Zenith ZBTSH Series User manual

Revised October, 1996
INSTRUCTION MANUAL
ZBTSH SERIES BYPASS/ISOLATION TRANSFER SWITCH
100 -400 AMPS
IMODEL
NO.
SERIAL NO.I L-..-=====

TABLE OF CONTENTS
Storage, Installation ......................................... 1
Cabinet (exterior, front view)
.................................. 2
Parts list (electrical)
......................................... 3
Top and lower panels, front view.
Switch details
.............................................. 4
Bypass and ATS Power Panels -Parts list
..................... 5
Bypass and ATS Control Panel Layout
......................... 6
Bypass and ATS Control Panel -Parts list
..................... 7
Operation of Bypass/Isolation Switch
........................... 8
Definitions and Operation Notes
............................... 9
ZBTSH Operation, Maintenance
........................... 10, 11
Troubleshooting Decisions ................................... 12
ARSM and Timer Adj., Lubrication ............................ 13
Torque Requirements
...................................... 14
Cabinet Dimensions ........................................ 15
Control Disconnect Plugs ................................... 16
Field Notes
............................................... 17
Bypass Control Panel Schematic Drawing
...................... 18
Typical Bypass and ATS Schematic Drawing ................... 19

STORAGE:
The ZBTSH should be stored in a clean dryarea. AVOID STORAGE BENEATH STEAM OR WATER PIPES.
Excessive moisture may damage the unit. The switch should only be stored on a level (horizontal) surface.
INSTALLATION:
1.
Lifting:
To lift and manuever the Bypass Switch use lifting angles. See Fig. 1 (below). CAUTION: Depen-
ding upon the model, aZBTSH weighs between
650- 700 lbs. Use adequate machineryand cables
to handle the load.
2.
Equipment Preparation:
a) . Check nameplate to assure switch system voltage and amperage is correct. Any discrepancy
should be immediately reported to a Zenith representative.
b) . Lock open breakers to normal and emergency lines.
3.
Cabinet Preparation:
a) . A small amount of cabinet work is required before the cables are connected. Cover the switch
and the controls to avoid metal fragments from entering mechanical and electrical com-
ponents. Visually verify that metal filings are removed from top bus support. (Use vacuum if
necessary).
b). Standard cable entry is through the top or bottom of the cabinet. Fig. 2 below shows one sug-
gested knockout order. For a guide to assist in the hole layout, refer to page 15.
4. Cable
and Wire Connections:
a). To remove possible oxide, clean cable conductor with a wire brush and apply a contact oxide
inhibitor. Insert cables into appropriate lugs.
b) . Connect all auxiliary wires for external electrical operation. Example: E-start, remote alarm lights
or buzzers, motor control contacts, etc. Allow enough slack in wires to allow movement of the
ATS to isolate position (approx. 1 ft.).
5.
Prior to the Unit's Energization:
a) . Remove any debris incurred due to installation (cut cable strands, m'etal filings, etc.).
b) . Inspect the unit and verify torque of cable and wire connections.
H
CABINET REMOVABLE
LIFTING ANGLES
TOP VIEW OF CABINET
EMERGENCY
TYPICAL LAYOUT FIG. 2
Note: When lifting the switch, a
spreader must be used. The height
H must be equal
to 0/2.
FIG. I
1

INSTRUCTION
NAMEPLATE
MANUAL
BYPASS
HANDLE (MBH)

A. CABINET ELECTRICAL PARTS
TAG DESCRIPTION PART NO.
LNA Normal Available Indicator
(G)
LEA Emergency Available Indicator (R)
LBN Bypass Normal Location Indicator
(G)
LBE Bypass Emergency Location Indicator (R)
LAT ATS Test Position Indicator
(A)
LAI ATS Isolate Position Indicator (A)
LIT ATS Inhibit Indicator (R)
LOS ATS Disconnect Switch
"Off" Indicator (R)
Flashing Bulb, PS-1272
COMMON PARTS BYPASS INDICATORS
Bulb Y500005
Socket PS-5046
Red Lens (R) PS-5047
Green Lens
(G)
PS-5048
Amber Lens
(A)
PS-5049
L1
L2 ATS Emergency Position Indicator
ATS Normal Position Indicator
Bulbs (Incandescent) P8-5105
Bulb Socket (Incandescent) PS-5046
Emergency Lens (Red) P8-5047
TS
Normal Lens (Green)
Test Switch
PS-5048
Operator, Momentary L-1025
Contact Block N.C. L-1029
Contact Mounting Base PS-3473
3
Rev. 11/94

~A 0B
0C NEUT.
r-- -
~EMERG.~
BYPASS
EMERGENCY
CONTACTS
T2 LOAD T3
~ ~ EN
N2 NORM. N3 ~
l. u- ~
Ill ENGINE
START
CONNECTIONS
\
r:
AB3+4
./
AB4
t--
DETAIL 2
DETAIL 2A
DETAIL
28
DETAIL 2C
DETAIL 2D
DETAIL 2E
NYLON
ROLLER
SWITCH DETAILS
I r
AI I AT-I, AT-2
\.
ZBTSH 4 POLE
4

B. BP-BYPASS AND ATS AUTOMATIC TRANSFER SWITCH POWER PANEL
TAG DESCRIPTION PART NUMBER BY AMPERAGE
Bypass 100 150 225 260 400
N1,
2, 3, N Normal }
E1, 2, 3, N Emergency LUGS P8-4418 P8-4418 P8-4418 S-1422 S-1422
T1, 2, 3, N Load
BYPASS Contact Assembly (Movable & Stationary for 3 Pole Units)
N1,2,3
Normal 46P-1104A 46P-1104B 46P-1104C 46P-1104D 46P-1104E
N (Sw. Neut. Norm.) 46P-1105A 46P-1105B 46P-1105C 46P-1105D 46P-1105E
E1,2,3 Emergency 46P-1106A 46P-1106B 46P-1106C 46P-1106D 46P-1106E
N (Sw. Neut. Emerg.) 46P-1107A 46P-1107B 46P-1107C 46P-1107D 46P-1107E
ATS Contact Assembly (Movable & Stationary for 3 Pole Units)
NL1, 2, 3 Normal 46P-1100A 46P-1100B 46P-1100C 46P-1100D 46P-1100E
N (Sw. Neut. Norm) 46P-1101A 46P-1101B 46P-1101C 46P-1101D 46P-1101E
EL1, 2, 3 Emergency 46P-1102A 46P-1102B 46P-1102C 46P-1102D 46P-1102E
N (Sw. Neut. Emerg.) 46P-1103A 46P-1103B 46P-1103C 46P-1103D 46P-1103E
Arc Grid Assy. 46P-1099
XBN,XBE
Bypass Step-Down VOLTAGE PART NO.
Transformer 25VA 120/240
K-3061
Secondary 24V 208/416 K-3063
220/440 K-3064
240/480 K-3062
380 K-3067
575 K-3065
600 K-3066
CNE Main ATS Ooerating Coils
Voltage Systems
No. Volts
Ph Wire Coil Volts Poles PART NO.
-1 120 1 2 120 2
K-2178
-2 120/240 1 3 240 2,3 K-2189
-3 240 3 3 240 3 K-2189
-38 120/240 3 4 240 3,4 K-2189
-4 120/208 3 4 208 3,4 K-2177
-5 480 3 3 480 3 K-2176
-6 575/600 3 3 575/600 3 K-2196
-7 277/480 3 4 480 3,4 K-2176
-9 240/416 3 4 416 3,4 K-2188
-91 220/380 3 4 380 3,4 K-2188
SN
CN1 Limit Switch
SE
CE1 Limit Switch
A3 ATS Emergency Position Switch L-3002 (Detail 2)
A4 ATS Normal Position Switch
SCN/SCE CNE Limit Switches L-3079 (Detail 2a)
AA ATS Auto Location Switch
AE1, 2 ATS Isolate/Remove Location Switch
L-3071 (Detail 2b)
PLS1,2 Position Lever Switch
AI ATS Isolate Location Switch L-3070 (Detail 2c)
AT1, 2 ATS Test Location Switch
AB3/ABE Bypass Emergency Position Switch
AB4/ABN Bypass Normal Position Switch L-5021 (Detail 2d)
NA4 Normal TRS Limit Switch
EA3 Emergency TRS Limit Switch
BTE Bypass Emergency Position Switch
BTN Bypass Normal Positiion Switch
TSE ATS Engaged Switch L-3054 (Detail 2e)
BLL Bypass Lock Location Switch
ALL ATS Lock Location Switch
OS ATS Solenoid Disconnect Switch
Operator 2-Position Maintain L-4018
Contact Block N.C.
(1)
L-1029
Contact Block N.O. (2) L-1028
Contact Block Mounting Plate P8-3473
BPS Bypass Interlock Solenoid K-2180
TRS Transfer Release Solenoid K-2180
5 Rev. 11/94

C. BYPASS CONTROL PANEL
CA
Will LIAOI
TO fiiAJII•
POIIIII.L
TOIIII
BOTTOM VIEW
TB·L TB-R
,--------,
I XBN ,:to I }TYPICAl. JUII•I~ 1
WUUHI 'OR 4te a 410
I :::
I
VOLT IYifllll.
41
I I
~-------~
tiOTIIfP' Sl'ITIM IS
411
Oft 410 YOLTS. Will
TRANSPOftlllltl AI
SHOWN AIOYI\ IP
lftflll II ZOI ft 140
VOI..TS.WIR!TIIANS•
FOfii!MIRS AI SHOWN
IlL OW·
,..-------,
I I }
XII XBE =~~O -TYI'ICAL -~•
1
~
WINING F~ ZOI •
:
::: Ol - 140 _, IYifllll.
I I
L----- --~
I uu: •·-• •o• 140 • •ao-.r IYifiiiS.
1111··~ fOil 101 I 411VOLT IYITIIII.
D. ATS CONTROL PANEL (SSRCP) CHART 1
TO POWER PAI\£L
JUMPERS IIU CHART II
..••. 11:1.1
Jl JZ J:S J4 JO , • .17 Jl Jl JIO Jll
Jumper Connects
Points Remove When Accessories Used
J1
23,23A 81
J2 23A,238 82
J3 238,
23C 83
J4
23C, 23Z
JIN, TS, C/0
J5 23Z,27
T, YN
J6
25, 25Z T3, R4
J7 28,28Z
Sl, C, C/0
J8
28Z, 29 PI & U
J9
33A, 33Y
ER1, 2, 3, J1E
J10
33Z,37 w
J11
35, 35Z R4, W3
6

C. BYPASS CONTROL PANEL (46P-1079) INCLUDES PARTS BELOW
( TAG DESCRIPTION PART NUMBER
BR1,
2. 3 Bridge Rectifier PS-5076
RNH Normal Voltage Relay Y260000
R1
Resistor RNH, 30 ohm PS-4056
R2
Resistor LOS, 120 ohm PS-4057
01 Diode PS-4812
CA Capacitor
RNH PS-4058
ATR Auxilary Test Relay Y260000
D. ATS CONTROL PANEL (SSRCP) STANDARD ITEMS
TAG DESCRIPTION VOLTAGE 50/60 HZ PART NO.
XN,XE
Control Transformers
(See Note
1)
120V K-3076
208V K-3070
240 or 480V
K-3071
416V K-3089
B-1,
2, 3 Phase Relays
Solid State
(See Note
1)
120V K-1185
208 or 240V K-1186
480V K-1188
VFSM Voltage Frequency Sensor 120V K-1192R
CR Control Relay 120V K-1204
AT Bypass T Relay 120V K-1204
CN1/CE1 CNE Transfer Relays (not shown) 120V K-1120
J1-J11 Jumpers PS-5067
(OPTIONAL ITEMS)
TAG DESCRIPTION VOLTAGE PART NUMBER
T Time Delay to Normal, Timer Solid State 120V
.1 Sec. to 9990 Hrs. (Adj.) K-1230
u Engine Cool Down, Timer Solid State 120V
.1 Sec. to 9990 Hrs. (Adj.) K-1230
w Time Delay Emergency, Timer Solid State 120V
.1 Sec. to 9990 Hrs. (Adj.) K-1230
PI
Time Delay Engine Start, Timer 120V (.5 to 6 sec. Adjustable)
K-1201
P2 Optional (Mounted below SSRCP) 120V (300 Sec. Adjustable) K-1061
Notes:
1. If -6 voltage system (575/600V) is supplied, then XN, XE is K-3087 and B1,2, 3 is K-1185 (120V) supplied with XB
(575;600V/120V) 3 phase transformer assembly. B1,
2, 3 mounted below SSRCP.
7
Rev. 11/94

BYPASS/ISOLATION SWITCH OPERATION
BP- Bypass Switch, Indicated by Contacts BN/BE, is a 3 Position Switch
ATS- Automatic Transfer Switch
-:. EMERGENCY
BE ,._,...p-_._+ lOAD
1. Automatic
BNJ_~~:"- ~ NORMAL
1. Manually operated Bypass Switch contacts (BN/BE) are open
and the
ATS is supplying the load. (Fig. 1).
AT
2. Disconnect Switch (OS) is in "Auto" position. -
FIG. I BP IS OPEN WrrH ATS N
NORMAL POSITION.
-:.EMERGENCY
BE lOAD
2. To Bypass ATS
BN,/;_( ~J ~ ~ NORMAL
1. Open bottom cabinet door and turn OS to "Inhibit".
2. Position Manual Bypass Handle (MBH) to same power source AT
as ATS (Fig. 2).
·-
FIG.2 BP IS BYPASS NORMAL WITH
ATS IN NORMAL. POSITION.
3. To Test ATS
1. Bypass per above instructions.
---.- ..... ~ EMERGENCY
BE
..,_,...p-_._+ LOAD
BN L -.c ~ORMAL
2. Move ATS Location Handle (ALH) to "Test" location.
3. Turn
OS to "Auto".
.l_
4. Test Switch (TS) on bottom cabinet door will allow electrical
Fn3 8P IS BYPASS NJRioiAL. WITH
testing of ATS. (Fig. 3).
ATS IN TESI' lOCATXlN. CATS
l.OAO CCNNECTION IS OPEN)
4. To Isolate ATS
1. Bypass per above instructions.
2. Move ALH to "Isolate" location.
5. To Remove ATS
1. Bypass and Isolate per above
instructions.
2. Move ALH to "Release" location.
3. Disconnect multi-pin plugs and ex-
ternal connections.
4. Lift ATS out of drawer.
6. To Reconnect ATS
1. Place A TS into drawer slots, (front
rollers first).
2.. Turn OS to "Inhibit" position.
3. Position ATS to same source as
Bypass Switch.
4. Reconnect Multi-pin plugs and exter-
nal connections.
5. Push ATS inward to engage carriage.
6. Move ALH to "Test" location (as in-
dicated by light).
7. Turn OS to "Auto" position and use
TS to electrically operate ATS.
8. Turn OS to "Inhibit" position.
BE'ij: EMERGENCY
LOAD
BN NOIWAL.
·~
Fn4 8P IS IM'ASS NORMAL WITH·
ATS IN ISOLATE LOCATIOK
9. Move ALH to "Auto" location.
10. Turn OS to "Auto" and position
MBH to "Open".
11. ATS now fully automatic (Fig. 1).
7. Notes
1. OS in "Inhibit" position will prevent
A
TS electrical operation.
2.
Do not use excessive force on
mechanical handles (interlocks pre-
vent incorrect sequencing).
3. When ATS is in Test or Isolate,
Bypass Switch
is a manual transfer
switch to either available power
source.
4. To operate Bypass Switch when
ATS is in Test or Isolate, position
MBH to available power source (in-
dicated
on light panel).
5. Above figures depict Bypass Normal;
sequence
is same for Bypass
Emergency.
8

DEFINITIONS:
BP -Bypass/Isolation Switch
) It
is a manually operated device used in conjunction with an Automatic Transfer Switch (ATS) to
provide a means of directly connecting load conductors to a power source, and of disconnecting
the Automatic Transfer Switch.
The
BP can also be used as a Manual Transfer Switch in the event of a power failure while the
ATS
is in the TEST, ISOLATE, or RELEASE positions.
ATS -Automatic Transfer Switch
Is a self-acting equipment for transferring one or more load conductorconnections from one power
source to another.
DS- Disconnect Switch
Inhibits operation of ATS Main Coil (CNE).
In the "AUTO" position, the ATS operates normally.
In the "INHIBIT" position the main coil (CNE) cannot be energized, and automatic transfer in either
direction cannot take place.
MBH -Manual Bypass Handle
Actuates the Bypass Operator.
Center for Bypass Open.
Down for Normal Bypass.
~or Emergency Bypass.
TS- Test Switch
Simulates Normal line failure when open.
OPERATION NOTES:
1. The ATS will not operate if:
a). Harness plugs are not connected.
b). DS is in the 'INHIBIT' position.
c). ATS is not in 'AUTO' or 'TEST' location.
d). ATS is in 'AUTO' location and BYPASS SWITCH is not open.
2. The MBH will not operate if:
a). ALH is not engaged in one of the following: AUTO- TEST- ISOLATE.
b). If source selected is opposite of the ATS position while in the AUTO location.
c). ATS is in 'TEST' or 'ISOLATE' location and source selected is not available.
3. The ALH (ATS Location Handle) will not operate if:
a). BP and ATS are not positioned to same source.
b). Power is not available.
c). Harness Plugs are not connected.
d). ATS has reached limit of travel to 'AUTO' or 'ISOLATE'.
9

READ THE FOLLOWING PARAGRAPHS BEFORE PROCEEDING TO ''TEST PROCEDURE''.
{THIS PROCEDURE IS ONLY
TO BE PERFORMED BY AUTHORIZED PERSONNEL)
CAUTION: Loads controlled by Bypass/Isolation Transfer Switch may cause PER-
SONAL INJURY by UNAUTHORIZED PERSONNEL operating or testing
this equipment.
Checkall wiring diagrams that have been supplied for added options that
may affect external equipment: For example; Starting and Stopping of
Elevators and Motors.
A 'Control Panel Test'
or a test with the ATS in the TEST LOCATION runs
the EMERGENCY SOURCE with no load. A no load operation may be
detrimental to the engine, and the Engine/Generator Manufacturer should
be consulted.
Allow sufficient time on the U timer for engine to safely cool down.
RECOMMENDED TIMER SETTINGS:
T - Restoration to Normal .............. 30 minutes (Factory set)
U - Engine Cooldown/Stop
.............. 5 minutes (Factory set)
W - Engine Warmup
.................... 1 second (Factory set)
P1 -Engine Start. ..................... 3 seconds (Factory set)
TEST PROCEDURE
The ATS can be tested in either of two locations:
1 ). AUTO LOCATION
2). TEST LOCTION
1). "AUTO LOCATION":
Full Transfer Test -This test checks the complete operation
of the ATS by transferring
and interrupting the load's power source from 'Normal' to 'Emergency'.
Depress TS (Test Switch) until Generator starts and the
'W' timer times out (timer will indicate ON).
ATS will transfer
to Emergency.
Release TS (this resets TS to AUTO). Normal restoration timer 'T' will time out (will indicate ON)
which will energize the CR relay causing ATS to retransfer back
to Normal.
Engine/Generator will shut down after timer U times out. Full Transfer Test is now complete.
2). "TEST LOCATION":
This procedure is recommended for Preventive Maintenance (PM) of ATS without interrupting the
Load thru the BYPASS/ISOLATION SWITCH. Refer to Page 8 (Step 3).
NOTE: TEST LOCATION is recommended after maintenance
of ATS.
10
Rev. 11/94

OPERATION OF AUTOMATIC TRANSFER SWITCH
Operation:
When the normal line (NL) falls to the preset dropout point, or if any normal phase fails, the phase relay(s)
will
drop out disconnecting the CR relay.
When emergency line (EL) voltage and frequency reach at least
90% of rated value, the VFSM relay is energiz-
ed.
The RT relay is now energized to operate the CE1 relay thru theSE cutout switch causing the main
transfer coil CNE to operate thru the SCE limit switch. The load is now transferred to the emergency line
supply.
The SE and SCE limit switches operate to disconnectthe CE1 relay and CNE transfer coil. Thetransfer
switch is
now locked mechanically only. Limit switches SN and SCN operate to complete the circuit for the
next closing operation to normal.
When the normal line voltage restores to the preset value, the phase relay(s), (81, 2, 3) operate to energize
the normal restoration timer T. After the set time delay, the timer contact closes to energize CR relay. The
CN1 relay is now energized thru the SN cutout switch causing the main transfer coil CNE to operate thru
the SCN limit switch. The load is now re-transferred back to the normal line supply. The SN and SCN limit
switches operate to di~connect the CN1 relay and CNE transfercoil. The transfer is now locked mechanical-
ly only. Limit switches SE and SCE operate for the next emergency operation.
MAINTENANCE
Electrical Test:
The ATS may be electrically tested for preventive maintenance (referto page 10 "Test Procedure"). After com-
pletion
of an electrical test, the ATS should be returned to the Auto Operation Mode. If the ATS malfunctions,
troubleshoot
the switch, referring to page 12, and replace any faulty part(s) immediately.
Inspection:
CONTACTS -The movable and stationary contacts are a vital part of the ZBTSH and must be kept clean.
To inspect the ATS contacts, place ATS in Isolate location (see page 8). Examine the contacts.
Any surface deposits must be removed with a clean cloth (DO NOT USE EMERY CLOTH OR A FILE).
After
the movable and stationary contacts are wiped clean (no discoloration or deposits), return the ZBTSH
to Auto Mode.
CURRENT CARRYING PARTS- An easily detected but abnormal condition is the discoloration of current
carrying parts (particularlycopper). Discoloration appears as darkened materials or finishes. Any discolored
parts
should be cleaned. WARNING: ANY MAINTENANCE SHOULD ONLY BE DONE WHILE THE POWER
IS OFF! If the discoloration persists, contact the factory.
11

PROCESS
INORMAL OPERATitjG CONDITIONS I
l
URN .. T$"" SWITCH 0 TEST
IUNTIL TRANSFER TO EMERGENCY!
W BEGINS TIMING
RT I N RGI
I. ATS TRANSFERS TO
EMERGENCY AND
MECHANICALLY LOCKS.
2. LIMIT SWITCHES SE, A3
ARE DE-ACTIVATED
3. Ll IS ENERGIZED
T BEGINS TIMING
CR ENERGIZED
I. ATS TRANSFERS TO NORMAL
AND MECHANICALLY LOCKS.
2. LIMIT SWITCHES SN, A4
ARE ACTUATED.
3. L2 IS ENERGIZED.
4, U BEGINS TIMING.
TABLE 3 "TROUBLE SHOOTING"
DECISIONS CORRECTIONS
CHECK IF ENGINE
START CIRCUIT IS
RECEIVING E·CONTACT
CLOSURE.
I. CHECK SE LIMIT
SWITCH.
2. CHECK FOR
DEFECTI'VE CCE.
1. RELEASE TS SWITCH.
-,..:~--------412. WAIT FORT TO
COMP'LETE TIMING.
3. TURN 1)$ TO. ON.
I. CHECK SN LIMIT
L-.:..=::.....----------· 2. ~mroEFECTIVE
CNI.
1. CHECK OS SWITCH.
2. CO<ECK SOLENOID.
3. REPEAT TEST
I. CHECK DEFECTIVE U.
I. CHECK DEFECTIVE
ENGINE START DEVICE.
12

New Solid State Time Delay
r-- -::- -. -:-."
I ',
\ --- _ .. '~-
Accessories T, U, W Solid State Timers Adjustable in
Seconds, Minutes and Hours (Plug-In Style).
To select a time unit, operate the pushbuttons of the rightmost
thumbwheel switch until the desired time unit
is shown in win-
dow. The time unit can be selected by pushing the plus
(+)bot-
tom button or the minus(-) top button. The desired time is specified
by operating the three thumbwheel switches
in the middle of the
front panel.
Setting of the timer at 000 will result in
an infinite delay. The
min. setting for OSA-A timers is 1
/,
0 of 1 second
as shown. See
instructions.
0.1 I
0 0 1
Sec.
Close Differential (ARSM) Relay Adjustment
The voltage points at which the relay operates are adjustable.
When the relay pulls in,
an audible click is heard, and the LED
will come on.
Setting the Relay:
If the relay should
be set with a variable voltage supply (Variac):
1. Turn pick-up control fully clockwise.
2. Turn drop-out control fully counterclockwise.
3. Set Variac pick-up voltage to desired level.
4. Very slowly rotate pick-up adjustment counterclockwise until
relay picks up. (LED will energize).
5. Set Variac drop-out voltage to desired level.
6. Very slowly rotate drop-out adjustment clockwise until relay
drops out (LED de-energizes).
Verify settings by raising voltage until relay picks up, then lower
voltage until relay drops out, making sure that relay operates at
desired voltage levels.
LUBRICATION
The cams of the ZBTSH are lubricated with Super Lube PTFE grease, and gears with Dow Chemicals
"Molykote"
(321 R or GN paste). These lubricants provide adequate lubrication for a clean and properly main-
tained switch's lifetime. Should debris contaminate the mechanism, clean and apply additional lubricants.
Mobiltemp SHC-32
is used on isolating contacts.
LUBRICATION MAINTENANCE CHART
Date Inspected Date Lubricated Lubricant Used (Cams) (Gears)
13
Notes

TORQUE REQUIREMENTS FOR FIELD CONNECTIONS
NOTICE
TIGHTENING TORQUES FOR
FIELD WIRING TERMINALS
Socket Size
Across Flats, Inch
1/8
5/32
3/16
7/32
1/4
5/16
3/8
1/2
9/16
Tightening Torque
Pound-Inches
45
100
120
150
200
275
375
500
600
TORQUE REQUIREMENTS FOR ELECTRICAL CONNECTIONS
All current carrying parts use compression washers and should be torqued to the values presented below.
Caution:
DO NOT OVE RTORQUE WASHERS; follow the given torque values.
TORQUE REQUIREMENTS (inch- lb. except denoted by+ are ft.- lb.)
BOLT
SIZE GRADE 5 SOCKET
HEAD SET
SCREW
COMPRESSION
WASHERS
1 2
1/4- 20 75 120 52 80 87
5/16- 18
157 225 105 159 170
3/8. 16 [phone] +23 +26
1/2. 13
[phone] +56 +59
WIRE CONNECTION LUG BOLTING TORQUE
TIGHTENING TORQUE BOLT DIA. (inch) TORQUE (ft.
-lb.)
WIRE COND. SCREW DRIVER
SIZE
AWG or MM TORQUE (inch -lb.)
{- .
\
1/4 OR LESS
6
5/16
11
3/8 19
7/16 30
1/2 40
5/8
OR MORE
55
18-16AWG
19
14- 8 19
6- 4 36
14

.\
INSIDE
IU:NOVA!l.E
f..FT AHCLI;S
IYPASS tNEfiCENCY
HOfiNAL AVAILAILE
IYPASS NOlltNAL
ATI ISOLATE
ATS TIJT
DISCONNECT SWITCH
INKIIIT POSITION
..L~~~!==;;;;;;;;;;~~;;;;~~·u "'"'"t
~roT
Ill.
CONT .. OL fiANEL
OF
CAIINET 00011•
LUG
CONFIGURATION
t)•POLEI
3 POLE
ZBIIH ~liD
• I c D E
"f
G
~ZZI5PI F-1510 79
oiZll.
liO
llll
12
1114
llll
-ISPI
F-1510
79
oiZll.
liO
llll
12
1114
llll
DISCONNECT SWITCH
NfHIIIT POSITION
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15 REV. 8/93

DISCONNECT PLUGS
ZBTSH
100-400 AMPS (
PA1
LOCKING TAB
TEST PLUG
22 42
21 41
{ON ATS) {ON BYPASS)
PC
LOCKING TAB
CABINET
LIGHT
ATS
ATS
CONTROL
PANEL
POWER PANEL LAYOUT
CONTROL PLUG
10/96
(
16

FIELD NOTES
(
MODELNO: --------------------------------------------------------
SERIALNO: ______________________________________________________ _
DATESHIPPED: -----------------------------------------------------
START·UPDATE: __________________________________________________ ____
DRAWING SUPPLIED: -----------------------------------------------
TEST AND MAINTENANCE NOTES:
DATE
TESTED
PROBLEMS
NOTES
17

2
3
4
7
•
•
10
ll
1Z
13
14
15
ENGINE START CIRCUIT
BYPASS CONTROL SCHEMATIC
PERMIT CIRCUITS
25Z ATR 25ZA
~r--=o
NORMAL TRANSFER
PERMIT CIRCUIT
IN AUTO AND
TEST POSITIONS
35Z ATR 35ZA
~~
EMERGENCY TRANSFER
PERM IT CIRCUIT
IN AUTO AND
TEST POSITIONS
LNA - NORMAL AVAILABLE LIGHT
LEA - EMERGENCY AVAILABLE LIGHT
RNH - NORMALLY HELD RELAY
01 - DIODE
R1 - RESISTOR. RNH
C - CAPACITOR. RNH
BR-1.2.3 - BRIDGE RECTIFIER
AA-1 -
BTN -
BTE -
BPS -
AA-2 -
ALL -
AT-2 -
LIMIT SWITCH. ATS AUTO LOCATION
LIMIT SWITCH. BYPASS TRANSFER NORMAL
IMBH MOVEMENT TO NORMALl
LIMIT SWITCH. BYPASS TRANSFER EMERG.
IMBH MOVEMENT TO EMERGENCYJ
BYPASS SOLENOID
LIMIT SWITCH. ATS AUTO LOCATION
LIMIT SWITCH. ATS LOCK LOCATION
LIMIT SWITCH. ATS TEST LOCATION
LAT -LIGHT. ATS TEST LOCATION
AI - LIMIT SWITCH. ATS ISOLATE LOCATION
LAI -LIGHT. ATS ISOLATE LOCATION
BLL - LIMIT SWITCH. BYPASS LOCK LOCATION
PLS-1- PERMISSIVE LIMIT SHITCH
TSE - LIMIT SWITCH. TRANSFER SWITCH ENGAGED
TRS - SOLENOID. TRANSFER RELEASE
NA-4 - LIMIT SHITCH. ATS IN NORMAL
EA-3 - LIMIT SWITCH• ATS IN EMERGENCY
LBE -LIGHT. BYPASS EMERGENCY
LBN -LIGHT. BYPASS NORMAL
AB4 - LIMIT SWITCH. BYPASS NORMAL
AB3-1- LIMIT SHITCH. BYPASS EMERGENCY
PLS-2- PERMISSIVE LIMIT SHITCH
ATR - AUTO/TEST RELAY
AT-1 - LIMIT SWITCH. ATS TEST LOCATION
LIT -LIGHT. ATS INHIBIT
OS - ATS DISCONNECT SHITCH
R2 - RESISTOR. LOS
LOS
-LIGHT. DISCONNECT SHITCH INHIBIT
POSITION
ALH - ATS LOCATION HANDLE
LIMIT SWITCH
X =
ATS
ATfe
~:'fPASS
OCATION
J.too MODE
ACTUATED
~
li ~~
01-
~~
~
l-UI
i!l!:!
AA-1.2 X
AT-1.2 X
AI
XX
ALL
X X X X
TSE
X X X
AE-1.2 X X
!NA-4
X
EA-3 X
AB4
X
AB3-1.2.3 X
BLL
X X X
PLS-1.2
ACTIVATED HHEN
lUI IS OPERATED
CHART
LIM IT SWITCHES
oNO
~NO
~
NOT NC
ACTUATED
r---,
ILOCATEI!
I ON I
~
I IITS I
I I
~
18
---~ ..
(
10/96