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GE ZBTSD User's Manual

1. pg 12 L4OUT L30UT Lithium Battery Exerciser Battery L20UT Replacement K 4100 BR2032 ervice Life 10 Years gperation IN PHASL MONITOR R50 ON OFF pq 12 L10UT YNIN YEIN TSNLIN User Access Code Default 121212 1 OVER VOI TAGF R1 1 or R1 3 ON OFF pg 11 Q2 TSL IN oed Bil 2 S121N 551 24 Hour Service 773 299 6600 OOOOOOOOOOOOOO S1UNDFR FREQUENCY ON OFF pg 8 Entelli Switch MX250 S OVER VOI TAGF Figure 11 ON OFF pg 8 2 OVER FREQUENCY ON OFF pg 8 PHASE IMBALANCE V ON OI pg 13 PHASE ROIAIION MAICH R16 ON OFT pg 11 LOAD DISCONNECI ID UMD pg 13 I RANSI LR ALARM ON OFF pg 10 NFTWORK 7NFT ON OFF pg 13 3 Opilonal Accessories m16 ZBTS ZBTSD Operation and Maintenance Manual 71R 4000A GE Zenith Controls Entelli Switch 250 User Setup SET Menu EE Change adjustable values 01 50 a are through the SET menu MORE TEST Enter six digit access code The factory assigned six digit access code 1 2 VAB is located on the back of the controller VBC VBC VCA VCA MORE CFG SET ESC TE 1 warne 5 Controller Inputs must be relay Isolated 6 ae ae g Engine Start Relay De Energized SE ek ranean USER SEI UP E amp sour E mon O xcu nevre our SEI SYSIEM CLOCK 09 13 ol MOTOR DISC OUT
2. 71R 4000B 1 06 GE Zenith Controls ZBTS ZBTSD Series Bypass Isolation Transfer Switches 100 4000 Amps Operation and Maintenance Manual Authorized Service For GE parts and service call 773 299 6600 Table of Contents Introduction ge a e e a ii Testing E E do pedet A A 19 Safetyi iicet gu hes cael esis en cake 1 ATS Testing sisip ees evhe sites oe geet 19 Equipment Inspection and Storage 1 Standard Transition 19 Final Equipment Inspection 1 Delayed Transition 19 Mounting 1 Sequence of Operation 20 Installation 2 Standard Transition 20 Power Connections 2 Delayed Transition 20 Engine Start Control Connections 2 3 Controls Power Supply CPS 21 Initial Energization 3 4 Schematics Standard amp Delay 22 Control Connections 5 Troubleshooting amp Diagnostics 23 Entelli Switch 250 Microprocessor Controller 6 Maintenance and Testing 24 Overview bind Gee eng hale EA 6 Inspection and Cleaning 24 LCD amp Keypad 6 cece 7 Serco 24 User Setting for Voltage amp Frequency 8 Jesting d
3. Both power sources must be disconnected before manual operation of the switch A preventive maintenance program will insure high reliability and long life for the transfer switch The preventive maintenance program for the transfer switch should include the following items Inspection and Cleaning The switch should be inspected for any accumulation of dust dirt or moisture and should be cleaned by vacuuming or wiping with a dry cloth or soft brush do not use a blower since debris may become lodged in the electrical and mechanical components and cause damage Remove the transfer switch barriers and check the condition of the contacts Any surface deposits must be removed with a clean cloth do not use emery cloth or a file If the contacts are pitted or worn excessively they should be replaced A general inspection of mechanical integrity should be made to include loose broken or badly worn parts Servicing All worn or inoperative parts must be replaced using GE Zenith recommended replacement parts Please refer to the Replacement Parts manual for specific part information and ordering procedures Please contact the GE Zenith Technical Services Department for the Replacement Parts manual The operating mechanism of the transfer switch is lubricated with Lubriplate 105 The lubricant applied at the factory provides adequate lubrication for the lifetime of the switch Should debris contaminate the mechanism clean and a
4. 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 S1 OK 5 Close the External up stream Source 2 line 21 56 circuit breaker MON 23 APR 2002 6 Start the engine generator in MANUAL mode NOTE When the voltage and frequency reach preset values the Source 2 Available LED will illuminate 7 Verify the phase to phase voltages at Source 2 line terminals 8 Verify that the phase rotation of A Source 2 is the same as the phase f rotation of Source 1 Entelli Switch 250 9 Shut down the generator s engine Place in Automatic Mode Figure 5 LCD and keypad 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 AUTO 1l Complete the visual inspection of the transfer switch 12 Close the enclosure 13 Lock the enclosure A WARNING A When performing a hi pot or dielectric test on the power section DISCONNECT the control panel plugs from the microprocessor to avoid potential damage ZBTS ZBTSD Operation and Maintenance Manual 71R 4000A GE Zenith Controls Installation conra A DANGER A HAZARDOUS VOLTAGE Can Cause Severe Injury or Death Turn OFF all power before installation adjustment or removal of transf
5. Load and Neutral terminals are located in the rear of switch 2600 3000 4000 and arranged for bus bar locations Table 1 Tightening Torque for Lugs Engine Start Socket Size Control Connections Across Flats Engine start control wires connect to control terminals 1 8 beside the Entelli Switch 250 Engine start terminals are 5 32 indicated by a schematic symbol the symbol indicates the contact state for a de energized normal source 3 16 Figure 2 shows the engine start contacts 7 32 Make all other necessary control connections to the control panel terminal blocks per the schematics 5 16 supplied with the ATS 3 8 NOTE All control wires 18 12 AWG must be 1 2 torqued to 19 in Ibs 9 16 Table 2 m2 ZBTS ZBTSD Operation and Maintenance Manual 71R 4000A GE Zenith Controls Installation conta DANGER A 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 Contact rating is 6 H 10 Ampere at 120VAC or 28VDC Gold plated Figure 2 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 c
6. Total Life Transfers N2P Days Powered Up Total Transfers to S2 Total S1 Failures Time SI available in Hrs Time S2 available in Hrs N1P F Fan contact operates when generator is running HT Heater and Thermostat K Frequency Meter Door mount K P Frequency Indication for S1 and S2 L LNP Center off position LCD Indicator Indicating LED lights L1 Indicates Switch in Source 2 position L2 Indicates Switch in Source 1 position L3 Indicates Source 1 available L4 Indicates Source 2 available m10 ZBTS ZBTSD Operation and Maintenance Manual 71R 4000A GE Zenith Controls m Accessory Definitions 1 Single Phase Amp Meter M2 Three Phase Amp Meter M80 3000 Digital Power Monitor M82 5200 Digital Power Meter M83A EPM 5300 Digital Power Meter with Modbus Port MS83B 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 M836A EPM 9650 Digital Power Meter Wye or Delta RS232 or RS485 M36B EPM 9650 Digital Power Meter Wye or Delta RS232 or RS485 N1 Running Time Meter Door mount N2 Operation Counter Door Mount P1 Time Delay Source 2 Start Adjustable 0 10 seconds Standard setting is 3 seconds Adjust via SET menu see page 18 P2 Time Delay S2 Start Adjustable 1 6 to 300 seconds
7. Clock Exerciser Load No Load Allows the Generator to start and run unloaded or to simulate a power failure start Generator and run under load Can be configured by end user for 1 7 14 28 365 day cycle See page 16 CDT Load or NO Load One event exerciser with adjustable Engine exercise timer Exercise duration can be set between 5 and 60 minutes in 1 minute increments Can be configured to run every 1 7 14 or 28 days Factory Default is 20minutes When exerciser is impending E appears in the upper right hand corner of LCD screen See page 15 for instructions Configured via CFG see page 17 Set via SET menu see page 18 CTAP Alarm Panel on transfer to Source 2 with Silence button DS Disconnect Switch Auto Inhibit Inhibits transfer in either direction when in inhibit Allows automatic operation when in Auto 40 400 Amps optional 600 4000 Amps standard DT Delayed Transition Only Time Delay from Neutral Switch position to Source 1 position Adjustable 0 10 minutes in 1 second incre ments Standard setting is 5 seconds Adjust via SET menu see page 18 DW Delayed Transition Only Time Delay from Neutral Switch position to Source 2 position Adjustable 0 10 minutes in 1 second incre ments 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
8. Q2 Remote Peak Shave or Area Protection Circuit Energize Q2 to simulate Source 1 Line failure causing the Generator to start and transfer the load to Source 2 Should Emergency fail during this operation Transfer Switch will retransfer back to Source 1 Q3 Remote inhibit transfer to Source 2 circuit Energize Q3 input to allow transfer to Source 2 To enable Q3 option engage Q3 jumper m GE Zenith Controls Q7 Inhibit transfer to Source 1 circuit Energize Q7 input to prevent transfer to Source 1 R1 1 R1 3 Source 1 Over Voltage sensing for single and three phase systems Source 1 Over Voltage Fail Factory Default 11096 This adjustment determines the maximum acceptable over voltage Adjust via the SET menu Range is 105 to 11046 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 10596 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 296 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 featur
9. 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 5 SE S D O CO J Co CO 1B 66001066 2 21 22 15 1B Du n i EI TUT jul UUU Primary Voltage at 50 60 Hz 120V 208 220V 230 240V 277V 380 400V 416 440V 460 480V 575 600V m GE Zenith Controls CPS Assembly Part No 50P 1224 50P 1225 50P 1226 50P 1227 50P 1228 50P 1229 50P 1230 50P 1231 ZBTS ZBTSD Operation and Maintenance Manual 71R 4000A 50P 1200 50P 1201 50P 1202 50P 1203 50P 1204 50P 1205 50P 1206 50P 1207 25m Controls Power Supply CPS vona Standard Transition CPS Schematic 20 21 22 XN1 XN2 800 XE1 31 XE2 24V 900 9026 10V 904 903 XN1 SOURCE 1 CONTROL TRANSFORMER XN2 SOURCE 1 3 PHASE SENSING
10. 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 ZBTS ZBTSD Operation and Maintenance Manual 71R 4000A GE Zenith Controls Accessory Group Packages Table 3 Accessories Group Packages cop ________ o o o o p e 9 o o DT _____________ ___ _ __ o _ pw 9 9 9 9 9 9 o o o o o u oe o o o o o T o Standard Accessory included in the group package Optional Accessory not included but can be added to group package Optional Accessory Can not be used with accessory having the same symbol N A Denotes an Accessory with 2 circuits as a standard Delayed Transition Units Only Denotes an Accessory with 3 circuits as a standard Optional for 40 400 Amp W GE Zenith Controls ZBTS ZBTSD Operation and Maintenance Manual 71R 4000A 9m Accessory Definitions 6 Test Switch Momentary 6A Test Switch Maintained Auto Momentary Test 6AP Test Switch Maintained Momentary
11. UAYLIGH I SAVINGS ON OFF Ez msn ome O messi x CLOCK FXFRCISFR CUP 1 1 pg 10 amp 15 om P Rapaz EXER 52 RUNTIME CDT omarm meaac pg 10 amp 14 IE S1 UNUER VOI IAGF pg 8 H ouput source LNOUT Fail 5 Restore O Lithium Battery O TE aan S1 UNDFR FRFQUFNCY pg 8 S au L9 YEN Fail O Restore O E m Ko 24 Hour Service 773 299 6600 81 OVER VOLTAGE pg 11 ME ease aar Fail Entelli Switch MX250 Restore Figure 11 S1 OVER FREQUENCY pg 8 TIME DELAY S2 START P1 Foil 11 Restore AY 7 SIABI F W S2 UNDER VOLTAGE pg 8 pg 13 Fail Restore LOAD PRESIGNAL TD T3 W3 pg 17 S2 UNDER FREQUENCY pg 8 Fail LOAD DISCONNECT TD UMD Restore pg 13 2 OVER VOLTAGE pg 8 Fail Restore ATS OPEN TIME TO 2 DW DELAY units only pg 10 TIME DELAY 1 STABLE T pg 12 52 OVER FREQUENCY 09 8 l ail Restore ATS OPEN TIME TO 1 DT DHI AY units only pg 10 SHI PHASE IMBAI ANCE VI S SIUP DELAY U pg 17 FAIL 5 RESTORE 3 pg 13 CAI IBRAIF S1 pg 10 SCT PIIASE IMBALANCE VI AY 30 seconds pg 13 CAI BRAIF S7 pg 10 L Optional Accessories m GE Zenith Controls ZBTS ZBTSD Operation and Maintenance Manual 71R 4000A 17m Entelli Switch 250 User Setup System Info EM View System Data 01 50 T FRI 31 MAY 2003 Enter six digit access code MORE TEST Th
12. any of its components 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 CABINET front connected transfer switches Figure 1 NOTE When lifting the switch using a spreader bar height H must be equal to half of distance D Power Connections Screw Type Terminals for External Power Connections Switch Size Source 1 Source 2 amp Load Terminals Neutral Bar When Required Amps Cable Per Pole Range of Wire Sizes No of Cables Range of Wire Sizes 40 1 8 AWG to 1 0 8 AWG to 1 0 80 8 AWG to 1 0 8 AWG to 1 0 100 8 AWG to 1 0 8 AWG to 1 0 150 8 AWG to 300 MCM 1 1 1 8 AWG to 3 0 200 225 2500 1 6 AWG to 250 MCM 6 AWG to 300 MCM 260 300 400 4 AWG to 600 MCM 4 AWG to 300 MCM 600 2 AWG to 600 MCM 2 AWG to 600 MCM 800 1000 1200 2 AWG to 600 MCM 2 AWG to 600 MCM 1600 2000 Line
13. frequency reach the preset Restore Values the time delay to Source 2 Timer W begins its timing cycle to ensure voltage and frequency stabilization before transfer A manual pushbutton BYPASS is provid ed to bypass the W time delay if desired After the W time delay the MX controller initiates a transfer signal through the SCR E to operate the main transfer opera tor 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 power reach the preset Restore values the controller initiates re transfer to Source lsequence The delay to Source 1 Timer T begins its timing cycle to ensure voltage and frequency stabiliza tion before retransfer A manual pushbutton BYPASS is provided to bypass the T time delay if desired After the T time delay the 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 pushbut ton 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 T
14. 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 12P 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 14 Test Auto Source 1 Selector Door mount SW1 Auto Off Start Engine control selector Door mount Keyed or no
15. 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 BE SOURCE 2 LOAD BN SOURCE 1 ATS FIG 1 BP IS OPEN WITH ATS IN SOURCE 1 SOURCE 2 BE LOAD BN SOURCE 1 ATS FIG 2 BP IN SOURCE 1 WITH ATS IN SOURCE 1 SOURCE 2 BE LOAD BN SOURCE 1 ATS LOAD CONNECTIONS ARE OPEN SOURCE 2 PE LOAD BN SOURCE 1 ME ATS FIG 4 BP IN SOURCE 1 WITH ATS ISOLATED Figure 14 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 22 ZBTS ZBTSD Operation and Maint
16. the next value to be changed Press BACK when complete 8 Press MORE repeatedly until SET USER SETUP Press BACK then ESC to the 1 OK screen e 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 Pres 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 SI OK Screen Notes e 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 Avalue 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 Load No Load CDP Exercis
17. utilizing keypad 6B Test Switch Maintained Auto Momentary Test Key Operated 6C Test Switch Maintained Auto Maintained Test Key Operated A1 Auxiliary Contact operates on Source 1 line failure ATE Auxiliary Contact operates on Source 2 line failure Auxiliary Contact Closed in emergency Source 2 Additional Available 10 max and need to be specified A4 Auxiliary Contact Closed in normal Source 1 Additional Available 10 max and need to be specified A62 Sequential Universal Motor Load Disconnect Circuit Normally closed auxiliary contacts for motor loads Open 0 60 seconds prior to transfer after transfer or both in either direction then re close in timed sequence after transfer ABS Auxiliary Contact Closed in bypass emergency Source 2 S P D T Standard up to 400 Amp Additional Available 10 max and need to be specified AB4 Auxiliary Contact Closed in bypass normal Source 1 S P D T Standard up to 400 Amp Additional Available 10 max and need to be specified B9 Battery charger connections Calibrate While monitoring the actual Phase to Phase voltage lev els 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
18. 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 Ifthe 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 1 OK screen press MORE then SET 2 Press MORE repeatedly until SET EXERCISER screen Press SEL 4 Enter ACCESS code located on white label on the back of the controller 5 Press SEL ge Indicates of Exercise Periods ndicates type of Exerciser DAILY WEEKLY 14 DAY 28 DAY or 365 DAY ndicates Exerciser start Time for DAILY Exerciser Time amp Day for WEEKLY Exerciser Time Date amp Month for 14 DAY 28 DAY and 365 DAY Exerciser 24 Hour System m GE Zenith Controls Cursor Up and Down Use to change values To previous field or to exit screen 2 ZBTS ZBTSD Operation and Maintenance Manual 71R 4000A 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
19. EE ees 24 Accessory Group Packages 9 ZBTSH ZBTSDH 25 Accessory 10 13 Standard Control Panel Layout SSRCP 25 How to Set the System Clock 13 Panel Mount Control Relays 25 CDT One Event Timer Exerciser 14 Sequence of Operation 26 CDP Clock Exerciser 15 Adjustments and Settings 27 User Setup CFG Menu 16 Solid State Timers 27 User Setup SET Menu 17 Voltage Frequency Sensor VSFM 27 User Setup System Info 18 Solid State Phase 27 Bypass Isolation Operation 21 100 400 Amps 22 600 1200 Amps 23 1600 4000 Amps 24 introduction GE Zenith Transfer Switches are used to provide a continuous source of power for lighting and other critical loads by auto matically transferring from source 1 power to source 2 power in the event that source 1 voltage falls below preset limits 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 Voltage sensing and system control is performed via a state of the art m
20. ET 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 Press SEL 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 Load Transfer or NO XFR No Load Transfer 12 Press SAVE 13 Press MORE repeatedly to BACK then S1 OK screen IW 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 day
21. MX controller initiates a transfer sig nal 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 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 pushbut ton BYPASS is provided to bypass the U time delay if desired Upon completion of the U timing cycle the controller sends an Engine stop signal Table 4 Timer Designations as they appear in the SET menu W Standard Transition Time Delay S2 Start Time Delay S2 Stable DW T DT Time Delay S1 Stable Delayed Transition Time Delay S2 Start Time Delay S2 Stable Transfer to Source 2 gt Source 1 Fails ATS Open Time to S2 Time Delay S1 Stable ATS Open Time to 51 Transfer to Source 1 Engine S 1 d Cooldown Returns m20 ZBTS ZBTSD Operation and Maintenance Manual 71R 4000A GE Zenith Controls Sequence of Operation Bypass lsolation Operation An automatic transfer switc
22. PRE XFR engine generator set When the second source is HEUTE available the manual handle of the bypass may be operated to transfer the load to the available source UH Interlocks prevent both this transfer if the ATS is in ntl Switch 250 the circuit and connected to the opposite source or reconnection of the ATS unless the positions match on the bypass control will automatically start the oA olsconneer Figure 13 WARNING 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 W GE Zenith Controls ZBTS ZBTSD Operation and Maintenance Manual 71R 4000A 21m 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
23. TEM CLOCK using the MORE key 4 Press SEL 5 ENTER ACCESS CODE located on the white label on the back of the controller Press SEL m 6 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 m GE Zenith Controls 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 18 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 4100 Battery will last 5 years and provides power to retain clock function only Controller functions without battery ZBTS ZBTSD Operation and Maintenance Manual 71R 4000A 13m CDT One Event Timer Exerciser 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 S
24. TRANSFORMER XE1 SOURCE 2 CONTROL TRANSFORMER XE2 SOURCE 2 3 PHASE SENSING TRANSFORMER SOURCE 2 24V OUTPUT SOURCE 1 24V OUTPUT 3 PHASE SOURCE 2 JC CV SCR E JC BLANK BLANK GROUND lt lt C V SCR E CONTROL VOLTAGE SOURCE 2 C V SCR N CONTROL VOLTAGE SOURCE 1 COMMON SINGLE PHASE SOURCE 2 SENSING 3 PHASE SOURCE 1 SENSING Figure 18 SOURCE 2 CONTROL POWER Delayed Transition CPS Schematic 20 21 22 XN2 24V 800 9026 30 31 SOURCE 1 CONTROL POWER J5 32 XN1 SOURCE 1 CONTROL TRANSFORMER XN2 SOURCE 1 3 PHASE SENSING TRANSFORMER XE1 SOURCE 2 CONTROL TRANSFORMER XE2 SOURCE 2 3 PHASE SENSING TRANSFORMER SOURCE 2 24V OUTPUT SOURCE 1 24V OUTPUT 3 PHASE SOURCE 2 SENSING C V SCR EO CONTROL VOLTAGE OPEN SOURCE 2 C V SCR NO CONTROL VOLTAGE OPEN SOURCE 1 GROUND C V SCR E CONTROL VOLTAGE SOURCE 2 908 C V SCR N CONTROL VOLTAGE SOURCE 1 COMMON SINGLE PHASE SOURCE 2 SENSING 3 PHASE SOURCE 1 SENSING SOURCE 1 CONTROL POWER SOURCE 2 CONTROL POWER gt Figure 19 26 ZBTS ZBTSD Operation and Maintenance Manual 71R 4000A GE Zenith Controls Troubleshooting and Diagnostics A DANGER A HAZARDOUS VOLTAGES CAN CAUSE SEVERE INJURY OR DEATH These charts m
25. ay 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 con troller 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 m GE Zenith Controls SYSTEM TEST FAST XFR MORE TEST LOAD XFR Entelli Switch 250 i Figure 12 Immediately after re transfe
26. ay indicate problems that require authorized GE Zenith service personnel Hazardous voltages may exist on termination plugs other than those that go into the Entelli Switch 250 General Troubleshooting The following troubleshooting guide is used to recognize and determine basic faults When using this guide it will ask several questions about the condition of the switch This guide will then list an order of the possible faults You will then look at the first suspected fault to determine if it is the problem If it is not a fault you go to the Engine does not START Engine does not stop ATS will not transfer to SOURCE 2 ATS will not transfer to SOURCE 1 m GE Zenith Controls Annunciation SOURCE 2 AVAILABLE LED off LCD Display TD Engine Cool Down second suspected fault If you go through all of the suspected faults or the chart instructs you to call a GE Zenith Representative for further assistance NOTE When you use the troubleshooting charts the Annunciation column refers to the LED s on the control panel Possible Cause s Engine start wires not terminated properly Corrective Action Check engine start connections Generator is in OFF position U timing cycle not complete Investigate why Engine Control Switch was turned off Check U timer setting SOURCE 1 POSITION and SOURCE 1 and SOURCE 2 AVAILABLE LEDs on but U timer has timed out SOURCE 2 AVAILABLE LED o
27. e Indicator Exercise duration for this event in hours and minutes up to 10 hours per event SAVE Figure 10 To save value and to move cursor to next field to be changed 15m Entelli Switch 250 User Setup CFG Menu Turn options ON or OFF via 1 OK 01 50 keypad through the CFG menu FRI 31 MAY 2003 MORE TEST Enter six digit access code The factory assigned six digit access code is located on the back of the controller 1 VAB 2 VAB VBC VBC VCA VCA MORE SET ESC Controller Inputs must be relay Isolated Engine Start Relay De Energized me CONFIG Network Communications USER SETUP option Gene Input Voltage MORE BACK PROG 1 PROG 2 GRD Input Sink LS OUT Controller Outputs have Limited Source Capacit NIA OUT ue Use only GE Zenith specified Output Modules ELEV PRE OUT ALARM OUT STEOUT MOTOR DISC OUT x Output TMS IN Contacts LIMER EXERCISER CDI 1 7 14 28 Day pq 10 amp 14 CLOCK FXFRCISTR LOAD OR NO LOAD CDP 1 7 14 28 365 Day pg 10 amp 15 INHIB gt S1 INHIB gt S2 LSIN 6 Maintained Momentary pg 10 R1 Output RI Output Input and output availability Contact Rating 10A 250 VAC or 30 VDC subject to factory configuration IRANSFER COMMI 13 ON OFT pg 12 412v Output Source LNOUT AUIO MANUAL S5 or S12
28. e factory assigned six digit access code is located on the back of the controller PHASE TO PHASE VOLTAGE S1 amp S2 jam ew relay tolarea Engine Start Relay De Energized M A E FREQUENCY INDICATION FOR S1 amp S2 74 Network Communications H AAA K P pg 10 dione Voltage To PLANT EXERCISER Next Impending Exerciser a M shows only if set Ops SYSTEM INFO PIS Serial Unit Serial B mE Rev Software Revision output Event Log Sequentially Numbered Log 9 Md dios of 16 events that track P mesz date time reason and action taken J T Data Total Life Transfers N2P ki Days Powered Up Total Transfers to 2 input and output avatability area nea subject to factory configuration Total S1 Failures Time S1 available in Hrs Time S2 available in Hrs N1P 12v Output Source LNOUT 1400 CHANGE USER ACCESS CODE L30UT Lithium Battery Exerciser Battery L20UT Replacement K 4100 BR2032 ervice Life 10 Years L1 OUT operation YNIN XEN User Access Code Default 121212 TSNLIN Q2 TSL IN 2 S121N 24 773 299 6600 SSIN Entelli Switch MX250 Figure 11 18 ZBTS ZBTSD Operation and Maintenance Manual 71R 4000A GE Zenith Controls Testing A NOTICE A A periodic test of the transfer switch under
29. e prevents Line Source to Line Source trans fers 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 ZBTS ZBTSD Operation and Maintenance Manual 71R 4000A 118 Accessory Definitions R50 In Phase Monitor this feature restricts Live to Live Source Transfers to occur unless both Sources are within 7 electrical degrees or less of each other live Source to live Source transfers usually occur during transfer back to Source 1 or during Testing R50 does not change the operation of the Automatic Transfer Switch in a power failure mode After all timer functions have elapsed the CHECKING FOR SOURCE SYNCHRO NISM will be displayed as well as the direction of transfer S1 S2 for example denotes transfer from Source 1 to Source2 When synchronism is accomplished transfer will take place Notes If S2 Frequency is less than S1 Frequency display will show a series of symbols If S2 Frequency is greater than S1 Frequency display will show a series of symbols Each o
30. enance Manual 71R 4000A GE Zenith Controls E Sequence of Operation cont d 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 illumi
31. er 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 neces sary to prevent condensation Operating Storage Temperature Temperature Ambient Humidity 30 C to 40 400 AMP 5 to 95 75 C molded shell non con 22 F to 20 C to 65 C densing 167 F 4 F to 149 F 40 4000 AMP all other frame and panel types 20 C to 60 C 4 F to 140 F Final Equipment Inspection Prior to energizing the transfer switch 1 Remove any debris incurred with a vacuum due to shipment or installation A WARNING A Do not use a blower since debris may become lodged in the electrical and mechanical components and cause damage 2 Verify that all cabled connections are correct and that phase rotation of both sources match 3 Check engine start connections 4 Verify the correct connection of all control wires 5 Check settings of all timers and adjust as 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 Each GE Zenith transfer switch is factory wired and tested A complete info
32. er switch or any of its components Control Connections Figure 6 Engine Start Connections Input Output Connectors to Modules To Power Panel A complete information package is furnished with each transfer switch including a complete connection diagram and schematic which details all necessary control circuit field connections The engine start control wires connect to the engine start relay terminals located to the left of the microprocessor Figure 6 shows the location of these terminals Clock Program Backup Battery Remove protective strip to enable clock functions Network Connector To CPS Box The terminals are clearly identified by a label on the microcontroller backplate In the case of manual trans fer switches or in other applications not requiring the microprocessor clearly marked terminal blocks are provided in the upper left corner of the control panel for the engine start control wires m GE Zenith Controls ZBTS ZBTSD Operation and Maintenance Manual 71R 4000A 5m Entelli Switch 250 Controller Entelli Switch 250 Controller Consists of two major assemblies Engine Start Relay P I The Microprocessor contains the following Interface 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 outp
33. ff Engine start wires not terminated correctly Check Engine Start Connections Generator in MANUAL SOURCE 2 voltage or frequency not within acceptable parameters Place generator in AUTO Check Engine Start Connections Generator Breaker Generator Output and Engine Control Switch None Power supply connector unplugged Plug in connector LCD Display S1____ TD XFR 51 gt 52 Time Remaining LCD Display ATS Open Time Remaining __ W timing cycle not complete DW timing cycle not complete Check W Timer setting Check DW Timer setting SOURCE 1 AVAILABLE LED off SOURCE 1 voltage or frequency not within acceptable parameters Check utility and utility breakers None Power supply connector unplugged Plug in connector LCD Display Diagnostic Code 001 Limit switch or RT box connector unplugged Call Technical Services LCD Display S1 OK Time Remaining Bypass T timing cycle not complete Check T Timer setting LCD Display ATS Open Time Remaining TD timing cycle not complete Check DTTimer setting Table 5 ZBTS ZBTSD Operation and Maintenance Manual 71R 4000A 27m Maintenance and Testing A CAUTION A 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 A WARNING A
34. h equipped with a bypass isola tion switch provides the ability to withdraw the ATS for test ing 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 cont d BYPASS SOURCE 2 BYPASS SOURCE 1 ATS INHIBIT SOURCE 2 AVAILABLE SOURCE 1 AVAILABLE ATS ISOLATED DISCONNECT SWITCH INHIBIT POSITION
35. icrocontroller located on the cabinet door It is designed to give highly accurate control of the transfer switch system 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 52 or Source 2 relate to an Emergency or Alternative Power Source 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 22 2 No 178 and IEC Listed under Standard 947 Safety A DANGER A HAZARDOUS VOLTAGE Can Cause Severe Injury or Death Turn OFF all power before installation adjustment or removal of transfer switch or any of its components The safe operation of your switch is GE Zenith s focus The proper storage installation operation and mainte nance will help increase the life of the switch A CAUTION A Due to hazardous voltage and current GE Zenith rec ommends that a GE Zenith Certified technician or a qualified electrician must perform the installation and maintenance of the switch Equipment Inspection and Storage Once you have received the transfer switch inspect it for any damage This includes damage to the enclosure power panel control panel and wiring harness If any damage is found or suspected file a claim as soon as possible with the carri
36. load conditions is recommended to insure proper operation See National Electric Code articles 700 and 701 ATS Testing Start generator and verify proper voltage frequency and phase sequence match to Source 1 Shut down gen set and place in Auto Complete the visual inspection of the transfer switch and close the cabinet door Initiate the test by pressing the TEST button on the LCD keypad The controller will then prompt for your access code After entering the code three test options will appear XFR LOAD FAST TEST and NO XFR See Figure 12 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 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 Del
37. 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 9096 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 9896 in 196 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 transfe
38. me 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 trans fer 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 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 l Remove battery protective white plastic strip near P relay Press MORE then press SET 3 Press MORE and scroll to SET SYS
39. n keyed operation available SW2 Auto Off Engine control selector Door mount Keyed or non keyed operation available SWS3 Source Priority Selector Switch Door mount Allows selection of Source 1 or Source 2 to be the Prime Source Transfer Switch will transfer to selected Prime Source if that Source is available Keyed or non keyed operation available T Time Delay S1 Source 1 Stable Timer To delay trans fer to Source 1 immediate retransfer on Source 2 fail ure Adjustable 0 60 minutes in 1 second increments Standard setting is 30 minutes Adjust via SET menu see page 18 T3 W3 Elevator Pre Signal Auxiliary Contacts Open 0 60 seconds prior to transfer to either direction re closes after transfer U S2 Source 2 Stop Delay Timer Allows Engine to run unloaded after switch retransfer to Source 1 Adjustable 0 60 minutes in 1 second increments Standard setting is 5 minutes Adjust via SET menu see page 18 m12 ZBTS ZBTSD Operation and Maintenance Manual 71R 4000A GE Zenith Controls m Accessory Definitions 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 Vi Voltage Imbalance Three Phase For a three phase source this feature monitors phase voltage ratios based on a selected range within a selected ti
40. nated 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 BE SOURCE 2 LOAD BN SOURCE 1 ATS FIG 1 BP IS OPEN WITH ATS IN SOURCE 1 SOURCE 2 BE LOAD BN SOURCE 1 ATS FIG 2 BP IN SOURCE 1 WITH ATS IN SOURCE 1 SOURCE 2 BE LOAD BN SOURCE 1 ATS LOAD CONNECTIONS ARE OPEN SOURCE 2 PE LOAD BN SOURCE 1 ME ATS FIG 4 BP IN SOURCE 1 WITH ATS ISOLATED Figure 14 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 m GE Zenith Controls ZBTS ZBTSD Operation and Maintenance Manual 71R 4000A 23m Sequence of Operation cont d 1600 4000 AMP 1 Automatic a Manually operated Bypass Switch contacts BN BE are open and ATS is supplying load b Disconnect S
41. ng menu is primarily used to show or change time and voltage settings The CFG menu is primarily used to turn an option on or off When scrolling through these menus no changes can be made without entry of the access code The factory set six digit access code is located on a white label on the back of the unit see figure 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 Source 2 Position LED Red indicates Power Panel ATS is closed to Source 2 position Source 1 LED Green indicates Source 1 is acceptable for use Source 1 Position LED Green indicates Power Panel ATS is closed to Source 1 position Source 2 Red indicates Source 2 is acceptable for use LCD Screen Exercise Event Impending S1 OK Current Time 01 50 Day and FRI 31 MAY 2003 SET Menu Date of Display MORE CFG Menus MORE CFG TEST Entelli Switch 259 1 or the word 2 or the word on the LCD above the key The word above the key changes depending on which screen is being displayed TEST SET on the LCD above the key The word above the key changes depending on which screen is being displayed 4 or the w
42. nhibit 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 BE SOURCE 2 LOAD BN SOURCE 1 ATS FIG 1 BP IS OPEN WITH ATS IN SOURCE 1 SOURCE 2 BE LOAD BN SOURCE 1 ATS FIG 2 BP IN SOURCE 1 WITH ATS IN SOURCE 1 SOURCE 2 BE LOAD BN SOURCE 1 ATS LOAD CONNECTIONS ARE OPEN SOURCE 2 PE LOAD BN SOURCE 1 ME ATS FIG 4 BP IN SOURCE 1 WITH ATS ISOLATED Figure 14 u24 ZBTS ZBTSD Operation and Maintenance Manual 71R 4000A GE Zenith Controls Controls Power Supply CPS 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
43. on trol 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 Bypass ENGINE Selector START Switch BYPASS CONNECTIONS Manual Bypass BP Handle Bypass Control Module A4 2 TRANSFER SWITCH ATS Figure 3 Typical m GE Zenith Controls linitial 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 con
44. ord 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 Figure 9 m GE Zenith Controls ZBTS ZBTSD Operation and Maintenance Manual 71R 4000A 7m User Setting for Voltage amp 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
45. pply additional Lubriplate GE Zenith can provide complete preventative main tenance 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 micro controller 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 s
46. r 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 de pendent on the frequency difference between the two Sources Source 1 is usually a Utility and the frequency is not within the control of the consumer Source 2 needs to be adjusted to create an adequate difference in order for the transfer to happen a timely fashion Note For optimum performance Source 2 Generator should be adjusted a Maximum of 2 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
47. r 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 sta bilization 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 Deactivating the test switch initiates re transfe
48. r to Source 1 Over Voltage Fail Factory Default 11096 This adjustment determines the maximum acceptable Over Voltage Adjust via the SET menu Range is 10596 to 110 in 1 increments see page 17 Once exceed ed the T timer will be bypassed to expedite the transfer to Source 1 Over Voltage Restore Factory Default 10596 This adjustment determines the minimum acceptable Over Voltage threshold at which the transfer switch is allowed to transfer to Source 2 Adjust via the SET menu Range is 103 to 105 in 1 increments see page 17 Restore must be a minimum of 2 below Fail setting Under Frequency Restore Factory Default 95 This adjustment determines the minimum acceptable frequency required to transfer to Source 2 Adjust via the SET menu Range is 90 to 100 in 1 increments see page 17 Once satisfied the W timer will begin timing to transfer to Source 2 Under Frequency Fail Factory Default 90 5 seconds minimum This adjustment determines the low frequency threshold Adjust via the SET menu Range is 88 to 98 in 1 increments see page 17 Fail must be a minimum of 2 below Restore setting Once satisfied the W timer will begin timing to transfer to Source 2 Over Frequency Fail Factory Default 105 This adjustment determines the maximum acceptable Over Frequency Adjust via the SET menu Range is 103 to 105 in 1 increments see page 17 Once exceeded the
49. r to Source lsequence 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 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 ZBTS ZBTSD Operation and Maintenance Manual 71R 4000A 19m 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
50. ransition 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 pro vided to bypass the T time delay if desired After the T time delay the
51. rmation 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 A CAUTION Before drilling conduit entry holes or any accessory mounting holes cover and protect the switch and control panel to prevent dirt and metal fragments from entering the mechanical and electrical components Failure to do so may result in damage and malfunction of the switch ZBTS ZBTSD Operation and Maintenance Manual 71R 4000A m GE Zenith Controls LAE LL ES A DANGER HAZARDOUS VOLTAGE Can Cause Severe Injury or Death Turn OFF all power before installation adjustment or removal of transfer switch or
52. s From 51 screen 1 Press TEST 2 Pres MORE 3 Press START TEST TIMER to initiate Test e Ifthe 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 SI 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 Pres MORE 3 Press BYPASS EXER To re institute
53. the next exercise event back press CANCL BPASS How to initiate a new exercise start time 1 Press TEST 2 Pres 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 m14 ZBTS ZBTSD Operation and Maintenance Manual 71R 4000A GE Zenith Controls 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 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 24 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
54. troller 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 A is the same as the phase rotation of y Source 2 10 Shut down the generator s engine CE 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 GE Zenith Controls SERIAL NUMBER RATING VOLTS AMPS SYSTEM VOLTS MODEL NUMBER Figure 4 A CAUTIONS Certain accessories per specific schematics can inhibit automatic transfer Engine Gen Set could start when engine control wires are attached ZBTS ZBTSD Operation and Maintenance Manual 71R 4000A Installation conta Initial Energization conta ME e nna After all options and accessories are checked and 2 i enclosure s verified follow these steps to set up the ATS Refer to 5c Place the Disconnect Switch in the Entelli Switch 250 display Figure 5 The annunciation NOTE This step is only performed if the LEDs illuminate to indicate 1 source availability DS Option was purchased 2 ATS position and 3 Entelli Switch 250 control 4 Close the external upstream Source 1 function timing circuit breaker NOTES Source 1 Available and Source 1 Position LED s will illuminate
55. ut Entelli Switch 250 Board Battery Strip b Pre Signal to transfer W3 and and UMD output optional c Poem 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 l 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 CPS The Controls Power Supply CPS Figure 7 Contains transformers which drop line voltage to control level for controller input and SCR inputs see figure 7 S1 OK 21 56 MON 23 APR 2002 Entelli Switch 250 Figure 8 n6 ZBTS ZBTSD Operation and Maintenance Manual 71R 4000A GE Zenith Controls Entelli Switch 250 Controller con LCD amp 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 setti
56. witch 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 I
57. witch will start retransfer to Source 1 The switch will complete its retransfer to Source 1 after the time delay of the T timer The U engine overrun timer allows the engine generator to run unloaded for a preset cool down period NOTE A periodic test of the transfer switch under load conditions is recommended to insure proper operation See National Electric Code articles 700 and 701 WARNING When performing a hi pot or dielectric test on the power section DISCONNECT the control panel plugs from the microprocessor to avoid potential damage 28 ZBTS ZBTSD Operation and Maintenance Manual 71R 4000A GE Zenith Controls W GE Zenith Controls ZBTSH ZBTSDH Operation and Maintenance Manual 71R 4000A 290 m C3 GE Zenith Controls A Product of GE Consumer amp Industrial General Electric Company 830 West 40 Street Chicago IL 60609 USA 773 299 6600 Fax 630 652 4501 www geelectrical com

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