ABB Zenith ZT30 User manual

—

OPERATION AND MAINTENANCE MANUAL

Zenith ZT30 and ZB30

Short-time rated ATS and

Bypass Isolation ATS

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Table of Contents

Section 1: General Information ....................................... 4

...................................... 5

Section 3: Lifting, Mounting and Installation ATS & Bypass............... 6

Unpacking the ATS............................................ . 6

Lifting and Mounting Guidance ................................ . 7

Tools Needed for Installation and Maintenance ................. . 9

Power Cable Connection ...................................... . 9

Section 4: Standalone ATS Operations ................................ 10

Sequence of Operations – Manual Mode ....................... . 12

Sequence of Operations – Automatic Mode .................... . 13

Section 5: Bypass Isolation ATS Operations ........................... 18

Sequence of Operations – Manual Mode – Isolation ............. . 21

ATS Sequence of Operations – Manual Mode ................... . 21

Bypass ATS Sequence of Operations – Racking Operations....... . 22

Sequence of Operation – Automatic mode - Isolation ATS........ . 25

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Section 6.0: Entelli-Switch 250 Controller ............................. 28

Section 6.1: Entelli-Switch 350 Controller ............................. 44

Section 7: Accessories Description ................................... 56

List of Major Accessory Items................................. . 56

Table T7-1: Troubleshooting and Diagnostics................... . 57

Table T7-2: Replacement Parts List ............................ . 59

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Hazard Categories

The following important highlighted information appears

throughout this document to warn of potential hazards or

Carefully read all instructions andbecome familiar

with the devices before trying to install, operate,

service or maintain this equipment.

Indicates a hazardous situation which, if not

avoided, will result indeath or serious injury.

Indicates a hazardous situation which, if not

avoided, could result indeath or serious injury.

Failure to comply with these instructions

may result in product damage.

Indicatesimportant information that must be

remembered and aidsinjob performance.

NOTICE

WARNING

Warranty

This document is based on information available at the

time of

to ensure accuracy, the information contained herein

does not cover all details or variations in hardware

andsoftware, nordoes it provide for every possible

contingency in connection with installation, operation,

andmaintenance. Features may be described herein that

are notpresent in all hardware and software systems.

ABB Zenith Controls assumes no obligation of notice to holders

of this document with respect to changes subsequently made.

ABB Zenith Controls makes no representation or warranty,

expressed, implied, or statutory, with respect to, andassumes

usefulness of the information contained herein. No warrantees

is required concerning any aspect of the Automatic

Transfer Switch operation or maintenance.

Section 1: General Information

Warranty Period:

The Warranty Period for ZTE, ZTS, ZTG, and ZT30

Series transfer switch Products is twenty-four (24)

months from the date of shipment.

Notes: This warranty is valid only in theUnited States and for

Replacement parts are warranted for a period of ninety

(90) days when installed by an authorized seller factory or

authorized sellerservice station.

WARNING

CAUTION

NOTICE

DANGER

5ZenithAutomatic Transfer Switch| new.abb.com/low-voltage

Quality Assurance

All ABB Zenith Automatic Transfer Switches (Standalone

and Bypass Isolation) have been designed and

manufactured to the highest technical standards. Strict

Product Serial Number

Please have the serial number available when

communicating about the Automatic Transfer Switch.

Each Automatic Transfer Switch has a unique serial

number located on the fascia (Refer to Figure S4-2).

Measurement Units

Product Rating

For UL 1008 withstand and close on short circuit rating refer to

ABB Publication Number TB1102.

Product Ratings will be available on the Rating Label applied on

the Product.

Production Description

ABB Zenith Automatic Transfer Switch is suitable for application

on power systems up to 600 VAC 50/60 Hz systems.

Storage

Do notstore Automatic Transfer Switch in corrosive

environments above LC1 (sea salt mist) andG1 as per

ANSI/ISA-S71.04-1985. Failure to comply with these

instructions may result in product damage. Store

Automatic Transfer Switch and related accessories in

a clean, dry location in their original packaging.

Notice :

Final inspection of the equipment should beperformed prior

to energizing the automatic transfer switch as below.

1. Remove anydirt or debris that may have collected during

shipment or installation. NEVER usehigh pressure blowing

air. This could drive dirt orother foreign objects into

electrical or mechanical components which could cause

damage. Use an industrial quality vacuum cleaner to remove

anydirt or foreign objects.

2. Be certain all cable connections are correct and that the

phase rotation of both sources match.

3. Inspect the engine start connections and verify the correct

connectionof all control wires.

4. Check all programmable setpoints and adjust as necessary.

In addition, adjust anyoptional accessories as required.

5. Be certain that the actual lug torque values are in keeping

with the requirements outlined in the instruction book to

insure the integrity of power connections.

6. Check to be sure that all covers and barriers are properly

installed and fastened.

7. If any damage is found or suspected, le a claim as soon

as possible with the carrier & notify thenearest ABB Zenith

representative orcall 1-800-637-1738 option 3.

6Zenith Automatic Transfer Switch| new.abb.com/low-voltage

service and maintain all electrical equipment.

Failure to comply with these instructions

could result indeath or serious injury.

Improper Installation,

Operation andMaintenance CHARACTERISTIC PARAMETER

Operating Temperature -20 ºC to 65 ºC

Storage Temperature -30 ºC to 75 ºC

Relative Humidity 5% to 95% Non-Condensing

Altitude < 2000m

Table T2-1: Environmental conditions

Temperature

STANDARD DESCRIPTION (S) AND NUMBER(S) TITLE

UL 1008 (1000A-3000A Open Style & Enclosed)Standard for Safety - Transfer Switch Equipment

Seismic (1000A-3000A) IBC-2006 & IEEE 693-2005 andOSHPD

IEC 60947-6-1 (2600A-4000A Open Style only) Standard for Transfer Switching Equipment

GB/T 14048.11 (2600A -4000A Open Style only) Standard for Transfer Switching Equipment

Section 3:Lifting, Mounting and Installation

Unpacking the ATS

The safe operation of your switch at all times isABB Zenith focus. Itmust be recognized that hazardous

voltages and currents can exist during normal operation and any maintenance on the transfer switch must

be performed utilizing appropriate safety measures. Installation,adjustment, maintenance or removal of the

Prior to installation store the transfer switch in a clean dry location, protected from dirt & water. Provideampleair circulation

&heat if necessary to prevent condensation. See table T2-1 for recommended storage & ambient operating temperatures.

ABB ZenithAutomatic transfer switches are packaged as per the standard packaging regulatory standards

requirement suitable for domestic and internationalshipment through all modes of transportation

(Air, Sea & Road). Once you unpack the units please make sure that all the components are received

as per the BOM. For any missing items contact your local ABB Zenith service representative.

CAUTION

NOTICE

WARNING

Turn OFF all power before installation, adjustment or

removal of transfer switchor any of its components.

Hazardous Volatge Can Cause

Severe Injury Or Death

WARNING

DANGER

7ZenithAutomatic Transfer Switch| new.abb.com/low-voltage

Due to hazardous voltages and currents, ABB recommends

that an ABB Certified technician or a qualified electrician

perform the installation& maintenance of the switch

Lifting Guidelinesfor Enclosed

ATS/Bypass Isolation ATS

1. ABB Zenith ATS are mounted onto a wooden pallet using the

bolts & nuts. Please remove the bolts & nuts prior to lifting

2. ABB Zenith ATS enclosures have the provisions for lifting

through the standard overhead lifting devices

3. Position the lifting device across the top of the enclosure.

Engage the lifting hooks and adjust lifting positions such

that thehooks are out

4. Refer to the dimensional drawing for the center of gravity

(denoted as CG), weight information & lifting provision to

select the properly rated lifting devices

5. While lifting the units through the lifting chains it is

recommended to maintain 30 degree angleas shown in

gure S3-2

6. Refer gure S3-1 for lifting provisions on the enclosure top

7. ABB Zenith ATS & Isolation Bypass units should be lifted using

properly rated lifting devices

Before drilling conduit entry holes or anyaccessory

mounting holes, cover and protect the switch and

control panel to prevent dirt and metal fragments from

entering the mechanical and electrical components

of the switch. Failure to do somay result in damage

and malfunctionof the switch and void the warranty.

Lifting Guidelinesfor Open Style

ATS/ Bypass Isolation ATS

1. ABB Zenith Open style ATS/Isolation Bypass units are

mountedonto a wooden pallet using required brackets

2. Electrical Panel & Auxiliary Panels are mounted using

separate brackets on to the wooden pallet

3. Controller & other electronic components are mounted

inside a separate cardboard box on the wooden pallet.

4. ABB Zenith ATS enclosures have the provisions for lifting

through the standard overhead lifting devices

5. Position the lifting device across the top of the units as

shown in gure S3-1 Engage the lifting hooks and adjust

lifting positions such that the hooks are out

6. Refer the dimensional drawing for the CG, weight

information&lifting provision to select the properly rated

lifting devices

7. While lifting the units through the lifting chains it is

recommended to maintain min 30 degree angle as shown in

gure S3-2

8. ABB Zenith ATS & Isolation Bypass units should be lifted using

properly rated lifting devices.

Lifting I Bolts

Min 30º angle

Figure S3-1 : ATS enclosed assembly

Figure S3-2: Lifting angle

Lifting Slots

Figure S3-3 : Isolation ATS assembly

WARNING

CAUTION

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ATS &Bypass Isolation

ATS Mounting:

1. Anchoring provisions are provided on all the ABB Zenith ATS &

Bypass Isolationenclosures.

2. For open style ATS & Bypass Isolation ATS mounting please

refer to the dimensional drawings shipped available on

ABB Critical Power Website http://www.geindustrial.com/

products/critical-power.

3. For open style units we recommend the doorcut out

pattern & other electrical controls mounting as shown in

the dimensional drawings. For any questions please contact

your local ABB Zenith Service Representative.

Lifting Provision for Open Style ATS (IEC/GB) Lifting Provision of Open Style ATS (1000A-3000A-UL)

Lower surface of the frame

members shall be used for lifting

Figure S3-3: Open style ATS Figure S3-4 : Open style ATS

Figure S3- 5: Open style Bypass Isolation ATS (1000A-4000A)

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Basic Tools Needed for Installation and Maintenance

TOOL NAME TASK(S)

17mm wrench or socket Mechanical orcompressionlug installation

1/2" socket Power cable connection

4mm and 5mm hex Inspection of contacts - Removal of top/bottom cover

Phillips screwdriver Removal and installation of Fascia

Inspection of ATS limit switches

Current transformers adjustments

CustomerI/O adjustment

19mm wrench or socket Mounting of Standalone ATS into enclosure

Table T3-1: Required hand tools for common installation and maintenance tasks

Table T3-1 provides a list of hand tools required to perform common installation,

operation and maintenance of the ZT30 Automatic Transfer Switch.

Torque values:

1) Power cable connectors: Refer to ATS Fascia (Front Cover)

2) All othercomponents: Consult factory

Power Cable Connection

AMPERAGE PART NUMBER WIRE RANGE

1000A-2000A 2600A-3000A

Mechanical lug S-3060 S-1529 #2 – 750 kcmil

Compression lug PS-8419 500 kcmil

Compression lug PS-8467 600 kcmil

Compression lug PS-8420 750 kcmil

Table T3-2: Listing ofmechanical and compression lug

AMPERAGE DRAWING NUMBER

1000A-2000A 2600A-3000A

Mechanical lug O-4106 O-4106

Compression lug O-4107 O-4107

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Power Cable Access Location

Power cablescan be accessed from the rear or side by removing panel screws carefully. While installing the units keep adequate

space in the sides& rear of the unit for ease of accessing the power cables. It is recommended not to stand on anyof the

components while accessing the power cables.

Section 4: Standalone ATS Product Operation

controller& enclosures. Refer the electrical schematic diagram provided for the electrical connections. Follow all the warning

& caution instructions before energizing the unit. Operate the switch manuallybefore making the electricalconnections.

Removable

Side and

Rear Covers

Removable

Side Covers

for Cable

and

Interlocking

Access

Removable Rear Covers for Cable Access

Options Panel

ATS Mechanical

Indicator Panel

MX Controller HMI

Control Switch

Options Panel

Access Panel

Electrical Panel

Fiscia

Options Panel

(on request)

Figure S3-6 : Standalone ATS –NEMA1 Enclosure FrontIso view Figure S3-7 : Bypass Isolation ATS NEMA1 Enclosure Rear Iso view

Figure S4-1: Front viewof ATS (Standalone) in an enclosure (MX350 variant). Figure S4-2: Front view of ATS (Standalone) in an enclosure (MX350 variant).

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