GE ZTX User Manual 2
g
62R-2000C
7/02
ZTX SERIES
40-400 Amps
GE Zenith Controls
Operation and Maintenance Manual
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1ii
How to Remove the Cover . . . . . . . . . . . . . . . . . . .11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Equipment Inspection and Storage . . . . . . . .12
Final Equipment Inspection . . . . . . . . . . . . . .12
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Power Connections . . . . . . . . . . . . . . . . . . . . .13
Engine Start Control Connections . . . . . . . . .14
RM4 Exerciser Option . . . . . . . . . . . . . . . . . .15
Functional Test . . . . . . . . . . . . . . . . . . . . . . . .16
RMF Control Interface . . . . . . . . . . . . . . . . . . . . . .17
Optional Indicator LED’s . . . . . . . . . . . . . . . .17
Optional Pushbuttons . . . . . . . . . . . . . . . . . . .17
Automatic Transfer Generator Testing . . . . . .18
Transfer Generator Testing . . . . . . . . . . . . . . .18
LED Diagnostic Flash Codes . . . . . . . . . . . . . .18
Automtic Generator Exerciser . . . . . . . . . . . .19
Selecting Exercisor without Transfer . . . . . . .19
Selecting Exercisor with Transfer . . . . . . . . . .19
Page
Engine Controller Accesoory Board . . . . . . . . . . .110
Example Systems . . . . . . . . . . . . . . . . . . . . . . . . . .11
Partial Coverage Systems . . . . . . . . . . . . . . . . .11
Total Coverage Systems . . . . . . . . . . . . . . . . . .11
Typical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . .12
Power Circuit Schematic . . . . . . . . . . . . . . . . .12
Power Panel Layout . . . . . . . . . . . . . . . . . . . . .12
Interconnect Plug . . . . . . . . . . . . . . . . . . . . . .12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .13
General Troubleshooting . . . . . . . . . . . . .13, 14
Table of Contents
Introduction
GE Zenith Transfer Switches are used to provide a continuous source of power for lighting and other critical loads by
automatically transferring from the normal source of power to an emergency source of power in the event that the normal source voltage falls below preset limits.
Voltage sensing and system control is performed via a state-of-the-art microcontroller located on the cabinet door. It is
designed to give highly accurate control of the transfer switch system.
All GE Zenith transfer switches are designed for use on emergency or standby systems, and are rated for total system or
motor loads. Transfer switches are UL Listed under Standard 1008 and CSA Certified under Standard C22.2 No. 178 and
IEC Listed under Standard 947.
NOTE
: A protective device such as a molded care circuit breaker or fused
disconnect switch MUST be installed on both sources of incoming
power for circuit potection and as a disconnection device.
Authorized Service
For GE parts and service, call: 773 299-6600
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GE Zenith Controls 1
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ZTX Operation and Maintenance Manual (62
R-2000)
How to Remove the Cover
Loosen but do not remove four cover screws. Lift cover
off the four screws and hang on two screws (2 bottom
or 2 right-hand). See Figure i and ii.
This will prevent damage to the cable. The cable may
also be disconnected at the controller or keypad.
Figure i
Figure ii
NOTE: Reattach cable before installing cover.
DANGER
HAZARDOUS VOLTAGE
Will shock, burn or cause death.
Do not remove cover until ALL
power is disconnected.
Re-installation of cover is required
after maintenance or service.
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2 GE Zenith Controls
■■
ZTX Operation and Maintenance Manual (62
R-2000)
Each GE Zenith transfer switch is factory wired and
tested. A complete information package is furnished
with each switch which includes:
a. Sequence of operation.
b. Description and operation of
all accessories supplied.
c. Power panel connection diagram
and schematic.
d. Description and identification of
all customer field connections.
Installation of GE Zenith transfer switches includes:
a. Mounting the transfer switch cabinet.
b. Connection of all Normal, Emergency,
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 here.
Enough room should
be allowed to open
the cabinet doors
fully for inspection
and servicing of the
switch per NEC and
local codes.
Installation
DANGER
HAZARDOUS VOLTAGE
(Can Cause Severe Injury or Death)
Turn OFF all power before installation, adjustment, or removal of transfer switch or any of its components.
The safe operation of your switch is GE
Zenith’s focus.
The proper storage, installation, operation and maintenance will help increase the life of the switch.
Equipment Inspection
and Storage
Once you have received the transfer switch, inspect
it for any damage. This includes damage to the enclosure, power panel, control panel and wiring harness. If
any damage is found or suspected, file a claim as soon as
possible with the carrier and notify the nearest
GE Zenith
representative.
Before installation, it is necessary to store the transfer
switch in a clean dry place, protected from dirt and
water. Provide ample air circulation and heat, if necessary, to prevent condensation.
5% to 95%
(non-condensing)
-30°C to
+75°C
(-22°F to
+167°F)
-20°C to +65°C
(-4°F to +149°F)
Operating
Storage Temperature
Temperature (Ambient): Humidity
CAUTION
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.
Final Equipment Inspection
Prior to energizing the transfer switch:
1. Remove any debris incurred, with a vacuum,
due to shipment or installation.
WARNING
Do not use a blower since debris may
become lodged in the electrical and
mechanical components and cause damage.
NOTE: Lug torque values are specified
in the power panel manual.
5. Make sure that all covers and barriers are
installed and properly fastened.
NOTE: Power panels ship from GE Zenith
in the Normal Position.
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.
D
CABINET
LIFTING EYES
SPREADER BAR
H
45°
NOTE: When lifting the switch using a spreader bar,
height H must be equal to half of distance D.
2. Verify that all cabled connections are correct.
3. Check engine start connections and verify
the correct connection of all control wires.
4. Check the lug torque values of the power
connections.
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GE Zenith Controls 3
■■
ZTX Operation and Maintenance Manual (62
R-2000)
Install
load
cables
first.
Tip!
Table 1
Screw Type Terminals for External Power Connections
Switch Size
(Amps)
40
80
100
150
Utility, Generator and Load Terminals
1 #8 to 3/0 AWG
Cable Per Pole Range of Wire Sizes
1 #8 to 3/0 AWG
1 #8 to 3/0 AWG
1 #8 to 3/0 AWG
Fully Rated Neutral Bar (When Required)
3 #8 to 1/0 AWG
No. of Cables Range of Wire Sizes
3 #8 to 1/0 AWG
3 #8 to 1/0 AWG
3 #8 AWG to 300 MCM
200, 225, 250*
300, 400
1 #6 AWG to 250 MCM
1 #4 AWG to 600 MCM
3 #6 AWG to 300 MCM
3 #4 AWG to 300 MCM
* IEC Rating Only
Installation
(cont’d)
Figure 2 - Power Panel
Power Connections
GE Zenith transfer switches are supplied with UL listed
solderless screw type terminals as standard for the
Normal, Emergency and Load power connections.
Table 1 lists the number and sizes of cable lugs supplied
as standard for each switch amp rating.
DANGER
HAZARDOUS VOLTAGE
(Can Cause Severe Injury or Death)
Turn OFF all power before installation, adjustment, or removal of transfer switch or any of its components.
Connect the Normal, Emergency, and Load conductors
to the clearly marked terminals on the transfer switch.
Remove surface oxides from cables by cleaning with a
wire brush. Verify that all connections are correct before
tightening the lugs. All cable lug connections must be
tightened to the proper torque values as shown in Table 2.
NOTE
: Do not run cables or wiring behind
front-connected transfer switches.
TERMINALS
LOAD
UTILITY
TERMINALS
BR
T1 T2 T3
N1 N3
N2
OPTIONAL A4 CONTACT
OPERATES WHEN IN
UTILITY POSITION
JP
Exerciser
CONTROLLER
SWITCH
POSITION
INDICATOR
N
E3
E2
E1
GENERATOR
TERMINALS
T = Load N = Utility E = Generator
ENGINE
START
OPTIONAL A3 CONTACT
OPERATES WHEN IN
GENERATOR POSITION
OPTIONAL ENGINE CONTROLS
OR AIR CONDITION DISCONNECT
OR 3 PHASE BOARD
3 AND 4 POLE ONLY
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4 GE Zenith Controls
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ZTX Operation and Maintenance Manual (62
R-2000)
Installation
(cont’d)
Control Connections
Connecting Engine Start may cause Generator to
start. Before connecting, turn Generator OFF.
With the Generator breaker open and the Generator
control switch off, install the Generator start connections.
Note:
N = Utility Position
E = Generator Position
Manual operation is possible for maintenance purposes only.
Manual operation of the switch can be checked before it
is operated electrically.
With all power off, insert a Phillips screwdriver or equivalent
size tool into the manual operator socket and operate
the transfer switch between the Utility and Generator
positions. The transfer switch should operate smoothly
without binding. Return the switch to the Utility position,
remove the screwdriver.
Figure 3
Figure 4
Table 2
Tightening Torque for Lugs
Socket Size
Across Flats
Torque
Lb. - In. Lb. - Ft.
451/8 4
1005/32 8
1203/16 10
1507/32 12
2001/4 17
2755/16 23
3753/8 31
5001/2 42
6009/16 50
The engine-start terminals are clearly identified by a
label on the microcontroller backplate. In the case of
manual transfer switches, or in other applications not
requiring the microprocessor, clearly marked terminal
blocks are provided in the upper left corner of the control
panel for the engine start control wires.
Terminals for field connections to the A3 Emergency
auxiliary contacts and the A4 Normal auxiliary contacts
are also provided. These terminals are clearly marked
and appear on the side of the power panel. On 400 amp
metal frame units these terminals appear on the bracket
above the operator handle.
DANGER
HAZARDOUS VOLTAGE
(Can Cause Severe Injury or Death)
Turn OFF all power before installation, adjustment, or removal of transfer switch or any of its components.
Figure 3
g
SERIAL NUMBER:
RA
TING
: VOLTS -
AMPS -
SYSTEM VOLTS:
MODEL NUMBER:
HZ -
PHASE -
GE Zenith Controls
JP
AB
B
Exerciser
123
A
6
5
4
CONTROLLER
Close to Start
Opens to Stop
Engine Start
Contact Output
Contact Rating
28Vdc @ 5 amps
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