ABB Zenith ZTG T Series User manual

OPERATION, MAINTENANCE, AND INSTALLATION GUIDE
Zenith ZTG T-series
For ZTG(D/CT) T-series automatic
transfer switches 1600-3000 A,
208-480 Vac

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ZENITH ZTG(D/CT) T-SERIES 1600-3000 A

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OPERATION, MAINTENANCE, AND INSTALLATION GUIDE
—
Receiving, handling and storage
Receiving and handling
Upon receipt, carefully inspect the trans-
fer switch for damage that may have oc-
curred during transit. If damage is evi-
dent, or there is visible indication of
rough handling, immediately file a dam-
age claim with the transportation com-
pany, and notify your local ABB sales
office.
Do not remove the shipping packaging
until ready to install the switch.
Storage
If the unit will not be placed into service
immediately, store the transfer switch in
its original package in a clean, dry loca-
tion. To prevent condensation, maintain a
uniform temperature. Store the unit in a
heated building, allowing adequate air
circulation and protection from dirt and
moisture. Storing the unit outdoors could
cause harmful condensation inside the
transfer switch enclosure.
HAZARD OF EQUIPMENT
OVERTURNING
When moving with a fork lift, do not
remove the shipping packaging until the
device is in its final location.
Failure to follow this instruction may
result in personal injury or equipment
damage.
Warning
Indicates a hazardous situation that, if not
avoided, could result in death or serious
injury.

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ZENITH ZTG(D/CT) T-SERIES 1600-3000 A
—
Read these safety instructions
carefully before using this product!
HAZARD OF ELECTRIC SHOCK,
EXPLOSION, OR ARC FLASH
• Apply appropriate personal protective
equipment and follow safe electrical
work practices.
• This equipment must only be installed
and serviced by qualified electrical per-
sonnel.
• Before performing visual inspections,
tests, or maintenance on the equip-
ment, disconnect all sources of electric
power. Assume that all circuits are live
unless they are completely de-ener-
gized, tested, grounded, and tagged.
Pay particular attention to the design of
the power system. Consider all sources
of power, including the possibility of
backfeeding.
• Disconnect all sources of electric power
before removing or making source side
or load side connections to the transfer
switch.
• Always use a properly rated voltage
sensing device at all line and load con-
nections to confirm transfer switch is
disconnected from all live electrical
sources.
• Turn off power supplying transfer
switch before doing any other work on
or inside switch.
Failure to follow these instructions could
result in death or serious injury.
Danger
Indicates a hazardous situation that,
if not avoided, will result in death or
serious injury.

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OPERATION, MAINTENANCE, AND INSTALLATION GUIDE
2
—
Operation, maintenance,
and installation
instruction
Automatic transfer
switches, Zenith
ZTG T-series ATS
INSTALLATION INSTRUCTIONS,
ZENITH ZTG T-SERIES ATS,
CHAPTERS 9–11
OPERATION AND MAINTENANCE
INSTRUCTIONS, ZENITH
ZTG T-SERIES ATS,
CHAPTERS 1–8

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ZENITH ZTG(D/CT) T-SERIES 1600-3000 A

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OPERATION, MAINTENANCE, AND INSTALLATION GUIDE
—
Operation and
maintenance instruction
Automatic transfer
switches, Zenith
ZTG T-series ATS
1. Introduction 11
1.1 Hazard Categories 11
1.2 Definitions 12
1.3 Warranty 13
1.4 Product Specification 14
2. Product overview 15
2.1 General overview 16
2.1.1 Operation types 18
2.2 HMI 19
2.3 LED functionally in HMI 20
2.4 Zenith ZTG (D/CT)T-series features 22
2.5 Typical applications 25
2.6 Sequence of operations 27
2.6.1 Switching sequence / Automatic
(open / delayed transition) 27
2.6.2 Switching sequence / Automatic
(open / delayed transition) 33
2.7 Special features description 37

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ZENITH ZTG(D/CT) T-SERIES 1600-3000 A
3. General operation 39
3.1 Position indication 39
3.1.1 Position indication - R5 39
3.2 Operating of automatic Transfer Switch
Equipment 40
3.2.1 Operation of Automatic Transfer
Switch equipment -R5 41
4. Navigating HMI menu 43
4.1 Start Menu 43
4.1.1 Start screens 45
4.1.2 Enter-key, main menu
4.1.3 Esc key 59
5. Electronic accessories 61
5.1 Using Ekip Connect -software 62
5.2 Using Ekip Programming -module 63
5.2.1 LED indications 63
5.3 Auxiliary power supply module 64
5.3.1 Electrical characteristics 64
5.3.2 LED indications 64
5.4 Using Ekip Signalling 2K-_ -module 65
5.4.1 Electrical characteristics of Ekip
Signalling 2K-_ -module 65
5.4.2 Access from the display / Ekip
Signalling 2K-_ -module 65
5.4.3 LED indications and inputs/outputs
of Ekip Signalling 2K-_ -module 69
5.5 Using Ekip Com _ -modules 70
5.5.1 Ekip Com Modbus RTU -module 70
5.5.2 Ekip Com Profibus DP -module 73
5.5.3 Ekip Com DeviceNet -module 76
5.5.4 Ekip Com Modbus TCP -module 80
5.5.5 Ekip Com Profinet -module 84
5.5.6 Ekip Com EtherNet/IP -module 87

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OPERATION, MAINTENANCE, AND INSTALLATION GUIDE
6. Troubleshooting 91
6.1 Alarms 91
6.2 Warnings 93
6.3 Information 94
7. Technical data 95
7.1 General technical data 95
7.2 Circuit diagrams 98
7.3 Overall dimensions 102
8. Maintenance 103
9. Panel installation 105
9.1 Basic Tools for Installation
and Maintenance 106
9.2 Equipment Inspection and Storage 106
9.3 Lifting and mounting the panel 107
9.4 Mounting the automatic transfer switch 110
9.4.1 Mounting hole dimensions 110
9.4.2 Mounting hole dimensions
(stand-alone ATS, no enclosure) 111
9.4.3 HMI Installation 113
9.5 Wire Connection 114
9.6 Final Equipment Inspection 115
10. Accessories 117
10.1 Auxiliary power supply and Ekip -modules 117
10.2 HMI protective cover 119
11. Replacement parts 119

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ZENITH ZTG(D/CT) T-SERIES 1600-3000 A

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OPERATION, MAINTENANCE, AND INSTALLATION GUIDE
—
1. Introduction
This manual describes the installation,
basic operation, and maintenance
of the Zenith ZTG(D/CT) T-series
1600-3000 A, 208-480 Vac automatic
transfer switches, manufactured by ABB.
Installation instructions for the transfer
switch and available accessories can be
found in Chapters 9 and 10.
—
1.1 Hazard Categories
The following important highlighted
information appears throughout this
document 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.
Warning
Indicates a hazardous situation that, if not
avoided, could result in death or serious
injury.
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.

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ZENITH ZTG(D/CT) T-SERIES 1600-3000 A
—
1.2 Definitions
ATS
Automatic transfer switches
Ekip
Electronic accessories / Ekip-modules;
communication, signaling and
connectivity modules
HMI
Control interface (Human Machine
Interface), operating and configuration
Programming port
Only for Ekip Programming and Ekip
Bluetooth -modules (USB port)
S1
SOURCE 1, power supply
S2
SOURCE 2, power supply
Zenith ZTG T-series ATS
Business, Industrial and Mission critical
enclosed automatic transfer switches,
product name
Load Shed
Digital output function for signaling a
downstream load to disconnect. This
functionality is different than the legacy
Zenith R15 Load Shed which is an input for
the ATS to disconnect generator when
signaled.

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OPERATION, MAINTENANCE, AND INSTALLATION GUIDE
—
1.3 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
variations in hardware and software,
nor does it provide for every possible
contingency in connection with
installation, operation, and maintenance.
Features may be described herein that are
not present in all hardware and software
systems.
ABB Zenith assumes no obligation of
notice to holders of this document with
respect to changes subsequently made.
ABB Zenith makes no representation or
warranty, expressed, implied, or
statutory, and assumes no responsibility
for the accuracy, completeness,
sufficiency, or usefulness of the
information contained herein. No
warrantees of merchantability or fitness
for purpose shall apply.
Contact your local sales office if further
information is required concerning any
aspect of the automatic transfer switch
operation or maintenance.
Warranty Period
The Warranty Period for ZTG T-series
transfer switch products is twenty-four
(24) months from the date of
shipment.
Notes: This warranty is valid only in the
United States and for products sold and
installed within seller-specified countries.
Replacement parts are warranted for a
period of 90 days when installed by a
factory or an authorized service station.
Contact Service team at: [phone]
or [e-mail] for 24-hour
support.

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ZENITH ZTG(D/CT) T-SERIES 1600-3000 A
—
1.4 Product Specification
Quality Assurance
All ABB Zenith automatic transfer
switches have been designed and
manufactured to the highest technical
standards. Strict procedures ensure first-
class product quality.
Product Serial Number
Please have the serial number available
when communicating about the
automatic transfer switch. The serial
number can be found on the product
nameplate affixed to each power panel
assembly. See example below.
Product Rating / Applicable Standards
For UL 1008 ‘withstand’ and ‘close on
short circuit’ ratings, refer to ABB
publication number 1SCC303020C0201.
Fig. 1 Sample nameplate
 ZENITH ZTG
AUTOMATIC TRANSFER SWITCH FOR USE IN EMERGENCY SYSTEMS
Serial number US1150191900001
Model number ZGAD300PS3M8XPXTXX
Voltage
Rated current
Frequency
Phase
Transition type
460 - 480 Vac
3000 A
50/60 Hz
3 Phase
Delayed

The available operation types for automatic transfer
switches:
• Open (standard) transition Zenith ZTG T-series ATS,
type codes beginning ZGAO_from 1600-3000 A,
208-480 Vac
• Delayed transition Zenith ZTGD T-series ATS,
type codes beginning ZGAD_ from 1600-3000 A,
208-480 Vac
• Closed transition Zenith ZTGCT T-series ATS,
type codes beginning ZSGC_from 1600-3000 A,
208-480 Vac
—
2. Product overview
Zenith ZTG T-series automatic transfer switches, from
1600 A up to 3000 A, are designed for use in Business,
Industrial and Mission critical low voltage automatic
transfer switch applications. Zenith ZTG T-series automatic
transfer switches can be operated electrically by control
interface (HMI) or manually by using the handle.
Configuration is done by LCD HMI.

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ZENITH ZTG(D/CT) T-SERIES 1600-3000 A
—
2.1 General overview
C – Controller
C – 1 Rating plug
C – 2 Source 1
C – 3 Source 2
C – 4 EKIP ACCESS
Communications Module
C-1 C-2
C-3
C-4
A
Programming Port
- only for Ekip Programming and
Ekip Connect Software
A. Level 3 HMI
B. Automatic transfer switch (ATS)
C. ATS control unit
D. Handle for manual operation
E. Engine start terminal blocks
F. Document holder (R5 only)
F
B
D
C
E

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OPERATION, MAINTENANCE, AND INSTALLATION GUIDE
Standard Transition Shown
B-ATS - R5
1. Customer Auxliary contact connection points
2. SCR Assemblies
3. Customer manual operating ports
4. Transfer Coil Solenoids
5. Arc Chute Assemblies (Arc Quenching assemblies)
6. Movable Contact Assemblies
7. Position Limit Switches Auxiliary Contact Limit Switches
8. Mechanical Drive Assembly -mechanical interlock system
Source position status
I = contacts closed
O = contacts open
3
Covers Removed
8
4
7
5
1
6
2

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ZENITH ZTG(D/CT) T-SERIES 1600-3000 A
Operation types, ZTG T-series ATS Ekip-modules suitable
Delayed transition, ZTGD
Closed transition, ZTGCT Open transition, ZTG
ZTG T-series HMI (with LCD screen) and connections of control circuit
Suitable
—
Table 2.1 The differences of level types / operation types and the suitability of Ekip-modules
2.1.1 Operation types
In this table you can find the differences
of the automatic transfer switch open and
delayed transition operation types. Due
to the different transition types, there are
variances with HMI and on wiring of I/O
contacts. For more information on HMIs,
see Chapter 2.2.
IS1 S2
Load
OII II S1 S2
Load
I
l
ON
ll
ON
Auto
Alarm reset
AUTO
!
S1 S2
LOAD
lll
O
O
OFF
Esc
l
ON
ll
ON
Auto
Alarm reset
AUTO
!
S1 S2
LOAD
lll
Esc

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OPERATION, MAINTENANCE, AND INSTALLATION GUIDE
The HMI is the control interface
(Human Machine Interface) of the ATS.
Zenith ZTG T-series has a LCD HMI with
push buttons. The HMI is used for
configuring parameters for automatic
operation.
—
2.2 HMI
I - O - II (or II - O - I)
ZTG:
HMI with
LCD screen
—
Fig. 2.1 The HMI form will correspond to the type of
ZTG T-series - open, delayed, or closed transition
l
ON
ll
ON
Auto
Alarm reset
AUTO
!
S1 S2
LOAD
lll
O
O
OFF
Esc
l
ON
ll
ON
AUTO
!
S1 S2
LOAD
lll
O
O
OFF

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ZENITH ZTG(D/CT) T-SERIES 1600-3000 A
LED Indication Description
Power led
Lamp
test
l
Off
load
test
ll
Auto
Alarm reset
On
load
test
Bypass
time
delay
Generator
stop delay
4 min
30 s
ΔU 10% / Δf 5%
ΔU 15% / Δf 10%
ΔU 20% / Δf 10%
0
1
2
3
4
5
10
15
20
30
S1 Failure
delay [s] S1 Return delay [min]
Manual
retransfer
On
Priority
No priority
In-phase
monitor
On
AUTO
!
S1 S2
LOAD
lll
O
ON, fixed light Power supply and communication present
 Power supply present, communication
absent between switch and the HMI
OFF No power available for HMI.
S1 and S2 leds
Off
load
test
ll
ON
Auto
Alarm reset
On
load
test
Bypass
time
delay
4 min
30 s
4
5
10
15
20
30
S1 Return
delay [min]
4 s
0 s
O
OFF
Manual
retransfer
Auto
config
Priority
In-phase
monitor
AUTO
!
LOAD
lll
O
S1 S2
ON, fixed light 
defined limits
 Undervoltage
 
 Unbalance
 Overvoltage
 
 Phase missing
 Generator stop delay ongoing
OFF No voltage
—
2.3 LED functionality in HMI
—
Fig. 2.2 On left: LEDs in OXB_, delayed transition, I - O - II. On right: LEDs in OXA_, open transition I - II.
I - O - II I - II
Manual
retransfer
Auto
config
Priority
In-phase
monitor
AUTO
!
S1 S2
LOAD
lll
O
Lamp
test
l
ON
Off
load
test
ll
ON
Auto
Alarm reset
On
load
test
Bypass
time
delay
Generator
stop delay
4 min
30 s
ΔU 20% / Δf 10%
0
1
2
3
4
5
10
15
20
30
S1 Failure
delay [s] S1 Return delay [min]
O Position
delay
4 s
0 s
O
OFF
Manual
retransfer
Auto
config
Priority
In-phase
monitor
AUTO
!
S1 S2
LOAD
lll
LED functionality is common to every HMI-type.