ZTG/ZTGD Operation and Maintenance Manual
Contents
1. E R E IR LN T d b e i ed 5 yo of o 7 o o i clelelel 40 80 Amps Amps AS NEN Stock Numbers by Amperage as Spares 40 80 100 400 600 N 1 2 3 N Cable Connection Lug S 2591 S 2591 S 1393F 2 Wire Size 84 600 4 600 42 600 MCM MAIN SECONDARY 120 K 2245B 58P 1106 208 240 K 2246B 58P 1107 380 415 K 2247B 58P 1108 ENSE peu 440 480 22488 58P 1109 575 600 K 2249B 58P 1110 575 600 K 2249B 58P 1110 Handle Manual n E3054 Handle Grip L 3078 4 Auxiliary Contacts L 3078 SNO SEO Coil Cutout Switch 3521 SCR N SCR E SCR P PS 8895 30 ZTG ZTGD Operation and Maintenance Manual 70R 1000D GE Zenith Controls Power Panel and Replacement Parts wona Delayed Transition 800 to 1200 Amps TERMINAL BLOCKS SN1 2 3 47 GRID SCR NO TERMINAL BLOCKS SCR EO MOVABLE CONTACT Pa SE1 2 3 4 SCR E STATIONARY CONTACT m Recommended Stock Numbers by Amperage escription as Spares 1000 1200 NL 1 2 3 EL 1 2 3 i 2 1392F T 123 Cable Connection Lug CU Wire 4 600MCM 2 NN EN TN Stationary Contact Assembly Kit 26P 1336 Arc Grid Assembly Kit 23P 1366 Movable Contact Assembly Kit 26P 1334 Movable Contact 26P 1335 SCR N SCR E SCR NO SCR EO SCR 5 8896 SN SNO Limit Switch 23P 1535 L 23P 1533 R SE SEO Limit Switch 23P2. Engine Start Control Connections Engine start control wires connect to control terminals beside the MX150 Engine start terminals are indicated by a schematic symbol the symbol indicates the contact state for a de energized normal source Figure 3 shows the engine start contacts Make all other necessary control connections to the con trol panel terminal blocks per the schematics supplied with the ATS NOTE All control wires 18 12 AWG must be torqued to 19 in Ibs Tightening Torque for Lugs Socket Size Across Flats 1 8 5 32 3 16 7 32 1 4 5 16 3 8 1 2 9 16 Table 2 LES ZTG ZTGD Operation and Maintenance Manual 70R 1000D GE Zenith Controls B Installation conta A DANGER A 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 Control Connections Figure 2 Engine Start Connections Input Output Connectors to I O Modules Firme bahar Panel A complete information package is furnished with each transfer switch including a complete connection diagram and schematic which details all necessary control circuit field connections The engine start control wires connect to the engine start relay terminals located to the left of the microprocessor Figure 2 shows the location of these terminals
3. Source 1 LED Green Source 1 Position LED Green Power Panel ATS Source 2 Red indicates Source 1 is indicates Power Panel ATS is closed to indicates Source 2 acceptable for use is closed to Source 1 position Source 2 position is acceptable for use LCD Screen Exercise Event Impending CurrentTime Day and SETM Date of Display m MORE Menu TEST Menu Keypad 112 31 4 4 or the word on the LCD above the key The word above the key changes depending on which screen is being displayed 1 or the word 2 or the word 3 or the word on the LCD above the key on the LCD above the key on the LCD above the key The word above the key The word above the key The word above the key changes depending on which changes depending on which changes depending on which screen is being displayed screen is being displayed screen is being displayed Figure 8 W GE Zenith Controls ZTG ZTGD Operation and Maintenance Manual 70R 1000D User Setting for Voltage amp Frequency Source 1 Voltage Restore Factory Default 90 This adjustment determines the minimum acceptable voltage required to transfer to Source 1 Adjust via the SET menu Range is 85 to 100 in 1 increments see page 18 Once satisfied the T timer will begin timing to transfer to Source 1 Voltage Fail Factory Default 80 This adjustment determines the low voltage threshold Adjust via the SET menu Range is 75 to
4. W GE Zenith Controls Clock Program Backup Battery Remove protective strip to enable clock functions Network Connector To R T Box The terminals are clearly identified by a label on the microcontroller backplate In the case of manual trans fer 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 ZTG ZTGD Operation and Maintenance Manual 70R 1000D 5 Installation conta A DANGER A 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 P Relay Engine Start Figure 3 Engine Start Control Connections 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 con trol panel for the engine start control wires Terminals for field connections to the A3 Source 2 auxiliary contacts and the A4 Source 1 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 Initial Energization Before proce
5. press MORE then SET 15 Press MORE repeatedly until EXER 52 RUN TIME screen 16 Press SEL 17 Enter ACCESS code located on white label on the back of the controller 18 Press SEL 19 Cursor is indicated as a line under character to be changed Change values with up and down keys 20 Press SAVE when complete 2 Press MORE repeatedly until SET USER SETUP then press BACK then ESC to the 81 OK screen m 14 ZTG ZTGD Operation and Maintenance Manual 70R 1000D GE Zenith Controls CDT One Event Timer Exerciser conta How to Initiate CDT Exerciser and to start an exercise cycle every 1 7 14 or 28 days From 51 screen 1 Press TEST 2 Pres MORE 3 Press START TEST TIMER to initiate Test e Ifthe CDT Exerciser is Factory configured for a Load Exerciser the Controller will immediately start a load exercise The controller will start the generator transfer the load to Source 2 and remain in Source 2 for the duration set for EXER 2 RUN TIME in the SET menu The controller will retransfer the load back to Source 1 after the S1 stable timer has timed out and run the generator unloaded for the duration of the S2 stop delay timer Engine Cool Down Timer Ifthe CDT Exerciser is Factory configured for a No Load Exerciser the Controller will immediately start a No load exercise The controller will start the generator and run it unloaded for the duration of the S2 stop delay timer Engine Cool Down Timer Exercise
6. 1536 L 23P 1534 R A3 Emergency Position Auxiliary Contact 23P 1536 4 Normal Position Auxiliary Contact 23P 1535 DS Disconnect Switch Operator L 4009 Contact Block L 1020 CN CNO r CE CEO Main Operator Solenoids See Chart Below Volts Ph Wire Coil VDC Pole 800 1200 240 3 3 240 3 K 2147 120 208 3 4 208 34 2147 480 3 3 480 3 K 2157 277 480 3 4 480 34 2157 240 416 3 4 416 3 Consult Factory W GE Zenith Controls ZTG ZTGD Operation and Maintenance Manual 70R 1000D 31m Power Panel and Replacement Parts wona Delayed Transition 1600 to 3000 Amps ARC GRID ASSEMBLY MOVABLE CONTACT STATIONARY CONTACT Tag Description Recommended Stock Numbers by Amperage as Spares 1600 2000 3000 E 2 5 1 12662 T 23 Cable Connection Lug CU Wire Optional NLN ELN 8 600MCM 2 Stationary Contact Assembly Kit 23P 4134X 23P 4134Y 23P 4134Z Arc Grid Assembly Kit 23P 1171 23P 1171 23P 1171 Movable Contact Assembly Kit 23P 1400 23P 1400 23P 1344 pisicing Main Operator Solenoids See Chart Below SCR NO SCR EO SOR PS 8806 Volts Ph Wire Coil VDC Pole 120 1 2 120 2 S P O S P O S P O 120 240 1 3 240 2 3 K 2151 K 2151 K 2151 240 3 3 240 3 K 2151 K 2151 K 2151 120 208 3 4 208 34 K 2151 K 2151 K 2151 480 3 3 480 3 K 2160 K 2160 K 2160 575 3 3 575 600 3 S P O S P O S P O 277 480 3 4 480 3 4 K 2160 K 2160 K 2
7. 807 806 805 SOURCE 1 CONTROL POWER 906 905 SOURCE 2 CONTROL POWER J5 W GE Zenith Controls ZTG ZTGD Operation and Maintenance Manual 70R 1000D 23m Troubleshooting and Diagnostics A DANGER A HAZARDOUS VOLTAGES CAN CAUSE SEVERE INJURY OR DEATH These charts may indicate problems that require authorized GE Zenith service personnel Hazardous voltages may exist on termination plugs other than those that go into the MX150 General Troubleshooting The following troubleshooting guide is used to recognize and determine basic faults When using this guide it will ask several questions about the condition of the switch This guide will then list an order of the possible faults You will then look at the first suspected fault to determine if it is the problem If it is not a fault you go to the second suspected fault If you go through all of the Engine does not START Engine does not stop ATS will not transfer to SOURCE 2 Annunciation SOURCE 2 AVAILABLE LED off LCD Display TD Engine Cool Down the control panel Possible Cause s Engine start wires not terminated properly suspected faults or the chart instructs you to call a GE Zenith Representative for further assistance NOTE When you use the troubleshooting charts the Annunciation column refers to the LED s on Corrective Action Check engine start connections Generator is in OFF position U timing cycle not complete Inv
8. 98 in 1 increments see page 18 Fail must be a minimum of 2 below Restore setting Once voltage falls below threshold P timer begins timing to signal Source 2 Generator to start Source 2 Voltage Restore Factory Default 90 This adjustment determines the minimum acceptable voltage required to transfer to Source 2 Adjust via the SET menu Range is 85 to 100 in 1 increments see page 18 Once satisfied the W timer will begin timing to transfer to Source 2 Voltage Fail Factory Default 80 This adjustment determines the low voltage threshold Adjust via the SET menu Range is 75 to 98 in 1 increments see page 18 Fail must be a minimum of 2 below Restore setting Once voltage falls below threshold T timer will be bypassed to expedite the transfer to Source 1 Frequency Restore Factory Default 9596 This adjustment determines the minimum acceptable frequency required to transfer to Source 2 Adjust via the SET menu Range is 90 to 10096 in 196 increments see page 18 Once satisfied the W timer will begin timing to transfer to Source 2 Frequency Fail Factory Default 90 This adjustment determines the low frequency threshold Adjust via the SET menu Range is 88 to 98 in 1 increments see page 18 Fail must be a minimum of 2 below Restore setting Once satisfied the W timer will begin timing to transfer to Source 2 Standard Features MSTDG Option Pkg
9. Switch in a power failure mode After all timer functions have elapsed the CHECKING FOR SOURCE SYNCHRO NISM will be displayed as well as the direction of transfer S1 S2 for example denotes transfer from Source 1 to Source2 When synchronism is accomplished transfer will take place Notes If S2 Frequency is less than S1 Frequency display will show a series of symbols If S2 Frequency is greater than S1 Frequency display will show a series of symbols Each or symbol represents 10 electrical degrees out of phase maximum of 18 symbols 180 electrical degrees can be monitored The number of or symbols decrease as the two sources approach synchronism and increase as the two sources drift out of synchronism If S1 and S2 Frequencies are identical the display will show a series of alternating symbols 271 which also indicate the approximate out of phase degrees m GE Zenith Controls In the event that the Sources do not come within 7 electrical degrees of each other within 60 seconds the unit will display the message SYNCH CHECKING and will allow the user to BYPASS If the BYPASS button is pressed the unit will display the message WARNING MAY CAUSE DAMAGE TO THE LOAD Pressing XFR will actually bypass the R50 Since R50 is a passive device the length of time it takes to reach Synchronism is de pendent on the frequency difference between the two Sources Sourc
10. TRANSFORMER 24V 10V 11V 24V 10V 11V e e e e S S S S S 8 3 S 515 3 8 8 5 5 a a a a a o a o a 900 18 SOURCE 2 24V OUTPUT 800 SOURCE 1 24V OUTPUT T 907 3 PHASE SOURCE 2 4 o 808 BLANK Y 908 cy Y BLANI Y Cv GND SCRE GROUND JC 901 SCR N an lt SCR E CONTROL VOLTAGE SOURCE 2 801 lt CV SCR N CONTROL VOLTAGE SOURCE 1 Jc 902 COMMON 903 904 SINGLE PHASE SOURCE 2 SENSING 803 804 3 PHASE SOURCE 1 SENSING 807 806 805 SOURCE 1 CONTROL POWER 906 905 SOURCE 2 CONTROL POWER 0 J5 Delayed Transition CPS Schematic 20 21 30 32 XN1 SOURCE 1 CONTROL TRANSFORMER XN2 SOURCE 13 PHASE SENSING TRANSFORMER le le 2 XE1 SOURCE 2 CONTROL TRANSFORMER E99999999999999999 999 E999999999909999999 TANG DAR UAR XE2 SOURCE 2 3 PHASE SENSING 24V 10V nV 24V 10V TRANSFORMER e e e e e e e wo e 8 8 8 8 amp S 5 8 Ei 900 SOURCE 2 24V OUTPUT 800 SOURCE 1 24V OUTPUT 907 3 PHASE SOURCE 2 SENSING V mU JC 808 SCR EO CONTROL VOLTAGE OPEN SOURCE 2 cy Y o 908 508 SCR NO CONTROL VOLTAGE OPEN SOURCE 1 Cv A GND SCR EO SCR N SCR E GROUND 9 p 901 901 Jc A lt pu CV SCR E CONTROL VOLTAGE SOURCE 2 801 J SCR N CONTROL VOLTAGE SOURCE 1 808 902 COMMON 908 903 904 SINGLE PHASE SOURCE 2 SENSING 803 804 3 PHASE SOURCE 1 SENSING
11. a 12 4 2 Fai R1 Output R1 Output Restore Input and output availability Contact Rating 10A 250 VAC or 30 VDC subject to factory configuration 2 UNDER VOLTAGE pg 10 Fai Restore 412v Output Source LN OUT S2 UNDER FREQUENCY pg 10 pity Fai Lithium Battery Exerciser Battery Restore Replacement K 4100 882032 ervice Life 10 Years L1 OUT m YNIN YEIN TSNLIN Q2 TSL IN 5121 SET PHASE IMBALANCE VI FAIL 5 3 pg 12 User Access Code Default 121212 SET PHASE IMBALANCE VI TIME DELAY 30 seconds pg 12 24 Hour Service 773 299 6600 OOOOOOOOOOOOO0 TIME DELAY S2 START P1 MX150 pg 11 TIME DELAY S2 STABLE W Figure 9 pg 11 LOAD PRESIGNAL TD T3 W3 pg 13 LOAD DISCONNECT TD UMD pg 13 ATS OPEN TIME TO S2 DW DELAY units only pg 10 TIME DELAY 51 STABLE T pg 11 ATS OPEN TIME TO S1 DT DELAY units only pg 10 S2 STOP DELAY U pg 11 CALIBRATE S1 pg 10 CALIBRATE 52 pg 10 Optional Accessories m 18 ZTG ZTGD Operation and Maintenance Manual 70R 1000D GE Zenith Controls B MX150 User Setup System Info View System Data S1 OK 01 50 Enter six digit access code FRI 31 MAY 2003 The factory assigned six digit access code MORE TEST is located on the back of the controller PHASE TO PHASE VOLTAGE S1 amp S2 FREQUENCY INDICATION FOR S1 amp S2 5 e ef
12. oe Network Communications K P pg 11 Option Ville PLANT EXERCISER E Next Impending Exerciser i shows only if set o wiaour toes ELEV PRE OUT ALARM OUT 4 SYSTEM INFO lt Serial UnitSerialf LT Rev Software Revision output Event Log Sequentially Numbered Log mosi of 16 events that track p mesz 1 t 1 1 date time reason and action taken I I 14 12 21 24 22 Data Total Life Transfers N2P i coge RI Output Lh m s T Input and output availability Contact Rating 10A 250 VAC or 30 VDC otal Transfers to S2 subject to factory configuration Total S1 Failures Time S1 available in Hrs Time S2 available in Hrs N1P 12v Output Source LNOUT L4 OUT Lithium Battery Exerciser Battery Replacement K 4100 882032 ervice Life 10 Years CHANGE USER ACCESS CODE L1 OUT YNIN YEIN TSNLIN Q2 TSL IN 5121 User Access Code Default 121212 24 Hour Service 773 299 6600 MX150 Figure 9 W GE Zenith Controls ZTG ZTGD Operation and Maintenance Manual 70R 1000D 19m A NOTICEA A periodic test of the transfer switch under load conditions is recommended to insure proper operation See National Electric Code articles 700 and 701 ATS Testing Start generator and verify proper voltage frequency and phase sequence match t
13. retransfer to Source 1 Adjustable 0 60 minutes in 1 second increments Standard setting is 5 minutes Adjust via SET menu see page 18 Time Delay S2 Source 2 Stable Timer To delay trans fer to Source 2 Adjustable 0 5 minutes in 1 second increments Standard setting is 1 second Adjust via SET menu see page 18 YEN Bypass Timers Key utilizing Keypad When applicable the system prompts the user to press a button to bypass T or W Timers should the user so desires ZTG ZTGD Operation and Maintenance Manual 70R 1000D 11 Standard Features MEXEG Option Pkg In addition to the features listed under the MSTDG Option Package this enhanced package includes the following features A3 Additional Auxiliary contact closed when switch is in Source 2 position A4 Additional Auxiliary contact Closed when the transfer switch is in Source 1 position replaces Clock Exerciser Load No Load Allows the Generator to start and run unloaded or to simulate a power failure start Generator and run under load Can be configured by end user for 1 7 14 28 365 day cycle VI Voltage Imbalance Three Phase For a three phase source this feature monitors phase voltage ratios based on a selected range within a selected time window Should any phase fall below the selected lower window limit or exceed the selected higher window limit within the selected time frame the controller initiates tra
14. 1400 23P 1400 CN CE Pole 120 2 SPO SPO SPO 2 3 K 2123F K 2123F K 2123F za 4 K 2127F K 2127F K 2127F 3 K 2125F K 2125F K 2125F Main Operating Coils nd 4 K 2128F K 2128F K 2128F 3 K 2153F K 2153F K 2153F 575 600 4 K 2154F K 2154F K 2154F 3 K 2120F K 2120F K 2120F 299 4 K 2130F K 2130F K 2130F 416 3 K 2126F K 2126F K 2126F SN CCN Cutout Switch 23P 1352 23P 1352 SE CCE Cutout Switch 23P 1356 23P 1356 A3 Emergency Position Auxiliary Contact Qty 1 23P 1356 Qty 2 23P 1357 Qty 3 23P 1353 Qty 4 23P 1355 A4 Normal Position Auxiliary Contact Qty 1 23P 1352 Qty 2 23P 1353 Qty 3 23P 1357 Qty 4 23P 1359 Operator DS Disconnect Switch older versions 2008 Operator L 4009 Contact Block L 1020 Block L 1020 SCR N SCR E SCR xi PS 8896 W GE Zenith Controls ZTG ZTGD Operation and Maintenance Manual 70R 1000D 29m Power Panel and Replacement Parts con Delayed Transition 40 to 600 Amps CN CE dre i ollellalm o 1 T2 T3 TN eene e E1 E2 EN N1 N2 N3 NN o SCR N SNO SN A4 SE A3 SEO SCR E 100 400 Amps zm
15. 160 120 240 2 4 240 4 K 2151 K 2151 K 2151 240 416 3 4 416 3 Consult Factory SN SNO 1 2 Switch Bracket Assembly 23P 1540 23P 1540 23P 1540 SE SEO 1 2 Switch Bracket Assembly 23P 1541 23P 1541 23P 1541 SN SNO 3 4 Switch Bracket Assembly 23P 1542 23P 1542 23P 1542 SE SEO 3 4 Switch Bracket Assembly 23P 1543 23P 1543 23P 1543 32 ZTG ZTGD Operation and Maintenance Manual 70R 1000D GE Zenith Controls m GE Zenith Controls ZTG ZTGD Operation and Maintenance Manual 70R 1000D 33 m 34 ZTG ZTGD Operation and Maintenance Manual 70R 1000D GE Zenith Controls m GE Zenith Controls ZTG ZTGD Operation and Maintenance Manual 70R 1000D 35 m 96 GE Zenith Controls A Product of GE Industrial Systems General Electric Company 830 West 40 Street Chicago IL 60609 USA 773 299 6600 Fax 773 247 7805 www geindustrial com
16. 27 SCR N SCR E SCR ALL V PS 8895 A3 A4 Auxiliary Contacts ALL V L 3078 26 ZTG ZTGD Operation and Maintenance Manual 70R 1000D GE Zenith Controls Power Panel and Replacement Parts con Standard Transition 400 to 600 Amps Molded Type N1 N2 N3 NN Ti T2 TN gt o oH ouo fo fol o o SCRN i o SE T o SCR E 1 ma E1 E2 EN MA Recommended Stock Numbers by Amperage Description as Spares 400 600 N 1 2 3 N Cable Connection Lug S 2701 S 1393F 1 2 3 N 1 2 3 Wire Size 4 600 MCM 2 600 MCM 120 K 2245B CN CE Solenoid 208 220 K 2246B 380 416 K 2247B 440 480 K 2248B 575 600 K 2249B SN SE Coil Cutout Switches L 3078 4 Auxiliary Contacts SCR N SCR E SCR i PS 8895 W GE Zenith Controls ZTG ZTGD Operation and Maintenance Manual 70R 1000D 27 Power Panel and Replacement Parts wona Standard Transition 800 to 1200 Amps STATIONARY CONTACT ARC GRID REMOVED FOR CLARITY MOVABLE CONTACT Tag Description Recommended Stock Numbers by Amperage as Sp
17. 6 Test Switch Momentary Auxiliary Contact Closed when the switch is in Source 2 position A4 Auxiliary Contact Closed when the switch is in Source 1 position Calibrate While monitoring the actual Phase to Phase voltage lev els and Frequency with a calibrated test equipment the Phase to Phase voltage sensing and Frequency can be adjusted accordingly Calibration capabilities are available for Frequency and AB BC CA Phase to Phase voltage for both Sources Adjust via SET menu see page 18 CDT Load or NO Load One event exerciser with adjustable Engine exercise timer Exercise duration can be set between 5 and 60 minutes in 1 minute increments Can be configured to run every 1 7 14 or 28 days Factory Default is 20minutes When exerciser is impending E appears in the upper right hand corner of LCD screen See page 14 15 for instructions Configured via CFG see page 17 Set via SET menu see page 18 DS Disconnect Switch Auto Inhibit Inhibits transfer in either direction when in inhibit Allows automatic operation when in Auto 800 4000 Amp units DT Delayed Transition Only Time Delay from Neutral Switch position to Source 1 position Adjustable 0 10 minutes in 1 second incre ments Standard setting is 5 seconds Adjust via SET menu see page 18 DW Delayed Transition Only Time Delay from Neutral Switch position to Source 2 position Adjustable 0 10 minutes in 1 second incre ments
18. Communications Interface Card ZTG ZTGD Operation and Maintenance Manual 70R 1000D 13m How to Set the System Clock How to Set the System Clock Set System Clock time and date If the clock is not set the display will show SET SYSTEM CLOCK on the second line of the 51 OK screen The S1 OK screen will show time hours and minutes on the second line if the system clock has been set Date on third line Setting the System Clock Start from S1 OK screen l Remove battery protective white plastic strip near P relay 2 Press MORE then press SET 3 Press MORE and scroll to SET SYSTEM CLOCK using the MORE key Press SEL 5 ENTER ACCESS CODE located on the white label on the back of the controller Press SEL Use the up and down keys to change the hour value A 9 8 Press SAVE this will enter this value and move cursor to minutes 9 Use the up and down keys to change the minutes 10 Press SAVE this will enter this value and move cursor to month 11 Use the up and down key up to change the month 12 Press SAVE This will enter this value and complete the clock setting 18 Use the up and down keys to change the date 14 Press SAVE this will enter this value and move cursor to year 15 Use the up and down keys to change year 16 Press SAVE this will enter this value and compete the clock setting 17 To edit settings press SEL and repeat steps 6 16 18 If the setting is satisfactory press MORE unit t
19. G Option Pkg 12 800 1200 Amps 28 Optional Accessories 13 1600 3000 Amps 29 How to Set the System Clock 14 Delayed Transition 30 CDT One Event Timer Exerciser 14 15 40 600 Amps 30 CDP Clock 16 800 1200 Amps 31 User Setup CFG Menu 17 1600 3000 Amps 32 User Setup Menu 18 User Setup System Info 19 Testimg eoru Rieko a Pe Ses 20 Standard Transition 20 Delayed Transition 20 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
20. GE Zenith Controls ZTG ZTGD Series Transfer Switches 40 3000 Amps 70R 1000D i 11 04 Operation and Maintenance Manual Authorized Service For GE Zenith parts and service call 773 299 6600 Table of Contents Introduction 2 eee 2 Sequence of Operation 21 Safety ong AUR tetas 3 Standard Transition 21 Equipment Inspection and Storage 3 Delayed Transition 21 Final Equipment Inspection 3 Controls Power Supply CPS 22 Installation Cae ee VEI 3 Schematics Standard amp Delay 23 os 3 Troubleshooting amp Diagnostics 24 Power Connections 4 Maintenance and Testing 25 Engine Start Control Connections 4 6 Inspection and Cleaning 25 Initial Energization 6 7 SETANE cuc ondes eg heating hates 25 MX150 Microprocessor Controller 8 NE ENIM 25 OVGEVIEW Go Ios LI Leda oed 8 Power Panel amp Replacement Parts 26 LCD amp Keypad 9 Standard Transition 26 User Setting for Voltage amp Frequency 10 40 260 AMPS ai chess apse gr T E RE ERN 26 Standard Features MSTDG Option Pkg 10 11 400 600 Amps 27 Standard Features MEXE
21. Standard setting is 5 seconds Adjust via SET menu see page 18 Engine Start Contact m 10 ZTG ZTGD Operation and Maintenance Manual 70R 1000D GE Zenith Controls Std Features MSTDG Option Pkg EL P Event Log Sequentially Numbered Log of 16 events that track date time reason and action taken System Data Total Life Transfers N2P Days Powered Up Total Transfers to S2 Total S1 Failures Time 51 available in Hrs Time S2 available in Hrs N1P K P Frequency Indication for 51 and S2 L LNP Center off position LCD Indicator Indicating LED lights L1 Indicates Switch in Source 2 position L2 Indicates Switch in Source 1 position L3 Indicates Source 1 available L4 Indicates Source 2 available P1 Time Delay Source 2 Start Adjustable 0 10 seconds Standard setting is 3 seconds Adjust via SET menu see page 18 Q2 Peak Shave Remote Load Test Input for Peak Shave or Remote Load Test Includes automatic return to Source 1 if Source 2 fails and Source 1 present R2E Under voltage sensing of Source 2 for single phase R17 replaces R2E for Utility to Utility switches R50 In Phase Monitor this feature restricts Live to Live Source Transfers to occur unless both Sources are within 7 electrical degrees or less of each other live Source to live Source transfers usually occur during transfer back to Source 1 or during Testing R50 does not change the operation of the Automatic Transfer
22. al Services Department for the Replacement Parts manual The operating mechanism of the transfer switch is lubricated with Lubriplate 105 The lubricant applied at the factory provides adequate lubrication for the lifetime of the switch Should debris contaminate the mechanism clean and apply additional Lubriplate GE Zenith can provide complete preventative main tenance services Please contact the GE Zenith Technical Services Department for additional information W GE Zenith Controls CDT battery replacement lithium batteries may last up to 10 years however it is recommended that battery replacement be included in a 3 5 year service cycle The battery maintains the exerceser memory only and does not otherwise affect the operation Testing A manual operator handle is provided with the transfer switch for maintenance purposes only Manual operation of the switch must be checked before it is operated electrically Both power sources must be disconnected before manual operation of the switch Insert the handle and operate the transfer switch between the Source 1 and Source 2 positions The transfer switch should operate smoothly without binding Return the switch to Source 1 position remove the handle and return it to the holder provided After completing the inspection cleaning and servicing of the transfer switch reinstall the switch cover and close and lock the cabinet door Reclose the circuit breakers feeding the uti
23. anual 70R 1000D GE Zenith Controls Installation conta Initial Energization After all options and accessories are checked and veri 5 Close the External up stream Source 2 line fied follow these steps to set up the ATS Refer to MX150 circuit breaker display Figure 5 The annunciation LEDs illuminate to 6 Start the engine generator in MANUAL mode indicate 1 source availability 2 ATS position and 3 MX150 control function timing NOTE When the voltage and frequency reach preset values the Source 2 Available LED will illuminate 7 Verify the phase to phase voltages at Source 2 line terminals 8 Verify that the phase rotation of A Source 2 is the same as the phase f y rotation of Source 1 C B 9 Shut down the generator s engine wa Place in Automatic Mode NOTE Source 2 Available LED will turn off NOTE The engine generator will continue to run for the duration of Source 2 Stop Delay Timer 10 Place the disconnect switch to ENABLE 11 Complete the visual inspection of the transfer switch 2 3 4 19 Close the enclosure 13 Lock the enclosure MX150 Figure 5 LCD and keypad WAR N N G When performing hi pot or 1 Unlock the enclosure dielectric test on the power section 2 Open the enclosure DISCONNECT the control panel plugs from 3 Place the Disconnect Switch in the Inhibit the microprocessor to avoid potential damage NOTE This step is o
24. ares 800 1200 N 1 23 N Cable Connection Lug S1392F 4 E 1 2 3 N 1 2 3 Wire Size 312 600 Stationary Contact Assembly Kit Consult Factory Arc Grid Assembly Kit 23P 1366 Movable Contact Assembly Kit Consult Factory 208 240 2 3 4 K 2147 Main Operating Coils 380 416 3 K 2168 480 3 4 K 2157 575 600 3 4 K 2187 SN Cutout Switch 23P 1333 23P 1333 SE CCE Cutout Switch 23P 1327 23P 1452 A3 Emergency Position Auxiliary Contact Qty 1 23P 1327 Qty 2 23P 1328 Qty 3 23P 1334 Qty 4 23P 1336 A4 Normal Position Auxiliary Contact Qty 1 23P 1333 Qty 2 23P 1334 Qty 3 23P 1328 Qty 4 23P 1330 Operator DS Disconnect Switch older versions Cus Operator L 4009 Contact Block L 1020 Block L 1020 SCR N SCR E SCR PS 8896 m 28 ZTG ZTGD Operation and Maintenance Manual 70R 1000D GE Zenith Controls Power Panel and Replacement Parts con Standard Transition 1600 to 3000 Amps ARCH GRID ASSEMBLY STATIONARY CONTACT MOVEABLE CONTACT ARCH GRID REMOVED FOR CLARITY Tag Description Recommended Stock Numbers by Amperage as Spares 1600 2000 3000 Cable Connection Lug S1126F 2 Optional 51126 2 Optional S1126F 2 Optional Wire Size 8 2 600 MCM 8 2 600 MCM 8 2 600 MCM Stationary Contact Assembly Kit 23P 1594 23P 1594 23P 1594 Arc Grid Assembly Kit 23P 1171 23P 1171 23P 1171 Movable Contact Assembly Kit 23P 1400 23P
25. ator and run under load Can be configured by the end user for 1 7 14 28 or 365 day cycles Atotal of 7 independent No Load exercise periods up to 10 hours each can be programmed for each of the daily weekly 14 day and 28 day exercisers Atotal of 12 independent No Load exercise periods up to 10 hours can be programmed for the 365 day Exerciser How to Configure CFG the Exerciser 1 Beginning from the S1 OK screen press MORE then CFG 2 Press MORE to scroll to CONFIG CLOCK EXERCISER screen 3 The third line of the CONFG CLOCK EXERCISER will show either DAILY WEEKLY 14 DAY 28 DAY 365 DAY or OFF If the third line of the CONFG CLOCK EXERCISER shows DAILY WEEKLY 14 DAY 28 DAY or 365 DAY as desired press MORE repeatedly to BACK Press ESC then proceed to the SET menu to set the EXERCISER 5 If the third line of the CONFG CLOCK EXERCISER shows OFF continue 6 Press SEL 7 Enter ACCESS code located on white label on the back of the controller 8 Press UP or DOWN to select DAILY WEEKLY 14 DAY 28 DAY or 365 DAY as desired 9 Press SAVE Press MORE repeatedly to BACK then ESC to 1 OK screen How to set SET the DAILY Exerciser l Beginning from the 1 OK screen press MORE then SET 2 Press MORE repeatedly until SET EXERCISER 6 Cursor is indicated as a line under character to be changed Change values with up and down keys Press SAVE after each entry to s
26. ave value and to move to the next value to be changed Press BACK when complete 8 Press MORE repeatedly until SET USER SETUP Press BACK then ESC to the S1 OK screen e How to Bypass Cancel an exercise during an exercise cycle 1 Press BPASS 2 Allow the controller to complete the Engine cool down cycle If the CD Exerciser is configured or Set for a No Load Exercise Or allow the controller to complete retransfer to Source 1 If the CD Exerciser is configured for a Load Exerciser How to Bypass the next exercise event and Keep the rest of scheduled events unchanged 1 Press TEST 2 Pres MORE 3 Press BYPASS EXER To re institute the next exercise event back press CANCL BPASS How to check the next exercise event 1 From 51 OK screen press MORE three times 2 The unit will display the PLANT EXERCISER NEXT event in DAYS HOURS and MINUTES 3 Press ESC to S1 OK Screen Notes e In the 51 OK screen an E appears in the upper right hand corner of LCD screen when exercise is impending For Load Exerciser actual exercise period ATS in S2 position CDT Exerciser timing period T S1 Stable Timer timing period Avalue greater than zero must be entered in the screen Exerciser duration field to be accepted as a valid 3 Press SEL exercise period 4 Enter ACCESS code located on white label The Exercise cycle will be repeated on a regular on the back of the controller basis as programmed and
27. delay an Engine start Signal is sent to Source 2 When Source 2 voltage and frequency reach the preset Restore values the time delay to open Source 1 timer W begins its timing cycle to ensure voltage and frequency stabilization before re transfer A manual pushbutton BYPASS is provided to bypass the W time delay if desired After the W time delay the MX controller initiates a transfer signal through the SCR NO to operate the main transfer operator The load is now transferred to the Open position The time delay to Source 2 timer DW begins its timing cycle After the DW time delay the MX controller initiates a transfer signal through the SCR E to operate the main transfer operator The load is now transferred to Source 2 line The transfer switch is mechanically locked SN limit switch awaits the next operation to Source 1 Restoration of Source 1 Power When Source 1 power reach the preset Restore values the controller initiates re transfer to Source 1 sequence The delay to open Source 2 Timer T begins its timing cycle to ensure voltage and frequency stabilization before retransfer A manual pushbutton BYPASS is provided to bypass the T time delay if desired After the T time delay the MX controller initiates a transfer signal through the SCR EO to operate the main transfer operator The load is now transferred to the Open position The time delay to Source 1 timer DT begins its timing cycle After the DT time dela
28. e 1 is usually a Utility and the frequency is not within the control of the consumer Source 2 needs to be adjusted to create an adequate difference in order for the transfer to happen a timely fashion Note For optimum performance Source 2 Generator should be adjusted a Maximum of 2 Hertz above or below the Utility frequency minimum of 0 1 Hertz 58 to 59 9 or 60 1 to 62 Hertz Adjustment of Generator to 60Hertz could cause lengthy transfer delay R50 Feature can be turned ON or OFF via CFG Menu see page 17 Factory Default if OFF S13 Transfer Commit Configured via CFG menu see page 17 When this Feature is set to OFF The transfer Switch is not committed to transfer unless the outage duration is longer than the timers that precede the transfer to Source 2 position This assumes that the outage will be an isolated event When this Feature is set to ON The transfer Switch is committed to transfer to Source 2 position once the W timer has begun timing even if Source 1 power returns before the transfer to Source 2 This is to ensure that the transfer takes place because one outage may be followed by another T Time Delay S1 Source 1 Stable Timer To delay trans fer to Source 1 immediate retransfer on Source 2 fail ure Adjustable 0 60 minutes in 1 second increments Standard setting is 30 minutes Adjust via SET menu see page 18 U S2 Source 2 Stop Delay Timer Allows Engine to run unloaded after switch
29. e 2 When Source 2 voltage and frequency reach the preset Restore Values the time delay to Source 2 Timer W begins its timing cycle to ensure voltage and frequency stabilization before transfer A manual pushbutton BYPASS is provided to bypass the W time delay if desired After the W time delay the MX con troller initiates a transfer signal through the SCR E to operate the main transfer operator The load is now transferred to Source 2 line The transfer switch is mechanically locked SN limit switch awaits the next operation to Source 1 Restoration of Source 1 Power Deactivating the test switch initiates re transfer to Source 1 sequence The delay to Source 1 Timer T begins its timing cycle to ensure voltage and frequency stabilization before retransfer A manual push button BYPASS is provided to bypass the T time delay if desired After the T time delay the MX controller initiates a transfer signal through the SCR N to operate the main transfer operator The load is now transferred to Source 1 line The transfer switch is mechani cally locked SE limit switch awaits the next operation to Source 2 Immediately after re transfer the 52 Stop Delay Timer Delay 1 2 3 4 ii Figure 10 to Engine Stop U begins its cycle to allow Source 2 Engine to run unloaded A manual pushbutton BYPASS is provided to bypass the U time delay if desired Upon completion of the U timing cycle the controller sends an Engine sto
30. eding refer to the information package supplied with the ATS and read and understand the information on all accessories provided 1 Unlock the enclosure 2 Open the enclosure 3 Verify the correct system voltage NOTE The equipment rating nameplate on the transfer switch lists the voltage See Figure 4 4 Close Source 1 circuit breaker NOTE The controller will illuminate Source 1 Available LED if proper voltage is sensed 5 Verify the phase to phase voltages at the Normal line terminals 6 Close the Source 2 circuit breaker 7 Start the generator engine Contact rating is 10 Ampere at 120VAC or 28VDC Gold plated NOTE The controller will illuminate Source 2 Available LED when preset voltage and frequency levels are reached 8 Verify the phase to phase voltages at Source 1 line terminals 9 Verify that the phase rotation of Source 1 4 AN is the same as the phase rotation of Source 2 C B 10 Shut down the generator engine we 11 Place the starting control in the Automatic position 12 Complete the visual inspection of the transfer switch 13 Close the enclosure 14 Lock the enclosure GE Zenith Controls SERIAL NUMBER RATING VOLTS AMPS SYSTEM VOLTS MODEL NUMBER Figure 4 A CAUTIONS Certain accessories per specific schematics can inhibit automatic transfer Engine Gen Set could start when engine control wires are attached n6 ZTG ZTGD Operation and Maintenance M
31. esired After the W time delay the MX controller initiates a transfer signal through the SCR E to operate the main transfer operator The load is now transferred to Source 2 line The transfer switch is mechanically locked SN limit switch awaits the next operation to Source 1 Restoration of Source 1 Power When Source 1 power reach the preset Restore values the controller initiates re transfer to Source The delay to Source 1 Timer T begins its timing cycle to ensure voltage and frequency stabilization before retransfer A manual pushbutton BYPASS is provided to bypass the T time delay if desired After the T time delay the MX controller initiates a transfer signal through the SCR N to operate the main transfer opera tor The load is now transferred to Source 1 line The transfer switch is mechanically locked SE limit switch awaits the next operation to Source 2 Immediately after re transfer the S2 Stop Delay Timer Delay to Engine Stop U begins its cycle to allow Source 2 Engine to run unloaded A manual pushbut ton BYPASS is provided to bypass the U time delay if desired Upon completion of the U timing cycle the controller sends an Engine stop signal Delayed Transition Source 1 Power Failure When Source 1 voltage or frequency has fallen below the preset Fail values the controller initiates the Time Delay Source 2 Start Engine Start Timer P cycle Upon completion of the P time
32. estigate why Engine Control Switch was turned off Check U timer setting ZTG Series ATS will not transfer to SOURCE 1 SOURCE 1 POSITION and SOURCE 1 and SOURCE 2 AVAILABLE LEDs on but U timer has timed out SOURCE 2 AVAILABLE LED off Engine start wires not terminated correctly Check Engine Start Connections Generator in MANUAL SOURCE 2 voltage or frequency not within acceptable parameters Place generator in AUTO Check Engine Start Connections Generator Breaker Generator Output and Engine Control Switch None Power supply connector unplugged Plug in connector ZTGD Series LCD Display S1____ TD XFR 51 gt 52 Time Remaining ___ LCD Display ATS Open Time Remaining __ _ W timing cycle not complete DW timing cycle not complete Check W Timer setting Check DW Timer setting SOURCE 1 AVAILABLE LED off SOURCE 1 voltage or frequency not within acceptable parameters Check utility and utility breakers None Power supply connector unplugged Plug in connector LCD Display Diagnostic Code 001 Limit switch or RT box connector unplugged Call Technical Services LCD Display S1 OK Time Remaining Bypass T timing cycle not complete Check T Timer setting LCD Display ATS Open Time Remaining ___ TD timing cycle not complete Check DT Timer setting 24 ZTG ZTGD Operation and Maintena
33. hen returns to the SET menu then press BACK then ESC Replacement battery part K 4100 Battery will last 5 years and provides power to retain clock function only Controller functions without battery CDT One Event Timer Exerciser Load No Load One event Exerciser with adjustable Timer Exercise duration can be set between 5 and 60 minutes in 1 minute increments Can be configured to run every 1 7 14 or 28 days Factory default is 20 minutes How to CONFIGURE CFG and Set SET the Timer Exerciser l Beginning from the S1 OK screen press MORE then CFG 2 Press MORE to scroll to CONFIG TIMER EXERCISER screen 3 The third line of the CONFG TIMER EXERCISER will show either DAILY WEEKLY 14 DAY 28 DAY or OFF 4 If the third line of the CONFG TIMER EXERCISER shows DAILY WEEKLY 14 DAY or 28 DAY as desired then proceed to step 10 5 If the third line of the CONFG TIMER EXERCISER shows OFF or if another timer selection is desired continue 6 Press SEL 7 Enter ACCESS code located on white label on the back of the controller 8 Press UP or DOWN to select DAILY WEEKLY 14 DAY or 28 DAY as desired 9 Press SAVE 10 Press MORE to scroll to CONFG TIMER EXERCISER XFR or NO XFR 11 Press Up or Down to select Load Transfer or NO XFR No Load Transfer 12 Press SAVE 13 Press MORE repeatedly to BACK then S1 OK screen Set SET the Exerciser 14 Beginning from the S1 OK screen
34. iagram 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 Source 1 Source 2 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 in Figure 1 Enough room should be allowed to open the cabinet doors fully for inspection and servicing of the switch per NEC and local codes 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 ZTG ZTGD Operation and Maintenance Manual 70R 1000D 3m RES C LL ES ate A 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 Power Connections y Ri GE Zenith transfer switches are supplied with UL listed iE PREADER egy solderless screw type terminals as standard for the H Source 1 Source 2 and Load power connections Table 1 li
35. ing voltage to the printed circuit board power for the MX150 printed circuit board and an isolates the MX150 from the line voltage further protecting application of sensing voltage proportional to line voltage the controller from harmful line transients t a 2 2 22 4 5 3 l Primary CPS Voltage Assembly at 50 60 Hz Part No 120V 50P 1224 50P 1200 208 220V 50P 1225 50P 1201 230 240V 50P 1226 50P 1202 2TIN 50P 1227 50 1203 380 400V 50 1228 50 1204 416 440V 50P 1229 50 1205 460 480V 50P 1230 50P 1206 575 600V 50P 1231 50P 1207 22 ZTG ZTGD Operation and Maintenance Manual 70R 1000D GE Zenith Controls Controls Power Supply CPS wora Standard Transition CPS Schematic 20 21 30 31 SOURCE 1 CONTROL TRANSFORMER XN2 SOURCE 1 PHASE SENSING TRANSFORMER XN1 XN2 e XE1 XE1 SOURCE 2 CONTROL TRANSFORMER 9999999999 999999999 9 229909 52999999990 009 9999999 EU US AU TY XE2 SOURCE 2 3 PHASE SENSING
36. initiated in the SET menu 5 Press SEL depending on what Exerciser was configured selected in the CFG menu Indicates of y Exercise Periods Load No Load CDP Indicates type of Exerciser Exercise Indicator DAILY WEEKLY 14 DAY 28 DAY or 365 DAY Exercise duration for this T 5 event in hours and minutes Indicates Exerciser start up to 10 hours per event Time for DAILY Exerciser Time amp Day for WEEKLY Exerciser Time Date amp Month for 14 DAY Up and Down 28 DAY and 365 DAY Exerciser Use to change values So To previous ol epee 2 field to be changed m 16 ZTG ZTGD Operation and Maintenance Manual 70R 1000D GE Zenith Controls B MX150 User Setup CFG Menu Turn options ON or OFF via S1 OK 01 50 keypad through the CFG menu D STAT 2003 Enter six digit access code JST The factory assigned six digit access code is located on the back of the controller 1 VAB AME 2 VAB BIN 404 1 WARNING VBC ___ Controller Inputs must be relay Isolated V C A me Engine Start Mm pec M FG S ET E SC 2 PROG 1 PROG2 GRD l G O NIA OUT USER SETUP O M R E B AC K O MOTOR DISC OUT INHIB gt S1 O INHIB gt S2 R1 Output R1 Output TI M ER EXERC SER CDT Input and output availability Contact Rating 10A 250 VAC or 30 VDC J4 subject to factory co
37. lity and generator sources to the switch Initiate the electrical transfer test by activating the TS test switch P timer will time out and the micro controller will send an engine start signal When the W time has elapsed the switch will complete its transfer by closing into Source 2 Deactivating the test switch will start retransfer to Source 1 The switch will complete its retransfer to Source 1 after the time delay of the T timer The U engine overrun timer allows the engine generator to run unloaded for a preset cool down period NOTE A periodic test of the transfer switch under load conditions is recommended to insure proper operation See National Electric Code articles 700 and 701 A WARNING When performing a hi pot or dielectric test on the power section DISCONNECT the control panel plugs from the microprocessor to avoid potential damage ZTG ZTGD Operation and Maintenance Manual 70R 1000D 25m Power Panel and Replacement Parts Standard Transition 40 to 260 Amps Solenoid Type SCR 2251 SCR E CN CE SCN SCE Recommended Tag Description as Spares Voltage 40 to 260 Amps Part 120V K 2207 208V K 2208 220V K 2208 240V K 2228 CN CE Solenoid ui 277V K 2211 380 416V K 2212 440 480V K 2209 575 600V K 2213 Solenoid Plunger and Link ALL V 57P 1030 SCN SCE Coil Cutout Switch 120 480V L 3078 SCN SCE Coil Cutout Switch 600V L 40
38. nce Manual 70R 1000D GE Zenith Controls Maintenance and Testing A CAUTION A Due to hazardous voltage and current GE Zenith recommends that a GE Zenith Certified technician or a qualified electrician must perform the installation and maintenance of the switch A WARNING A Both power sources must be disconnected before manual operation of the switch A preventive maintenance program will insure high reliability and long life for the transfer switch The preventive maintenance program for the transfer switch should include the following items Inspection and Cleaning The switch should be inspected for any accumulation of dust dirt or moisture and should be cleaned by vacuuming or wiping with a dry cloth or soft brush do not use a blower since debris may become lodged in the electrical and mechanical components and cause damage Remove the transfer switch barriers and check the condition of the contacts Any surface deposits must be removed with a clean cloth do not use emery cloth or a file If the contacts are pitted or worn excessively they should be replaced A general inspection of mechanical integrity should be made to include loose broken or badly worn parts Servicing All worn or inoperative parts must be replaced using GE Zenith recommended replacement parts Please refer to the Replacement Parts manual for specific part information and ordering procedures Please contact the GE Zenith Technic
39. nfiguration 1 7 14 28 Day pg 14 15 X CLOCK EXERCISER CE e ei e LUAD CDP ee Lithium Battery Exerciser Battery 1 7 14 28 365 Day pg 16 uA Replacement K 4100 6R2052 YNIN TEST KEY 6 amen Momenta ry pg 10 5 sum 24 Hour Service 773 299 6600 MX150 TRANSFER COMMIT 513 ON OFF pg 11 Figure 9 IN PHASE MONITOR R50 ON OFF pg 11 PHASE IMBALANCE VI ON OFF pg 12 LOAD DISCONNECT TD UMD pg 13 NETWORK ZNET ON OFF pg 13 Optional Accessories W GE Zenith Controls ZTG ZTGD Operation and Maintenance Manual 70R 1000D 17H MX150 User Setup SET Menu 51 OK Change adjustable values 01 50 FRI 31 MAY 2003 through the SET menu MORE TEST Enter six digit access code The factory assigned six digit access code NBR AVARE is located on the back of the controller __ MORE CFG SET 5 USER SETUP ee Te Cael Network Communications Rm Controller Inputs must be relay Isolated Option MORE BACK J2 Customer 23 Voltage E GRD Input Inputs SET SYSTEM CLOCK pg 14 i 2 DAYLIGHT SAVINGS ON OFF ALARM OUT 12 CLOCK EXERCISER a 22 16 MOTOR DISC OUT N Output EXER S2 RUNTIME CDT INHIB gt S1 pg 14 15 INHIB gt S2 51 UNDER VOLTAGE 1 I I B pg 10 n
40. nly performed if the DS Option was purchased 4 Close the external up stream Source 1 circuit breaker NOTES Source 1 Available and Source 1 Position LED s will illuminate If Source 1 Available LED does not illuminate verify that Source 1 Voltage is above the preset restore value The Gen Set will start and run while Source 2 stop Delay Timer is timing W GE Zenith Controls ZTG ZTGD Operation and Maintenance Manual 70R 1000D 7 IMX150 Microprocessor Controller MX150 Controller Consists of two major assemblies The Microprocessor contains the following Engine Start Relay P A 150 Board Customer Input and Output I O for system interface Located on the left hand side of the back of the unit see figure 6 l I O accessories that can be found here are a Engine start relay P output b Pre Signal to transfer and UMD output optional ma Transfer Inhibit Q3 and Q7 input a optional d Remote test Q2 input optional e Network interface ZNET input output optional B LCD and Keypad located on the exterior of the door see figure 7 1 User accessibility to the following a LED indication of source availability b LED indication of transfer switch position c LCD screen indicates 1 timer count down numeric 2 event reporting text d Keypad provides user interface to in conjunction with LCD screen 1 Setting sensors and timers 2 Configu
41. nsfer to the other source Range 596 to 20 of Nominal voltage 10 to 30 seconds window user adjustable Resolution 1 Increments Minimum Differential 2 between Fail and Restore settings Factory default 10 Fail 8 Restore 30 Seconds See CFG Menu page 17 to configure ON or OFF See SET Menu page 18 to set Percentage and time windows ZTG ZTGD Operation and Maintenance Manual 70R 1000D GE Zenith Controls Optional Accessories 6A Test Switch Maintained Momentary 6AP Test Switch Maintained Momentary utilizing Keypad A1 Auxiliary Contact operates on Source 1 line failure ATE Auxiliary Contact operates on Source 2 line failure Auxiliary Contacts Closed when the transfer switch is in Source 2 position A4 Auxiliary Contacts Closed when the transfer switch is in Source 1 position A62 Sequential Universal Motor Load Disconnect Circuit Normally closed Auxiliary contacts for Motor Loads Open 0 60 seconds prior to transfer after transfer or both in either direction then re close in timed sequence after transfer Factory default 20 seconds CTAP Alarm Panel on transfer to Source 2 with Silence button DS Disconnect Switch Auto Inhibit Inhibits transfer in either direction when in inhibit Allows automatic operation when in Auto 40 600 Amp units HT Heater and Thermostat Manual Manual Transfer Switch transfers in either direction by de
42. o Source 1 Shut down gen set and place in Auto Complete the visual inspection of the transfer switch and close the cabinet door Initiate the test by pressing the TEST button on the LCD keypad The controller will then prompt for your access code After entering the code three test options will appear XFR LOAD FAST TEST and NO XFR See Figure 10 LOAD test starts the generator and using the current timer settings transfers the load to Source 2 FAST TEST test presets timer values to a maximum 30 seconds during the test After completion of the test all timers are reset to their original values T3 W3 DT and DW remain NO test starts the generator but does not transfer the load to the Source 2 Press and hold the desired test option button until the switch transfers to Source 2 load test or until the generator has been run for the desired amount of time no load test Releasing the test button before W timer timeout will abort the test Exception when the transfer commit option is configured ON To test lamps press TEST then scroll through MORE then press LAMP TEST To cancel LAMP TEST press MORE Standard Transition When the test is initiated the controller initiates the Time Delay Source 2 Start Timer Engine Start Timer P cycle A manual CANCEL button is provided to cancel the test if desired Upon completion of the P time delay an Engine start Signal is sent to Sourc
43. oller initiates a transfer signal through the SCR EO to operate the main transfer operator The load is now transferred to the Open position The time delay to Source 1 timer DT begins its timing cycle After the DT time delay the MX controller initiates a transfer signal through the SCR N to operate the main transfer operator The load is now transferred to Source 1 line The transfer switch is mechanically locked SE limit switch awaits the next operation to Source 2 Immediately after re transfer the S2 Stop Delay Timer Delay to Engine Stop U begins its cycle to allow Source 2 Engine to run unloaded A manual pushbutton BYPASS is provided to bypass the U time delay if desired Upon completion of the U timing cycle the controller sends an Engine stop signal m 20 ZTG ZTGD Operation and Maintenance Manual 70R 1000D GE Zenith Controls Sequence of Operation Standard Transition Source 1 Power Failure When Source 1 voltage or frequency has fallen below the preset Fail values the controller initiates the Time Delay Source 2 Start Timer Engine Start Timer P cycle Upon completion of the P time delay an Engine start Signal is sent to Source 2 When Source 2 voltage and frequency reach the preset Restore Values the time delay to Source 2 Timer W begins its timing cycle to ensure voltage and frequency stabilization before transfer A manual pushbutton BYPASS is provided to bypass the W time delay if d
44. p signal Delayed Transition Source 1 Power Failure When the test is initiated the controller initiates the Time Delay Source 2 Start Engine Start Timer P cycle A manual CANCEL button is provided to cancel the test if desired Upon completion of the P time delay an Engine start Signal is sent to Source 2 When Source 2 voltage and frequency reach the preset Restore values the time delay to open Source 1 timer W begins its timing cycle to ensure voltage and frequency sta bilization before re transfer A manual pushbutton BYPASS is provided to bypass the W time delay if desired After the W time delay the MX controller initiates a transfer signal through the SCR NO to operate the main transfer operator The load is now transferred to the Open position The time delay to Source 2 timer DW begins its timing cycle After the DW time delay the MX controller initiates a transfer signal through the SCR E to operate the main transfer operator The load is now trans ferred to Source 2 line The transfer switch is mechanically locked SN limit switch awaits the next operation to Source 1 Restoration of Source 1 Power Deactivating the test switch initiates re transfer to Source sequence The delay to open Source 2 Timer T begins its timing cycle to ensure voltage and frequency stabilization before retransfer A manual pushbutton BYPASS is provided to bypass the T time delay if desired After the T time delay the MX contr
45. pressing designated pushbuttons M380 Digital Power Meter with Display Amps Volts and Frequency m GE Zenith Controls M82 Digital Meter w Display of Amps Watts Volts Frequency KVA KVAR PF etc MS83A Digital Meter w Diplay of Amps Watts Volts Frequency KVA KVAR PF etc Plus THD capability w Modbus T3 WS3 Elevator Pre Signal Auxiliary Contacts Open 0 60 seconds prior to transfer to either direction re closes after transfer Factory default 20 seconds UMD Universal Motor Load Disconnect Circuit Auxiliary Contact opens 0 5 minutes prior to transfer in either direction re closes after transfer Can be configured by end user for Pre transfer Post transfer or both Factory default 15 seconds Vi Voltage Imbalance Three Phase For a three phase source this feature monitors phase voltage ratios based on a selected range within a selected time window Should any phase fall below the selected lower window limit or exceed the selected higher window limit within the selected time frame the controller initiates transfer to the other source Range 5 to 20 of Nominal voltage 10 to 30 seconds window user adjustable Resolution 1 Increments Minimum Differential 2 between Fail and Restore settings Factory default 10 Fail 8 Restore 30 Seconds See CFG Menu page 17 to configure ON or OFF See SET Menu page 18 to set Percentage and time windows ZNET Network
46. 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 disconnection device All references made within this manual about the term S1 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 Safety Installation A DANGER A 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 A CAUTION A 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 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 if it is necessary store the transfer switch in a clean dry place protected from dirt and water Provide ample air circula
47. ring logic accessories IL The Controls Power Supply CPS Contains transformers which drop line voltage to control level for controller input and SCR inputs see figure 6 Figure 6 1 2 3 4 MX150 Figure 7 a8 ZTG ZTGD Operation and Maintenance Manual 70R 1000D GE Zenith Controls B MX150 Microprocessor Controller wono LCD amp Keypad These options are accessible through the LCD and keypad see figure below To become familiar with the options loaded into a particular unit scrolling through the SET and CFG menu will show the descriptions of the options see pages 17 These menus are the very same menus that are used to access the setting and or configuration of these options The SET setting menu is primarily used to show or change time and voltage settings The CFG menu is primarily used to turn an option on or off When scrolling through these menus no changes can be made without entry of the access code The factory set six digit access code is located on a white label on the back of the unit see figure 9 pgs 17 19 The MX150 has many logic options Each controller is downloaded with options at the time of manufacture The collection of options that any one controller has is specified at the time of order placement The following pages include all the options that can reside in the controller Not all units include all options Source 2 Position LED Red indicates
48. sts the number and sizes of cable lugs supplied as standard for each switch amp rating Connect the Source 1 Source 2 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 CABINET front connected transfer switches Figure 1 NOTE When lifting the switch using a spreader bar height H must be equal to half of distance D Power Connections Screw Type Terminals for External Power Connections Neutral Bar When Required Range of Wire Sizes No of Cables 8 to 3 0 AWG 3 Source 1 Source 2 amp Load Terminals Cable Per Pole 40 1 Switch Size Amps Range of Wire Sizes 14 to 1 0 AWG 80 8 to 3 0 AWG 14 to 1 0 AWG 100 8 to 3 0 AWG 14 to 1 0 AWG 150 8 to 3 0 AWG 6 AWG to 350 MCM 200 225 260 6 AWG to 250 MCM 6 AWG to 350 MCM 6 AWG to 350 MCM 6 AWG to 350 MCM 400 4 AWG to 600 MCM 4 AWG to 600 MCM 600 2 AWG to 600 MCM CO W 4 AWG to 600 MCM 800 1000 1200 2 AWG to 600 MCM 4 AWG to 600 MCM 1600 2000 2600 3000 Table 1 BIN 2 AWG 600 MCM 4 AWG to 600 MCM
49. tion and heat if neces sary to prevent condensation Operating Storage Temperature Temperature Ambient Humidity 30 C to 40 400 AMP 5 to 95 75 C molded shell non con 22 F to 20 C to 65 C densing 167 F 4 F to 149 F 40 4000 AMP all other frame and panel types 20 C to 60 C 4 F to 140 F Final Equipment Inspection Prior to energizing the transfer switch 1 Remove any debris incurred with a vacuum due to shipment or installation A WARNING A Do not use a blower since debris may become lodged in the electrical and mechanical components and cause damage m GE Zenith Controls 2 Verify that all cabled connections are correct and that phase rotation of both sources match 3 Check engine start connections 4 Verify the correct connection of all control wires 5 Check settings of all timers and adjust as necessary 6 Adjust any optional accessories as required 7 Check the lug torque values of the power connections NOTE Lug torque values are specified in table 2 on pg 4 8 Make sure that all covers and barriers are installed and properly fastened NOTE Power panels ship from GE Zenith in Source 1 Position Each GE Zenith transfer switch is factory wired and tested 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 d
50. will be repeated at the same time as initiated on every 1 7 14 or 28 days according to the selection made in the Configure CFG menu How to Bypass Cancel an exercise during an exercise cycle 1 Press BPASS 2 Allow the controller to complete the Engine cool down cycle If the CDT Exerciser is Factory configured for a No Load Exerciser Or allow the controller to complete retransfer to Source 1 If the CDT Exerciser is Factory configured for a Load Exerciser m GE Zenith Controls How to Bypass the next exercise event and Keep the rest of scheduled events unchanged 1 Press Test 2 Pres MORE 3 Press BYPASS EXER To re institute the next exercise event back press CANCL BPASS How to initiate a new exercise start time 1 Press TEST 2 Pres MORE 3 Press EXER CANCL 4 Press START TIMER TEST How to check the next exercise event 1 From S1 OK screen press MORE three times 2 The unit will display the PLANT EXERCISER NEXT event in DAYS HOURS and MINUTES 3 Press ESC to 51 OK Screen Notes appears in the upper right hand corner of LCD screen when exercise is impending For Load Exerciser actual exercise period ATS in S2 position CDT Exerciser timing period T S1 stable Timer timing period ZTG ZTGD Operation and Maintenance Manual 70R 1000D 15m CDP Clock Exerciser Load No Load Clock Exerciser Allows the Generator to start and run unloaded or to simulate a power failure start Gener
51. y the MX controller initiates a transfer signal throught the SCR N to operate the main transfer operator The load is now transferred to Source 1 line The transfer switch is mechanically locked SE limit switch awaits the next operation to Source 2 Immediately after re transfer the S2 Stop Delay Timer Delay to Engine Stop U begins its cycle to allow Source 2 Engine to run unloaded A manual pushbut ton BYPASS is provided to bypass the U time delay if desired Upon completion of the U timing cycle the controller sends an Engine stop signal Table 3 Standard Timer Designations as they appear in the SET menu Time Delay 52 Start W Time Delay S2 Stable DW T Time Delay S1 Stable DT Delay Source 1 Fails Time Delay 52 Start Transfer to Source 2 m GE Zenith Controls Time Delay S2 Stable gt ATS Open Time to S2 Source 1 Time Delay S1 Stable Returns ATS Open Time to SI Transfer to Source 1 _ gt ZTG ZTGD Operation and Maintenance Manual 70R 1000D Engine Cooldown 21m Controls Power Supply CPS Standard and Delay Transition Each MX150 microprocessor based ATS controller This is accomplished by the Controls Power Supply CPS requires a Controls Power Supply CPS to apply line This method of switching operator voltage and applying voltage to the ATS operator via SCRs Also required is power and sens
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