run under load. Specify weekly,
bi-weekly or calendar schedule
L Indicating LED Pilot Lights:
L3 Indicates normal source available
L4 Indicates emergency source available
P2 Time Delay - Engine Start: Adjustable 0.5 to 300 seconds
Q2 Peak Shave/Remote Load Test: Input for peakshave or remote load test; includes
automatic return to normal if emergency source fails and normal is present; 120
VAC or 24 VDC
R4 In-Phase Monitor: Prevents transfer until two sources are in relative synchronism
R43 In-Phase Monitor: Prevents transfer until two sources are in relative synchronism
S1 Four-position selector switch (Stop - Hand Crank - Test - Automatic)
S2 Disconnect switch in series with accessory E to disconnect engine-starting circuit
S3 Source selector switch circuit; to select either source as primary
T3/W3Time Delays - Presignal for Auxiliary Control: Prior to transfer between two live
sources in either direction, provides an adjustable (factory set at 20 second) presignal
contact closure
W100 Time Delay on Transfer to Emergency: To delay transfer to emergency after verifying
emergency source available; standard setting 1 sec., adjustable 0-15 sec.
YEN Pushbutton Bypass of T&W Timers
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