GE ZTS Series Operation And Maintenance Download

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GE Zenith Controls

ZTS/ZTSD Series Transfer Switches

40-4000 Amps

71R-3000

5/03

Operation and Maintenance Manual

Summary of Contents for ZTS Series

Page 1: ...GE Zenith Controls e ZTS ZTSD Series Transfer Switches 40 4000 Amps 71R 3000 5 03 Operation and Maintenance Manual ...

Page 2: ...mps 32 1600 3000 Amps 33 4000 Amps 34 ZTSH ZTSDH ZTSDL ZTSHL ZTSDHL 35 Standard Control Panel Layout SSRCP 35 Panel Mount Control Relays 35 Sequence of Operation 36 Adjustments and Settings 37 Solid State Timers 37 Voltage Frequency Sensor VSFM 37 Solid State Phase Relay 37 Introduction GE Zenith Transfer Switches are used to provide a continuous source of power for lighting and other critical loa...

Page 3: ... 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...

Page 4: ...adTerminals Neutral Bar When Required Cable Per Pole Range of Wire Sizes No of Cables Range of Wire Sizes 40 1 8 AWG to 1 0 3 8 AWG to 1 0 80 1 8 AWG to 1 0 3 8 AWG to 1 0 100 1 8 AWG to 1 0 3 8 AWG to 1 0 150 1 8 AWG to 3 0 3 8 AWG to 300 MCM 200 225 2500 1 6 AWG to 250 MCM 3 6 AWG to 300 MCM 260 300 400 1 4 AWG to 600 MCM 3 4 AWG to 300 MCM 600 2 2 AWG to 600 MCM 8 2 AWG to 600 MCM 800 1000 1200...

Page 5: ...ackage 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 3 4 Close Source 1 circuit breaker NOTE The controller will illuminate Source 1 Available LED if proper voltage is sensed 5 Verify the ...

Page 6: ...alue The Gen Set will start and run while Source 2 stop Delay Timer is timing 5 Close the External up stream Source 2 line circuit breaker 6 Start the engine generator in MANUAL mode NOTE When the voltage and frequency reach preset values the Source 2 Available LED will illuminate 7 Verify the phase to phase voltages at Source 2 line terminals 8 Verify that the phase rotation of Source 2 is the sa...

Page 7: ...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 5 shows the location of these terminals The terminals are clearly identified by a label on the microcontroller backplate In the case of manual trans fer ...

Page 8: ...ing a LED indication of source availability b LED indication of transfer switch position c LCD screen indicates 1 timer count down numeric 2 event reporting text d Keypad provides user interface to in conjunction with LCD screen 1 Setting sensors and timers 2 Configuring logic accessories II The R T box relay transformer box contains the following see figure 6 A Relays which are required for contr...

Page 9: ...time of order placement The following pages include all the options that can reside in the controller Not all units include all options Entelli Switch 250 S1 OK 01 50 FRI 31 MAY 2003 Source 2 Red indicates Source 2 is acceptable for use Source 1 LED Green indicates Source 1 is acceptable for use Exercise Event Impending SET Menu MORE CFG TEST SET 1 or the word on the LCD above the key The word abo...

Page 10: ...5 to 100 in 1 increments see page 17 Once satisfied the W timer will begin timing to transfer to Source 2 Under Voltage Fail Factory Default 80 This adjustment determines the low voltage threshold Adjust via the SET menu Range is 75 to 98 in 1 increments see page 17 Fail must be a minimum of 2 below Restore setting Once voltage falls below threshold T timer will be bypassed to expedite the transfe...

Page 11: ...S13P T T3 W3 U UMD VI W YEN 2 2 3 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 GE Zenith Controls...

Page 12: ...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 ...

Page 13: ...Over Voltage sensing for single and three phase systems Source 1 Over Voltage Fail Factory Default 110 This adjustment determines the maximum acceptable over voltage Adjust via the SET menu Range is 105 to 110 in 1 increments see page 18 Once exceeded the P timer begins timing to signal the Generator to start Source 1 Over Voltage Restore Factory Default 105 This adjustment determines the minimum ...

Page 14: ... page 17 Factory Default if OFF S5P Auto Semi Manual selector In Auto position retransfer to Source 1 is automatic after the T timer has timed out The T time delay is bypassed if Source 2 fails In Manual retransfer to Source 1 is upon depression of BYPASS DELAY button YEN or if Source 2 fails S12P Auto Manual Selector In Auto position the Automatic Transfer Switch functions automatically as specif...

Page 15: ...ck Set System Clock time and date If the clock is not set the display will show SET SYSTEM CLOCK on the second line of the S1 OK screen The S1 OK screen will show time hours and minutes on the second line if the system clock has been set Date on third line Setting the System Clock Start from S1 OK screen 1 Remove battery protective white plastic strip near P relay 2 Press MORE then press SET 3 Pre...

Page 16: ...ser is Factory configured for a Load Exerciser the Controller will immediately start a load exercise The controller will start the generator transfer the load to Source 2 and remain in Source 2 for the duration set for EXER S2 RUN TIME in the SET menu The controller will retransfer the load back to Source 1 after the S1 stable timer has timed out and run the generator unloaded for the duration of ...

Page 17: ...atedly until SET USER SETUP Press BACK then ESC to the S1 OK screen How to Bypass Cancel an exercise during an exercise cycle 1 Press BPASS 2 Allow the controller to complete the Engine cool down cycle If the CD Exerciser is configured or Set for a No Load Exercise Or allow the controller to complete retransfer to Source 1 If the CD Exerciser is configured for a Load Exerciser How to Bypass the ne...

Page 18: ...R1 Output 5 6 7 R1 Output 14 15 16 R2 Output 8 9 10 R2 Output Contact Rating 10A 277VAC or 30VDC 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 PROG 1 PROG 2 GRD Input Sink LS OUT NIA OUT ELEV PRE OUT ALARM OUT STE OUT MOTOR DISC OUT TMS IN INHIB S1 INHIB S2 LS IN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 12V Output Source LN OUT L4 OUT L3 OUT L2 OUT L1 OUT YN IN YE IN TSNL IN Q2 TSL IN S12 IN S5 IN 11 12 13 5 6 7...

Page 19: ...UT NIA OUT ELEV PRE OUT ALARM OUT STE OUT MOTOR DISC OUT TMS IN INHIB S1 INHIB S2 LS IN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 12V Output Source LN OUT L4 OUT L3 OUT L2 OUT L1 OUT YN IN YE IN TSNL IN Q2 TSL IN S12 IN S5 IN 11 12 13 5 6 7 14 15 16 8 9 10 1 2 3 4 Output Contacts Output Contacts From J2 J4 Output J4 3 4 14 13 12 11 10 9 1 2 3 5 6 7 8 J2 3 N O N C To J2 J4 Input Customer Input Voltage WARNI...

Page 20: ...OUT TMS IN INHIB S1 INHIB S2 LS IN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 12V Output Source LN OUT L4 OUT L3 OUT L2 OUT L1 OUT YN IN YE IN TSNL IN Q2 TSL IN S12 IN S5 IN 11 12 13 5 6 7 14 15 16 8 9 10 R1 1 2 R2 3 4 Output Contacts Output Contacts From J2 J4 Output J4 3 4 14 13 12 11 10 9 1 2 3 5 6 7 8 J2 3 N O N C To J2 J4 Input Customer Input Voltage WARNING 1 Controller inputs must be relay isolated 2...

Page 21: ...ed to bypass the T time delay if desired After the T time delay the CCN relay energizes the CN solenoid to retransfer the switch to Source 1 The SN limit switch activates to de energize the CCN relay Immediately after re transfer the S2 Stop Delay Timer Delay to Engine Stop U begins its cycle to allow Source 2 Engine Entelli Switch 250 S Y S T E M T E S T FA S T X F R N O M O R E T E S T L O A D X...

Page 22: ...h the preset Restore values the time delay to open Source 1 timer W begins its timing cycle to ensure voltage and frequency stabiliza tion before re transfer A manual pushbutton BYPASS is provided to bypass the W time delay if desired After the W time delay the CCNO relay energizes the CNO solenoid to open the transfer switch out of Source 1 position The time delay to Source 2 timer DW begins its ...

Page 23: ...3 40 225 Amp Molded Power Section 40 3000 Amp All Other Standard Types Transformer Usage see Figure 12 Transformer Usage see Figure 13 R T Box Primary 1 VA 25 VA Assembly Voltage XFMR XFMR Part No at 50 60 Hz Part No Part No 57P 1015 120V K 3216 K 3224 57P 1016 208 220V K 3217 K 3225 57P 1017 230 240V K 3218 K 3226 57P 1018 277V K 3219 K 3227 57P 1019 380 400V K 3220 K 3228 57P 1020 416 440V K 322...

Page 24: ...216 K 3224 50P 1035 208 220V K 3217 K 3225 50P 1036 230 240V K 3218 K 3226 50P 1037 277V K 3219 K 3227 50P 1038 380 400V K 3220 K 3228 50P 1039 416 440V K 3221 K 3229 50P 1040 460 480V K 3222 K 3230 50P 1041 575 600V K 3223 K 3231 Item Part No Description Qty 1 See Chart Transformer 25 VA 2 2 See Chart Transformer 1 VA 2 3 K 1260 Coil Control Relay 24V 4 ZTS ZTSD Operation and Maintenance Manual 7...

Page 25: ...OL POWER SOURCE 2 CONTROL POWER Figure 15 DelayedTransition R T Box Schematic 20 21 22 30 31 32 GND 903 902 801 901 807 804 803 904 905 906 805 806 J5 24V 10V 11V XE1 24V 10V 11V 10V XN1 XN2 CCN CCE 800 900 18 1 CCEO CCNO 908 808 10V XE2 907 XN1 SOURCE1 CONTROLTRANSFORMER XN2 SOURCE1 3 PHASE SENSINGTRANSFORMER XE1 SOURCE 2 CONTROLTRANSFORMER XE2 SOURCE 2 3 PHASE SENSINGTRANSFORMER SOURCE 2 24V OUT...

Page 26: ...oes not stop LCD Display TD Engine Cool Down U timing cycle not complete Check U timer setting SOURCE 1 POSITION and SOURCE 1 and SOURCE 2 AVAILABLE LEDs on but U timer has timed out Engine start wires not terminated correctly Check Engine Start Connections Generator in MANUAL Place generator in AUTO ATS will not transfer to SOURCE 2 SOURCE 2 AVAILABLE LED off SOURCE 2 voltage or frequency not wit...

Page 27: ...ase 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 switc...

Page 28: ...utout Switch SCN SCE Coil Cutout Switch BR Rectifier Figure 17 VOLTAGE 40 TO 200 AMPS 120 K 2207 208 K 2208 220 K 2208 240 K 2228 277 K 2211 380 416 K 2212 440 480 K 2209 575 600 K 2213 ALL 57P 1030 120 480V L 3078 600V L 4027 ALL PS 5076 A3 A4 Auxiliary Contacts L 3078 26 ZTS ZTSD Operation and Maintenance Manual 71R 3000 GE Zenith Controls ...

Page 29: ...Spares 225 250 26 6 60 300 400 N 1 2 3 N Cable Connection Lug S 2701 S 2701 S 2701 E 1 2 3 N T 1 2 3 N Wire Size 4 600 MCM 4 600 MCM Coil Volts 120 K 2245B 208 220 K 2246B CN CE Solenoid 380 416 K 2247B 440 480 K 2248B 575 600 K 2249B SN SE Coil Cutout Switches L 3078 A3 A4 Auxiliary Contacts BR Rectifier PS 5076 GE Zenith Controls ZTS ZTSD Operation and Maintenance Manual 71R 3000 27 ...

Page 30: ...ils Coil Volts Poles 120 2 K 2090F K 2073F K 2073F K 2073F 240 2 K 2092F K 2070F K 2070F K 2070F 3 K 2078F K 2070F K 2070F K 2070F 4 K 2091F K 2074F K 2074F K 2074F 208 3 4 K 2091F K 2074F K 2074F K 2074F 575 600 3 4 K 2095 K 2155 K 2155 K 2155 480 3 K 2080F K 2071F K 2071F K 2071F 4 K 2079F K 2071F K 2071F K 2071F 416 3 K 2080F K 2071F K 2071F K 2071F SN CCN Cut out Switch 23P 1333 SE CCE Cut out...

Page 31: ...1400 23P 1400 CN CE Main Operating Coils Coil Volts Poles 120 2 SPO SPO SPO 240 2 3 K 2123F K 2123F K 2123F 4 K 2127F K 2127F K 2127F 208 3 K 2125F K 2125F K 2125F 4 K 2128F K 2128F K 2128F 575 600 3 K 2153F K 2153F K 2153F 4 K 2154F K 2154F K 2154F 480 3 K 2120F K 2120F K 2120F 4 K 2130F K 2130F K 2130F 416 3 K 2126F K 2126F K 2126F SN CCN Cut out Switch 23P 1352 SE CCE Cut out Switch 23P 1356 A3...

Page 32: ... 1640 CN CE Main Operating Coils Coil Volts Poles 240 3 K 2219 4 K 2219 208 3 K 2226 4 K 2226 575 600 3 K 2221 4 K 2221 480 3 K 2218 4 K 2218 416 3 K 2220 SN CCN Cut out Switch 23P 1352 SE CCE Cut out Switch 23P 1356 A3 Emergency Position Aux Contact Qty 1 23p 1356 Qty 2 23p 1357 Qty 3 23p 1353 Qty 4 23p 1355 A4 Normal Position Aux Contact Qty 1 23p 1352 Qty 2 23p 1353 Qty 3 23p 1357 Qty 4 23p 135...

Page 33: ... Lug S 2515 S 2701 E 1 2 3 N T 1 2 3 N Wire Size 8 MCM 3 0 4 600 MCM Coil Volts MAIN SECONDARY 120 K 2245B 58P 1106 208 240 K 2246B 58P 1107 380 415 K 2247B 58P 1108 CN CE Solenoid 440 480 K 2248B 58P 1109 575 600 K 2249B 58P 1110 575 600 K 2249B 58P 1110 Handle Manual E3054 Handle Grip L 3078 A3 A4 Auxiliary Contacts L 3078 SNO SEO Coil Cutout Switch E3521 BR Rectifier 380V PS 5076 BR Rectifier P...

Page 34: ...Switch 23P 1535 L 23P 1533 R SE SEO Limit Switch 23P 1536 L 23P 1534 R A3 Emergency Position Auxiliary Contact 23P 1536 A4 Normal Position Auxiliary Contact 23P 1535 DS Disconnect Switch Operator L 4009 Contact Block L 1020 CN CNO CE CEO Main Operator Solenoids See Chart Below Solenoid Part No Volts Ph Wire Coil VDC Pole 600 240 3 3 240 3 K 2145 120 208 3 4 208 3 4 K 2146 480 3 3 480 3 K 2158 277 ...

Page 35: ...elow CE CEO Voltage System Solenoid Part No Volts Ph Wire Coil VDC Pole 120 1 2 120 2 S P O S P O S P O 120 240 1 3 240 2 3 K 2151 K 2151 K 2151 240 3 3 240 3 K 2151 K 2151 K 2151 120 208 3 4 208 3 4 K 2151 K 2151 K 2151 480 3 3 480 3 K 2160 K 2160 K 2160 575 3 3 575 600 3 S P O S P O S P O 277 480 3 4 480 3 4 K 2160 K 2160 K 2160 120 240 2 4 240 4 K 2151 K 2151 K 2151 240 416 3 4 416 3 Consult Fa...

Page 36: ...N CE Main Operating Coils Coil Volts Poles 240 3 K 2215 4 K 2215 208 3 K 2227 4 K 2227 575 600 3 K 2217 4 K 2217 480 3 K 2214 4 K 2214 416 3 SPO SN SNO CCN Cut out Switch 23P 1568 SE SEO CCE Cut out Switch 23P 1569 A3 Emergency Position Aux Contact Qty 1 23p 1356 Qty 2 23p 1357 Qty 3 23p 1353 Qty 4 23p 1355 A4 Normal Position Aux Contact Qty 1 23p 1352 Qty 2 23p 1353 Qty 3 23p 1357 Qty 4 23p 1359 ...

Page 37: ...3 J1E J10 33Z 37 W J11 35 35Z R4 W3 Panel Mount Control Relays ATS T U W L2 P1 B3 RT B2 B1 VFSM Figure 28 NORMAL SOURCE 1 L1 EMER SOURCE 2 PRESS TO TEST HOLD UNTIL TRANSFER TS TAG DESCRIPTION L1 L2 ATS Source 2 EMER Position Indicator ATS Source 1 NORMAL Position Indicator Lens Source 1 NORMAL Lens Source 2 EMER Bulb Socket Source 2 EMER Bulb Source 1 NORMAL Bulb TS Test Switch Operator Momentary ...

Page 38: ...s to Source 2 The switch is mechanically locked in Source 2 position The power relay and Source 2 operator are de ener gized when the SE limit switch is activated by the operator The SN limit switch is deactivated at the same time readying Source 1 control circuit for retransfer when Source 1 is restored The sequence for retransfer to Source 1 begins automat ically when the voltage on all phases o...

Page 39: ...ay be adjusted by rotating the adjustment screw as shown in Figure 31 Counter clockwise rotation increases the pickup voltage Restore Pickup Voltage at 100 Frequency Adjustable 80 to 95 Factory Set 90 Restore Pickup Frequency Adjustable 80 to 100 Figure 30 Factory Set 95 Solid State Phase Relay ARSM The restore or pickup and fail or dropout points may be adjusted by using the following procedure U...

Page 40: ...g GE Zenith Controls A Product of GE Industrial Systems General Electric Company 830 West 40th Street Chicago IL 60609 USA 773 299 6600 Fax 773 247 7805 www geindustrial com ...

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