GE Zenith Controls ZTX User manual

72R-1000
9/05
ZTX Series Automatic Transfer Switches
40-400 Amps
GE Zenith Controls
Operation and Maintenance Manual
e

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 auto-
matically 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 MUSTbe 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.

■■GE Zenith Controls 1■■
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 mainte-
nance 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 enclo-
sure, 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-con-
densing)
-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.

■■2GE Zenith Controls ■■
ZTX Operation and Maintenance Manual (72R-1000)
GENERAT
OR
TERMINAL
S
N
BR
U
TILIT
Y
TERMINAL
S
LOAD
TERMINALS
T1
T2
T
3
N1
N
3
E1
E
3
E2
N2
T = Load N = Utilit
y
E = Generato
r
OPTIONAL A4 CONTACT
T
I
ON
OPERATES WHEN IN
ERA
T
UTILITY POSITION
ILIT
Y
OPTIONAL A3 CONTACT
TI
ON
OPERATES WHEN IN
ERA
T
GENERATOR POSITION
NER
A
SWITCH
POSITION
INDICAT
OR
JP
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 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.

■■GE Zenith Controls 3■■
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
g
SERIAL NUMBER:
RATING: VOLTS -
AMPS -
SYSTEM VOLTS:
MODEL NUMBER:
HZ -
PHASE -
GE Zenith Controls
JP
Battery
Connection
Figure 2