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
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.
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.
—
Receiving, handling and storag
Read these safety instructions
carefully before using this produce
Warning
Indicates a hazardous situation that, if not
avoided, 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
—
Operation and
maintenance instruction
Automatic transfer
switches, Zenith
ZTG T-series ATS
1. Introduction 6
1.1 Hazard Categories 6
1.2 Warranty 7
2. Product overview 8
2.1 General overview 8
2.2 LED functionally in HMI 10
2.3 Zenith ZTG (D/CT)T-series features 12
2.4 Operation 15
3. General operation 18
3.1 Position indication 18
3.1.1 Position indication - R5 18
3.2 Operating of automatic Transfer Switch
Equipment 19
3.2.1 Operation of Automatic Transfer
Switch equipment -R5 20
4. Navigating HMI menu 21
4.1 Start Menu 21
4.1.1 Start screens 23
4.1.2 Enter key, main menu 24
4.1.3 Esc key 37

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OPERATION, MAINTENANCE, AND INSTALLATION GUIDE
5. Electronic accessories 38
6. Troubleshooting 39
6.1 Alarms 39
6.2 Warnings 41
6.3 Information 42
7. Technical data 43
7.1 General technical data 43
7.2 Circuit diagrams 46
8. Maintenance 49
9. Panel installation 50
9.1 Basic Tools for Installation
and Maintenance 51
9.2 Equipment Inspection and Storage 51
9.3 Lifting and mounting the panel 52
9.4 Mounting the automatic transfer switch 55
9.4.1 Mounting hole dimensions 55
9.4.2 Mounting hole dimensions
(stand-alone ATS, no enclosure) 56
9.5 Wire Connection 57
9.6 Final Equipment Inspection 58
9.7 Initial power supply and Ekip-modules 59
10. Accessories 60
10.1 Auxiliary power supply and Ekip -modules 60
11. Replacement parts 62

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ZENITH ZTG(D/CT) T-SERIES 1600-3000 A
—
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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OPERATION, MAINTENANCE, AND INSTALLATION GUIDE
—
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
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.
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

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ZENITH ZTG(D/CT) T-SERIES 1600-3000 A
—
2 Product overview
—
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
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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OPERATION, MAINTENANCE, AND INSTALLATION GUIDE
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 1 The differences of level types / operation types and the suitability of Ekip-modules
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.
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
HMI
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.

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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
 Invalid frequency
 Unbalance
 Overvoltage
 Incorrect phase sequence
 Phase missing
 Generator stop delay ongoing
OFF No voltage
—
2.2 LED functionality in HMI
—
Fig, 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.

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OPERATION, MAINTENANCE, AND INSTALLATION GUIDE
I, II and 0 leds
Lamp
test
l
ON
Off
load
test
ll
ON
Auto
Alarm reset
On
load
test
Bypass
time
delay
O
OFF
Manual
retransfer
Auto
config
Priority
In-phase
monitor
AUTO
!
S1 S2
LOAD
ll
O
l
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
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
ll
O
l
Lamp
test
l
ON
Off
load
test
ll
ON
Auto
Alarm reset
On
load
test
Bypass
time
delay
4 min
30 s
0
1
2
3
4
5
10
15
20
30
S1 Failure
delay [s] S1 Return delay [min]
4 s
0 s
O
OFF
Manual
retransfer
On
Priority
No priority
In-phase
monitor
On
AUTO
!
S1 S2
LOAD
ll
O
l
ON, fixed light Switch position is indicated with fixed
light in I, O or II led. Only one can be
illuminated
 Indicating running time delay
Load led
ON
Off
load
test
ll
ON
Auto
Alarm reset
On
load
test
Bypass
time
delay
Generator
stop delay
4 min
30 s
4
5
10
15
20
30
S1 Return
delay [min]
O Position
delay
4 s
0 s
O
OFF
Dropout ΔU / Δf
Manual
retransfer
ΔU 5% / Δf 5%
On
Off
Priority
No priority
Source 1
In-phase
monitor
Off
On
AUTO
!
S1 S2
lll
O
LOAD
ON Supply ok and connected to load
OFF Connected supply to load not ok or load
disconnected (switch in O position)
Auto led
ON, fixed light Switch is in automatic mode
 Test on load
 Test off load
 If blinks simultaneously with Alarm led


'Inhibit transfer' digital input is activated.
 Autoconfig completed
Alarm led
ON
Off
load
test
ll
ON
Auto
Alarm reset
On
load
test
Bypass
time
delay
4 min
515 30 4 s
O
OFF
Manual
retransfer
On
Off
Priority
No priority
Source 1
AUTO
S2
!
OFF No alarms
ON, fixed light Handle attached, locked, other alarm
 Control Alarm
 Auto configuration ongoing
 Control Retry
 Auto mode off
 If blinks simultaneously with Alarm led


'Inhibit transfer' digital input is activated.
If Auto led is fixed light then manual
retransfer is required.
—
Table 2 LED functionality, common to every HMI-type
ll
ON
Auto
Alarm reset
Bypass
time
delay
!
S2
AUTO

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ZENITH ZTG(D/CT) T-SERIES 1600-3000 A
—
2.3 Zenith ZTG (D/CT) T-series features
Feature comparison ZTG(D/CT) (LCD screen) controls
Ampere sizes available 
Rated voltage 
Rated frequency 
Phase system Single and Three
Number of poles 
Neutral configuration
Switched Yes
Product type
Open transition (I - II) Yes
Delayed transition (I - O - II or II - O - I) Yes
Closed transition (I - O - II or II - O - I) Yes
Voltage and frequency settings
 
 
 
 
 
 
 
 
Time delay settings
 
 
 
  

13
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OPERATION, MAINTENANCE, AND INSTALLATION GUIDE
Feature comparison ZTG(D/CT) (LCD screen) controls
Generator stop delay, min 
Center-OFF delay, sec 
 
 
 
 
 
 
 
 
Load shed delay, sec 
Source failure detections
No voltage Yes
Undervoltage Yes
Overvoltage Yes
Phase missing Yes
Voltage unbalance Yes
Invalid frequency Yes
Incorrect phase sequence Yes
Features
Controls Touch + keys
 Yes
Open transition - Standard digital inputs/outputs 
Delayed transition - Standard digital inputs/
outputs

Programmable digital inputs/outputs Yes
Auto config (voltage, frequency, phase system) Yes
Auto config (voltage frequency, phase system) Yes

14
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ZENITH ZTG(D/CT) T-SERIES 1600-3000 A
Feature comparison ZTG(D/CT) (LCD screen) controls
Source priority 
Manual re-transfer Yes
In-phase monitor Yes
Genset exercising: on-load, off-load Yes
In-built power meter module Yes
Load shedding Yes
Real time clock Yes
Event log Yes
Predictive maintenance Yes
Harmonics measuring Voltage, current
Field-mount accessories
Auxiliary contacts for position indication Yes
Digital input/output modules Yes
 Yes
Communication modules Yes
Connectivity
 Yes
Modbus/TCP Yes
Profibus DP Yes
ProfiNet Yes
DeviceNet Yes
Ethernet IP Yes
Ekip Com Hub (monitoring via ABB Ability™: EDCS) Yes
Enclosures
 Yes
For applications
Mains - Mains Yes
Mains - Generator Yes
Contact ABB for applications with smaller than 20 KVA gensets.
—
Table 3 ATS features not limited to what is in the table above

15
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OPERATION, MAINTENANCE, AND INSTALLATION GUIDE
The switching sequence can be summarized in the following steps:
1. An anomaly occurs on SOURCE 1
2. Override momentary S1 outage delay
3. Generator start
4. SOURCE 2 OK
5. Transfer from S1 to S2 delay
6. Pre-transfer signal on
7. Load shed signal on
8. Pre-transfer S1 to S2 delay
9. Load shed delay
10. Transfer switch (SOURCE 1) to position O
11. Center-off delay (only with Delayed transition I - O - II type)
12. Transfer switch (SOURCE 2) to position II
13. Post-transfer S1 to S2 delay
14. Pre-transfer signal off
The re-transfer sequency can be summarized in the following steps:
1. SOURCE 1 is restored
2. Transfer from S2 to S1 delay
3. Pre-transfer signal on
4. Pre-transfer S2 to S1 delay
5. Transfer switch (SOURCE 2) to position O
6. Center-off delay (only with Delayed transition I - O - II type)
7. Transfer switch (SOURCE 1) to position I
8. Load shed signal off
9. Generator stop delay
10. Post-transfer S2 to S1 delay
11. Pre-transfer signal off
12. Generator stop
13. SOURCE 2 off
—
2.4 Operation
Switching sequence / Automatic
Open / Delayed transition

16
1
ZENITH ZTG(D/CT) T-SERIES 1600-3000 A
SOURCE 2 Priority (No generator)
The switching sequence can be summarized in the following steps:
1. An anomaly occurs on SOURCE 2
2. Override momentary S2 outage delay
3. Transfer from S2 to S1 delay
4. Pre-transfer signal on
5. Load shed signal on
6. Pre-transfer S2 to S1 delay
7. Load shed delay
8. Transfer switch (SOURCE 2) to position O
9. Center-off delay (only with Delayed transition I - O - II type)
10. Transfer switch (SOURCE 1) to position I
11. Post-transfer S2 to S1 delay
12. Pre-transfer signal off
And the re-transfer sequence can be summarized in the following steps:
1. SOURCE 2 is restored
2. Transfer from S1 to S2 delay
3. Pre-transfer signal on
4. Pre-transfer S1 to S2 delay
5. Transfer switch (SOURCE 1) to position O
6. Center-off delay (only with Delayed transition I - O - II type)
7. Transfer switch (SOURCE 2) to position I
8. Load shed signal off
9. Post-transfer S1 to S2 delay
10. Pre-transfer signal off

17
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OPERATION, MAINTENANCE, AND INSTALLATION GUIDE
Closed Transition
SOURCE 1 Priority (SOURCE 2 = Generator)
The switching sequence can be summarized in the following steps:
1. Activate test on load (HMI or digital input)
2. Generator start
3. Run engine warm-up timer
4. Pre-transfer S1 to S2 delay
5. Check source synchronization
6. Close SOURCE 2 contacts
7. Open SOURCE 1 contacts, start ETT timer (parallel mode)
8. Post-transfer S1 to S2 delay
The re-transfer sequence can be summa¬rized in the following steps:
1. Cancel test on load (HMI or digital input)
2. SOURCE 1 availability timer
3. Pre-transfer S2 to S1 delay
4. Check source synchronization
5. Close SOURCE 1 contacts
6. Open SOURCE 2 contacts, start ETT timer (parallel mode)
7. Post-transfer S2 to S1 delay
8. Run engine cool down timer
9. Generator stop

18
1
ZENITH ZTG(D/CT) T-SERIES 1600-3000 A
—
3.1 Position indication
3.1.1 Position Indication - R5
—
3 Operation of Automatic
Transfer Switch Equipment
—
Fig. 3 View of Automatic Transfer Switch (Standalone) Panel Highlighting Customer Points of Interest.
Applicable for Standard, Delay, and Close Transition Type Automatic Transfer Switch Euipment.
Source Indication with
manual operating
direction of handle for
respective source.
Contact position status



19
1
OPERATION, MAINTENANCE, AND INSTALLATION GUIDE
—
3.2 Operation of Automatic Transfer Switch Equipment
Danger
Hazardous Voltage May Cause Severe Injury or
Death
Manual opening and closing of the contacts
shall only be performed with no power
available.
Failure to comply with these instructions may
result in death or serious injury.
Warning
Improper Installation Operation and
Maintenance
Ensure only quali_ed personnel install, operate,
service and maintain all electrical equipment.
DISCONNECT all power sources prior to instal-
lation, operation, service, and maintenance of
all electrical equipment. These activities shall
be performed only by certifed ABB Zenith tech-
nicians or qualifed electricians. Only use the
charging handle to perform manual operation
of the transfer switch. No motorized device
shall be used as a substitute.
Failure to comply with these instructions may
result in death or serious injury.
NOTE: Prior to operating the ATS in manual
mode, the HMI settings must be changed from
Automatic transfer mode to Manual transfer
mode (see Section 4.3).
• See Section 3.2.1 for R5 ATS manual
operation procedure

20
1
ZENITH ZTG(D/CT) T-SERIES 1600-3000 A
—
Fig. 4 Operating Handle Inserted for Manual Operation.
4. Rotate handle with two hands, in the
direction as shown on the markings, to
achieve the proper contact state (Fig. 5).
3.2.1 Operation of Automatic Transfer Switch Equipment - R5
—
Fig. 5 Source Ha1- Souce 2 Direction of Handle Rotation
for Contact Closure


Stand-alone ABB Zenith automatic trans-
fer switches are not designed to be oper-
ated manually under load. In the event the
automatic transfer switch has to be oper-
ated manually, with no power available,
please follow these steps:
1. Verify all voltage input sources to the
automatic transfer switch have been re-
moved with proper LOTO procedures
followed. Consider stored energy sources
as well.
2. Verify all load connections have been
removed with proper LOTO procedures
followed. Consider stored energy for
load equipment as well.
3. Insert the manual handle into the de-
sired port of the automatic transfer
switch (Fig. 5).
5. Verify that the rotation of the handle
has come to full rest with markings
clearly visible in the status window.
Be sure to rotate the handle until no
further travel is permissible, but DO NOT
over-rotate. Over-rotation of handle may
lead to equipment damage. Remove the
manual operating handle and return it to
the proper storage location before
conducting any electrical transfers.
6. To return to Automatic transfer mode,
return both source contacts to Open po-
sition and return the HMI Transfer Set-
tings to Automatic transfer mode (see
Section 4.3).