GE Zenith Controls ZTG / ZTGD Series Transfer Switches 40-3000 Amps 70R-1000D 11/04 Operation and Maintenance Manual
Authorized Service For GE Zenith parts and service, call: (773) 299-6600 Table of Contents Page Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Equipment Inspection and Storage . . . . . . . . .13 Final Equipment Inspection . . . . . . . . . . . . . . .13 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety / Installation DANGER HAZARDOUS VOLTAGE (Can Cause Severe Injury or Death) Turn OFF all power before installation, adjustment, or removal of transfer switch or any of its components. The safe operation of your switch is GE Zenith’s focus. The proper storage, installation, operation and maintenance will help increase the life of the switch. 3. 4.
Installation (cont’d) DANGER HAZARDOUS VOLTAGE (Can Cause Severe Injury or Death) Turn OFF all power before installation, adjustment, or removal of transfer switch or any of its components. Power Connections SPREADER BAR GE Zenith transfer switches are supplied with UL listed solderless screw type terminals as standard for the Source 1, Source 2 and Load power connections. Table 1 lists the number and sizes of cable lugs supplied as standard for each switch amp rating.
Installation (cont’d) DANGER HAZARDOUS VOLTAGE (Can Cause Severe Injury or Death) Turn OFF all power before installation, adjustment, or removal of transfer switch or any of its components.
Installation (cont’d) DANGER HAZARDOUS VOLTAGE (Can Cause Severe Injury or Death) Turn OFF all power before installation, adjustment, or removal of transfer switch or any of its components. E 4 1 5 P Relay 2 (Engine Start) 6 Contact rating is 10 Ampere at 120VAC or 28VDC Gold plated 3 Figure 3 Engine Start Control Connections The engine-start terminals are clearly identified by a label on the microcontroller backplate.
Installation (cont’d) Initial Energization (cont’d) After all options and accessories are checked and verified, follow these steps to set up the ATS. Refer to MX150 display Figure 5. The annunciation LEDs illuminate to indicate (1) source availability, (2) ATS position, and (3) MX150 control function (timing). 5. 6. NOTE: 7. 8. 9. S1 OK 21:56 MON 23 APR 2002 MORE TEST Close the External (up-stream) Source 2 line circuit breaker. Start the engine generator in MANUAL mode.
MX150 Microprocessor Controller MX150 Controller Consists of two major assemblies: I. Engine Start Relay P The Microprocessor contains the following: I/O Interface A. B. II. MX150 Board MX150 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) 1. I/O accessories that can be found here are: a. Engine start relay P output b. Pre-Signal to transfer T3, W3 and UMD output (optional) c.
MX150 Microprocessor Controller (cont’d) LCD & 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.
User Setting for Voltage & 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 98% in 1% increments (see page 18).
Std. Features, MSTDG Option Pkg. (cont’d) 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 S1 available in Hrs Time S2 available in Hrs. (N1P) 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.
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. CDP (replaces CDT) 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.
Optional Accessories 6A M82 Test Switch, Maintained / Momentary Digital Meter w/Display of Amps, Watts, Volts, Frequency, KVA, KVAR, PF, etc. 6AP Test Switch, Maintained / Momentary, utilizing Keypad M83A A1 Digital Meter w/Diplay of Amps, Watts, Volts, Frequency, KVA, KVAR, PF, etc. Plus THD capability w/Modbus. Auxiliary Contact, operates on Source 1 line failure. T3/W3 A1E Auxiliary Contact, operates on Source 2 line failure.
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 S1 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) 1. Remove battery protective white plastic strip near P relay. * 2. Press MORE then press SET. 3.
CDT One Event Timer Exerciser (cont’d) How to Initiate CDT Exerciser and to start an exercise cycle every 1, 7, 14, or 28 days How to Bypass the next exercise event and Keep the rest of scheduled events unchanged From S1 screen 1) Press TEST 2) Press MORE 3) Press START TEST TIMER (to initiate Test). • If the CDT Exerciser is Factory configured for a Load Exerciser, the Controller will immediately start a load exercise.
CDP Clock 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 save value and to move to the next value to be changed. 7. Press BACK when complete. 8. Press MORE repeatedly until SET USER SETUP. Press BACK then ESC to the S1 OK screen. Load / No-Load Clock Exerciser Allows the Generator to start and run unloaded or to simulate a power failure, start Generator and run under load.
MX150 User Setup - CFG Menu Turn options ON or OFF via keypad through the CFG menu S 1 OK 01: 50 F RI 31 MAY 2003 MO RE TES T 1 VAB = ___ VBC = ___ VCA = ___ M O RE C FG Enter six digit access code (The factory assigned six-digit access code is located on the back of the controller) 2 VA B = ___ WARNING 1 2 4 5 1 A2 (-) Engine Start Relay (De-Energized) S ET Controller Inputs must be relay Isolated.
MX150 User Setup - SET Menu Change adjustable values through the SET menu. S1 OK 01: 50 F R I 3 1 M AY 2 0 0 3 MORE TEST 1 VA B = _ _ _ VBC = ___ VCA = ___ MORE CFG 2 VA B = _ _ _ SET Enter six digit access code (The factory assigned six-digit access code is located on the back of the controller) ESC MORE 1 A2 (-) Engine Start Relay (De-Energized) BACK Controller Inputs must be relay Isolated.
MX150 User Setup - System Info View System Data S1 OK 01: 50 FRI 31 MAY 2003 M OR E TEST Enter six digit access code (The factory assigned six-digit access code is located on the back of the controller) WARNING 1 2 4 5 1 Controller Inputs must be relay Isolated. 3 6 A2 (-) Engine Start Relay (De-Energized) A1 (+) 14 RELAY Network Communications (Option) J2 * 11 12 COM J2-3 Customer Input Voltage N.O N.
Testing NOTICE 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 to Source 1). Shut down gen set and place in Auto. Complete the visual inspection of the transfer switch, and close the cabinet door. SYSTEM TEST FA S T X F R NO MORE TEST LOAD XFR Initiate the test by pressing the TEST button on the LCD keypad.
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.
Controls Power Supply (CPS) Standard and Delay Transition Each MX150 microprocessor based ATS controller requires a Controls Power Supply (CPS) to apply line voltage to the ATS operator via SCRs. Also required is power for the MX150 printed circuit board and an application of sensing voltage proportional to line voltage. ■ 22 This is accomplished by the Controls Power Supply (CPS).
Controls Power Supply (CPS) (cont’d) Standard Transition CPS Schematic 20 21 22 30 31 32 XN1 - SOURCE 1 CONTROL TRANSFORMER XN2 - SOURCE 1 3 PHASE SENSING TRANSFORMER XN1 XN2 XE1 XE1 - SOURCE 2 CONTROL TRANSFORMER XE2 XE2 - SOURCE 2 3 PHASE SENSING TRANSFORMER 907 904 905 906 11V 903 902 900 10V 904 24V 807 804 10V 806 805 11V 803 804 10V 902 800 24V 900 (18) 800 SOURCE 2 24V OUTPUT SOURCE 1 24V OUTPUT 907 3 PHASE SOURCE 2 808 JC C.V. SCR-N JC 908 C.V.
Troubleshooting and Diagnostics DANGER 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.
Maintenance and Testing CAUTION 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. WARNING 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.
Power Panel and Replacement Parts Standard Transition - 40 to 260 Amps Solenoid Type SCR-N SCR-E T1 T2 N1 N2 E1 E2 T3 N3 TN NN CN/CE E3 EN SCN/SCE - ■ 26 - ZTG/ZTGD Operation and Maintenance Manual (70R-1000D) GE Zenith Controls ■
Power Panel and Replacement Parts (cont’d) Standard Transition - 400 to 600 Amps Molded Type T1 T2 T3 TN N1 N2 N3 NN SCR-N CN/CE SN A4 SE A3 SCR-E E1 - E2 E3 EN - ■ GE Zenith Controls ZTG/ZTGD Operation and Maintenance Manual (70R-1000D) 27 ■
Power Panel and Replacement Parts (cont’d) Standard Transition - 800 to 1200 Amps ARC GRID NN N1 N2 N3 SCR-N CN A4 A4 A3 SN DS A3 SCR-E SE EN E1 E2 STATIONARY CONTACT (ARC GRID REMOVED FOR CLARITY) Tag N 1,2,3, N E 1,2,3, N T 1,2,3, N MOVABLE CONTACT Recommended as Spares Description Cable Connection Lug Stock Numbers by Amperage 800-1200 S1392F (4) Wire Size #2-600 MCM Stationary Contact Assembly Kit Consult Factory Arc Grid Assembly Kit 23P-1366 Movable Contact Assembly Kit CN/
Power Panel and Replacement Parts (cont’d) Standard Transition - 1600 to 3000 Amps ARCH GRID ASSEMBLY NN CN A4 N1 N2 N3 E1 E2 E3 SN SCR-N DS SCR-E A3 EN SE CE STATIONARY CONTACT (ARCH GRID REMOVED FOR CLARITY) Tag N 1,2,3, N E 1,2,3, N T 1,2,3, N MOVEABLE CONTACT Stock Numbers by Amperage Recommended as Spares Description Cable Connection Lug Wire Size 1600 2000 3000 S1126F (2) Optional S1126F (2) Optional S1126F (2) Optional (8) #2-600 MCM (8) #2-600 MCM (8) #2-600 MCM Stat
Power Panel and Replacement Parts (cont’d) Delayed Transition - 40 to 600 Amps T1 T2 T3 N1 N2 N3 NN TN SCR-N CN/CE SNO SN/A4 SE/A3 SEO SCR-E E1 E2 E3 EN 100-400 Amps 600 Amps 40-80 Amps Tag N 1,2,3 N E 1,2,3 N T 1,2,3 N CN/CE Stock Numbers by Amperage Recommended as Spares Description Cable Connection Lug Wire Size 40-80 100-400 600 S-2591 S-2591 S-1393F #4-600 MCM Solenoid * Handle-Manual #4-600 MCM MAIN SECONDARY 120 K-2245B 58P-1106 208/240 K-2246B 58P-1107 380
Power Panel and Replacement Parts (cont’d) Delayed Transition - 800 to 1200 Amps T1 T2 N1 T3 N2 N3 TERMINAL A4 BLOCKS SCR-N SN1, 2, 3, 4 ARC GRID SCR-NO TERMINAL A3 BLOCKS SCR-EO MOVABLE CONTACT SE1, 2, 3, 4 SCR-E STATIONARY CONTACT E1 SCR-N/SCR-E SCR-NO/SCR-EO SCR ■ GE Zenith Controls E2 E3 PS-8896 ZTG/ZTGD Operation and Maintenance Manual (70R-1000D) 31 ■
Power Panel and Replacement Parts (cont’d) Delayed Transition - 1600 to 3000 Amps NN N2 N1 CN/ CNO N3 ARC GRID ASSEMBLY SCR-N SCR-NO SCR-EO SCR-E CE/ CEO EN E2 E1 E3 MOVABLE CONTACT STATIONARY CONTACT Tag N1,2,3 E1,2,3 T1,2,3 NLN,ELN Recommended as Spares Description Stock Numbers by Amperage 1600 2000 3000 S-1126F(2) Optional (8) 600MCM-2 Cable Connection Lug, CU Wire Stationary Contact Assembly Kit 23P-4134X 23P-4134Y 23P-4134Z Arc Grid Assembly Kit 23P-1171 23P-1171 23P-117
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GE Zenith Controls A Product of GE Industrial Systems General Electric Company 830 West 40 th Street, Chicago, IL 60609 USA 773 299-6600, Fax: 773 247-7805 www.geindustrial.
