GE ZTX User Manual

72R-1000 9/05

ZTX Series Automatic Transfer Switches

40-400 Amps

GE Zenith Controls

Operation and Maintenance Manual

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1ii

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Equipment Inspection and Storage . . . . . . . . .11

Final Equipment Inspection . . . . . . . . . . . . . . .11

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Power Connections . . . . . . . . . . . . . . . . . . . . . .12

Engine Start Control Connections . . . . . . . . .13

Exerciser Option . . . . . . . . . . . . . . . . . . . . . . . .14

Functional Test . . . . . . . . . . . . . . . . . . . . . . . . .15

Jumper Positions . . . . . . . . . . . . . . . . . . . . . . . . .6

Control Interface . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Indicator LED’s . . . . . . . . . . . . . . . . . . . . . . . . .17

Pushbuttons . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Using the Keypad Controls . . . . . . . . . . . . . . . .18

Automatic Generator Exerciser . . . . . . . . . . . .19

In-Phase Monitor Operation . . . . . . . . . . . . .110

Page

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

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . .13

Standard Transition 40-200 Amps . . . . . . . . . .13

Standard Transition 225-400 Amps . . . . . . . . .14

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Table of Contents

Authorized Service

For GE parts and service, call: 773 299-6600

Introduction

GE Zenith Transfer Switches are used to provide a continuous source of power for lighting and other critical loads by automatically transferring from source 1 power to source 2 power in the event that source 1 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.

NOTES: A protective device such as a molded case circuit breaker or fused

disconnect switch MUS

T be installed on both sources of incoming

power for circuit protection and as a disconnection device.

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 “S2” or “Source 2” relate to an Emergency or Alternative Power Source.

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GE Zenith Controls 1

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ZTX Operation and Maintenance Manual (72R-1000)

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

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.

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.

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.

NOTE: When lifting the switch using a spreader bar,

height H must be equal to half of distance D.

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2 GE Zenith Controls

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ZTX Operation and Maintenance Manual (72R-1000)

3N3

Install

load

cables

first.

Tip!

Table 1

Screw Type Terminals for External Power Connections

Switch Size

(Amps)

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 1 - 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

TILIT

TERMINAL

LOAD

ERA ILIT

SWITCH POSITION INDICAT

ERA

GENERAT

TERMINAL

T = Load N = Utility E = Generato

NER

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GE Zenith Controls 3

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ZTX Operation and Maintenance Manual (72R-1000)

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 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

SERIAL NUMBER:

TING

: VOLTS -

AMPS -

SYSTEM VOLTS:

MODEL NUMBER:

HZ -

PHASE -

GE Zenith Controls

Figure 2

Battery Connection

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4 GE Zenith Controls

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ZTX Operation and Maintenance Manual (72R-1000)

Installation

(cont’d)

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.

ATTENTION!

This applies only to the switches with the RM4-CAT exerciser option:

Only after ATS installation, connect a commercial-grade alkaline 9V battery to the MX60 controller via the harness connected to the controller. The battery should be placed in the holder installed just above the controller. The battery is used to maintain the exerciser function in the event of power outage. The battery should be replaced at least once a year. If the battery is not

installed and/or replaced as recommended, an exerciser set from the front panel will lose its settings during power outages and the exerciser will not work.

Note: Batter

y life if reduced if neither source is available. Typical battery life when both sources are unavailable is 21 days.

Should the battery connection become disconnected in shipping, take the controller cover off and plug the harness into the receptacle in the top right corner of the MX controller as shown in figure 2 and 5. Reinstall the cover and connect the battery.

Battery and Holder

Battery Harness

MX60 Controller

(Under Cover)

Figure 5

+ 12 hidden pages