GE Monogram ZTX Switch User Manual
Contents
1. 1 2 OPTIONAL CONTACT OPERATES WHEN IN GENERATOR GENERATOR POSITION TERMINALS T Load N Utility Generator Figure 2 Power Panel E GE Zenith Controls ZTX Operation and Maintenance Manual 62R 2000 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 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 JP 3555 i BA Exerciser CONTROLLER Close to Start Opens to Stop Contact Rating 28Vdc 5 amps 2 2 SY Figure 3 A Engine Start Contact Output 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 clearly2. so wol low o_ Loads Transfer Switch Utility o Source Lomo oO Generator Circuit Source Breaker Utility Panel Load ee oe Distribution Panel Total Coverage System Transfer Switch Utility c Generator Source Circuit Circuit Source Breaker Breaker Main Breaker Panel All Loads 118 E GE Zenith Controls ZTX Operation and Maintenance Manual 62R 2000 Typical Diagrams Power Circuit Schematic NN N3 F N1 2 NORMAL LINE yy 1 2 LOAD D gt a 4 POLE OPTIONAL OPTIONAL 30 a 1 2 EMERGENCY LINE NN N2 Oo 73 1 1 rein E2 lo _ gt _ gt Power Panel Layout SCN 2 SCE 2 SCN 1 SCE 1 1 2 NN GENERATOR TERM NALS LOAD TERMINALS T1 T2 T3 NN UTILITY TERMINALS N1 N2 N3 NN Ma d d I 4 SN 4 4 SE CCN SCN 1 SCE 1 CCE Oa lt o N2 SCN2 SCE 2 lt E2 Os NS o SN SN SCOM 9 gt SE
3. 0 SE gt 1 SN BR CNE SCN SCE NORMAL POSITION LIMIT SWITCH EMERGENCY POSITION LIMIT SWITCH BRIDGE RECTIFIER MAIN TRANSFER OPERATOR CNE LIMIT SWITCHES SWITCH SHOWN IN NORMAL POSITION NO POWER AVAILABLE Interconnect Plug OPTIONAL 3 4 N2 N3 E2 3 ZTX Operation and Maintenance Manual 62R 2000 GE Zenith Controls Troubleshooting 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 Service must be performed by qualified personnel Generator will not start Transfer switch does not transfer to Utility Transfer switch does not transfer to Generator Generator will not stop All LEDs off Possible Cause P timer has not lapsed Corrective Action See factory settings on Page 6 Generator control switch not in Auto Refer to generator instruction manual Engine Start contact not wired to generator See Figure 3 Page 4 Starter battery is dead Refer to generator instruction manual No fuel T timer has not lapsed Refer to generator instruction manual See factory settings on Page 6 Exercise in progress See Page 9 Utility breaker open or tripped Clear fault and reset Utility voltage out of range Wait for utility to return to a
4. 6 Flashes 2 Missing NOTE Faults that trigger the original SAG timer emergency source not available for longer than the GS timer interval will continue to be indicated on the Emergency Source LED at the original continuous 5 Hz rate m14 ZTX Operation and Maintenance Manual 62R 2000 GE Zenith Controls E GE Zenith Controls ZTX Operation and Maintenance Manual 62R 2000 15 GE Zenith Controls GE Industrial Systems Power Equipment Business 830 W 40 Street Chicago IL 60609 USA 773 299 6600 Fax 630 850 6899 www zenithcontrols com
5. 75 C 4 F to 149 F non con 22 F to densing 167 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 2 Verify that all cabled connections are correct 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 sure that all covers and barriers are installed and properly fastened NOTE Power panels ship from GE Zenith in the Normal Position Each GE Zenith transfer switch is factory wired and tested A complete information package is furnished with each switch which includes a Sequence of operation b Description and operation of all accessories supplied c Power panel connection diagram and schematic d Description and identification of all customer field connections Installation of GE Zenith transfer switches includes a Mounting the transfer switch cabinet b Connection of all Normal Emergency and Load cables or bus bars c Connection of external control circuits as required Mounting Adequate lifting means must be used to mount the transfer switch into place The recommended method for moving the trans
6. Sensor Input Temperature sensor contact to be normally open closed by over temperature condition Approximately five seconds after the engine starter signal is sent if terminal is connected to ground Starter and Fuel Run outputs are opened and locked out After cause is determined and corrective action is taken and verified by a qualified technician the controller can be reset via the reset button Fuel Run Contact Output This output is activated closed whenever the engine is running This will keep the fuel valve open as needed and will cut fuel supply during the above mentioned lockouts or when the engine is no longer called to run Start Contact Output This output is activated closed during cranking of the engine Output will deactivate once the controller senses that the generator output has reached 33 of frequency indicating engine has reached running RPM Generator Battery Input This input is required to support the controller s operation Controller Generator Battery Input 12 Vdc _ 9 X10 Engine Controller 1 2 4 5 X6 t t _ Start Contact Output 28 Vdc 5 amps Input Input Temperature Oil Pressure Sensor Sensor 12 Vde 12 Vde Fuel Run Contact Output 28 Vdc 5 amps ZTX Operation and Maintenance Manual 62R 2000 GE Zenith Controls Example Systems Partial Coverage System
7. power Rapidly Flashing Generator Rapidly Flashing Generator Availability LED Q Position LED Generator failed to start E Switch did not transfer to Generator position Generator starts but failed to reach proper operating parameters Rapidly Flashing Utility Generator became over loaded for an extended Position LED period of time i E Switch did not transfer to Utility position NOTE All fault alarms be cleared by depressing the reset button Optional generator crank board see generator fault flash table on page 14 ZTX Operation and Maintenance Manual 628 2000 GE Zenith Controls RM4 Control Interface Optional 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 Automatic Generator Exerciser The automatic generator exerciser comes preset with a 28 day exerciser schedule the customer unit s preset day cycle may vary due to specifications from the generator supplier The exerciser when enabled will automatically start the generator every twenty eighth day and run the unit loaded or unloaded for 10 minutes The exerciser interval is selectable through JP jumper selection on the con troller board The selections are 7 14 21 or 28 day Selecting Exerciser Without Transfer To start the automatic exerciser without transfer depress the E
8. 62R 2000C 7 02 2 SERIES 40 400 Amps GE Zenith Controls Operation and Maintenance Manual Authorized Service For GE parts and service call 773 299 6600 Table of Contents Introduction ii Engine Controller Accesoory Board 10 How to Remove the Cover 1 Example Systems 11 Installation 2 Partial Coverage Systems 11 Equipment Inspection and Storage 2 Total Coverage Systems 11 Final Equipment Inspection 2 Typical Diagrams 12 Mounting eee eee 2 Power Circuit Schematic 12 Power Connections 3 Power Panel 12 Engine Start Control Connections 4 Interconnect Plug 12 RM4 Exerciser Option 5 Troubleshooting 13 Functional Test 6 General Troubleshooting 13 14 RMF Control Interface 7 Optional Indicator LED s 7 Optional Pushbuttons 7 Automatic Transfer Generator Testing 8 Transfer Generator Testing 8 LED Diagnostic Flash Codes 8 Automtic Generator Exerciser 9 Selecting Exercisor without Transfer 9 Selecting E
9. Pressing and releasing the generator Start Stop button will cancel the current test The exerciser will go off at approximately the same time it was started 7 14 21 or 28 days later NOTE Transfer will cause short interruption of power A DANGER Turn OFF all power before selecting JP CDT SELECT AN See Figure 3 Page 4 7 Day 21 Day O O O O OO h CO Ooo B A B A 14 Day 28 Day O k O O h O h O k B A VOLTAGE FREQUENCY SELECT AN See Figure 3 Page 4 Do not adjust the jumper positions This service to be performed by qualified personnel only 208 V 220 V 240 V q N 60 Hz Figure 6 GE Zenith Controls ZTX Operation and Maintenance Manual 62R 2000 ou Engine Controller Accessory Board Optional Oil Pressure Sensor Input Oil pressure contact to be normally open held closed by adequate oil pressure Approximately five seconds after emngine starter signal is sent if terminal X3 is open to ground or returns to open state thereafter the generator Starter and Fuel Run outputs are opened and locked out After cause is deter mined and corrective action is taken and verified by quali fied technician controller can be reset via reset button Temperature
10. al Generator Position LEDs go off and the Utility Position LED illuminates The delay engine stop timer U begins its timing cycle The generator runs unloaded for the duration of the U timing cycle When the timer completes its timing cycle the generator will stop The optional Generator Available LED goes off Factory Settings 90 Nominal tor Pickup Volt Generator Pickup Voltage Line Voltage 80 Nominal Utility Dropout Voltage Line Voltage 80 Nominal t Volt Generator Dropout Voltage Line Voltage 90 Nominal Utility Pickup Fi Line Frequency 95 Nominal Generator Pickup Frequency Line Frequency T Timer Delay to Utility 5 minutes Timer Engine Start 5 seconds U Timer Engine 5 minutes Cool Down Table 3 W Timer Delay to Generator 20 seconds Factory default settings customer time settings may vary due to specifications from the generator supplier 9 9 m6 ZTX Operation and Maintenance Manual 62R 2000 GE Zenith Controls RM4 Control Interface Optional 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 Optional Indicator LEDs Utility available Green LED When on indicates the utility source is acceptable Utility position Green LED When on indicates that the transfer switch is connected to the util
11. cceptable level See factory settings on Page 6 Control harness unplugged W timer has not lapsed With all power disconnected reconnect harness See factory settings on Page 6 Generator breaker open or tripped Refer to generator instruction manual Generator voltage out of range Refer to generator instruction manual Control harness unplugged U timer has not lapsed With all power disconnected reconnect harness See factory settings on Page 6 Exercise in progress See page 9 Engine control switch in run position Keypad cable unplugged Refer to generator instruction manual With all power disconnected reconnect harness Sources unavailable and or source breakers tripped or open Clear fault and reset breakers and or check source availability GE Zenith Controls ZTX Operation and Maintenance Manual 62R 2000 13 E Troubleshooting 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 Service must be performed by qualified personnel Generator Fault Flash Table Generator Failed to Start GFS Timeout 2 Flashes 2 Missing Generator Under Speed Fault 3 Flashes 2 Missing Generator Over Speed Fault 4 Flashes 2 Missing Generator Over Temperature Fault 5 Flashes 2 Missing Generator Low Oil Pressure Fault
12. fer switch using the lifting eyes where supplied and a spreader bar is illustrated here Enough room should be allowed to open the cabinet doors SPREADER BAR fully for inspection and servicing of the switch per NEC and local codes CABINET NOTE When lifting the switch using a spreader bar height H must be equal to half of distance D A CAUTION A 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 m2 ZTX Operation and Maintenance Manual 62R 2000 GE Zenith Controls 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 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 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 tigh
13. ity Generator available Red LED When on indicates the generator source is acceptable Generator position Red LED When on indicates that Q the transfer switch is connected to the generator Load Amber LED When on indicates that the load is connected to an acceptable source 1 WITH TRAM FER Figure 5 7 tional Pushbuttons Generator Start Stop push button Pressing and holding this button for approximately 5 seconds will cause the generator to start Pressing this button a second time will stop the generator Exerciser Start Stop push button When this button is depressed it will enable the automatic exerciser mode Pressing this button a second time will cancel the automatic exerciser mode Reset push button Pressing this button will clear the fault indications Transfer push button Pressing this button will force the unit to transfer from one position to another when both sources are available E GE Zenith Controls ZTX Operation and Maintenance Manual 62R 2000 78 RM4 Control Interface Optional 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 Automatic Transfer Generator Transfer Generator Testing Testing One Time Test Forcing Operation with Keypad Verify that the aa UTILITY available and Verify that the transfer switch UTILITY a
14. 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 GE Zenith Controls SERIAL NUMBER RATING VOLTS AMPS SYSTEM VOLTS MODEL NUMBER Figure 3 Note N Utility Position 8 E Generator Position A Figure 4 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 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 m4 ZTX Operation and Maintenance Manual 62R 2000 GE Zenith Controls 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 ATTENTION This applies only to the switches with the RM4 CAT exerciser option installed and or replaced as recommended the exerciser clock will lose its settings and the exerciser Upon installation connect the MX50 90 controlle
15. nnected Re installation of cover is required after maintenance or service Figure i FRONT VIEW W COVER ON BOTTOM Figure ii FRONT VIEW W COVER TO THE RIGHT E GE Zenith Controls ZTX Operation and Maintenance Manual 62R 2000 AE ELOA 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 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 neces sary to prevent condensation Operating Storage Temperature Temperature Ambient Humidity 30 C to 20 C to 65 C 5 to 95
16. r to a will not work 9 battery not supplied via the harness that is con nected to the controller The battery should be placed in the holder installed just above the controller This is Should the harness become disconnected in shipping to ensure that the setting in the exercisor clock are take the controller cover off and plug the harness in the retained in the event of power outage The battery receptacle in the top right corner of the MX controller should be replaced once a year If the battery is not Reinstall the cover and connect the battery Battery and Holder Battery Harness MX50 90 Controller E GE Zenith Controls ZTX Operation and Maintenance Manual 62R 2000 5m 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 Functional Test The functional testing of the transfer switch consists of electrical tests described in this section Before proceed ing read and understand all instructions and review the operation of all accessories provided To begin the test close the Utility source circuit breaker The controller will illuminate the optional Utility Available LED when proper voltage is sensed Verify the phase to phase voltages at the Utility line terminals Next close the Generator source breaker and start the engine generator The optional Generator A
17. tened to the proper torque values as shown in Table 2 as standard for each switch amp rating Switch Size Amps NOTE Do not run cables or wiring behind front connected transfer switches Screw Type Terminals for External Power Connections 40 80 100 150 200 225 250 300 400 Table 1 IEC Rating Only Utility Generator and Load Terminals Fully Rated Neutral Bar When Required Cable Per Pole Range of Wire Sizes No of Cables Range of Wire Sizes 8 to 3 0 AWG 3 8 to 1 0 AWG 8 to 3 0 AWG 8 to 1 0 AWG 8 to 3 0 AWG 8 to 1 0 AWG 8 to 3 0 AWG 8 AWG to 300 MCM 6 AWG to 250 MCM 6 AWG to 300 MCM 4 AWG to 600 MCM LOAD TERMINALS ON ot gt UTILITY 2 73 TERMINALS 7 N d OPTIONAL A4 CONTACT Install AH NT N3 OPERATES WHEN IN load N BR i UTILITY POSITION ol cables first e e e OPTIONAL ENGINE CONTROLS g OR AIR CONDITION DISCONNECT t OR 3 PHASE BOARD ENGINE 4 POLE ONLY posmon 4 INDICATOR
18. vailable LED will illuminate when proper voltage and frequency levels is sensed If Generator LED is flashing use the Reset button to clear Check the phase to phase voltages at the Generator line terminals On three phase units verify that the phase rotation of the Generator source is same as Utility source After the sources have been verified shut down the engine generator and put the starting control in the automatic posi tion Complete the visual inspection of the transfer switch and replace the cabinet cover or close the cabinet door Factory Settings 90 Nominal tility Pickup Volt Line Voltage Initiate the electrical transfer test by opening the Utility side breaker The delay to engine start timer P begins its timing cycle After the P timer has completed its timing cycle the engine start contacts close to start the generator When Generator voltage and frequency reach preset pickup points the optional Generator Available LED illuminates Simultaneously the delay to Generator timer W begins its timing cycle When the W time delay is completed the switch will transfer to Generator The optional Utility Position LED goes off and the optional Generator Position LED illuminates Reclose the Utility breaker to retransfer to Utility The delay to Utility timer T begins its timing cycle When the T timer has completed its timing cycle the switch will transfer into Utility The option
19. vailable and posi position LEDs are illuminated ion LED illuminated O tion s are illuminated Press and hold the GENERATOR START STOP button Press and hold the GENERATOR START STOP button for 5 and the TRANSFER for 5 seconds This will seconds This will start the generator cause the generator to start Once the eng has started the Generator LED will illuminate Verify that the GENERATOR available LED has illuminated Once the GENERATOR power LED has come on the transfer switch will now switch the load to the Generator The GENERATOR position LED will illuminate Press the TRANSFER button The switch will transfer to the Generator source position The GENERATOR position LED will now be illuminated The transfer switch will be connected to the generator for 5 minutes Then the switch will automatically return to the utility and the UTILITY Position LED will illuminate Pressing the TRANSFER button again will cause the unit to transfer to the utility power source The UTILITY position LED will illuminate The generator will cool down for 5 minutes Timer and then shut down The GENERATOR LED will go off Q Pressing the GENERATOR START STOP button will stop This completes the automatic test the generator Q Pressing and releasing the generator Start Stop button will cancel current test LED Diagnostic Flash Codes NOTE Transfer will cause short interruption of
20. xerciser Start Stop button The generator will start and run for 10 minutes Once this first exercise is com plete the generator LED will flash at a 1 second interval indicating the exerciser is enabled Once the exerciser times out 7 14 21 or 28 day interval the generator will start and run again for 10 minutes This will repeat until the exerciser is disabled To stop the exerciser mode depress the exerciser Start Stop again and the generator light will stop flashing indicating the exerciser mode has been canceled Selecting Exerciser With Transfer To enable the automatic exerciser with transfer depress the Exerciser Start Stop button and the transfer button The generator will start and the load will be transferred to the generator After 10 minutes the load will be transferred back to the utility Once this first exercise is complete the generator LED and the Generator position LED will flash at a 1 interval indicating the exerciser is enabled Once the exerciser has timed out 7 14 21 or 28 day interval the generator will start and transfer the load to Generator power for 10 minutes At the end of this 10 minute period the unit will transfer the load back to the utility and the generator will shut off This will repeat until the exerciser is disabled To stop the exerciser mode depress the exerciser Start Stop again and the generator light will stop flashing indicating the exerciser mode has been canceled
21. xercisor with Transfer 9 introduction GE Zenith Transfer Switches are used to provide a continuous source of power for lighting and other critical loads by automatically transferring from the normal source of power to an emergency source of power in the event that the nor mal source voltage falls below preset limits Voltage sensing and system control is performed via a state of the art microcontroller located on the cabinet door It is designed to give highly accurate control of the transfer switch system All GE Zenith transfer switches are designed for use on emergency or standby systems and are rated for total system or motor loads Transfer switches are UL Listed under Standard 1008 and CSA Certified under Standard C22 2 No 178 and IEC Listed under Standard 947 NOTE A protective device such as a molded care circuit breaker or fused disconnect switch MUST be installed on both sources of incoming power for circuit potection and as a disconnection device How to Remove the Cover Loosen but do not remove four cover screws Lift cover off the four screws and hang on two screws 2 bottom or 2 right hand See Figure i and This will prevent damage to the cable The cable may also be disconnected at the controller or keypad NOTE Reattach cable before installing cover DANGER HAZARDOUS VOLTAGE Will shock burn or cause death Do not remove cover until ALL power is disco
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