GE Zenith Controls Operation & Maintenance Manual

70R-1000D

11/04

ZTG/ZTGD Series Transfer Switches

40-3000 Amps

GE Zenith Controls

Operation and Maintenance Manual

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Equipment Inspection and Storage . . . . . . . . .13

Final Equipment Inspection . . . . . . . . . . . . . . .13

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Power Connections . . . . . . . . . . . . . . . . . . . . . .14

Engine Start Control Connections . . . . . . . .14-6

Initial Energization . . . . . . . . . . . . . . . . . . . .16-7

MX150 Microprocessor Controller . . . . . . . . . . . . .18

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

LCD & Keypad . . . . . . . . . . . . . . . . . . . . . . . . . .19

User Setting for Voltage & Frequency . . . . . .110

Standard Features, MSTDG Option Pkg. . .10-11

Standard Features, MEXEG Option Pkg. . . . .12

Optional Accessories . . . . . . . . . . . . . . . . . . . . .13

How to Set the System Clock . . . . . . . . . . . . . .14

CDT One Event Timer Exerciser . . . . . . . .14-15

CDP Clock Exerciser . . . . . . . . . . . . . . . . . . . . .16

User Setup - CFG Menu . . . . . . . . . . . . . . . . . .17

User Setup - SET Menu . . . . . . . . . . . . . . . . . .18

User Setup - System Info . . . . . . . . . . . . . . . . . .19

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120

Standard Transition . . . . . . . . . . . . . . . . . . . . .120

Delayed Transition . . . . . . . . . . . . . . . . . . . . . .20

Page

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . .21

Standard Transition . . . . . . . . . . . . . . . . . . . . .121

Delayed Transition . . . . . . . . . . . . . . . . . . . . . .21

Controls Power Supply (CPS) . . . . . . . . . . . . . . . . .22

Schematics, Standard & Delay . . . . . . . . . . . .123

Troubleshooting & Diagnostics . . . . . . . . . . . . . . . .24

Maintenance and Testing . . . . . . . . . . . . . . . . . . . . .25

Inspection and Cleaning . . . . . . . . . . . . . . . . .25

Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125

Power Panel & Replacement Parts . . . . . . . . . . . . .26

Standard Transition . . . . . . . . . . . . . . . . . . . . . .26

40-260 Amps . . . . . . . . . . . . . . . . . . . . . . . . . . .26

400-600 Amps . . . . . . . . . . . . . . . . . . . . . . . . . .27

800-1200 Amps . . . . . . . . . . . . . . . . . . . . . . . . .28

1600-3000 Amps . . . . . . . . . . . . . . . . . . . . . . . .29

Delayed Transition . . . . . . . . . . . . . . . . . . . . . .30

40-600 Amps . . . . . . . . . . . . . . . . . . . . . . . . . . .30

800-1200 Amps . . . . . . . . . . . . . . . . . . . . . . . . .31

1600-3000 Amps . . . . . . . . . . . . . . . . . . . . . . . .32

Table of Contents

Introduction

GE Zenith Transfer Switches are used to provide a continuous source of power for lighting and other critical loads by auto-

matically transferring from source 1 power to source 2 power in the event that source 1 voltage falls below preset limits.

Voltage sensing and system control is performed via a state-of-the-art microcontroller located on the cabinet door.

It is designed to give highly accurate control of the transfer switch system.

All GE Zenith transfer switches are designed for use on emergency or standby systems, and are rated for total system or

motor loads. Transfer switches are UL Listed under Standard 1008 and CSA Certified under Standard C22.2 No. 178 and

IEC Listed under Standard 947.

NOTES: A protective device such as a molded case circuit breaker or fused

disconnect switch 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” or

“Source 1” relate to a Normal Power Source. All references made

about the term “S2” or “Source 2” relate to an Emergency

or Alternative Power Source.

Authorized Service

For GE Zenith parts and service, call: (773) 299-6600

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ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

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 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.

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 mainte-

nance will help increase the life of the switch.

Equipment Inspection

and Storage

Once you have received the transfer switch, inspect

it for any damage. This includes damage to the

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

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 circulation and heat, if neces-

sary, to prevent condensation.

5% to 95%

(non-con-

densing)

-30°C to

+75°C

(-22°F to

+167°F)

40-400

AMP

(molded shell)

-20°C to +65°C

(-4°F to +149°F)

40-4000

AMP

(all other frame

and panel types)

-20°C to +60°C

(-4°F to +140°F)

Operating

Storage Temperature

Temperature (Ambient): Humidity

CAUTION

Due to hazardous voltage and current, GE Zenith rec-

ommends that a

GE Zenith Certified technician or a

qualified electrician must perform the

installation and maintenance of the switch.

Final Equipment Inspection

Prior to energizing the transfer switch:

1. Remove any debris incurred, with a vacuum, due

to shipment or installation.

WARNING

Do not use a blower since debris may

become lodged in the electrical and

mechanical components and cause damage.

2. Verify that all cabled connections are

correct 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.

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.

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ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

Table 2

Tightening Torque for Lugs

Socket Size

Across Flats

Torque

Lb. - In.

Lb. - Ft.

1/8

100

5/32

120

3/16

150

7/32

200

1/4

275

5/16

375

3/8

500

1/2

600

9/16

Installation (cont’d)

CABINET

LIFTING EYES

SPREADER BAR

45°

Figure 1

Power Connections

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.

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

front-connected transfer switches.

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.

Table 1

Power Connections: Screw Type Terminals for External Power Connections

Switch Size

(Amps)

100

150

200, 225

400

600

800, 1000, 1200

Source 1, Source 2 & Load Terminals

1 #8 to 3/0 AWG

Cable Per Pole Range of Wire Sizes

1 #8 to 3/0 AWG

1 #6 AWG to 250 MCM

1 #4 AWG to 600 MCM

2 #2 AWG to 600 MCM

4 #2 AWG to 600 MCM

Neutral Bar (When Required)

3 #14 to 1/0 AWG

No. of Cables Range of Wire Sizes

3 #14 to 1/0 AWG

3 #6 AWG to 350 MCM

4 #4 AWG to 600 MCM

260

1 #6 AWG to 350 MCM 3 #6 AWG to 350 MCM

8 #4 AWG to 600 MCM

12 #4 AWG to 600 MCM

1600, 2000

2600, 3000

8 #2 AWG to 600 MCM

#4 AWG to 600 MCM

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/lbs.

NOTE

: When lifting the switch using a spreader bar,

height H must be equal to half of distance D.

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ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

Installation (cont’d)

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.

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.

To R/T Box

To Power

Panel

Input/Output

Connectors

to I/O Modules

Engine Start

Connections

Clock Program

Backup Battery

Remove protective

strip to enable clock

functions

Network Connector

Control Connections

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.

Figure 2

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ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

Installation (cont’d)

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 proceeding, 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.

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.

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

is the same as the phase rotation of

Source 2.

10. Shut down the generator engine.

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.

CAUTIONS

Certain accessories, per specific

schematics, can inhibit automatic transfer.

Engine Gen-Set could start when

engine control wires are attached.

Figure 4

SERIAL NUMBER:

TING: VOLTS -

AMPS -

SYSTEM VOLTS:

MODEL NUMBER:

HZ -

PHASE -

GE Zenith Controls

P Relay

(Engine Start)

Contact rating is

10 Ampere at 120VAC

or 28VDC Gold plated

Figure 3

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ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

Installation (cont’d)

5. Close the External (up-stream) Source 2 line

circuit breaker.

6. Start the engine generator in

MANUAL mode.

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

Source 2 is the same as the phase

rotation of Source 1.

9. Shut down the generator's engine.

(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.

12. Close the enclosure.

13. Lock the enclosure.

MX150

Figure 5 – LCD and keypad

Initial Energization (cont’d)

After all options and accessories are checked and veri-

fied, 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).

1. Unlock the enclosure.

2. Open the enclosure.

3. Place the Disconnect Switch in the Inhibit.

NOTE

: This step is only 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.

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.

S1 OK

21:56

MON 23 APR 2002

MORE TEST

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ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

MX150 Microprocessor Controller

MX150 Controller

Consists of two major assemblies:

I. The Microprocessor contains the following:

A. 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. Transfer Inhibit Q3 and Q7 input

(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) Configuring logic accessories

II. The Controls Power Supply (CPS)

Contains transformers which drop line voltage to

control level for controller input and SCR inputs

(see figure 6).

Figure 7

Figure 6

I/O Interface

CPS

Engine Start Relay P

Battery Strip

and

Access

Code Label

MX150

Board

MX150

S1 OK

21:56

MON 23 APR 2002

MORE TEST

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ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

MX150 Microprocessor Controller (cont’d)

Figure 8

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. The CFG menu is primarily used to turn an

option on or off. When scrolling through these menus,

MX150

S1 OK

01: 50

FRI 31 MAY 2003

Source 2 (Red)

indicates Source 2

is acceptable for use

Source 1 LED (Green)

indicates Source 1 is

acceptable for use

Exercise Event

"Impending"

SET Menu

MORE CFG TEST SET

#1 or the word

on the LCD above the key.

The word above the key

changes depending on which

screen is being displayed.

#2 or the word

on the LCD above the key.

The word above the key

changes depending on which

screen is being displayed.

#3 or the word

on the LCD above the key.

The word above the key

changes depending on which

screen is being displayed.

#4 or the word

on the LCD above the key.

The word above the key

changes depending on which

screen is being displayed.

Current Time,

Day and

Date of Display

Source 1 Position LED (Green)

indicates Power Panel (ATS)

is closed to Source 1 position

Source 2 Position

LED (Red) indicates

Power Panel (ATS)

is closed to

Source 2 position

MORE Menu

CFG Menu

TEST Menu

Keypad

* E *

LCD Screen

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.

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ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

User Setting for Voltage & Frequency

Standard Features, MSTDG Option Pkg.

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).

"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: 95%

This adjustment determines the minimum acceptable

frequency required to transfer to Source 2.

Adjust via the SET menu. Range is 90% to 100% in

1% 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.

Test Switch, Momentary

Auxiliary Contact: Closed when the switch is in Source 2

position.

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).

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. Standard setting is 5 seconds.Adjust via SET

menu (see page 18)

Engine Start Contact

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ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

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)

K/P

Frequency Indication for S1 and S2

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.

Time Delay Source 2 Start. Adjustable 0-10 seconds.

Standard setting is 3 seconds.

Adjust via SET menu (see page 18)

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 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. A 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 (++++…) which also indicate the

approximate out of phase degrees

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. Source 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.

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)

(S2) Source 2 Stop Delay Timer. Allows Engine to run

unloaded after switch 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.

■

12 GE Zenith Controls

■

ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

In addition to the features listed under the

MSTDG Option Package, this enhanced package

includes the following features:

Additional Auxiliary contact: closed when switch is in

Source 2 position.

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.

Can be configured by end user for 1, 7, 14,

28, 365 day cycle.

Standard Features, MEXEG Option Pkg.

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

■

GE Zenith Controls 13

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ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

Test Switch, Maintained / Momentary

6AP

Test Switch, Maintained / Momentary, utilizing Keypad

Auxiliary Contact, operates on Source 1 line failure.

A1E

Auxiliary Contact, operates on Source 2 line failure.

Auxiliary Contacts: Closed when the transfer switch

is in Source 2 position.

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.

Disconnect Switch, Auto/Inhibit.

Inhibits transfer in either direction when in inhibit.

Allows automatic operation when in Auto.

(40-600 Amp units)

Heater and Thermostat.

Manual

Manual Transfer Switch transfers in either direction

by depressing designated pushbuttons.

M80

Digital Power Meter with Display: Amps, Volts, and

Frequency.

M82

Digital Meter w/Display of Amps, Watts, Volts,

Frequency, KVA, KVAR, PF, etc.

M83A

Digital Meter w/Diplay of Amps, Watts, Volts,

Frequency, KVA, KVAR, PF, etc. Plus THD capability

w/Modbus.

T3/W3

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

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 Communications Interface Card

Optional Accessories

■

14 GE Zenith Controls

■

ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

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. Press MORE and scroll to SET SYSTEM CLOCK

using the MORE key.

4. Press SEL.

5. ENTER ACCESS CODE located on the white label

on the back of the controller.

6. Press SEL.

7. Use the up and down keys to change the hour value.

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).

13. 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 then 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).

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

1. 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 XFR (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,

press MORE then SET.

15. Press MORE repeatedly until

EXER S2 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.

21. Press MORE repeatedly until SET USER SETUP

then press BACK then ESC to the S1 OK screen.

CDT One Event Timer Exerciser

■

GE Zenith Controls 15

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ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

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

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. The controller will start the

generator, transfer the load to Source 2 and remain

in Source 2 for the duration set for EXER S2 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).

• If the 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 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

How to Bypass the next exercise event and Keep

the rest of scheduled events unchanged

1) Press Test

2) Press 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) Press 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 S1 OK Screen.

Notes:

- *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.

SET

EXERCISER

00:00

To save value and to

move cursor to next

field to be changed.

Indicates # of

Exercise Periods

BACK

SAVE

Indicates type of Exerciser

DAILY, WEEKLY, 14-DAY,

28-DAY or 365-DAY

Indicates Exerciser start:

Time for DAILY Exerciser

Time & Day for WEEKLY Exerciser

Time, Date & Month for 14-DAY,

28-DAY and 365-DAY Exerciser

(24 Hour System)

To previous field

or to exit screen.

Up and Down

Use to change values.

Cursor

NL#1

Load No-Load (CDP)

Exercise Indicator

Exercise duration for this

event in hours and minutes

up to 10 hours per event

■

16 GE Zenith Controls

■

ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

CDP Clock Exerciser

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. Can be configured by the end user for 1, 7, 14, 28,

or 365 day cycles.

• A total 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.

• A total 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.

4. 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.

10. Press MORE repeatedly to BACK then ESC

to S1 OK screen.

How to set (SET) the DAILY Exerciser

1. Beginning from the S1 OK screen, press MORE

then SET.

2. Press MORE repeatedly until SET EXERCISER

screen.

3. Press SEL.

4. Enter ACCESS code located on white label

on the back of the controller.

5. Press SEL

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.

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) Press 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 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 S1 OK Screen.

Notes:

• In the S1 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.

• A value greater than zero must be entered in the

Exerciser duration field to be accepted as a valid

exercise period.

• The Exercise cycle will be repeated on a regular

basis as programmed and initiated in the SET menu

depending on what Exerciser was configured

(selected) in the CFG menu.

■

GE Zenith Controls 17

■

ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

MX150 User Setup - CFG Menu

CONFIG

USER SETUP

MORE BACK

1 VAB = ___ 2 VAB = ___

VBC = ___

VCA = ___

MORE CFG SET ESC

S1 OK

01: 50

FRI 31 MAY 2003

MORE TEST

Optional Accessories

Turn options ON or OFF via

keypad through the CFG menu

Enter six digit access code

(The factory assigned six-digit access code

is located on the back of the controller)

Engine Start Relay (De-Energized)

Network Communications

(Option)

PROG 1

PROG 2

GRD (Input

Sink)

NIA OUT

ELEV. PRE. OUT

ALARM OUT

MOTOR DISC. OUT

INHIB.>S1

INHIB.>S2

+12v (Output Source)

LN OUT

L4 OUT

L3 OUT

L2 OUT

L1 OUT

YN IN

YE IN

TSNL IN

Q2/TSL IN

S12 IN

Lithium Battery

Exerciser Battery

Replacement-K-4100 (BR2032)

Service Life-10 Years

During normal operation

User Access Code

Default-121212

PRODUCT INFORMATION

www.geindustrial.com

24-Hour Service

(773)299-6600

MX150

(-)

(+)

RELAY

14 11 12

Customer

Input

Voltage

COM

J2-3

N.O N.C

J2/J4

Inputs

WARNING

Controller Inputs must be relay Isolated.

Controller Outputs have "Limited" Source Capacity.

Use only GE Zenith-specified Output Modules.

11 14

(+)

21 24 22

(-)

Output

Contacts

R1 Output

Contact Rating: 10A @ 250 VAC or 30 VDC

2421121411

Figure 9

■

18 GE Zenith Controls

■

ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

MX150 User Setup - SET Menu

SET

USER SETUP

MORE BACK

1 VAB = ___ 2 VAB = ___

VBC = ___

VCA = ___

MORE CFG SET ESC

S1 OK

01: 50

FRI 31 MAY 2003

MORE TEST

Optional Accessories

Change adjustable values

through the SET menu.

Enter six digit access code

(The factory assigned six-digit access code

is located on the back of the controller)

Figure 9

Engine Start Relay (De-Energized)

Network Communications

(Option)

PROG 1

PROG 2

GRD (Input

Sink)

NIA OUT

ELEV. PRE. OUT

ALARM OUT

MOTOR DISC. OUT

INHIB.>S1

INHIB.>S2

+12v (Output Source)

LN OUT

L4 OUT

L3 OUT

L2 OUT

L1 OUT

YN IN

YE IN

TSNL IN

Q2/TSL IN

S12 IN

Lithium Battery

Exerciser Battery

Replacement-K-4100 (BR2032)

Service Life-10 Years

During normal operation

User Access Code

Default-121212

PRODUCT INFORMATION

www.geindustrial.com

24-Hour Service

(773)299-6600

MX150

(-)

(+)

RELAY

14 11 12

Customer

Input

Voltage

COM

J2-3

N.O N.C

J2/J4

Inputs

WARNING

Controller Inputs must be relay Isolated.

Controller Outputs have "Limited" Source Capacity.

Use only GE Zenith-specified Output Modules.

11 14

(+)

21 24 22

(-)

Output

Contacts

R1 Output

Contact Rating: 10A @ 250 VAC or 30 VDC

2421121411

■

GE Zenith Controls 19

■

ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

MX150 User Setup - System Info

S1 OK

01: 50

FRI 31 MAY 2003

MORE TEST

View System Data

Enter six digit access code

(The factory assigned six-digit access code

is located on the back of the controller)

Figure 9

Engine Start Relay (De-Energized)

Network Communications

(Option)

PROG 1

PROG 2

GRD (Input

Sink)

NIA OUT

ELEV. PRE. OUT

ALARM OUT

MOTOR DISC. OUT

INHIB.>S1

INHIB.>S2

+12v (Output Source)

LN OUT

L4 OUT

L3 OUT

L2 OUT

L1 OUT

YN IN

YE IN

TSNL IN

Q2/TSL IN

S12 IN

Lithium Battery

Exerciser Battery

Replacement-K-4100 (BR2032)

Service Life-10 Years

During normal operation

User Access Code

Default-121212

PRODUCT INFORMATION

www.geindustrial.com

24-Hour Service

(773)299-6600

MX150

(-)

(+)

RELAY

14 11 12

Customer

Input

Voltage

COM

J2-3

N.O N.C

J2/J4

Inputs

WARNING

Controller Inputs must be relay Isolated.

Controller Outputs have "Limited" Source Capacity.

Use only GE Zenith-specified Output Modules.

11 14

(+)

21 24 22

(-)

Output

Contacts

R1 Output

Contact Rating: 10A @ 250 VAC or 30 VDC

2421121411

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.

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 1sequence.

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 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.

■

20 GE Zenith Controls

■

ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

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.

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).

• XFR 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 XFR 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

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 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 S2 Stop Delay Timer (Delay

Figure 10

MX150

SYSTEM TEST

FAST XFR NO

MORE TEST LOAD XFR

■

GE Zenith Controls 21

■

ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

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 desired. 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 1sequence.

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 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 delay, 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.

Timer Designations as they appear in the SET menu

ATS Type P W DW T DT U

Standard Time Delay Time Delay Time Delay S2 Stop

S2 Start S2 Stable S1 Stable Delay

Delay Time Delay Time Delay ATS Open Time Delay ATS Open S2 Stop

S2 Start S2 Stable Time to S2 S1 Stable Time to S1 Delay

Source 1 Transfer to Source 2

Source 1

Transfer to Source 1 Engine

Fails

Returns

Cooldown

Table 3

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22 GE Zenith Controls

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ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

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.

Controls Power Supply (CPS)

This is accomplished by the Controls Power Supply (CPS).

This method of switching operator voltage and applying

power and sensing voltage to the printed circuit board

isolates the MX150 from the line voltage, further protecting

the controller from harmful line transients.

Primary CPS CPS

Voltage Assembly Board

at 50/60 Hz Part No. No.

120V 50P-1224 50P-1200

208-220V 50P-1225 50P-1201

230-240V 50P-1226 50P-1202

277V 50P-1227 50P-1203

380-400V 50P-1228 50P-1204

416-440V 50P-1229 50P-1205

460-480V 50P-1230 50P-1206

575-600V 50P-1231 50P-1207

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GE Zenith Controls 23

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ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

Standard Transition CPS Schematic

Delayed Transition CPS Schematic

Controls Power Supply (CPS) (cont’d)

GND

903

902

801

901

807

804

803

904

905

906

805

806

(BLANK)

GROUND

C.V. SCR-E CONTROL VOLTAGE (SOURCE 2)

COMMON

24V 10V 11V

XE1

30 31

24V 10V 11V 10V

XN1 XN2

20 21 22

XN1 -

XN2 -

XE1 -

SOURCE 1 CONTROL TRANSFORMER

SOURCE 1 3 PHASE SENSING

TRANSFORMER

SOURCE 2 CONTROL TRANSFORMER

3 PHASE SOURCE 2

SINGLE PHASE SOURCE 2 SENSING

3-PHASE SOURCE 1 SENSING

SOURCE 1 CONTROL POWER

SOURCE 2 CONTROL POWER

800

902

804

803

805

806

804

807

900

902

904

903

905

906

800

900

SOURCE 2 24V OUTPUT

SOURCE 1 24V OUTPUT

(18)

(1)

XE2

907

904

907

XE2 - SOURCE 2 3 PHASE SENSING TRANSFORMER

808

908

C.V. SCR-N CONTROL VOLTAGE (SOURCE 1)

C.V.

SCR-N

801

C.V.

SCR-E

C.V. SCR-N CONTROL VOLTAGE (SOURCE 1)

C.V. SCR-E CONTROL VOLTAGE (SOURCE 2)

C.V. SCR-EO CONTROL VOLTAGE (OPEN SOURCE 2)

C.V. SCR-NO CONTROL VOLTAGE (OPEN SOURCE 1)

SCR-NO

908

C.V.

SCR-E

C.V.

901

908

808

SCR-EO

C.V.

801

SCR-N

C.V.

GND

907

903

902

801

901

807

804

803

904

905

906

805

806

GROUND

COMMON

24V 10V 11V 10V24V 10V 11V 10V

XN1 XN2

20 21 22

XN1 -

XN2 -

XE1 -

XE2 -

SOURCE 1 CONTROL TRANSFORMER

SOURCE 1 3 PHASE SENSING

TRANSFORMER

SOURCE 2 CONTROL TRANSFORMER

SOURCE 2 3 PHASE SENSING

TRANSFORMER

SINGLE PHASE SOURCE 2 SENSING

3-PHASE SOURCE 1 SENSING

SOURCE 1 CONTROL POWER

SOURCE 2 CONTROL POWER

800

902

804

803

805

806

804

807

900

902

904

903

905

906

904

907

800

900

SOURCE 2 24V OUTPUT

SOURCE 1 24V OUTPUT

(18)

(1)

908

808

XE1

XE2

31 32

3-PHASE SOURCE 2 SENSING

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24 GE Zenith Controls

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ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

Troubleshooting and Diagnostics

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.

Symptom Annunciation Possible Cause(s) Corrective Action

Engine does not START SOURCE 2

AVAILABLE

LED off

Engine start wires not

terminated properly

Check engine start connections

Engine does not stop

LCD Display -

“TD Engine Cool Down”

SOURCE 1 POSITION, and

SOURCE 1 and SOURCE 2

AVAILABLE LEDs on,

but U timer has timed out

U timing cycle not complete

Engine start wires not

terminated correctly

Generator in MANUAL

Check U timer setting

Check Engine Start Connections

Place generator in AUTO

ATS will not transfer

to SOURCE 2

SOURCE 2 AVAILABLE

LED off

None

SOURCE 2 voltage or frequency

not within acceptable parameters

Power supply connector unplugged

Check: Engine Start Connections,

Generator Breaker, Generator Output,

and Engine Control Switch

Plug in connector

ATS will not transfer

to SOURCE 1

SOURCE 1 AVAILABLE

LED off

None

SOURCE 1 voltage or frequency

not within acceptable parameters

Power supply connector unplugged

Check utility and utility breakers

Plug in connector

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

Generator is in OFF position

Investigate why Engine Control

Switch was turned off

LCD Display -

“S1 _ _ _ _ TD XFR S1>S2

Time Remaining _ _ _ _”

W timing cycle not complete Check W Timer setting

LCD Display -

“Diagnostic Code 001”

LCD Display -

“S1 OK

Time Remaining _ _ _ _

Bypass”

Limit switch or RT box

connector unplugged

T timing cycle not complete

Call Technical Services

Check T Timer setting

LCD Display -

“ATS Open

Time Remaining _ _ _ _”

DW timing cycle not complete Check DW Timer setting

ZTG Series

LCD Display -

“ATS Open

Time Remaining _ _ _ _”

TD timing cycle not complete Check DT Timer setting

ZTGD Series

DANGER

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

the control panel.

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GE Zenith Controls 25

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ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

Maintenance and Testing

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 Technical 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.

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 utility 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).

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.

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.

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26 GE Zenith Controls

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ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

Power Panel and Replacement Parts

Standard Transition - 40 to 260 Amps Solenoid Type

T1 T2 T3 TN

E1 E2 E3 EN

N1 N2 N3 NN

SCR-N

SCR-E

CN/CE

SCN/SCE

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GE Zenith Controls 27

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ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

Power Panel and Replacement Parts (cont’d)

Standard Transition - 400 to 600 Amps Molded Type

T1 T2 T3 TN

E1 E2 E3 EN

SCR-N

CN/CE

N1 N2 N3 NN

SCR-E

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28 GE Zenith Controls

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ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

Power Panel and Replacement Parts (cont’d)

Standard Transition - 800 to 1200 Amps

Stock Numbers by Amperage

Tag

Description

Recommended

as Spares

800-1200

Cable Connection Lug S1392F (4)

N 1,2,3, N

E 1,2,3, N

T 1,2,3, N

Wire Size #2-600 MCM

Stationary Contact Assembly Kit Consult Factory

Arc Grid Assembly Kit 23P-1366

Movable Contact Assembly Kit Consult Factory

CN/CE

Coil Volts Poles

2, 3, 4 K-2147

208/240

380/416 3 K-2168

480 3, 4 K-2157

3, 4 K-2187

575/600

Main Operating Coils

SN CCN 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

DS Disconnect Switch (older versions)

Operator

L-4009;

Contact

Block L-1020

* Operator L-4009; Contact Block L-1020

SCR-N/SCR-E SCR * PS-8896

A3 SE

MOVABLE CONTACT

SCR-E

ARC GRID

STATIONARY CONTACT

(ARC GRID REMOVED FOR CLARITY)

SCR-N

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GE Zenith Controls 29

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ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

Power Panel and Replacement Parts (cont’d)

Standard Transition - 1600 to 3000 Amps

Stock Numbers by Amperage

Tag

Description

Recommended

as Spares

1600 2000 3000

Cable Connection Lug S1126F (2) Optional S1126F (2) Optional S1126F (2) Optional

N 1,2,3, N

E 1,2,3, N

T 1,2,3, N

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-1400 23P-1400

CN/CE

Coil Volts Poles

120 2 SPO SPO SPO

2,3 K-2123F K-2123F K-2123F

240

4 K-2127F K-2127F K-2127F

3 K-2125F K-2125F K-2125F

208

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

480

4 K-2130F K-2130F K-2130F

Main Operating Coils

416 3 K-2126F K-2126F K-2126F

SN CCN Cutout Switch 23P-1352 23P-1352

SE CCE Cutout Switch 23P-1356 23P-1356

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

DS Disconnect Switch (older versions)

Operator

L-4009;

Contact

Block L-1020

* Operator L-4009; Contact Block L-1020

SCR-N, SCR-E SCR * PS-8896

SCR-E

SCR-N

A3 SE

ARCH GRID ASSEMBLY

MOVEABLE CONTACT

STATIONARY CONTACT

(ARCH GRID REMOVED FOR CLARITY)

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30 GE Zenith Controls

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ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

Power Panel and Replacement Parts (cont’d)

Delayed Transition - 40 to 600 Amps

40-80 Amps

600 Amps

100-400 Amps

Stock Numbers by Amperage

Tag Description

Recommended

as Spares

40-80 100-400

Cable Connection Lug S-2591 S-2591

N 1,2,3 N

E 1,2,3 N

T 1,2,3 N

Wire Size #4-600 MCM #4-600 MCM

Coil Volts

120 K-2245B

208/240 K-2246B

380/415 K-2247B

440/480 K-2248B

CN/CE Solenoid *

575/600 K-2249B

Handle-Manual * E3054

Handle-Grip L-3078

A3/A4 Auxiliary Contacts L-3078

SNO/SEO Coil Cutout Switch E-3521

SCR-N, SCR-E SCR * PS-8895

600

S-1393F

#2-600 MCM

MAIN

SECONDARY

58P-1106

58P-1107

58P-1108

58P-1109

58P-1110

575/600 K-2249B 58P-1110

T1 T2 T3 TN

E1 E2 E3 EN

SNO

SN/A4

SE/A3

SEO

SCR-N

SCR-E

CN/CE

N1 N2 N3 NN

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GE Zenith Controls 31

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ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

Power Panel and Replacement Parts (cont’d)

Delayed Transition - 800 to 1200 Amps

SCR-N/SCR-E

SCR PS-8896

SCR-NO/SCR-EO

MOVABLE CONTACT

ARC GRID

STATIONARY CONTACT

SE1, 2, 3, 4

SN1, 2, 3, 4

TERMINAL

BLOCKS

TERMINAL

BLOCKS

T1 T2 T3

N1 N2 N3

SCR-N

E1 E2 E3

SCR-NO

SCR-EO

SCR-E

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32 GE Zenith Controls

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ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

Power Panel and Replacement Parts (cont’d)

Delayed Transition - 1600 to 3000 Amps

SCR-N/SCR-E

SCR-NO/SCR-EO

SCR PS-8896*

Stock Numbers by Amperage

Tag Description

Recommended

as Spares

1600 2000 3000

N1,2,3

E1,2,3

T1,2,3

NLN,ELN

Cable Connection Lug, CU Wire

S-1126F(2)

Optional

(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

CN/CNO

CE/CEO

Main Operator Solenoids * See Chart Below

Voltage System

Volts Ph Wire Coil VDC Pole

Solenoid Part No.

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 3,4 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-2160

120/240 2 4 240 4 K-2151 K-2151 K-2151

240/416 3 4 416 3 Consult Factory

Operating Coil Hardware Kit

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

STATIONARY

CONTACT

MOVABLE

CONTACT

CE/

CEO

CN/

CNO

ARC GRID

ASSEMBLY

SCR-N

SCR-NO

SCR-EO

SCR-E

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GE Zenith Controls 33

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ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

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34 GE Zenith Controls

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ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

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GE Zenith Controls 35

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ZTG/ZTGD Operation and Maintenance Manual (70R-1000D)

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

GE Zenith Controls