ABB Zenith ZBTS T Series User guide

— Bypass-Isolation Automatic Transfer Switches 34ZBTS_30-1200A rev.A / 1SCC303043M0201, FW2.00
INSTALLATION AND OPERATING INSTRUCTION
Bypass-Isolation Automatic
Transfer Switches
Zenith ZBTS T-series, 100 - 1200 A

2Zenith ZBTS T-series 100-1200A, INSTALLATION AND OPERATING INSTRUCTION
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34ZBTS_30-1200A rev.A / 1SCC303043M0201
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Receiving, Handling and Storage
Receiving and Handling
Upon receipt, carefully inspect the By-
pass-Isolation Automatic Transfer Switch
for damage that may have occurred
during transit. If damage is evident, or
there is visible indication of rough han-
dling, immediately file a damage claim
with the transportation company, and no-
tify your local ABB sales office.
Do not remove the shipping package until
ready to install the Bypass-Isolation Auto-
matic Transfer Switch.
Storage
If the unit will not be placed into service
immediately, store the Bypass-Isolation
Automatic Transfer Switch on its original
package in a clean, dry location. To pre-
vent condensation, maintain a uniform
temperature. Store the unit in a tempera-
ture controlled building, allowing ade-
quate air circulation and protection from
dirt and moisture. Storing the unit out-
doors could cause harmful condensation
inside the Bypass-Isolation Automatic
Transfer Switch enclosure.
HAZARD OF EQUIPMENT
OVERTURNING
When moving with a fork lift, do not re-
move the shipping package until the de-
vice is in its final location.
Warning
Hazard of equipment overturning. Failure to
follow this instruction will result in personal
injury or equipment damage.

4Zenith ZBTS T-series 100-1200A, INSTALLATION AND OPERATING INSTRUCTION
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Read these safety instructions
carefully before using this product!
Warning
Indicates a hazardous situation that, if not
avoided, could result in death or serious injury
or equipment damage.
HI-POT OR DIELECTRIC TEST
• Performing a hi-pot or dielectric test on
the power section, Remove control volt-
age connectors from fixed type switch
and if switch is rack out type take it to
the ISOLATED locations.
• If the mechanism needs to be REMOVED
from the switch, see the Service instruc-
tion manual for details.
Danger
Hazard of electric shock, explosion, or arc
flash. Failure to follow these instructions
could result in death or serious injury or
equipment damage.
HAZARD OF ELECTRIC SHOCK,
EXPLOSION, OR ARC FLASH
• Wear appropriate personal protective
equipment and follow safe electrical
work practices.
• This equipment must only be installed
and serviced by qualified electrical per-
sonnel.
• Disconnect all sources of electrical sup-
ply before performing visual inspec-
tions, tests, service or maintenance on
the equipment. Assume that all circuits
are live unless they are completely
de-energized, tested, grounded, and
tagged. Pay particular attention to the
design of the power system. Consider
all sources of power, including the pos-
sibility of backfeeding.
• Turn off Bypass-isolation automatic
transfer switch before removing or
making load side connections.
• Always use a properly rated voltage
sensing device at all line and load to
confirm Bypass-isolation automatic
transfer switch is off.
Failure to follow these instructions could
result in death or serious injury.

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34ZBTS_30-1200A rev.A / 1SCC303043M0201
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Installation and
Operating Instruction
Bypass-Isolation
Automatic Transfer
Switches
INSTALLATION INSTRUCTIONS,
ZENITH ZBTS T-SERIES
100-1200A
CHAPTERS 7-8
OPERATING INSTRUCTIONS,
ZENITH ZBTS T-SERIES
100-1200A
CHAPTERS 1–6
4
DIMENSION DRAWINGS,
ZENITH ZBTS T-SERIES
100-1200A
CHAPTER 10
MAINTENANCE,
ZENITH ZBTS T-SERIES
100-1200A
CHAPTER 9
3

6Zenith ZBTS T-series 100-1200A, INSTALLATION AND OPERATING INSTRUCTION
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34ZBTS_30-1200A rev.A / 1SCC303043M0201
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Operating Instruction
Bypass-Isolation
Automatic Transfer
Switches, Zenith ZBTS
T-series 100-1200A
PART 1
1. Introduction 11
1.1 Hazard Categories 11
1.2 Warranty 12
1.3 Product Specification 13
1.4 Definitions 14
2. Product Overview 15
2.1 General Overview 17
2.2 Main and Control Connections 19
2.2.1 Main Connections 19
2.2.2 Control Connections 19
2.2.3 Interlocks 20
2.3 HMI 21
2.4 Bypass and ATS Switches, Features 22
3. Operating 25
3.1 LED Functionality in HMIs 25
3.2 Using the Control Interface HMI 27
3.2.1 Keypad 27
3.2.2 Navigating in Menu 27

8Zenith ZBTS T-series 100-1200A, INSTALLATION AND OPERATING INSTRUCTION
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3.3 HMI, menu tree 28
3.3.1 Start Menu 30
3.4 Description of Basic Functionality 35
3.4.1 How to draw out the switch to Test
and Isolated locations – Bypassing
the ATS switch 35
3.4.2 How to use the Draw-out
Mechanism to rack out the Switch 38
3.4.3 To Reconnect ATS Switch 42
4. Electronic Accessories 45
4.1 Auxiliary Power Supply Module OXEA1 46
4.1.1 Electrical Characteristics 46
4.1.2 Signallings 46
4.2 Ekip Supply Module 47
4.2.1 Electrical Characteristics 47
4.2.2 Signallings 47
4.3 Ekip Signalling 2K -module 48
4.3.1 Electrical characteristics of
Ekip Signalling 2K -module 48
4.3.2 Access from the display /
Ekip Signalling 2K -module 48
4.3.3 Signals and inputs/outputs of
Ekip Signalling 2K -module 52
5. Troubleshooting 53
5.1 Alarms 53
5.2 Warnings 56
5.3 Information 57

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34ZBTS_30-1200A rev.A / 1SCC303043M0201
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6. Technical Data 59
6.1 Technical Data of Bypass-Isolation
Transfer Switches 59
6.1.1 I/O Contacts, Default Settings /
Bypass-Isolation Automatic
Transfer Switch 62
6.2 Circuit Diagrams 63
PART 2
Installation Instruction 69
PART 3
Maintenance 83
Part 4
Dimension drawings 101

10 Zenith ZBTS T-series 100-1200A, INSTALLATION AND OPERATING INSTRUCTION
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34ZBTS_30-1200A rev.A / 1SCC303043M0201
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1. Introduction
Operating instruction part of the manual
(Chapters 1...6) describes the basic oper-
ation of the Bypass-isolation automatic
transfer switches Zenith ZBTS T-series
100-1200A, manufactured by ABB.
Mounting instructions for the Bypass-iso-
lation automatic transfer switches and for
the available accessories, see Part 2,
Chapters 7 and 8.
The regular maintenance instructions and
useful tricks for service operations are
descriped in Part 3, Chapter 9.
Dimension drawings, see Part 4,
Chapter 10.
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1.1 Hazard Categories
The following important highlighted in-
formation appears throughout this docu-
ment to warn of potential hazards or to
call attention to information that clarifies
a procedure.
Carefully read all instructions and become
familiar with the devices before trying to
install, operate, service or maintain this
equipment.
Danger
Indicates a hazardous situation that, if not
avoided, will result in death or serious injury
or equipment damage.
Warning
Indicates a hazardous situation that, if not
avoided, could result in death or serious injury
or equipment damage.
Caution
Indicates a hazardous situation that, if not
avoided, could result in minor or moderate in-
jury. Failure to comply with these instructions
may result in product damage.
Notice
It is used to notify of practices not related to
personal injury. Failure to comply with these
instructions may result in product damage.
The safe operation of your Bypass-Isola-
tion Automatic Transfer Switch is ABB’s
focus. The proper storage, installation,
operation and maintenance will help in-
crease the life of Bypass-Isolation Auto-
matic Transfer Switch.

12 Zenith ZBTS T-series 100-1200A, INSTALLATION AND OPERATING INSTRUCTION
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1.2 Warranty
This document is based on information
available at the time of its publication.
While efforts have been made to ensure
accuracy, the information contained
herein does not cover all details or varia-
tions in hardware and software, nor does
it provide for every possible contingency
in connection with installation, operation,
and maintenance. Features may be de-
scribed herein that are not present in all
hardware and software systems.
ABB Zenith assumes no obligation of no-
tice to holders of this document with re-
spect to changes subsequently made.
ABB Zenith makes no representation or
warranty, expressed, implied, or statu-
tory, and assumes no responsibility for
the accuracy, completeness, sufficiency,
or usefulness of the information con-
tained herein. No warrantees of mer-
chantability or fitness for purpose shall
apply.
Contact your local sales office if further
information is required concerning any
aspect of the Zenith ZBTS T-series By-
pass-Isolation automatic transfer switch
operation or maintenance.
Warranty Period
The Warranty Period for Zenith ZBTS T-se-
ries Bypass-Isolation automatic transfer
switch products is twenty-four (24)
months from the date of shipment.
Notes:
This warranty is valid only for products
sold in the United States – consult your lo-
cal ABB representative for Non-US war-
ranty terms and conditions.
For support in the United States, contact
service team at: [phone] or
epis.pqserv[email protected] for 24-hour
support.
For international support, contact
[e-mail].

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34ZBTS_30-1200A rev.A / 1SCC303043M0201
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1.3 Product Specification
Quality Assurance
All Zenith ZBTS T-series Bypass-Isolation
automatic transfer switches have been
designed and manufactured to the high-
est technical standards. Strict procedures
ensure firstclass product quality.
Product Rating / Applicable Standards
For UL 1008 ‘withstand’ and ‘close on
short circuit’ ratings, refer to ABB publica-
tion number 1SCC303020C0201.
Product Serial Number
Please have the serial number available
when communicating about the By-
pass-Isolation automatic transfer switch.
The serial number can be found on the
product nameplate affixed to each power
panel assembly. See example below.
ZENITH ZBTS
BYPASS/ISOLATION TRANSFER SWITCH
ZSDO120WB1S5TPTX4X
1200
000
Delayed Transition
Fig. 1.1 Sample nameplate

14 Zenith ZBTS T-series 100-1200A, INSTALLATION AND OPERATING INSTRUCTION
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1.4 Definitions
ATS
Automatic transfer switches
Ekip
Electronic accessories / Ekip-modules;
communication, signaling and
connectivity modules
HMI
Control interface (Human Machine
Interface), operating and configuration,
with touch scren (Level 4).
Level 4
HMI with touch screen and sensor module
OXCT_
OX_
Automatic transfer switches, type name
Programming port
Only for Ekip Programming -modules
(USB port)
Slide switch (in the ATS and Bypass)
Switch for operating mode selection
(Hand - Locking - AUTO), AUTO default
S1
Source 1, relate to a Normal Power Source
S2
Source 2, relate to an Emergency or
Alternative Power Source
TruONE™ATS
Automatic transfer switches, product
name
Zenith ZBTS T-series
Bypass-Isolation automatic transfer
switch, product name

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34ZBTS_30-1200A rev.A / 1SCC303043M0201
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Bypass-Isolation Automatic Transfer
Switch, consist of two ABB Zenith Auto-
matic Transfer Switches (TruONE ATS)
from 100A up to 1200A, are used to pro-
vide a continuous source of power for
critical loads. The transformation from
one source to another is performed auto-
matically even in the event that Source 1
voltage falls below preset limits.
System controller PCBA is located inside
of the bottom cabinet door, on control
panel (back side). ABB Zenith Automatic
Transfer Switch is designed for use on
emergency or stanby systems and are
rated for total system or motor loads.
—
2. Product Overview
Bypass-Isolation Automatic Transfer Switches, Zenith ZBTS
T-series, from 100 A up to 1200 A, are used to provide a
continuous source of power for critical loads by
automatically transferring from Source 1 power to Source 2
power in the event that Source 1 voltage falls below preset
limits. The Bypass-Isolation features allow the primary
automatic transfer switch to be inspected, tested, and
maintained without interrupting power to the load. They
also provide redundant power transfer if the ATS is disabled
or removed from service.
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Fig. 2.1 Bypass-Isolation Automatic
Transfer Switch, Zenith ZBTS T-series

16 Zenith ZBTS T-series 100-1200A, INSTALLATION AND OPERATING INSTRUCTION
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Notice
A protective device such as a moulded case
circuit breaker or fused disconnect switch
MUST be installed on both sources of incom-
ing power for circuit protection and as a dis-
connection device.
The Bypass-Isolation Automatic Transfer
Switch consists of these main modules:
• The two automatic transfer switches:
- ATS is always draw-out version (lower
switch module)
- Bypass can be fixed or draw-out
version (upper switch module)
• Customer main connections, Source 1,
Source 2 and Load, on the top of the
cabin
• The Control Plate (bottom module)
- Customer connections: Generator
start/stop terminals
- Control circuit
- Place for optional accessories
• Racking in/out -mechanism
• Both switches have operation panel HMI
at the door
The modules containing the switch are
connected to the busbars located at the
rear of the modules and the entire pack-
age is mounted in an enclosure. The ATS
switch in the lower switch module is al-
ways a draw-out version that includes an
in/out rack for easy maintenance. The up-
per switch module, the Bypass switch, is
available in either a fixed or draw-out ver-
sion, but all the functions are exactly the
same both Bypass and ATS switches.
The top module of enclosure is for cable
lugs for Source 1, Source 2 and for Load.
The lugs are located behind transparent
covers. See the location of lugs in Fig. 2.6.
The Control Plate is located in the bottom
module equipped with own inside door.
The front side of the door is reserved for
the customer connections e.g. generator
start/stop terminals and also included an
empty space for the accessories. Back
side of the Control Plate door are all other
components which are necessary for the
control system.
The switch racking in/out mechanism is
on enclosure’s door also in the upper
switch module, when the Bypass switch is
draw-out version. The tool for the racking
in/out system is located in the mecha-
nism behind the transparent cover. The
default location is the lower switch mod-
ule, where ATS is always the draw-out
version.
Danger
Hazardous voltage. Turn OFF all power before
installation, adjustment, or removal of the
transfer switch or any of its components.
Warning
Due to hazardous voltage and current, ABB
recommends that ABB certified technician or
qualified electrician perform the installation
and maintenance.

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1 Ground Terminal
2 Fixed Bypass in the picture
(alternative: Bypass is draw-out
version), behind transparent cover
3 Customer connections: Source 1,
Source 2 and Load, behind
transparent cover
4 Conduit area for the cable entries,
cable wiring directly to the
connectors
5 I/O connections (in Fixed Bypass)
6 Manual control by switch own handle
7 I/O connections in Connection
Module (for ATS)
8 Control Plate
9 Place for optional accessories
10 ATS, always the draw-out version
11 Racking in/out mechanism
12 Generator start/stop terminals
13 Product nameplate
—
Fig. 2.2 Bypass-Isolation Automatic Transfer
Switch overview (Bypass: fixed version)
—
2.1 General Overview
7
6
6
5 4 3 2 1
12 11 10 9 8 13

18 Zenith ZBTS T-series 100-1200A, INSTALLATION AND OPERATING INSTRUCTION
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1 Operation instruction
2 HMI unit on the door, Level 4 (touch)
for configuration and automatic
operation, operation of the Bypass
switch
3 Lifting eyes
4 HMI unit on the door, Level 4 (touch)
for configuration and automatic
operation, operation of ATS switch
5 Place for racking in/out tool
6 Racking in/out mechanism
7 Release of the door locking, for
authorized persons only
8 Place for racking in/out mechanism,
in case the Bypass switch is also
draw-out version
9 Situation of programming port in
both HMIs (Bypass and ATS switches),
only for Ekip Programming-module
—
Fig. 2.3 Bypass-Isolation Automatic Transfer
Switch overview (Bypass: fixed version)
9
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Fig. 2.5 The HMI units on the door
3 2 1
7 6 5 4
—
Fig. 2.4 Racking in/out mechanism
6
5
8

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34ZBTS_30-1200A rev.A / 1SCC303043M0201
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2.2 Main and Control Connections
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Fig. 2.6 Cable lugs for Source 1, for Source 2 and
for Load on the top module of enclosure
2.2.1 Main Connections
The top module of enclosure is for cable
lugs for Source 1, for Source 2 and for
Load. The lugs are located behind trans-
parent covers.
1 Cable lugs for Source 1
2 Cable lugs for Source 2
3 Cable lugs for Load
See mounting instructions, Part 2, chap-
ter 7.
2.2.2 Control Connections
The lowest module of enclosure, the Con-
trol Plate, is for control connections. The
customer connections such as “Gen.
Start/Stop” are on the Control Plate
(front side) and have terminal blocks for
very easy access. See next page where
the front side is described, see Fig. 2.8.
The back side of the Control Plate is de-
scriped in the Fig. 2.7.
1 Terminals for internal use
2 Protection devices
3 Transformers
4 Power Supply
5 Service terminals
6 PCBA
—
Fig. 2.7 Control Plate, back side
1 2 3
31 2 4 5 6

20 Zenith ZBTS T-series 100-1200A, INSTALLATION AND OPERATING INSTRUCTION
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The upper switch is the Bypass switch. It
can be fixed or draw-out version. In this
manual the Bypass switch is fixed. The
lower switch, ATS, is always draw-out
version.
1 Main connections
2 Fixed Bypass, I/O connections
3 Fixed Bypass, control voltage
connectors
4 Draw-out ATS, Connection Module,
control voltage and I/O connections
5 Control Plate, front side, see back
side on previous page
6 Generator start/stop terminals
7 Aux. voltage for Ekip modules / HMI
2.2.3 Interlocks
Automatic transfer switches are electri-
cally interlocked to prevent switches from
being operated to different sources at
the same time. The doors are mechani-
cally interlocked with draw-out switch
versions so that the doors do not open
when the switch is energized or in Con-
nected/Test locations. If the Bypass
switch is fixed, then there is no mechani-
cal interlock on the upper door.
The system provides the ability to with-
draw the ATS (or the Bypass switch, if it is
the draw-out version) for test and / or
maintenance purposes without interrupt-
ing the load. During operation, the con-
tacts of Bypass switch are closed parallel-
ing the ATS contacts, which then allows
withdrawal of the ATS to the “TEST” or
“ISOLATE” locations. The systems include
mechanical and electrical interlocks that
prevent cross-service.
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Fig. 2.8 Bypass-Isolation Automatic Transfer Switch
1
2
3
4
5
76