OPERATION AND MAINTENANCE MANUAL Zenith ZTG D series

Operation And Maintenance Manual Zenith Ztg D Series-Free PDF

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Authorized Service, For ABB Zenith parts and service call 773 299 6600. Table of Contents,Introduction 12 Sequence of Operation 21. Safety 13 Standard Transition 121, Equipment Inspection and Storage 13 Delayed Transition 21. Final Equipment Inspection 13 Controls Power Supply CPS 22. Installation 13 Schematics Standard Delay 123,Mounting 13 Troubleshooting Diagnostics 24. Power Connections 14 Maintenance and Testing 25, Engine Start Control Connections 14 6 Inspection and Cleaning 25.
Initial Energization 16 7 Servicing 125,MX150 Microprocessor Controller 18 Testing 125. Overview 18 Power Panel Replacement Parts 26,LCD Keypad 19 Standard Transition 26. User Setting for Voltage Frequency 110 40 260 Amps 26. Standard Features MSTDG Option Pkg 10 11 400 600 Amps 27. Standard Features MEXEG Option Pkg 12 800 1200 Amps 28. Optional Accessories 13 1600 3000 Amps 29, How to Set the System Clock 14 Delayed Transition 30. CDT One Event Timer Exerciser 14 15 40 600 Amps 30. CDP Clock Exerciser 16 800 1200 Amps 31,User Setup CFG Menu 17 1600 3000 Amps 32. User Setup SET Menu 18,User Setup System Info 19,Testing 120.
Standard Transition 120,Delayed Transition 20,Introduction. ABB Zenith Transfer Switches are used to provide a continuous source of power for lighting and other critical loads by auto. matically transferring from source 1 power to source 2 power in the event that source 1 voltage falls below preset limits. Voltage sensing and system control is performed via a state of the art microcontroller located on the cabinet door. It is designed to give highly accurate control of the transfer switch system. All ABB Zenith transfer switches are designed for use on emergency or standby systems and are rated for totalsystem or. motor loads Transfer switches are UL Listed under Standard 1008 and CSA Certified under Standard C22 2 No 178 and. IEC Listed under Standard 947, NOTES A protective device such as a molded case circuit breaker or fused. disconnect switch MUST be installed on both sources of incoming. power for circuit protection and as a disconnection device. All references made within this manual about the term S1 or. Source 1 relate to a Normal Power Source All references made. about the term S2 or Source 2 relate to an Emergency. or Alternative Power Source,Safety Installation,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. The safe operation of your switch is ABB Zenith s focus 2 Verify that all cabled connections are. The proper storage installation operation and mainte correct and that phase rotation of both sources. nance will help increase the life of the switch match. 3 Check engine start connections,CAUTION 4 Verify the correct connection of all.
control wires, Due to hazardous voltage and current ABB Zenith rec 5 Check settings of all timers and adjust. ommends that an ABB Zenith Certified technician or a as necessary. qualified electrician must perform the 6 Adjust any optional accessories as required. installation and maintenance of the switch 7 Check the lug torque values of the power. connections, Equipment Inspection NOTE Lug torque values are specified. in table 2 on pg 4, and Storage 8 Make sure that all covers and barriers are. Once you have received the transfer switch inspect installed and properly fastened. it for any damage This includes damage to the,NOTE Power panels ship from ABB Zenith. enclosure power panel control panel and wiring,in Source 1 Position.
harness If any damage is found or suspected file a claim. as soon as possible with the carrier and notify the nearest Each ABB Zenith transfer switch is factory wired and. ABB Zenith representative tested A complete information package is furnished. Before installation if it is necessary store the transfer with each switch which includes. switch in a clean dry place protected from dirt and a Sequence of operation. water Provide ample air circulation and heat if neces b Description and operation of. sary to prevent condensation all accessories supplied. c Power panel connection diagram,and schematic,Operating d Description and identification of. Storage Temperature all customer field connections. Temperature Ambient Humidity, Installation of ABB Zenith transfer switches includes. 30 C to 40 400 AMP 5 to 95 a Mounting the transfer switch cabinet. 75 C molded shell non con b Connection of Source 1 Source 2. 22 F to 20 C to 65 C densing and Load cables or bus bars. c Connection of external control,167 F 4 F to 149 F circuits as required. 40 4000 AMP,all other frame,Adequate lifting means must be used to mount the. and panel types transfer switch into place The recommended method for. 20 C to 60 C moving the transfer switch using the lifting eyes where. 4 F to 140 F supplied and a spreader bar is illustrated in Figure 1. Enough room should be allowed to open the cabinet, doors fully for inspection and servicing of the switch per.
NEC and local codes,Final Equipment Inspection,Prior to energizing the transfer switch. 1 Remove any debris incurred with a vacuum due, to shipment or installation Before drilling conduit entry holes or any. accessory mounting holes cover and protect,the switch and control panel to prevent dirt. WARNING and metal fragments from entering the,mechanical and electrical components. Do not use a blower since debris may, become lodged in the electrical and Failure to do so may result in.
mechanical components and cause damage damage and malfunction of the switch. ABB Zenith ZTG ZTGD Operation and Maintenance Manual 70R 1000D 3. Installation cont d,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. Power Connections, ABB Zenith transfer switches are supplied with UL listed SPREADER BAR. solderless screw type terminals as standard for the H. Source 1 Source 2 and Load power connections, Table 1 lists the number and sizes of cable lugs supplied. as standard for each switch amp rating, Connect the Source 1 Source 2 and Load conductors LIFTING EYES. to the clearly marked terminals on the transfer switch. Remove surface oxides from cables by cleaning with a. wire brush Verify that all connections are correct before. tightening the lugs All cable lug connections must be. tightened to the proper torque values as shown in,NOTE Do not run cables or wiring behind CABINET D.
front connected transfer switches,NOTE When lifting the switch using a spreader bar. height H must be equal to half of distance D, Power Connections Screw Type Terminals for External Power Connections. Switch Size Source 1 Source 2 Load Terminals Neutral Bar When Required. Amps Cable Per Pole Range of Wire Sizes No of Cables Range of Wire Sizes. 40 1 8 to 3 0 AWG 3 14 to 1 0 AWG,80 1 8 to 3 0 AWG 3 14 to 1 0 AWG. 100 1 8 to 3 0 AWG 3 14 to 1 0 AWG,150 1 8 to 3 0 AWG 3 6 AWG to 350 MCM. 200 225 1 6 AWG to 250 MCM 3 6 AWG to 350 MCM,260 1 6 AWG to 350 MCM 3 6 AWG to 350 MCM.
400 1 4 AWG to 600 MCM 4 4 AWG to 600 MCM,600 2 2 AWG to 600 MCM 8 4 AWG to 600 MCM. 800 1000 1200 4 2 AWG to 600 MCM 12 4 AWG to 600 MCM. 2600 3000 8 2 AWG to 600 MCM 24 4 AWG to 600 MCM,Tightening Torque for Lugs. Engine Start Socket Size Torque,Control Connections Across Flats Lb In Lb Ft. Engine start control wires connect to control terminals 1 8 45 4. beside the MX150 Engine start terminals are indicated by. 5 32 100 8, a schematic symbol the symbol indicates the contact. state for a de energized normal source Figure 3 shows 3 16 120 10. the engine start contacts 7 32 150 12,1 4 200 17, Make all other necessary control connections to the con.
trol panel terminal blocks per the schematics supplied 5 16 275 23. with the ATS 3 8 375 31, NOTE All control wires 18 12 AWG must be 1 2 500 42. torqued to 19 in lbs 9 16 600 50, 4 ZTG ZTGD Operation and Maintenance Manual 70R 1000D ABB Zenith. Installation cont d,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. Control Connections,Clock Program,Backup Battery,Engine Start Remove protective. Connections strip to enable clock,Network Connector.
Input Output,Connectors,to I O Modules,To R T Box, A complete information package is furnished with The terminals are clearly identified by a label on the. each transfer switch including a complete connection microcontroller backplate In the case of manual trans. diagram and schematic which details all necessary fer switches or in other applications not requiring the. control circuit field connections microprocessor clearly marked terminal blocks are. provided in the upper left corner of the control panel. The engine start control wires connect to the for the engine start control wires. engine start relay terminals located to the left,of the microprocessor Figure 2 shows the location. of these terminals, ABB Zenith ZTG ZTGD Operation and Maintenance Manual 70R 1000D 5. Installation cont d,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. E 5 2 Engine Start,Contact rating is,6 3 10 Ampere at 120VAC.
or 28VDC Gold plated,Engine Start,Control Connections. The engine start terminals are clearly identified by a NOTE The controller will illuminate Source 2. label on the microcontroller backplate In the case of Available LED when preset voltage. manual transfer switches or in other applications not and frequency levels are reached. requiring the microprocessor clearly marked terminal. blocks are provided in the upper left corner of the con 8 Verify the phase to phase voltages at Source 1. trol panel for the engine start control wires line terminals. 9 Verify that the phase rotation of Source 1, Terminals for field connections to the A3 Source 2 is the same as the phase rotation of. auxiliary contacts and the A4 Source 1 auxiliary contacts Source 2. are also provided These terminals are clearly marked 10 Shut down the generator engine. and appear on the side of the power panel On 400 11 Place the starting control in the Automatic position. amp metal frame units these terminals appear on the 12 Complete the visual inspection of the transfer switch. bracket above the operator handle 13 Close the enclosure. 14 Lock the enclosure,Initial Energization, Before proceeding refer to the information package. supplied with the ATS and read and understand the,information on all accessories provided. ABB Zenith,1 Unlock the enclosure SERIAL NUMBER,2 Open the enclosure RATING VOLTS HZ.
3 Verify the correct system voltage AMPS PHASE, NOTE The equipment rating nameplate on SYSTEM VOLTS. the transfer switch lists the voltage MODEL NUMBER. See Figure 4,4 Close Source 1 circuit breaker,NOTE The controller will illuminate Source 1. Available LED if proper voltage, 5 Verify the phase to phase voltages at the Normal Certain accessories per specific. line terminals schematics can inhibit automatic transfer. 6 Close the Source 2 circuit breaker Engine Gen Set could start when. 7 Start the generator engine engine control wires are attached. 6 ZTG ZTGD Operation and Maintenance Manual 70R 1000D ABB Zenith. Installation cont d,Initial Energization cont d, After all options and accessories are checked and veri 5 Close the External up stream Source 2 line. fied follow these steps to set up the ATS Refer to MX150 circuit breaker. display Figure 5 The annunciation LEDs illuminate to 6 Start the engine generator in MANUAL mode. indicate 1 source availability 2 ATS position and 3. NOTE When the voltage and frequency,MX150 control function timing.
reach preset values the Source 2,Available LED will illuminate. 7 Verify the phase to phase voltages at Source 2,line terminals. 8 Verify that the phase rotation of,Source 2 is the same as the phase. rotation of Source 1,9 Shut down the generator s engine. Place in Automatic Mode,S1 OK NOTE Source 2 Available LED.
will turn off, MON 23 APR 2002 NOTE The engine generator will continue. to run for the duration of Source 2,MORE TEST Stop Delay Timer. 10 Place the disconnect switch to ENABLE,11 Complete the visual inspection of the. transfer switch,12 Close the enclosure,13 Lock the enclosure. Figure 5 LCD and keypad,When performing a hi pot or.
1 Unlock the enclosure dielectric test on the power section. 2 Open the enclosure DISCONNECT the control panel plugs from. 3 Place the Disconnect Switch in the Inhibit the microprocessor to avoid potential damage. NOTE This step is only performed if the,DS Option was purchased. 4 Close the external up stream Source 1,circuit breaker. NOTES Source 1 Available and Source 1,Position LED s will illuminate. If Source 1 Available LED does not,illuminate verify that Source 1 Voltage. is above the preset restore value,The Gen Set will start and run while.
Source 2 stop Delay Timer is timing, ABB Zenith ZTG ZTGD Operation and Maintenance Manual 70R 1000D 7. MX150 Microprocessor Controller,MX150 Controller,Consists of. front connected transfer switches 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 Table 1 Power Connections Screw Type Terminals for External Power Connections Switch Size Amps 40 80 100 150 200 225 400 600 800 1000 1200

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