Page 1
g
62R-2000B
6/01
ZTX-RM SERIES
40-400 Amps
GE
Zenith Controls
Operation and Maintenance Manual
Page 2
NOTICE
This product is specially designed for light commercial or residential use only.
This product is not to be used in life-support or other emergency systems.
Table of Contents
Page
How to Remove the Cover ................................................................................................................................................................................................................01
Installation ..........................................................................................................................................................................................................................................................02
Equipment Inspection and Storage ............................................................................................................................................................................
02
Mounting
..................................................................................................................................................................................................................................................02
Power Connections ........................................................................................................................................................................................................................02
Control Connections....................................................................................................................................................................................................................04
Final Equipment Inspection................................................................................................................................................................................................04
Functional Test....................................................................................................................................................................................................................................
05
RM4 Control Interface (Optional) ..............................................................................................................................................................................................06
Optional Indicator LED
s/Pushbuttons ..................................................................................................................................................................06
Automatic Transfer Generator Testing (One Time Test)
..........................................................................................................................07
Transfer Generator Testing (Forcing Operation with Keypad) ..............................................................................................................07
LED Diagnostic Flash Codes ................................................................................................................................................................................................07
Automatic Generator Exerciser
......................................................................................................................................................................................
08
Selecting Exerciser Without Transfer
........................................................................................................................................................................08
Selecting Exerciser With Transfer ................................................................................................................................................................................08
Engine Controller Accessory Board (Optional) ..........................................................................................................................................................09
Oil Pressure Sensor Input ......................................................................................................................................................................................................
09
Temperature Sensor Input
....................................................................................................................................................................................................
09
Fuel/Run Contact Output
....................................................................................................................................................................................................09
Start Contact Output....................................................................................................................................................................................................................09
Generator Battery Input ..........................................................................................................................................................................................................
09
Example Systems
..........................................................................................................................................................................................................................................
10
Partial Coverage System
............................................................................................................................................................................................................10
Total Coverage System................................................................................................................................................................................................................10
Typical Diagram ............................................................................................................................................................................................................................................
11
Power Circuit Schematic
..........................................................................................................................................................................................................11
Power Panel Layout
......................................................................................................................................................................................................................
11
Interconnect Plug
............................................................................................................................................................................................................................11
Troubleshooting
............................................................................................................................................................................................................................................12
Generator Fault Flash Table ................................................................................................................................................................................................13
Page 3
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GE Zenith Controls 1
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ZTX-RM Operation and Maintenance Manual (62
R-2000)
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 ii.
This will prevent damage to the cable. The cable may
also be disconnected at the controller or keypad.
Figure i
Figure ii
NOTE: Reattach cable before installing cover.
! !
DANGER
HAZARDOUS VOLTAGE
Will shock, burn or cause death.
Do not remove cover until ALL
power is disconnected.
Re-installation of cover is required
after maintenance or service.
Page 4
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2 GE Zenith Controls
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ZTX-RM Operation and Maintenance Manual (62
R-2000)
Equipment Inspection and Storage
Inspect the transfer switch when received to detect any
damage which may have occurred during transit. If damage
is found or suspected, file claims with the carrier.
Before installation, store the transfer switch in a clean
dry place, protected from dirt and water. Provide ample
air circulation and heat to prevent condensation.
Storage Temperature: -30° C to +75° C
(-22° F to +167° F)
Operating Temperature -20° C to +65° C
(Ambient): (-4° F to +149° F)
Humidity: 5% to 95% (non-condensing)
Before installation, check the equipment rating nameplate on the transfer switch to verify the correct system
voltage.
*
Example nameplate is shown in Figure 1.
Mounting
Adequate lifting means must be used to mount the
transfer switch into place. Enough room should be
allowed to open the cabinet door fully for inspection
and servicing of the switch per NEC and local codes.
Before drilling conduit entry 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.
Power Connections
This transfer switch is supplied with UL listed
solderless screw type terminals. Table 2 (see
Page 3) lists the number and sizes of cable
lugs supplied for each switch amp rating.
Connect the Load, Generator and Utility conductors to
terminals on the transfer switch (see Figure 2, Page 3).
Remove surface oxides from cables by cleaning with a
wire brush. Verify that all connections are correct. All
cable lug connections must be tightened to the proper
torque values as shown in Table 1.
DANGER
HAZARDOUS VOLTAGE
(Can Cause Severe Injury or Death)
Turn OFF all power before installation, manual operation or removal of transfer switch or any of its components.
Connecting Engine Start may cause Generator to start. Before connecting, turn Generator OFF.
Installation
Table 1
Tightening Torque for Lugs
Socket Screw Size
Lb.-In. Torque Lb.-Ft.
451/8 4
1005/32 8
1203/16 10
1507/32 12
2001/4 17
2755/16 23
3753/8 31
5001/2 42
Installation must be performed by a licensed electrician and in accordance
with the National Electric Code and all local electrical codes.
Figure 1
g
SERIAL NUMBER:
RA
TING
:VOLTS -
AMPS -
SYSTEM VOLTS:
MODEL NUMBER:
HZ -
PHASE -
GE Zenith Controls
*
Page 5
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GE Zenith Controls 3
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ZTX-RM Operation and Maintenance Manual (62
R-2000)
Install
load
cables
first.
Tip!
Table 2
Screw Type Terminals for External Power Connections
Switch Size
(Amps)
40
80
100
150
Utility, Generator and Load Terminals
1 #8 to 3/0 AWG
Cable Per Pole Range of Wire Sizes
1 #8 to 3/0 AWG
1 #8 to 3/0 AWG
1 #8 to 3/0 AWG
Fully Rated Neutral Bar (When Required)
3 #8 to 1/0 AWG
No. of Cables Range of Wire Sizes
3 #8 to 1/0 AWG
3 #8 to 1/0 AWG
3 #8 AWG to 300 MCM
200, 225, 250*
300, 400
1 #6 AWG to 250 MCM
1 #4 AWG to 600 MCM
3 #6 AWG to 300 MCM
3 #4 AWG to 300 MCM
* IEC Rating Only
Installation
(cont’d)
Figure 2 - Power Panel
DANGER
HAZARDOUS VOLTAGE
(Can Cause Severe Injury or Death)
Turn OFF all power before installation, manual operation or removal of transfer switch or any of its components.
Connecting Engine Start may cause Generator to start. Before connecting, turn Generator OFF.
Installation must be performed by a licensed electrician and in accordance
with the National Electric Code and all local electrical codes.
TERMINALS
T1 T2 T3
N1 N3
SWITCH
POSITION
INDICATOR
UTILITY
TERMINALS
BR
N
LOAD
N2
OPTIONAL A4 CONTACT
OPERATES WHEN IN
UTILITY
POSITION
JP
Exerciser
CONTROLLER
ENGINE
START
OPTIONAL ENGINE CONTROLS
OR AIR CONDITION DISCONNECT
OR 3 PHASE BOARD
3 AND 4 POLE ONLY
E3
E2
E1
OPTIONAL A3 CONTACT
OPERATES WHEN IN
GENERATOR
GENERATOR
TERMINALS
POSITION
T = Load N = Utility E = Generator
Page 6
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4 GE Zenith Controls
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ZTX-RM Operation and Maintenance Manual (62
R-2000)
Installation
(cont’d)
Final Equipment Inspection
a. Remove any debris incurred due to shipment or
installation.
DO NOT use a blower since debris
may become lodged in the electrical and mechan-
ical components and cause damage.
b. Verify that all cabled connections are correct.
c. Check engine start connections and verify the
correct connection of all control wires.
d. Verify actual lug torque values as specified in
this manual (see Page 2, Table 1).
e. Make sure that all covers and barriers are
installed and properly fastened.
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.
Prior to energizing the transfer switch:
Note:
N = Utility Position
E = Generator Position
Manual operation is possible for maintenance purposes only.
Manual operation of the switch can be checked before it
is operated electrically.
With all power off, insert a Phillips screwdriver or equivalent
size tool into the manual operator socket and operate
the transfer switch between the Utility and Generator
positions. The transfer switch should operate smoothly
without binding. Return the switch to the Utility position,
remove the screwdriver.
Select the
exercise
interval
now while
the unit
is still
de-energized.
See
Page 8.
Tip!
Figure 3
Figure 4
DANGER
HAZARDOUS VOLTAGE
(Can Cause Severe Injury or Death)
Turn OFF all power before installation, manual operation or removal of transfer switch or any of its components.
Connecting Engine Start may cause Generator to start. Before connecting, turn Generator OFF.
Installation must be performed by a licensed electrician and in accordance
with the National Electric Code and all local electrical codes.
JP
AB
6
5
4
Exerciser
123
B
A
CONTROLLER
Close to Start
Opens to Stop
Engine Start
Contact Output
Contact Rating
28Vdc @ 5 amps
Page 7
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GE Zenith Controls 5
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ZTX-RM Operation and Maintenance Manual (62
R-2000)
Utility Pickup Voltage
90% Nominal
Line Voltage
Utility Dropout Voltage
80% Nominal
Line Voltage
Utility Pickup Frequency
90% Nominal
Line Frequency
(T) Timer/Delay to Utility 5 minutes*
(U) Timer/Engine
Cool Down
5 minutes*
Factory Settings
Functional Test
The functional testing of the transfer switch consists of
electrical tests described in this section. Before proceeding, 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 Available
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 position. Complete the visual inspection of the transfer switch,
and replace the cabinet cover (or close the cabinet door).
Functional Test
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 optional 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.
Installation
(cont’d)
Generator Pickup Voltage
90% Nominal
Line Voltage
Generator Dropout Voltage
80% Nominal
Line Voltage
Generator Pickup Frequency
95% Nominal
Line Frequency
(P) Timer/Engine Start 5 seconds*
(W) Timer/Delay to
Generator
20 seconds*
Factory Settings
Table 3
Installation must be performed by a licensed electrician and in accordance
with the National Electric Code and all local electrical codes.
DANGER
HAZARDOUS VOLTAGE
(Can Cause Severe Injury or Death)
Turn OFF all power before installation, manual operation or removal of transfer switch or any of its components.
Connecting Engine Start may cause Generator to start. Before connecting, turn Generator OFF.
* Factory default settings — customer time settings may vary due to specifications from the generator supplier.
Page 8
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6 GE Zenith Controls
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ZTX-RM Operation and Maintenance Manual (62
R-2000)
RM4 Control Interface (
Optional
)
Optional Pushbuttons
F. 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.
G. 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.
H. Reset push button. Pressing this button will clear the
fault indications.
I. Transfer push button. Pressing this button will force
the unit to transfer from one position to another when
both sources are available.
A
H
B
I
C
D
F
G
E
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 utility.
Generator available Red
LED. When on, indicates
the generator source is acceptable.
Generator position Red
LED. When on, indicates that
the transfer switch is connected to the generator.
Load Amber
LED. When on, indicates that the load
is connected to an acceptable source.
Figure 5
A
B
C
D
E
F
G
H
I
DANGER
HAZARDOUS VOLTAGE
(Can Cause Severe Injury or Death)
Turn OFF all power before installation, manual operation or removal of transfer switch or any of its components.
Connecting Engine Start may cause Generator to start. Before connecting, turn Generator OFF.
Page 9
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GE Zenith Controls 7
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ZTX-RM Operation and Maintenance Manual (62
R-2000)
Automatic Transfer Generator
Testing (One Time Test)
Verify that the transfer switch UTILITY available and
position LEDs are illuminated.
Press and hold the
GENERATOR START
/STOP
button
and the TRANSFER button for 5 seconds. This will
cause the generator to start. Once the generator has
started, the Generator LED will illuminate.
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.
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.
The generator will cool down for 5 minutes (U Timer)
and then shut down. The
GENERATOR LED will go off.
This completes the automatic test.
Transfer Generator Testing
(Forcing Operation with Keypad)
Verify that the transfer switch UTILITY available and position LEDs are illuminated.
Press and hold the
GENERATOR START/STOP button for 5
seconds. This will start the generator.
Verify that the
GENERATOR available LED
has illuminated.
Press the
TRANSFER button. The switch will transfer
to the Generator source position. The
GENERATOR
position LED will now be illuminated.
Pressing the
TRANSFER button again will cause the
unit to transfer to the utility power source. The
UTILITY
position LED will illuminate.
Pressing the
GENERATOR START
/STOP
button will stop
the generator.
RM4 Control Interface (
Optional
)
(cont’d)
DANGER
HAZARDOUS VOLTAGE
(Can Cause Severe Injury or Death)
Turn OFF all power before installation, manual operation or removal of transfer switch or any of its components.
Connecting Engine Start may cause Generator to start. Before connecting, turn Generator OFF.
* Pressing and releasing the generator Start/Stop button
will cancel current test.
C
C
D
B
F
A
B
F
C
D
B
F
+
A
B
+
LED Diagnostic Flash Codes
Rapidly Flashing Generator
Availability
LED
n Generator failed to start.
n Generator starts but failed to reach proper
operating parameters.
n Generator became over loaded for an extended
period of time.
n Optional generator crank board (see generator
fault flash table on page 13)
Rapidly Flashing Generator
Position
LED
n Switch did not transfer to Generator position.
Rapidly Flashing Utility
Position
LED
n Switch did not transfer to Utility position.
C
D
B
I
C
I
I
NOTE: All fault alarms can be cleared by
depressing the reset button.
NOTE: Transfer will cause short interruption of power.
Page 10
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8 GE Zenith Controls
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ZTX-RM Operation and Maintenance Manual (62
R-2000)
JP (CDT SELECT)
RM4 Control Interface (
Optional
)
(cont’d)
* 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.
Figure 6
DANGER
HAZARDOUS VOLTAGE
(Can Cause Severe Injury or Death)
Turn OFF all power before installation, manual operation or removal of transfer switch or any of its components.
Connecting Engine Start may cause Generator to start. Before connecting, turn Generator OFF.
See Figure 3, Page 4
DANGER
Turn OFF all power before selecting.
NOTE: Transfer will cause short interruption of power.
50 Hz
3
A B
60 Hz
3
A B
Do not adjust the jumper positions.
This service to be performed by qualified personnel only.
JP
(VOLTAGE
/
FREQUENCY SELECT
)
See Figure 3, Page 4
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 controller board. The selections are 7, 14, 21 or 28 day.
Selecting Exerciser Without Transfer
To start the automatic exerciser without transfer, depress
the Exerciser 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-second 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.
7 Day
4 5 6
BA
14 Day
4 5 6
BA
208 V
A B
2
1
220 V
A B
1
21 Day
BA
28 Day
BA
240 V
A B
2
1
4 5 6
4 5 6
2
Page 11
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GE Zenith Controls 9
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ZTX-RM Operation and Maintenance Manual (62
R-2000)
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 determined and corrective action is taken and verified by qualified technician, controller can be reset via reset button.
Temperature 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 X1 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.
Engine Controller Accessory Board
(Optional)
Controller
Engine
Controller
+
X1 X2 X3 X4
Temperature
Sensor
(12 Vdc)
–+–
Input
Input
Oil Pressure
Sensor
(12 Vdc)
Generator Battery Input
(12 Vdc)
X9 X10
+–
X5 X6
Start Contact Output
(28 Vdc @ 5 amps)
Fuel/Run Contact Output
(28 Vdc @ 5 amps)
Page 12
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10 GE Zenith Controls
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ZTX-RM Operation and Maintenance Manual (62
R-2000)
Example Systems
Circuit
Breaker
Main
Breaker
Panel
All Loads
Utility
Source
Transfer Switch
Circuit
Breaker
Generator
Source
Loads
Utility Panel
Utility
Source
Transfer Switch
Loads
Circuit
Breaker
Distribution Panel
Generator
Source
Partial Coverage System
Total Coverage System
Page 13
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GE Zenith Controls 11
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ZTX-RM Operation and Maintenance Manual (62
R-2000)
Typical Diagrams
Power Circuit Schematic
Power Panel Layout Interconnect Plug
Page 14
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12 GE Zenith Controls
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ZTX-RM Operation and Maintenance Manual (62
R-2000)
Troubleshooting
Symptom Possible Cause Corrective Action
Generator will not start
P timer has not lapsed See factory settings on Page 5
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 Refer to generator instruction manual
Transfer switch does not
transfer to Utility
T timer has not lapsed See factory settings on Page 5
Exercise in progress See Page 8
Utility breaker open or tripped Clear fault and reset
Utility voltage out of range
Wait for utility to return to acceptable
level. See factory settings on Page 5.
Control harness unplugged
With all power disconnected,
reconnect harness
Transfer switch does not
transfer to Generator
W timer has not lapsed See factory settings on Page 5
Generator breaker open or tripped Refer to generator instruction manual
Generator voltage out of range Refer to generator instruction manual
Control harness unplugged
With all power disconnected,
reconnect harness
Generator will not stop
U timer has not lapsed See factory settings on Page 5
Exercise in progress See page 8
Engine control switch in run position Refer to generator instruction manual
All LEDs off
Keypad cable unplugged
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
DANGER
HAZARDOUS VOLTAGE
(Can Cause Severe Injury or Death)
Turn OFF all power before installation, manual operation or removal of transfer switch or any of its components.
Connecting Engine Start may cause Generator to start. Before connecting, turn Generator OFF.
Service must be performed by qualified personnel.
Page 15
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GE Zenith Controls 13
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ZTX-RM Operation and Maintenance Manual (62
R-2000)
Troubleshooting
(cont’d)
Generator Failed to Start (GFSTimeout) 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 6 Flashes + 2 Missing
Generator Fault Flash Table
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.
DANGER
HAZARDOUS VOLTAGE
(Can Cause Severe Injury or Death)
Turn OFF all power before installation, manual operation or removal of transfer switch or any of its components.
Connecting Engine Start may cause Generator to start. Before connecting, turn Generator OFF.
Service must be performed by qualified personnel.
Page 16
GE
Industrial Systems –
Power Equipment Business
830
W
.
40
th
Street, Chicago, IL
60609
USA
773 299-6600, Fax: 630 850-6899
www.zenithcontrols.com
g
GE
Zenith Controls
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