GE Industrial Solutions ZBTE User Manual

GE Energy

Digital Energy

Zenith

ZTE/ZBTE Series

Transfer Switches
40-4000 Amps

Operation & Maintenance Manual

Authorized Service

For GE parts and service call: 1 + 800 637-1738, option #3 or 1 + 773 299-6600

Table of Contents

Introduction, Safety & Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Installation

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Inspection Prior to Initial Energization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Initial Testing & Energization of the Switch

Manual Testing of Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Electrical Testing of the Switch (Source 1 = utility, Source 2 = generator) . . . . . . . . . . . . . . . . . . . 5

The Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

The MX350 Controller

The MX350 Graphical Display & Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Switch Exerciser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Controller Power Supply (UTA – Universal Transformer Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Sequence of Operation for Bypass/Isolation Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Troubleshooting & Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Maintenance & Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Information subject to change without notice.
Please verify all details with

GE.

Zenith ZTE/ZBTE Series Operation & Maintenance Manual

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1

91R-1000

Introduction, Safety & Storage

GE transfer switches are used to provide a continuous
source of power for mission, process and healthcare
critical loads by automatically transferring from a pre­ferred source of power Source 1 (or Normal Source) to a
non-preferred alternate Source 2 (or Emergency) power
source (typically a generator) in the event that Source 1
operational parameters fall outside preset limits.

Voltage and current sensing and system controls are
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 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.

The safe operation of your switch at all times is GE’s focus.
It must be recognized that hazardous voltages and
currents can exist during normal operation and any
maintenance on the transfer switch must be performed
utilizing appropriate safety measures. Installation,

adjustment, maintenance or removal of the switch must
only be carried out by qualified personnel with all power
to the switch turned off. It is recommended that only
qualified electricians be allowed to install or provide
maintenance on the switch.

Regarding the switch itself, proper storage, installation,
operation and maintenance will help increase its operational
life. Upon initial receipt of the transfer switch, inspect for
any damage. This includes damage to the enclosure, power
panel, control panel and wiring harnesses. If any damage
is found or suspected, file a claim as soon as possible
with the carrier and notify the nearest GE representative,
or call 1 + 800 637-1738 or 1 + 773 299-6600.

Prior to installation store the transfer switch in a clean dry
location, protected from dirt and water. Provide ample air
circulation and heat, if necessary, to prevent condensation.
See Table 1 for recommended storage and ambient
operating temperatures.

NOTE

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 disconnect device.

All references made within this manual about the terms

“Source 1”, “S1” or “Preferred Source” relate to a “Normal”

power source (typically from a utility source). References made to

“Source 2”, “S2”, “Non-preferred Source” or “Alternate Source”

relate to an Emergency Source (many times a generator).

Table 1

Storage and Operating Ambient Temperatures

5% to 95%
(non-condensing)

-30°C to +75°C
(-22°F to +167°F)

40-400 AMP

(molded shell)

-20°C to +65°C
(-4°F to +149°F)

40-4000 AMP

(all other frame
and panel types)

-20°C to +60°C
(-4°F to +140°F)

Storage
Temperature

Humidity

Operating
Temperature
(Ambient)

Figure 1

Method of Moving Transfer Switch

NOTE: When lifting the switch using a spreader bar, height H

must be equal to half of distance 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.

!

CAUTION

Due to hazardous voltages and currents, GE recommends

that a GE Certified technician or a qualified electrician

perform the installation and maintenance of the switch.

91R-1000 Page

2 Zenith ZTE/ZBTE Series Operation & Maintenance Manual

Installation

When preparing to install the transfer switch, review the
documentation included with the unit. Each GE transfer
switch is factory wired and tested. A complete documen­tation package is furnished with each switch, providing
descriptions and schematics for the following:

a. Standard and non-standard control interface

signals and options.
b. Sequence of operations.
c. Standard indicators, pushbuttons and annunciators.
d. Controller failure and return settings and time delays.
e. Description of the programmable engine exerciser.
f. Standard programmable control of switch operation.
g. User-configurable input and output.
h. System schematics:

1. Overall switch system.

2. Universal transformer assembly (UTA) power supply.

3. Transfer switch device layout.

4. Transfer switch power panel layout.

5. Interconnect plugs.

6. Customer connection wiring.

Mounting

Adequate lifting means must be used to mount the
transfer switch into place. The recommended method
for moving the ATS using lifting eyes, where supplied, and
a spreader bar is illustrated in Figure 1. Enough room
should be allowed to open the cabinet door(s) fully for
inspection and servicing of the switch per NEC and
local codes.

Inspection Prior to Initial Energization

Prior to energizing the transfer switch, perform the following:

1. With a vacuum, remove any debris collected on
the switch during shipment or installation.

2. Check engine start connections. The engine-start
terminals are located on terminal block positions
1 through 3 (see Figures 2 and 3). The E contact
provides the engine start signal from the automatic
transfer switch controller to the genset. The terminal
block has two sets of A3 (Source 2 position) normally
open contacts (NO) and two sets of A4 (Source 1
position) NO contacts.

3. Verify the correct connection of all control wires.

4. Check settings of all timers and adjust as necessary.

5. Adjust any optional accessories as required.

6. Verify that all Source 1, Source 2 and Load cables
are correctly connected to the clearly marked
terminals on the unit.

7. Verify from Table 2 the number and sizes of cable
lugs, which are supplied as standard per the switch
amperage rating. Most transfer switches are sup­plied with UL listed solderless screw-type terminals
as standard for the Source 1, Source 2 and Load
power connections.

8. Verify equipment ground cable(s) are installed per
NEC and/or local codes.

9. Verify that all cable lug connections are tightened
in accordance with torque values in Table 3.

10. Remove surface oxides from cables by cleaning
with a wire brush.

11. Make sure that all covers and barriers are installed
and properly fastened.

NOTE

Power panels ship from GE connected to Source 1.

NOTE

All control wires (18-12 AWG) must be

torqued to 19 in/lbs (1.6 lb-ft) (2.2 N-m)

Table 2

Power Connections: Screw Type Terminals for External Power Connections

Switch Size (Amps)

Source 1, Source 2 & Load Terminals Neutral Bar (When Required)

Cable Per Pole Range of Wire Sizes No. of Cables per lug 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
225 1 #6 AWG to 250 MCM 3 #6 AWG to 300 MCM

260, 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 4 #2 AWG to 600 MCM 12 #2 AWG to 600 MCM

1600, 2000, 3000, 4000 Line, Load and Neutral terminals are located in the rear of switch and arranged with bare bus bar

!

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 of the switch.

Failure to do so may result in damage and

malfunction of the switch and void the warranty.

Zenith ZTE/ZBTE Series Operation & Maintenance Manual

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91R-1000

Table 3

Tightening Torque for Lugs

Figure 2

Typical Switch Component Arrangement Inside Enclosure
1200-1600A Bypass Shown Below

Terminal Block (

TB)

(Engine start contact terminals,
source 1 and 2 position contacts)

Input Relay (typ.)

Universal Transformer
Assembly (

UTA) Power Supply

ATS

Power

Panel

Backside of MX350
Graphical Control Panel

MX350 Modular Controller (

CPU, power

supply, sensing CT card, I/O cards, etc.)

Disconnect
Switch (DS)

Load

Current

Transformer (CT)

Block

Source 2

Source 1

Socket Size Across Flats Torque

in mm lb-in lb-ft N-m

1/8 3 45 4 5
5/32 4 100 8 11
3/16 5 120 10 14
7/32 5.5 150 12 17

1/4 6 200 17 23

5/16 8 275 23 31

3/8 10 375 31 42

1/2 13 500 42 56
9/16 14 600 50 68

Bypass Isolation

ATS Power Panel

Output Relay (typ.)

91R-1000 Page

4 Zenith ZTE/ZBTE Series Operation & Maintenance Manual

Figure 3

Representative Schematic of Terminal Board, Output Strip and Input Strip

Refer to Electrical Schematic Drawing for additional details

CUSTOMER USE

A1

OUT5

11

MX350 CONTROLLER

TO L-CARD SLOT “G” ON

G OUTPUT STRIP

OUTPUT-5

12A214

5-3

5-2

L5
L6

L4

L3

L2

L1

G2

G6

G4
G5

G3

J8

G1

800
802

J7

21-

+

OUTPUT-4

FACTORY USED (FOR ALARM)

FOR CUSTOMER USE

STATUS OUTPUT CONTACT

SHUNT TRIP EMERG. BKR.

LOAD SHED
STATUS OUTPUT CONTACT
FOR CUSTOMER USE

GE ZENITH

12

12

OUT4

A1
A2

OUT3

A1
A2

14

11

11

14

CONTROLS

12

12

A1

OUT1

OUT2

A2

A1

A2

11

14

11

14

802

4-2

4-3

5-1

4-1

3-3

3-2

2-3

3-1

1-3

2-2

1-2

2-1

1-1

(-)

OUTPUT
CONTACTS FOR

CONFIGURABLE

OTHERS

G INPUT STRIP

L9

MX350 CONTROLLER

TO L-CARD SLOT “G” ON

L13
L14

L12

L11

L10

G9

G13
G14

G12

G10
G11

L7
L8

802

800

J6

G8

G7

1
2

J5

-

+

(SUPPLIED BY OTHERS)

(SUPPLIED BY OTHERS)

(SEE NOTE 3)

(SEE NOTE 4)

(SEE NOTE 8)

CC

NO

12

12

12

IN7

A2

A1

IN5

IN6

A2

A1

A2

A1

14

11

14

11

14

11

COM

13

12

25ZA

NO

NO

CC

CC

IN1

11

A1

12

12

12

12

IN3

A1

IN4

A1

A2

A2

IN2

A1

A2

A2

11

11

14

14

11

14

14

GE ZENITH

CONTROLS

11

10

9

7

8

R15

NO

NO

CC

CC

Q2

DS

NO

C

FOR CUSTOMER USE

CONFIGURABLE INPUTS OPTION PACKAGE

OTHERS

COM

COM

CONNECTIONS OF THE TRANSFER SWITCH.

COMPONENTS DRAWN IN DASHED LINES ARE OPTION PACKAGE AND CUSTOMER

Q2 (TEST WITH LOAD) IS PROVIDED AS STANDARD (PRE-CONFIGURED) FEATURE.
R15 (LOAD SHED) IS PROVIDED AS AN OPTION (PRE-CONFIGURED) FEATURE.

ATS SHOWN IN SOURCE-1 POSITION WITH NO POWER AVAILABLE.

UNLESS OTHERWISE SPECIFIED ALL CUSTOMER CONNECTION WIRES TO BE #14 AWG.,

OUTPUT STRIP CONTACTS ARE RATED 10 AMPS AT 30VDC/250VAC.

ENGINE START CONTACT IS RATED 10 AMPS AT 28VDC/120VAC.

600V.

6.

7.

5.

4.

3.

2.

1.

NOTES

8. ENGINE START CONTACT MAY BE ON SEPARATE TERMINAL BLOCK FOR BYPASS
SWITCHES. REFER TO ELECTRICAL SCHEMATIC FOR TERMINAL LOCATION.

GE OTHERS

A4-1

A3-1

A3-2

CARD

8

K

8

C

C

C

7

9

E12

E11

E13

NO

NO

NO

A3-2

CA3-1

A3-1

CA4-1

A4-1

CA3-2

A4-2

C

AUX

NO

CA4-2

A4-2

CLOSED IN SOURCE 2 POSITION.

(2) NORMALLY OPEN CONTACTS.

FOR CUSTOMER USE.

FOR CUSTOMER USE

CONTACT

E

ENGINE START CONTACT

(2) NORMALLY OPEN CONTACTS

TB

FOR CUSTOMER USE.

HELD CLOSED IN SOURCE 1 POSITION

Non-Bypass ATS

Bypass ATS

8

K

CARD

8

9

7

A4-2

C

A4-1

C

A3-2

C

A3-1

C

AB4-5

C

AB3-6

C

PA3 T P1

GE OTHERS

TB

AUX

A4-2

NO

CA4-2

A4-1

NO

CA4-1

A3-2

NO

CA3-2

A3-1

NO

CA3-1

101

NO

100

99

NO

98

ENG. START

E11

E12

E13

(2) NORMALLY OPEN
CONTACTS, HELD CLOSED IN
SOURCE 1 POSITION FOR
CUSTOMER USE. SEE NOTE 1

(2) NORMALLY OPEN
CONTACTS, CLOSED IN
SOURCE 2 POSITION
FOR CUSTOMER USE.

CONTACT CLOSED WHEN BYPASS
IS IN SOURCE 1 POSITION.
FOR CUSTOMER USE.

CONTACT CLOSED WHEN BYPASS
IS IN SOURCE 2 POSITION.
FOR CUSTOMER USE.

E

CONTACT

ENGINE START CONTACT
FOR CUSTOMER USE