ABB Zenith ZTX Series Operation, Maintenance, And Installation Manual Download Page 72

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ABB Zenith Controls, Inc.

305 Gregson Drive
Cary, NC 27511

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Summary of Contents for Zenith ZTX Series

Page 1: ...OPER ATION MAINTENANCE AND INSTALL ATION GUIDE Zenith ZTX series For ZTX series automatic transfer switches 30 1200 A 200 480 Vac ...

Page 2: ...2 ...

Page 3: ...ately 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 cir culation 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 lif...

Page 4: ...ompletely 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 conf...

Page 5: ...tenance and installation instruction Automatic transfer switches Zenith ZTX series ATS INSTALLATION INSTRUCTIONS ZENITH ZTX SERIES ATS CHAPTERS 9 11 OPERATION AND MAINTENANCE INSTRUCTIONS ZENITH ZTX SERIES ATS CHAPTERS 1 8 ...

Page 6: ...6 Zenith ZTX Series ATS OPER ATION MAINTENANCE AND INSTALL ATION GUIDE 1 ...

Page 7: ... 1 4 Product Specification 14 2 Product overview 15 2 1 General overview 16 2 1 1 Operation types 17 2 2 HMI 18 2 3 Zenith ZTX series features 19 2 4 Typical applications 22 2 5 Sequence of operations 24 2 5 1 Switching sequence Automatic 24 2 6 Special features description 26 2 6 1 Automatic configuration 26 2 6 2 In phase monitor 26 2 6 3 Powering supply scenarios 26 ...

Page 8: ...4 Return to automatic mode operating by HMI 30 3 5 LED functionality in HMI 31 3 6 Using Level 2 DIP control interface HMI 33 3 6 1 Keypad 33 4 Navigating HMI menu 35 4 1 Configuration by DIP switch 35 5 Electronic accessories 37 5 1 Using Ekip Connect software 38 5 2 Using Ekip Bluetooth module 39 5 2 1 LED indications 39 5 3 Using Ekip Programming module 40 5 3 1 LED indications 40 ...

Page 9: ...9 1 6 Troubleshooting 41 6 1 Alarms 41 6 2 Warnings 43 6 3 Information 44 7 Technical data 45 7 1 General technical data 45 7 2 Circuit diagrams 48 7 3 Overall dimensions 49 8 Maintenance 53 ...

Page 10: ...10 Zenith ZTX Series ATS OPER ATION MAINTENANCE AND INSTALL ATION GUIDE 1 ...

Page 11: ...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 tha...

Page 12: ...terface Human Machine Interface operating and configuration Programming port Only for Ekip Programming and Ekip Bluetooth modules USB port Slide switch Switch for operating mode selection Hand Locking AUTO S1 SOURCE 1 power supply S2 SOURCE 2 power supply Zenith ZTX series ATS Small frame residential commercial light industrial enclosed automatic transfer switches product name ...

Page 13: ...ation 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 Perio...

Page 14: ... 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 Zenith ATS Powered by TruONE TM Withstand and Closing Ratings WCR Figure 1 1 Sample nameplate ZENITH ZTX AUTOMATIC TRANSFER SWITCH FOR USE IN EMERG...

Page 15: ... transfer switches from 30 A up to 1200 A are designed for use in residential commercial light industrial low voltage automatic transfer switch applications Zenith ZTX series automatic transfer switches can be operated electrically by DIP control interface HMI or manually by using the handle You can select the operating mode by the slide switch Hand Locking AUTO on switch front Configuration is do...

Page 16: ...automatic transfer switch to prevent automatic and manual operation 6 Handle for manual operation 7 Position indication 8 Terminals for control circuit connections behind the cover 9 Place for auxiliary contact block 10 Location of product identification label 11 Programming port only for Ekip Programming module and Ekip Connect software Fig 2 1 Automatic transfer switch Zenith ZTX powered by True...

Page 17: ...ections of control circuit Lamp test l ON Off load test ll ON Auto Alarm reset On load test Bypass time delay Dropout U f Manual retransfer Generator stop delay 4 min 30 s U 5 f 5 U 10 f 5 U 15 f 10 U 20 f 10 0 1 2 3 4 5 10 15 20 30 S1 Failure delay s S1 Return delay min On Off Auto config Start Ok Priority No priority Source 1 In phase monitor Off On AUTO S1 S2 LOAD l ll Not Suitable O1 C C NO NC...

Page 18: ...ers for automatic operation 2 2 HMI I II or II I ZTX HMI with DIP switches Fig 2 2 HMI type Lamp test l ON Off load test ll ON Auto Alarm reset On load test Bypass time delay Dropout U f Manual retransfer Generator stop delay 4 min 30 s U 5 f 5 U 10 f 5 U 15 f 10 U 20 f 10 0 1 2 3 4 5 10 15 20 30 S1 Failure delay s S1 Return delay min On Off Auto config Start Ok Priority No priority Source 1 In ph...

Page 19: ... 4 Neutral configuration Switched Yes Product type Open transition I II Yes Voltage and frequency settings Pick up Voltage Source 1 Fixed 2 above drop out Drop out Voltage Source 1 5 10 15 20 Pick up Voltage Source 2 Fixed 2 above drop out Drop out Voltage Source 2 5 10 15 20 Pick up Frequency Source 1 Fixed 1 above drop out Drop out Frequency Source 1 5 10 Pick up Frequency Source 2 Fixed 1 above...

Page 20: ...OAD l ll 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 DIP keys LED indications for ATS S1 and S2 status Yes Open transition Standard digital inputs outputs 0 1 Programmable digital inputs outputs No Auto config voltage frequency phase system Yes Source priority ...

Page 21: ...fig Start Ok Priority No priority Source 1 In phase monitor Off On AUTO S1 S2 LOAD l ll Field mount accessories Auxiliary contacts for position indication Yes Digital input output modules No 12 24 Vdc aux supply module for controller No Communication modules No For applications Mains1 Mains Yes Mains Generator2 Yes 1 Mains may also be referred to as Utility or Transformer 2 Contact ABB for applica...

Page 22: ...to choose and to switch between two power sources See possible supply phase scenarios on next page You have to define your own supply phase system reference Chapter 4 Navigating menu Parameters Power distribution systems Factory setting 3 phases with neutral 2 4 Typical applications Source 1 Source 2 Load OX_ Source 1 Source 2 Load OX_ Fig 2 3 Typical applications of automatic transfer switches ...

Page 23: ...hase two wire Single phase three wire Three phase four wire Three phase three wire Three phase with high leg delta D E F 200 480 Vac L N 200 480 Vac L L 200 480 Vac L L A07482 Phase A Phase B High Leg Phase C 240 Vac 240 Vac 208 Vac 240 Vac 120 Vac 120 Vac Neutral Phase A D Phase B Neutral Phase A E D D Phase A Phase B Phase C F F F Phase A Neutral Phase C Phase B D D F D F F Fig 2 4 Possible supp...

Page 24: ...can be summarized in the following steps An anomaly occurs on SOURCE 1 Override momentary S1 outage delay Generator start SOURCE 2 OK Transfer from S1 to S2 delay Transfer switch SOURCE 2 to position II The re transfer sequence can be summarized in the following steps SOURCE 1 is restored Transfer from S2 to S1 delay Transfer switch SOURCE 1 to position I Generator stop delay Generator stop SOURCE...

Page 25: ...itch position II SOURCE 1 OK SOURCE 2 OK Generator started Override momentary S1 outage delay Transfer from S1 to S2 delay Override momentary S2 outage delay Transfer from S2 to S1 delay Table 2 3 Automatic Switching Sequences SOURCE 1 Priority SOURCE 2 Generator ...

Page 26: ...asures and detects when both sources are in sync with each other The ATS will allow transfer from SOURCE 1 S1 to SOURCE 2 S2 only when they are in sync with each other Any of these conditions will prevent source transfer when In phase monitor is set to On Phase difference between sources remains greater than 5 degrees Phase order between sources is not the same Voltage amplitude is out of range Ph...

Page 27: ...indication Contact movement and position indica tion is indicated in the figure below open transition I II or II I Fig 3 1 Contact movement position indication Type ZTX Open transition ZTX I II 3 General operation A07483 ...

Page 28: ...on not in use after which the slide switch will move to the Locking mode automatically and the switch is allowed to be padlocked To set the operating handle back to its place refer to the left most picture in Fig 3 6 AUTO position Automatic control mode enabled ATS is operable in Auto matic mode or from the HMI manual control keys When the slide switch is moved to the AUTO position the ATS is func...

Page 29: ...Hand lift the handle from its place inside and place it to the operating position More information see animation Manual and automatic operation TruONE ATS https youtu be bosvSPVi2sM 3 3 Manual handle operation Warning Verify the condition of power source prior to manually transferring Manual operation may result in out of phase transfer when both sources are energized ...

Page 30: ...ing handle must set back to standby slot before moving to the automatic mode 3 4 Return to Automatic mode operating by HMI When operating the automatic transfer switch by HMI turn the slide switch to Automatic mode AUTO Notice The handle has to be standby slot not in use before turning to automatic mode When the slide switch is moved to the AUTO position the ATS will enter auto mode after a 3 seco...

Page 31: ...ply present communication absent between switch and the HMI OFF nnnn No power available for HMI S1 and S2 leds f d st ll ON Auto Alarm reset On load test Bypass time delay 4 min 30 s 10 15 20 30 S1 Return delay min 4 s 0 s O OFF Manual retransfer Auto config Priority In phase monitor AUTO LOAD l ll S1 S2 ON fixed light nnnn S1 or and S2 is present and within user defined limits 2 quick flashes 1s ...

Page 32: ...est 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 l ll O LOAD ON nnnn Supply ok and connected to load OFF nnnn Not connected to load Auto led ll ON Auto Alarm reset Bypass time delay S2 AUTO ON fixed light nnnn Swit...

Page 33: ...arm state If no active alarms toggle between automatic HMI control modes 6 I ON Operate switch to I position 7 II ON Operate switch to II position 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 delay s delay min 4 s 0 s O OFF Lamp test l ON Off load test ll ON Auto Alarm reset On load test Bypass time delay Dropout ΔU Δf Manual...

Page 34: ...34 1 Zenith ZTX Series ATS OPER ATION MAINTENANCE AND INSTALL ATION GUIDE ...

Page 35: ... parameters cannot be detected from the supplied voltage 2 In phase monitor On Enable in phase monitor Off Disable in phase monitor 3 Priority No priority Application Two Transformers No Priority selected Source 1 Application S1 Transformer S2 Generator selected Lamp test Off load test Auto Alarm reset On load test Bypass time delay Dropout ΔU Δf Manual retransfer Generator stop delay 4 min 30 s Δ...

Page 36: ... Un Un and measured frequency is in range 0 95 1 05 x nominal frequency fn 6 S1 Failure delay The time 0 1 2 3 4 5 10 15 20 30 s device waits after priority source failure before starting automatic transfer sequence from priority source to non priority source 7 S1 Return delay The time 0 1 2 3 4 5 10 15 20 30 min device waits after priority source return before starting automatic retransfer sequen...

Page 37: ...wer to the ATS panel before connecting Ekip modules Ekip Connect Sofware and Bluetooth and Programming modules are suitable for all ZTX 30 1200 A 200 480 Vac automatic transfer switches refer to chapters 5 1 5 3 for more details on Ekip Connect software Ekip Bluetooth module Ekip Programming module Fig 5 1 Programming and bluetooth modules 5 Electronic accessories ...

Page 38: ...ro soft Windows operating system To download it see the address below http www abb com abblibrary DownloadCenter Fig 5 2 Ekip Connect software With its communication function it allows you to Monitor the state of the automatic transfer switches connected and record information Configure the automatic transfer switches with customized parameters Create communication reports Reset configurations Fur...

Page 39: ...aws its power from a rechargeable lithium poly mer battery supplied with the unit It is connected directly to the programming port see Fig 5 6 powers the controller without the need for auxiliary voltage supply The programming port is only compatible for use with Ekip Bluetooth and Ekip Programming modules 5 2 1 LED indications Ekip Bluetooth module is switched on by pressing the power button on t...

Page 40: ...only compatible for use with Ekip Programming and Ekip Bluetooth modules Ekip Programming module allows you to With Ekip Connect software update the software and load set and read the pa rameters The Ekip Programming module draws its power from the PC and connects one side directly to the programming port see Fig 5 6 and on the other to the USB port of the PC with the cable supplied 5 3 1 LED indi...

Page 41: ...e and device configuration S1 phase missing One or two phases of source 1 are missing Check the power source and connections S1 unbalance Phases of source 1 are not symmetric Check the power source S1 phase rotation Phase rotation of source 1 is different from the value of parameter Phase sequence Connect the phases according to the configuration Table 6 1 Alarms list in ZTX via Ekip Connect 6 Tro...

Page 42: ...e frequency difference is above the accepted level S2 invalid frequency Frequency of source 2 is out of range set in parameters Drop out frequency upper threshold and Drop out frequency lower threshold Check the correlation between power source and device configuration Open I failure Alarm LED blinking Switch transfer from position I to O or II failed Reset alarm by pressing Auto button or via men...

Page 43: ...re warning Measured pole temperature is near the alarm level Control Retry Failed transfer sequence retry activated Auto Control Disabled Device is in manual operating mode Local Bus Module heartbeat error Configuration Configuration session ports are open RTC capacitor charging Real time clock is not yet operational date time setting is disabled as long as this warning is active RTC capacitor is ...

Page 44: ...nce active Test off Load Test off load sequence active Alarm Product Availability Digital output function activated In Position I Digital output function activated In Position II Digital output function activated Source 1 Available Digital output function activated Source 2 Available Digital output function activated Table 6 3 Info statements in ZTX via Ekip Connect ...

Page 45: ...g voltage range 20 Voltage measurement accuracy Rated frequency f 50 60 Hz Operating frequency range 20 Frequency measurement accuracy Rated impulse withstand voltage Uimp 6 kV U SOURCE 1 Operating voltage for control circuit 200 480 Vac Generator supply min power rating 20 kVA U SOURCE 2 Fig 7 1 Power supply for control and power switching circuits 7 Technical data 7 1 General technical data U SO...

Page 46: ... 1 5 A 30 Vdc Generator start stop NO 2 Generator start stop NC 3 Output relay features 24 14 AWG Common voltage supply 5 5 A 250 Vac AC 1 5 A 30 Vdc Programmable output default Product available 6 1 2 3 C NO NC 6 5 O1 C 10 11 12 13 C G I1 FIRE 24V AC15 AC12 AC13 Ue V Ie A Ue V Ie A P W Ie A P W 230 6 24 10 240 2 50 400 4 72 4 290 0 8 60 415 4 125 2 250 0 55 70 690 2 250 0 55 140 0 27 440 0 1 44 T...

Page 47: ... 200 480 37 500 50 ZTX 400 600A 200 480 40 500 50 ZTX 800 1200A 200 480 40 500 50 1 Under nominal conditions 2 Time from source fail detection to contact closing on already available secondary source 3 All times consider that all timers are set to 0 Table 7 3 Specified technical data of operating times Recommended Operating Storage Temperature Do not store the automatic transfer switch in corrosiv...

Page 48: ...48 1 Zenith ZTX Series ATS OPER ATION MAINTENANCE AND INSTALL ATION GUIDE 7 2 Circuit diagrams Fig 7 2 ZTX open transition circuit diagram ...

Page 49: ...610 14 356 3 A 159 72 46 1168 24 610 14 356 4 A 290 131 54 1372 28 711 19 5 495 600 2 B 278 126 54 1372 28 711 19 5 495 3 B 284 129 54 1372 28 711 19 5 495 4 B 290 131 54 1372 28 711 19 5 495 800 1200 3 C 482 219 74 1880 40 1016 19 5 495 4 C 515 234 74 1880 40 1016 19 5 495 1Enclosures Type 3R weights are up to 22 greater than Type 1 Enclosures 2Enclosures Type 3R dimensions differ Consult Tech Su...

Page 50: ...50 1 Zenith ZTX Series ATS OPER ATION MAINTENANCE AND INSTALL ATION GUIDE Figure A Figure B ...

Page 51: ...51 1 Figure C ...

Page 52: ...52 1 Zenith ZTX Series ATS OPER ATION MAINTENANCE AND INSTALL ATION GUIDE ...

Page 53: ...l as accessories are readily replaceable Refer to section 11 for replacement parts On the other hand when the contacts have seen a damaging fault event or have met the end of their endurance lifetime the whole switch should be replaced which can be done easily by replacing the complete TruONE power panel within the enclosure In the case you suspect a failure may be due to manufacturer defect and c...

Page 54: ...2 54 Zenith ZTX Series ATS OPER ATION MAINTENANCE AND INSTALL ATION GUIDE ...

Page 55: ...58 9 3 Lifting and mounting the panel 59 9 4 Mounting the automatic transfer switch 60 9 4 1 Mounting hole dimensions 60 9 5 Mounting of the handle 61 9 5 1 Mounting of the handle to operation position manual mode 62 9 5 2 Mounting of the Handle automatic mode 62 9 5 3 HMI Installation 63 9 6 Wire Connection 64 9 7 Final Equipment Inspection 64 9 8 Initial Energizing 65 ...

Page 56: ...2 56 Zenith ZTX Series ATS OPER ATION MAINTENANCE AND INSTALL ATION GUIDE 10 Accessories 67 10 1 Phase barriers 67 10 2 Auxiliary contact blocks 68 10 3 HMI protective cover 69 11 Replacement parts 71 ...

Page 57: ...al components which could cause dam age Use an industrial quality vacuum cleaner to remove any dirt or foreign objects Be certain all cable connections are correct and that the phase rotation of both sources match Inspect the engine start connections and ver ify the correct connection of all control wires Check all programmable set points and adjust as necessary In addition adjust any optional acc...

Page 58: ...stallation and maintenace tasks 9 2 Equipment Inspection and Storage Warning When performing a hi pot or dielectric test on the power section of the ATS panel DISCON NECT the complete electronics controller and mechanism section of the ATS from the power section to avoid potential damage to the electronics Once you have received the transfer switch inspect it for any damage This in cludes damage t...

Page 59: ... sea and road Once you un pack the units please make sure all the components are received as per the BOM For any missing items contact your local ABB Zenith service representative Danger Hazardous Voltage can Cause Severe Injury or Death Turn OFF all power before installation adjustment or removal of transfer switch or any of its components Warning Due to hazardous voltages and currents ABB recomm...

Page 60: ... 1 18 0 457 3 42 0 1067 20 0 508 47 25 1200 1 18 0 457 4 42 0 1067 20 0 508 47 25 1200 1 18 0 457 400 2 42 0 1067 20 0 508 47 25 1200 1 18 0 457 3 42 0 1067 20 0 508 47 25 1200 18 0 457 4 46 0 1168 24 0 610 51 25 1302 22 0 559 600 2 46 0 1168 24 0 610 51 25 1302 22 0 559 3 46 0 1168 24 0 610 51 25 1302 1 22 0 559 4 46 0 1168 24 0 610 51 25 1302 1 22 0 559 800 1200 3 66 0 1676 35 0 889 71 3 1810 1 ...

Page 61: ... operating position indication and the selection of the operating mode see the Chapter 3 2 Operating and locking More information see animation Manual and automatic operation TruONE ATS https youtu be bosvSPVi2sM Warning Verify the condition of power source prior to manually transferring Manual operation may result in out of phase transfer when both sources are energized 9 5 1 Mounting of the hand...

Page 62: ...e properly the slide switch will move to the Locking mode automatically and the switch is allowed to be padlocked if needed From the Locking mode the slide switch can be moved to the Automatic mode 9 5 2 Mounting of the Handle automatic mode A07484 Notice When the slide switch is moved to the AUTO position the ATS is functioning immediately in the automatic control mode 2 1 3 Automatic mode ...

Page 63: ...5 5 1 Max 3 m HMI RJ45 cable Fig 9 4 HMI can be mounted on the switch or the door door drilling HMI protective cover available as accessory type OXEC21 provides protection against accidental contact see Chapter 10 3 Mounting of accessories ...

Page 64: ...energizing the transfer switch 1 Remove any debris incurred with a vac uum due to shipment or installation 2 Verify that all cabled connections are correct and that phase rotation of both sources match 3 Check engine start connections 4 Verify the correct connection of all control wires 5 Check settings of all timers and adjust as necessary 6 Adjust any optional accessories as required 7 Check the...

Page 65: ...er 4 to AUTO 7 Ensure that all objects and debris are removed from enclosure and enclosure is closed and latched Energizing the panel 1 Close Source 1 circuit breaker NOTE The HMI should illuminate if line voltage is present and S1 LED should light up 2 Verify the phase to phase voltages at the Source 1 terminals 3 Initiate auto configure from HMI DIP switch and allow a few seconds for sys tem par...

Page 66: ...2 66 Zenith ZTX Series ATS OPER ATION MAINTENANCE AND INSTALL ATION GUIDE ...

Page 67: ...Discon nect all power sources before performing work inside the ATS panel Failure to do so may result in serious injury or death 10 1 Phase barriers Phase barriers must be used to maintain a clearance of 1 inch on the automatic transfer switch types They are included with the shipment of ZTX series ATS Panel Fig 10 1 Mounting of phase barriers type OXEB_ A07491 OXEB_ More information see animation...

Page 68: ...blocks Fig 10 2 Mounting of the auxiliary contact blocks type OA_ Fig 10 3 Labels for contact numbering Position OA1G10 OA3G01 SOURCE 1 S1 max 2 2 I O II SOURCE 2 S2 max 2 2 I O II Table 10 1 Contact positions 11 21 12 22 13 23 14 24 OA1G10 OA3G01 A07491 2 OA_ Max 4 2 pcs SOURCE 1 S1 SOURCE 2 S2 1 ...

Page 69: ... Nm 7 1 lb in 1 2 OXEC21 Type 3R IP54 UL Type 3R HMI protective cover type OXEC21 provides protection against water ingress It comes standard with NEMA 3R enclosures and is available as a replacement part Fig 10 4 Mounting of HMI protective cover type OXEC21 A07491 ...

Page 70: ...2 70 Zenith ZTX Series ATS OPER ATION MAINTENANCE AND INSTALL ATION GUIDE ...

Page 71: ... 200 480 Vac OXHANDLE 1600 0 18 Complete1 mechanism with electronics Open transition ZTX 200 480 Vac 30 260 Amps OXAMECH 2 L2 16 28 400 600 Amps OXAMECH 3 L2 21 12 800 1200 Amps OXAMECH 4 L2 23 32 Phase barrier 30 1200 Amps 3 pole OXEB1600 4 1 10 30 1200 Amps 4 pole OXEB1600 6 1 54 1Includes the tested field replaceable module complete with operating mechanism power module and controller Fig 11 1 ...

Page 72: ...2019 Copyright 2019 ABB All rights reserved Specifications subject to change without notice ABB Zenith Controls Inc 305 Gregson Drive Cary NC 27511 24 hour support ABB Technical Services 1 800 637 1738 epis pqservice abb com abb com lowvoltage Contact us ...

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