Unigear Manual

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UniGear ZS1

Installation, service and maintenance

Medium Voltage Product

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Your safety first – at all times!

This is why our instruction manual begins with the following recommendations:

• Only install switchgear and/or switchboards in closed rooms suitable for electrical

equip-ment.

• Ensure that installation, operation and maintenance are only carried out by specialist

electricians only.

• Fully comply with the legally recognized standards (IEC or local), the connection conditions

of the local electrical utility and the applicable safety at work regulations.

• Observe the relevant information in the instruction manual for all actions involving

switchgear and switchboards.

• Danger!

Pay special attention to the hazard notes in the instruction manual marked with this warning

symbol.

• Make sure that the specified data are not exceeded under switchgear or switchboard

operating conditions.

• Keep the instruction manual accessible to all personnel involved in installation, operation

and maintenance.

• The user’s personnel must act responsibly in all matters affecting safety at work and correct

handling of the switchgear.

WARNING

Always follow the instruction manual and respect the rules

of good engineering practice !

Hazardous voltage

can cause electrical shocks and burns.

Disconnect power, then earth and short-circuit before proceeding

with any work on this equipment.

If you have any further questions about this instruction manual, the members of our field

organization will be pleased to provide the required information.

We reserve all rights to this publication. Misuse, and including in particular, duplication and

making this manual - or extracts thereof available to third parties is prohibited. We do not

accept any responsibility for the information provided, which is subject to alternation.

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1. Summary

1.1 General

UniGear is the new name of the ZS1 switchgear in release 1.2 (ZS1.2). It is three-phase, metal-clad, air insulated switchgear and all the units are factory-assembled, type-tested and suitable for indoor applications up to 24 kV.

The units are designed as withdrawable modules and are fitted with a single busbar system. The withdrawable parts are equipped with circuit-breakers and contactors.

Details of the technical design and configuration of individual switchgear, such as the technical data, detailed equipment lists for the individual panels and comprehensive circuit documentation etc., can be found in the relevant order documents.

Note

The UniGear ZS1 switchgear is indicated in the test reports and type test certificates with the abbreviation ZS1.2

1.2 Standards and specifications

UniGear ZS1 switchgear panels comply with the standards and specifications for factory-assembled, metal-enclosed and type tested high voltage switchgear to IEC publications 62271-200 and 60694. In addition, in accordance with IEC 60529, the switchgear panels have the following degrees of protection: IP4X for the enclosure and IP2X for the partitions.

All other corresponding IEC publications, national or local safety at work regulations and safety regulations for production materials must be followed during erection and operation of these systems. Above and beyond this, the order-related data from ABB must be taken into account.

1.3 Operating conditions

1.3.1 Normal operating conditions

The switchgear are basically suitable for normal operating conditions for indoor switchgear and switchboards in accordance with IEC 60694. The following limit values, among others, apply: Ambient temperature:

Maximum +40 °C

Maximum 24 h average +35 °C

Minimum (according to “minus 5 indoor class”) -5 °C The maximum site altitude is 1000 m above sea level.

1.3.2 Special operating conditions

The switchgear are suitable for operation in the climate of Wda type according to IEC 60 721-2-1. Special operating conditions must be discussed with the manufacturer in advance. For example: • At site altitudes above 1000 m, the effects of the reduction in dielectric strength of the air on the

insulation level must be taken into account (please refer to diagram in figure 1/1).

• Increased ambient temperatures must be compensated for in the design of the busbars and branch conductors as well as for the withdrawable parts, otherwise the current carrying capacity will be limited. Heat dissipation in the switchgear panel can be assisted by fitting additional ventilation facilities.

Note on any special climatic operating conditions

When switchgear are operated in areas with high humidity and/or major rapid temperature fluctua-tions, there is a risk of dew deposits which must remain an exception in normal operating conditions for indoor switchgear. Preventive action (e.g. fitting electric heaters) must be taken in consultation with the manufacturer to avoid this condensation phenomenon and any resulting corrosion or other adverse effects. The control of the heaters depends on the relevant project and details must be taken from the order documents.

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2. Technical data

2.1 Electrical data

2.1.1 Main parameters for panels with circuit-breakers

Rated voltage kV 12 17.5 24

Rated power frequency withstand voltage kV 28 38 50

Rated lightning impulse withstand voltage kV 75 95 125

Rated frequency Hz 50/60

Rated current of busbars A …4000 …4000 …3150

Rated current of circuit-breaker branches A …4000 …4000 …2500

Rated peak withstand current 1) _kA _…125 _…125 _…80

Rated short-circuit breaking current of circuit-breaker kA …50 …50 …31,5

Rated short- time current 3 s 1) _kA _…50 _…50 _…31,5

1)_{The short-circuit withstand capacity of the instrument transformers must be taken into account separately.}

For individual switching device data, see the instruction manual for the relative switching device, as listed under 7.1.

Rated voltage kV 12 17.5 24

Rated power frequency withstand voltage kV 28 38 50

Rated lighting impulse withstand voltage kV 75 95 125

Rated frequency Hz 50/60

Rated current of busbars A ...4000 ...2500

Rated current of branches A ...630 ...630

Rated breaking current of switch-disconnector _A _...630 _...630

(power factor = 0.7)

Rated short-time withstand current of

switch-disconnector 1s 1) _kA _...25 _...20

Rated short-circuit making current kA ...40 ...38

Rated peak withstand current kA ...62.5 ...62.5

Auxiliary voltage V DC 24, 48, 110, 220;

AC 110, 230

1) _{The short-circuit withstand capacity of the instrument transformers must be taken into account separately.}

2.1.2 Main parameters for panels with NALF switch-disconnectors

2.2 Resistance to internal arc faults

The fault withstand capacity is as follows: 12 kV - 50 kAx 1s 17.5 kV - 50 kA 1s 24 kV - 31,5 kA 1s

The switchgear units have been tested according to IEC 62271-200 standard (appendix AA, class A, criteria 1 to 5) and also to PEHLA recommendation no. 4.

In individual cases, depending on the configuration of the switchgear panels and/or the switchgear room conditions (e.g. low ceiling height), additional measures may be necessary to ensure compliance with criterion 5.

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Dimension mm

Height A 2200/2595 1)

Width B

- Feeder panels up to 1250 A (31.5 kA) 5) ₅₅₀

- Feeder panels up to 1250 A (up to 31.5 kA) 4) ₆₅₀

- Feeder panels up to 1250 A (above 31.5 kA) 800

- Feeder panels 1600 - 2000 A 800 2)

- Feeder panels above 2000 A 1000

Depth C 1340/13903)

Height of the basic part of panel D 2100

E 1495

1) _{Height of the control cabinet is 705/1100mm (dimensions without gas-duct);} 2) _{1000mm available on request;}

3) _{12/17,5 kV-50kA the panel is always 1390mm depth;}

4) _{Feeders equipped with vacuum contactor are 650mm wide up to the 50kA short-time current;} 5) _{UniGear ZS1 550 series only.}

The dimension must be verified according to the documentation of the relevant order.

Rated current Weight

A Kg ...1250 800-850 1600 850-900 2000 850-900 2500 1200 3150 1200 4000 1400

2.3 Dimensions and weights

2.3.1 Dimensions and weights of 12/17,5 kV units

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2.3.2 Dimensions and weights of 24 kV units

Rated current Mass

A Kg

...1250 1000-1050

1600 1200

2000 1200

2500 1200

Weights of 24 kV panels (including withdrawable circuit-breaker parts)

Dimension mm

Height A 2325/2720 1)

Width B

- Feeder panels up to 1250 A 800 2)

- Feeder panels above 1250 A 1000

Depth C 1700

Height of the basic part of panel D 2200

E 1620

1) _{Height of the control cabinet is 705/1100 mm (dimensions without gas-duct).} 2) _{1000mm available on request.}

The dimension must be verified according to the documentation of the relevant order.

Dimension mm

Height A 2200/2595 1)

Width

- Outgoing and incoming panels with B 800

switch-disconnector 630 A

Depth C 1300/1340 2)

Height of basic part of panel D 2100

E 1495

1) Height of the control cabinet is 705/1100 mm (dimensions without gas-duct).

2) The depth of panel with the switch-disconnector in combination with HD4 circuit-breaker panels is recommended at 1340 mm, in other cases 1300 mm – always take into account the note 3).

3) The dimensions must be verified according to the documentation of relevant order.

2.3.3 Dimensions and weights of panels with the NALF 12/17.5 kV switch-disconnectors

Weights of 12/17,5 kV panel (including the switch-disconnector)

Outgoing and incoming panels of width 800 mm, approx. 750 kg.

2.3.4 Dimensions and weights of panels with the NALF 24 kV switch-disconnectors

Weights of 24 kV panel (including the switch-disconnector)

Outgoing and incoming panels of width 1000 mm, approx. 950 kg.

Dimension mm

Height A 2200/2595 1)

Width

- Outgoing and incoming panels with B 1000

switch-disconnector 630 A

Depth C 1520/1560 2)

Height of basic part of panel D 2100

E 1495

1) Height of the control cabinet is 705/1100 mm (dimensions without gas-duct).

2) The depth of panel with the switch-disconnector in combination with HD4 circuit-breaker panels is recommended at 1560 mm, in other cases 1520 mm – always take into account the note 3)

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3. Panel design and equipment

3.1 Basic structure and variants

The basis for the UniGear ZS1 panel is the incoming/outgoing feeder panel with SF6 ¹) or vacuum circuit breaker using insertion technology. It is divided into busbar compartment, circuit-breaker compartment, cable compartment and control cabinet for the secondary equipment. Apart from this, there are variants for all operating needs.

For busbar isolation, two panels are necessary, the coupling panel with the withdrawable circuit-breaker part and a bus riser panel (optional with busbar metering and earthing). In equipment without busbar isolation, a direct bar connection between the busbars will be established.

The UniGear ZS1 switchgear includes also the variant of incoming/outgoing panel with the switch-disconnector NAL-F with the stationary mounting of switch-switch-disconnector. The panel is divided into busbar compartment, switch-disconnector compartment including cables and control cabinet for the secondary equipment.

The UniGear ZS1 panels can also be set up in two rows; back to back fixed together in so-called duplex arrangement with a double busbar system.

Further details about installation and switchgear equipment can be obtained from the documents of relevant order.

¹) For series 550 only vacuum breaker is available.

3.2 Enclosure and partitioning (Figure 2)

The enclosure and internal partitions of the panels are of 2 mm thick high quality galvanised steel sheets.

The three high voltage compartments (busbar compartment, circuit-breaker compartment and cable connection compartment) are equipped with top-mounted and secured pressure relief flaps. These open in the case of overpressure due to an internal arc fault.

The front of the panel is closed off by pressure resistant doors which open to an angle of 130°. Cable and circuit-breaker compartments have their own doors.

The circuit-breaker compartments can be equipped with inspection windows made of security glass. Neighbouring panels are partitioned from one another by the side walls of each panel and, as a result of the design, the air cushion remains between these walls when the panels are jointed together. The enclosure is completed above by top-mounted pressure-relief flaps which, according to the rated branch conductor current, are made of sheet steel or expanded metal and below by means of floor covering 17, made of sheet metal which cannot be magnetized.

The pressure-relief flaps are secured with steel screws on one longitudinal side and on the other longitudinal side with plastic screws.

In the case of internal overpressure, the plastic screws are the point of rupture.

Arc fault current limitation can be achieved by undelayed circuit-breaker release, carried out by auxiliary switches operated by the pressure wave.

The switchgear can be equipped with the following systems:

• Ith limiter: the auxiliary switches 11.5 (figure 28) are operated by the pressure relief flaps. For units over 25 kA (see chapter 3-7);

• Fast recovery device: the auxiliary switches are mounted on the pressure sensors and operated by the sensor stroke pin (see chapter 3.6).

The necessary safety measures to counteract the effects of an internal arc fault must be ensured in relation to the ceiling height. In individual cases, this may require additional operator protection measures on the switchgear panels.

These measures include:

1. Mounting a pressure relief duct 50 on the top of the switchgear, with further channels leading out of the switchgear room in a form appropriate for the design of the building. The shock wave and arc discharge are channelled off in ducts (see chapter 5.8);

2. Mounting a pressure relief duct with blow-out apertures located above the duct at the ends of the switchgear and pointing towards the centre of the switchgear (diverter duct). The shock wave and arc discharge then emerge in an extremely attenuated form and in a location which is not critical for the operating personnel.

The rear wall of the busbars of busbar compartment 84, intermediate wall 9, mounting plate 12 with shutters 12.1/12.2 and horizontal partition 20, form part of the internal partitioning.

The internal metallic partitioning makes safe access to the circuit-breaker and cable compartments possible even when the busbars are live.

The low voltage compartment for the secondary equipment is completely protected from the high voltage area thanks to its steel-sheet casing.

On the end sides, cover plates ensure good appearance and are mechanically and thermally arc fault proof should such an event occur in the end panel.

Doors and rear walls as well as the cover plates are thoroughly cleaned and treated against corrosion before receiving a high quality double coating of paint.

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The finishing coat is in the standard RAL 7035 colour (special colours by agreement). Stoving completes the procedure and provides considerable insensitivity to impact and corrosion.

The circuit-breaker compartment and cable connection compartment doors are pressure resistant and can either be fitted with screws or manual closing systems (central handle).

3.2.1 Ventilation of the panels

Openings in the outer enclosure are needed for the purpose of ventilation in the case of certain rated currents in the busbars and branch bars.

For incoming air to the circuit-breaker compartment, the horizontal partition is provided with air-vents 20.2. IP4X degree of protection and safety in the case of any release of hot gas due to an arc fault are provided by flap 20.3 in the horizontal partition 20.

For outgoing air, the pressure relief flaps 1.1 are made of expanded metal instead of flat steel sheets. The shape and size of the vents in expanded metal provide the IP4X degree of protection.

In cases of higher ambient temperature (>40 °C) and/or increased frequency (60 Hz) it may be necessary to install a fan in the horizontal partition. This is not standard. Please refer to figures 109, 110. It is necessary to use forced fan ventilation in 3600 A and 4000 A panels for 12/17.5 kV rated voltage and in 2500 A panels for 24 kV rated voltage.

A Busbar compartment B Circuit-breaker compartment C Cable compartment D Low voltage compartment

1 Enclosure 1.1 Pressure relief flap 1.2 Control wiring duct

1.7 Pressure relief flap made of expanded metal 2 Branch conductor 3 Busbar 5 Isolating bushing 6 Earthing switch 7 Current transformer 8 Voltage transformer 9 Partition – removable 10 Control wiring plug connector 12 Mounting plate

12.1 Top shutter 12.2 Lower shutter

13 Withdrawable part

14 Earthing switch operating mechanism 14.1 Operating shaft for earthing switch

Figure 2: Example of UniGear ZS1

14.2 Slide 15.1 Terminal rack

16 Cable sealing end 17 Floor cover – split 18 Spindle mechanism 18.1 Spigot on spindle

18.2 Hole in spindle for insertion lever 19 Main earthing bar

20 Horizontal partition, removable 20.2 Ventilation grid 21 Cable clamp 84 Partition 1.7 12.1 15.1 10 1.2 13 12.2 19 20.2 18 14 21 20 1.1 1 2 3 84 5 12 7 6 17 8 18 18.1 18.2 14 14.1 14.2 20.2

A

B

D

C

16 1.2 9

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3.3 Compartments in the panels

3.3.1 Busbar compartment

The busbars 3 (figure 2) have a flat cross-section made of copper and are laid in sections from panel to panel. For higher rated currents (3150, 3600 and 4000 A), the busbars have a D-shaped cross-section.

According to the current rating, either single or double configuration is used. They are held by flat branch conductor 2 and, if installed, by busbar bushings 29. No special connection clamps are needed. Busbars and branch conductors for 17.5 kV and 24 kV are insulated by means of shrink-on sleeves. The bolt connections in the 17.5 kV and 24 kV busbars system are covered by insulating covers 58 (figure 3). The busbars for 12 kV units up to 2000 A are without any covers. Flat busbars 2500 A and D-shaped busbars 3150, 3600 and 4000 A are insulated and the connections are covered.

By means of bushing plates 28 and busbar bushings 29 (figures 61, 62) partitions can be created between panels. These partitions are necessary for higher rated short-time currents – see the following table.

Rated voltage Rated short-time withstand current Partitions

25 kA No 1)

12/17,5 kV 31.5 kA Every third panel 2)

40 kA, 50 kA Every panel 3)

24 kV 25 kA, 31.5 kA No 1)

Marine version All ratings Every panel 3)

1) _{In these panels, busbar bushing and bushing plates don’t need to be mounted. The dynamic strength of the busbar system is sufficient.} 2) _{In these panels, busbar bushing and bushing plates must be mounted in every third panel only when you have the sequence of 800}

and 1000mm wide. If these panels are positioned between 650mm wide panel they don’t need bushings because the dynamic strength of the busbar system is sufficient.

3) _{In these panels, busbar bushing and bushing plates must be mounted in every panel.}

According to customer requirements, this separation into individual panels by means of busbar bushings 29 and bushing plates 28 (figures 61, 62) can also be provided in switchgear panels where it is not technically necessary.

Top-mounted boxes with busbar earthing switches, or busbar voltage transformers can be placed above the units.

Figure 3: Example of insulating covers

58 58.5

3.3.2 Circuit-breaker compartment

The circuit-breaker compartment contains all the necessary equipment for reciprocal operation of the withdrawable part and the panel. Like the busbar compartment, it is metallically partitioned on all sides. The tulip isolating contacts 5, together with the fixed isolating contacts, are located in mounting plate 12 (figure 2).

The metal shutters 12.1/12.2, covering the insertion openings, are also included. The shutters are opened by means of actuating bars 13.16 (figure 6) of the withdrawable circuit-breaker part when inserting into the service position, and are closed when the latter is removed.

In the test/disconnected position of the withdrawable part, partitioning by separation is established in the main current circuit. Connection of the control wiring, required for test purposes, need not be interrupted when in the test/disconnected position.

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In the test/disconnected position, the withdrawable part is still completely inside the panel with the door closed. The ON/OFF pushbutton located on the circuit-breaker, and the mechanical indicators for ON/ OFF and CHARGED/DISCHARGED can be observed through an inspection window if the circuit breaker is in service position.

The switching operations are carried out with the doors closed. Installation of an additional mechanical switching device for manual operation of the circuit-breaker in the service position is also possible (see fig. 7, 8).

The socket 10.1 (figure 4) for the control wiring is mounted fixed in the circuit-breaker compartment.

Figure 4: View into the circuit-breaker compartment 10.1 Control wiring socket

12.1 Top shutter 12.2 Lower shutter

14 Earthing switch operating mechanism 14.1 Drive shaft

42 Right-hand travel rail 43.1 Duct cover, top left 43.3 Duct cover, top right

Figure 6: Withdrawable part of VD4 circuit-breaker pole side 13.16 Actuating bars 13.16 10.2 13.1 18.1 14 10.1 12.1 43.3 12.2 42 14/14.1

Figure 5: Circuit-breaker compartment open

Withdrawable part in disconnected position, control wiring plug connector open

10.2 Control wiring plug 13.1 Withdrawable part

14 Earthing switch operating mechanism 18.1 Square spigot

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45.2

45.1

45.3

Figure 7: Push button for mechanical ON/OFF breaker operation with the door closed (on request). If the withdrawable part is in the service position, operation is carried out using the knob which swings a push rod extension out. 45.1 Mechanical pushbutton

45.2 Turning knob

Figure 8: View of the push rod extension swung out by the knob at the front, with the withdrawable circuit-breaker part in service position and the door open

45.3 Swivelling push rod

3.3.3 Withdrawable parts (Figure 2)

1. Withdrawable circuit-breaker parts

The withdrawable breaker forms a complete module consisting of the vacuum circuit-breakers type VD4, Vmax or VM1, SF6 circuit-breaker type HD4, the withdrawable assembly 13.15 (figure 9), isolated contact arm 4.2 with contact system 4.3 and control wiring plug 10.2. The withdrawable assembly 13.15 and the circuit-breaker are coupled via a multi-pole control wiring plug connector 10.3 (figure 10).

The withdrawable assembly establishes the mechanical connection between the panel and the circuit-breaker. The fixed part is connected to the panel by forking, which is form coded on both sides. The moving part with the circuit-breaker is moved manually or by a motor by means of a spindle, between the service or test/disconnected positions with the front doors closed.

Service and test disconnected positions are set precisely by means of auxiliary switches, which register the final position reached and the angular position of the spindle.

The earthing connection between the withdrawable part and the panel is established by its rollers and travel rails 42 (figure 4), which are bolted onto the panel.

Withdrawable parts of the same design are interchangeable. In the case where the withdrawable parts have the same dimensions, but different circuit-breaker fittings, the control wiring plug coding prevents any erroneous connections between the withdrawable part and the panel.

The coding is indicated in the order documents (figure 23). 2. Withdrawable contactor parts (Figures 2, 11, 12)

In place of the circuit-breaker type, the withdrawable part can also be fitted with the V-Contact VSC type vacuum contactor.

V-Contact VSC is fitted with MV fuses 91.15 and can be used for rated voltage up to 12 kV. All the data mentioned in this chapter for circuit-breakers also apply to the contactors. 3. Other withdrawable parts

The withdrawable part can also be fitted with the following trucks: • metering voltage transformer truck with fuses;

• earthing truck without making capacity (for main busbar system and power cables); • earthing truck with making capacity (for main busbar system and power cables); • power cable testing truck;

• isolation truck;

• isolation truck with fuses; • shutter lifting truck.

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18.2 18.1 S9 S8 10.3

91.15

91.14 91.13 13.15

Figure 9: Withdrawable part with circuit-breaker, type VD4, operating mechanism side

13.15 Withdrawable assembly

Figure 11: V-Contact VSC type vacuum contactor – front view

91.13 Signalling device ON/OFF 91.14 Operating cycle counter

Figure 10: Withdrawable assembly for circuit-breaker, with auxiliary switches

S8 Test position indicator S9 Service position indicator 10.3 Control wiring plug connector for

Withdrawable assembly 18.1 Square spigot

18.2 Hole in spindle for insertion lever spindle

Figure 12: V-Contact type vacuum contactor – pole side 91.15 MV fuses

91.13 Signalling device ON/OFF 91.14 Operating cycle counter

3.3.4 Cable connection compartment (Figure 2)

The cable compartment contains current transformers 7, fixed and withdrawable voltage transformers 8, and earthing switch 6, according to individual operating requirements in each case.10

The cable compartment is constructed for installation of three current transformers. Should all three current transformers not be required, dummies will be installed in their place, using the same installation and connection procedures.

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The voltage transformers mounted fixed are connected on the primary side with flexible, fully- insulated cables which are inserted in the transformers.

The removable voltage transformers are fitted with HRC fuses. The EK6 type earthing switch can be used with either a manual or motor-operated mechanism.

Its switching position will be indicated both mechanically by indication on the shaft and electrically by means of the auxiliary switch. Earthing switch in 550 series cannot be equipped with a motor-operated mechanism.

Three surge arrestors can be mounted fixed, instead of one position of single-core cables.

Cable connection of 12/17.5 kV units

In the 550 and 650mm wide panel, up to three parallel plastic cables can be connected with single-core cable protection and push-on sealing ends with a maximum cross-section of 630mm². In the 800 or 1000mm wide panel, up to six parallel plastic cables can be connected with single-core cable protection and push-on sealing ends with a maximum cross-section of 630mm².

Customer requests regarding connections to bars, three-core cables, special cables or sealing ends of different types must be considered during the order-planning stage.

Cable connection of 24 kV units

In the 800mm wide panel, up to three parallel plastic cables can be connected with single-core cable protection and push-on sealing ends with a maximum cross-section of 500 mm².

In the 1000mm wide panel, up to six parallel plastic cables can be connected with single-core cable protection and push-on sealing ends with a maximum cross-section of 500 mm².

For more information regarding cable connection, see chapter 5.9.

For detailed information about cable connections, please make reference to the figures 102...106.

The cable connections are supplied without screws, washer and nuts; the supply of this material, according to the cable termination, is at Customer charge.

3.3.5 Control cabinet (Figures 2, 4)

The control cabinet is, for all control and protection aspects, suitable for both conventional or microprocessor control technology.

The height of the control cabinet is 705/1100mm. For details, see chapter 2.3.

If the secondary devices are not intended for door installation, they are mounted on DIN RAILS. They enable any subsequent changes to the wiring. In the lower part of the control cabinet, there are three rows of DIN RAILS on the swivelling DIN RAIL holder and, below these, there is an easily accessible auxiliary switch for the control wiring plug.

Secondary wiring inside the panel is in a duct on the right side of the panel. The left side of the panel is for the external wiring. The ducts are covered with steel sheet metal 43.1, 43.2. There are holes for sliding in the ring conductors at the side of the control cabinet.

3.3.6 Switch-disconnector and cable compartment in the panel with switch-disconnector

The switch-disconnector and cable compartment is merged. The switch-disconnector is mounted stationary and connected to busbars. The interconnection to the busbar compartment is carried out by means of bushings, which secures the separation of busbar compartment from all other switchgear compartments.

The switch-disconnector and cable compartment is also separated from other compartments by means of metal partitions.

The switch-disconnector can optionally contain an integrated earthing switch. The switching positions of the integrated earthing switch type E can be indicated by an auxiliary switch.

Closing and opening of the switch-disconnector is performed manually by means of a lever with the door closed. On request the device can be also mounted for motor operation of switch-disconnector. The switch-disconnector can consequently be operated not only locally but also remotely. The earthing switch is always operated locally by means of the operating lever.

The switchgear is constructed for the use of one-core cables as standard. The cable compartment usually contains supporting insulators for fastening cables. On request the cable compartment can contain the instrument current transformers instead of supported insulators. If all three current transformers are not required, the relevant insulators are installed instead of them.

Cable connection in the panels for 12 kV, 17.5 kV and 24 kV:

In the panel with switch-disconnector 1 plastic one-core cable can be connected on each phase with the cross-section up to 240mm² as standard.

Important note

In the case of any atypical cable connections an agreement must already be reached between customer and manufacturer in the technical preparation stage of order.

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1) In the case of a motor operator, the mechanical interlock or the locking magnet is replaced by an electrical interlock of the earthing switch. The manual emergency switch is not locked!

2) The locking magnet is not installed in the case of a motor operator; busbar earthing switches or the withdrawable parts are electrically locked. The manual emergency switch is not locked!

3) This interlock is not available for motor-operated withdrawable apparatus as a mechanical device.

3.4 Interlock/protection against erroneous operation

3.4.1 Panel internal interlocking (Figure 2)

To prevent hazardous situations and erroneous operation, there is a series of interlocks to protect both personnel and equipment:

• The withdrawable part can only be moved from the test/disconnected position (and back) when the circuit-breaker and earthing switch are off (i.e. the switch must be off beforehand.) In the intermediate position, the switch is mechanically interlocked. When the circuit-breakers have an electrical release, the interlock is also electrical;

• The circuit-breaker can only be switched on when the withdrawable part is in the test or service position. In the intermediate position, the switch is mechanically interlocked. When the circuit-breakers have an electrical release, the interlock is also electrical;

• In panels with digital control technology, prevention of malfunction of the switch can also be achieved by means of the control terminal (i.e. REF542plus);

• In the service or test positions, the circuit-breaker can only be switched off manually when no control voltage is applied and it cannot be closed (electromechanical interlock);

• Connecting and disconnecting the control wiring plug 10.2 (figure 5) is only possible in the test/ disconnected position of the withdrawable part;

• The earthing switch 6 can only be switched on if the withdrawable part is in the test/disconnected position or outside of the panel (mechanical interlock ¹);

• If the earthing switch is on, the withdrawable part cannot be moved from the test/disconnected position to the service position (mechanical interlock);

• Optionally there can be interlocking on shutters to prevent opening them manually. If it is applied then a shutter device needs to be ordered;

• Details of other possible interlocks, e.g. in connection with a locking magnet on the withdrawable part and/or earthing switch drive, can be obtained from the relevant order documents.

3.4.2 Door interlocking (Figures 13 to 20)

The panels can be equipped with the following interlocks (all optional):

• The apparatus (circuit-breaker or contactor) cannot be racked-in if the apparatus compartment door is open (figure 13, 14). ³);

• The apparatus compartment door cannot be opened if the apparatus (circuit-breaker or contactor) is in service or in an undefined position (figure 15, 16);

• The earthing switch cannot be operated if the cable compartment door is open (figure 17, 18); • The cable compartment door cannot be opened if the earthing switch is open (figure 19, 20).

Warning

It is important that when the front doors (circuit-breaker and cable) are supplied with screws, these screws are all fixed properly in order to guarantee the interlocks and the safety of the personnel in case of internal arc.

3.4.3 Interlocks between panels

• The busbar earthing switch can only be closed when all the withdrawable parts in the relative busbar section are in the test/disconnected position (electromechanical interlock ²);

• When the busbar earthing switch is closed, the withdrawable parts in the earthed busbar section cannot be moved from the test/disconnected position to the service position (electromechanical interlock ²).

3.4.4 Locking devices (Figure 2)

• The shutters 12.1/12.2 can be secured independently of each other with padlocks when the withdrawable circuit-breaker part has been removed;

• Access to the operating-shaft 14.1 of the earthing switch can be restricted with a padlock; • Access to the circuit-breaker racking slot can be restricted with a padlock;

• Access to the circuit-breaker compartment and the cable compartment can be restricted with a padlock.

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A

B

Figure 13: Circuit-breaker compartment door enabling device (A)

Figure 14: Circuit-breaker truck enabling slot (A)

Figure 16: Circuit-breaker compartment door locking pin (B) Figure 15: Circuit-breaker compartment door locking device (B)

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C

C1

C2

Pin ON Pin OFF

D

Figure 17: Cable compartment door enabling device (C)

Figure 18: Cable compartment door enabling slot (C1) and earthing switch enabling pin (C2)

Figure 19: Cable compartment door locking device (D)

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200.1

200

205.1 205

215

Figure 21: Switch-disconnector compartment – open position. Insulating plate in the isolating distance of switch-disconnector

200 Switch-disconnector 200.1 Position indicator of

switch-disconnector

205 Insulation partition wall 205.1 Movable insulation plate

3.4.5 Internal interlocking of panel with switch-disconnector

To prevent hazardous situations and erroneous operation, there is a series of interlocks to protect both personnel and equipment:

• The switch-disconnector can only be switched on if the earthing switch is off. The earthing switch can only be switched on if the switch-disconnector is off. The switch-disconnector and earthing switch are mutually mechanically interlocked;

• The door of the lower cable HV part on the panel can only be opened if the earthing switch is on. During closing of the earthing switch the insulating plate 205.1 (figure 21) is automatically inserted in the isolating distance of the switch-disconnector, which increases safety. This plate is automati-cally removed again during opening of the earthing switch;

• The earthing switch can only be operated if the cable compartment door is closed;

• If the control voltage is not connected, the switch-disconnector can only be opened and closed manually. Manual operation of switch-disconnector and earthing switch can be prevented if the slides 201.2 and 208.1 of the operating openings are locked up;

• In the panels with digital control techniques the protection against erroneous operation is basically carried out by means of panel software. But the earthing switch is operated locally by means of operating lever 215 (figure 22). The mechanical interlock between the switch-disconnector and earthing switch is still in operation;

• Details of other possible interlocks, e.g. in connection with a locking magnet on the switch-disconnector, can be obtained from the relevant order documents.

Warning

• The door of the upper HV part on the panel can only be opened if the off-circuit condition of the switch disconnector is verified. This means that the off-circuit condition must be unconditionally verified both on the upper and lower contacts of switch disconnector.

Figure 22: Preparation for the operation of earthing switch in panel with the switch-disconnector. Operating lever prepared for the operation OFF.

215 Operating lever

3.5 Circuit-breaker and contactor plug connector coding

The control wiring plug connector coding allows withdrawable parts for switching devices to be assigned to particular panels. This ensures, for example, that withdrawable parts with different rated currents or different control wiring circuits can only be used in the panels they are intended for.

Coding pins are fitted in the control wiring sockets 10.1 (figure 23) or control wiring plugs 10.2 (Figure 5), and engage with the corresponding bores of the relevant plug 10.2 or socket 10.1 when the two parts are connected.

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Figure 23: Control wiring plug connector coding, shown for a 58 pole connector 10.1 Control wiring socket

10.4 Centring strinking tabs

10.5 Bore for actuating pin of the control wiring plug for controlling the auxiliary switch Coding

The corresponding coding designation for the control wiring plug is given in brackets (10.2)

The coding pins can be fitted in the control wiring socket (10.1) and/or in the control wiring plug (10.2).

Basic design

The number of sockets is optional, but the basic assignment is 1, 8, 10, 20, 21, 31, 33 and 40. Sockets and pins can be mixed as required in the control wiring socket (10.1) and control wiring plug (10.2).

Circuit-breakers and contactors Plug pin coding (apparatus) Socket hole coding (panel)

12-17.5 kV 650 mm 800 mm 1000 mm B1 B2 B3 B4 B5 B6 B1 B2 B3 B4 B5 B6 400 A V • • • • 630 A VD4 VM1 HD4 • • • • 1250 A VD4 VM1 HD4 VD4 VM1 HD4 • • 1600 A VD4 VM1 HD4 VD4 VM1 • • • • 2000 A VD4 VM1 • • 2500 A VD4 VM1 HD4 • • • • 3150 A VD4 VM1 HD4 • • • • 3600 A VD4 VM1 HD4 • • • • 4000 A VD4 VM1 HD4 • • • •

Isolating trucks Plug pin coding (apparatus) Socket hole coding (panel)

12-17.5 kV 650 mm 800 mm 1000 mm B1 B2 B3 B4 B5 B6 B1 B2 B3 B4 B5 B6 400 A 630 A 17.12.32 1250 A • • • • 1600 A 17.20.50 2000 A • • • • 2500 A 17.25.50 • • • • 3150 A • • • • 3600 A 17.32.50 • • • • 4000 A • • • •

Circuit-breakers Plug pin coding (apparatus) Socket hole coding (panel)

24 kV 800 mm 1000 mm B1 B2 B3 B4 B5 B6 B1 B2 B3 B4 B5 B6 630 A VD4 VM1 HD4 VD4 VM1 • • • • 1250 A VD4 VM1 HD4 VD4 VM1 • • 1600 A VD4 VM1 HD4 • • • • 2000 A VD4 VM1 HD4 • • 2500 A VD4 VM1 HD4 • • • •

Isolating trucks Plug pin coding (apparatus) Socket hole coding (panel)

24 kV 800 mm 1000 mm B1 B2 B3 B4 B5 B6 B1 B2 B3 B4 B5 B6 630 A 1250 A 24.12.25 • • • • 1600 A 2000 A 24.25.25 2500 A • • • •

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3.6 Fast recovery device

UniGear ZS1 switchgear can optionally be equipped with “Fast Recovery Device”, a specific protection system.

This system is based on pressure sensors (figure 24), suitably located in the switchgear and directly connected to the shunt opening release installed in the circuit-breaker operating mechanism (figure 25).

The sensors detect the pressure rise front at the moment of an internal arc and promptly open the circuit-breaker.

Thanks to the “Fast recovery” system, only the part involved in the fault is selectively excluded in under 100ms (including the circuit-breaker opening time). Rapid elimination of the fault along with the metal segregation between compartments and the use of self-extinguishing materials drastically reduces any possible damage.

1

2

3 Figure 24: Pressure sensor Figure 25: Shunt opening release

Figure 26: Fast recovery system Figure 27: Testing equipment

Resetting the auxiliary contacts

1 Pressure reducer

2 Lever for opening the air valve 3 Manometer

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3.7 Ith Limiters

UniGear ZS1 switchgear can optionally be equipped with microswitches on the top of each unit. The microswitch generates a fault signal immediately when the overpressure flap is being opened. Reaction time is less then 15ms. The signal from microswitch can be sent directly to circuit-breaker OFF trigger.

Rapid elimination of the fault along with the metal segregation between compartments and the use of self-extinguishing materials drastically reduces any possible damage.

49.5

49.4 49.2 11.5

A) Valid for crouzet type microswitch

B) Valid for M1S 6610 type microswitch

Figure 28: Auxiliary Ith limiter switch. It may be necessary to move the auxiliary switches into their service position when the lifting eyebolts have been removed.

It is necessary to adjust the centre of the switch knob of the auxiliary switch to the centre of the pressure relief flap’s hole. Correct value of the adjustment of the auxiliary switches’ height in pressed position according to the particular type of the switch is on the figure A) or B).

11.5 Ith limiter

49.2 Pressure relief flap, made of steel sheet 49.4 Rupture bolt (plastic)

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4. Dispatch and storage

4.1 Condition on delivery

At the time of dispatch, the UniGear ZS1 panels are factory-assembled, the withdrawable parts are in the test position and the doors are closed.

The factory-assembled panels are checked at the works for completeness in terms of the order and simultaneously subjected to routine testing (normally without AC voltage testing of the busbars) according to IEC publication 62271-200, and are therefore tested for correct structure and function. The busbars are not assembled. The busbar material, fasteners and accessories are packed separately.

4.2 Packing

According to the kind of transport and country of destination, the panels remain unpacked or are welded in foil and packed in seaworthy crates. A drying agent is provided to protect them against moisture: • Panels with basic packing or without packing;

• Panels with seaworthy or similar packing (including packing for container shipments): - Sealed in polyethylene sheeting;

- Transport drying agent bags included; - Moisture indicator included;

• Observe the directions for use of the drying agent bags. The following applies: - Coloured indicator blue: contents dry;

- Coloured indicator pink: contents moist (relative humidity above 40%).

4.3 Transport

The transport units normally comprise individual panels and, in exceptional cases, small groups of panels. The panels are each fitted with four lifting eyebolts.

Transport panels upright. Take the high centre of gravity into account. Only ever carry out loading operations when it has been ensured that all precautionary measures to protect personnel and materials have been taken and use the following:

• Crane;

• Fork-lift truck and/or; • Manual trolley jack. Loading by crane:

• Fit lifting ropes of appropriate load capacity with spring catches (eyebolt diameter: 30 mm); • Keep an angle of at least 60° from the horizontal for the ropes leading to the crane hook; • Hang the unit using ALL four eyebolts!

For detailed information on switchgear handling, please refer to chapter 4.6.

Figure 29: Handling by crane 1.5 lifting eyebolt

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4.4 Delivery

The responsibilities of the consignee when the switchgear arrives at site include, but are not limited to, the following:

• Checking the consignment for completeness and lack of any damage (e.g. also for moisture and its detrimental effects). In case of doubt, the packing must be opened and then properly resealed, putting in new drying agent bags, when intermediate storage is necessary;

• If any quantities are short, or defects or transport damage are noted, these must be: - documented on the respective shipping document;

- notified to the relevant carrier or forwarding agent immediately in accordance with the relative liability regulations.

Note

Always take photographs to document any major damage.

4.5 Intermediate storage

Optimum intermediate storage, where this is necessary, without any negative consequences depends on compliance with a number of minimum conditions for the panels and assembly materials. 1.Panels with basic packing or without packing:

• A dry well-ventilated store room with a climate in accordance with IEC 60694; • The room temperature must not fall below –5 °C;

• There must not be any other negative environmental influences; • Store the panels upright;

• Do not stack panels; • Panels with basic packing:

- Open the packing, at least partially; • Panels without packing:

- Loosely cover with protective sheeting; - Ensure that there is sufficient air circulation;

• Check regularly for any condensation until installation is started.

2.Panels with seaworthy or similar packing with internal protective sheeting: • Store the transport units:

- protected from the weather; - in a dry place;

- safe from any damage; • Check the packing for damage;

• Check the drying agent (also see section 4.2): - on arrival of the consignment;

- subsequently at regular intervals;

• When the maximum storage period, starting from the date of packing, has been exceeded: - the protective function of the packing can no longer be guaranteed;

- take suitable action if intermediate storage is to continue.

Warning

Do not walk on the roof of the panels (rupture points in pressure relief devices!). The pressure relief devices and/or Ith Limiters could by damaged.

4.6 Handling

4.6.1 Switchgear

The switchgear sections are usually fixed to wooden pallets. Handling should be carried out by means of bridge or mobile cranes. Otherwise, use rollers or fork lift trucks.

Weights and dimensions of each section are listed in the shipping documents and in the plant drawings.

4.6.1.1 Handling with bridge crane or mobile crane and unpacking Handling the switchgear in the wood packing

The switchgear must be lifted by means of a crane and circular slings 1 (figure 30). The slings must be inserted according to the lifting symbols marked on the crate.

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Unpacking

• Remove the nails and crate lid and sides;

• Open the compartment door and loosen the bolts fixing the switchgear to the pallet; • Lift the cubicles by means of the crane following the instructions below;

• Remove the pallet;

• Position the unloading shims;

• Put the switchgear on the loading shims by using the crane.

Figure 30: Handling the switchgear in the wooden crate

Switchgear handling

• Only use a suitable balanced lifting system.

• Should an accidental fault cause a leakage of SF6, ventilate the room and carefully follow the

safety procedures prescribed in the IEC 1634 Standards.

After unpacking, lift the unit groups by means of a crane (figure 29). Use the eyebolts (1.5) and the ropes fitted with safety.

After installation of the panels, remove the eyebolts used for lifting.

4.6.1.2 Handling by means of rollers

• Only use rollers on a level floor.

• Move the switchgear section avoiding any possible tilting.

Lift the switchgear section by means of a bridge or mobile crane or using jacks (figure 29); remove the wooden pallet loosening the screws fixing it to the switchgear section base.

Put a sturdy metal sheet between the rollers and the unit base and place the switchgear on the sliding rollers.

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Figure 31: Handling by means of rollers

4.6.1.3 Handling by means of transpallet or fork lift trucks

• Only use transpallets or fork lift trucks on a level floor. • Move the switchgear section avoiding any tilting.

To guarantee stability, the switchgear must not be lifted too high. Check the levelness of the forks.

Sliding rollers

Metal sheet

4.6.2 Apparatus

The apparatus can be handled by means of cranes, fork lift trucks or using the truck provided by ABB. For each piece of apparatus follow the instructions below.

• While handling do not put any stress on the insulating parts and on the apparatus terminals. • Before handling the apparatus, make sure that the operating mechanism springs are

discharged and that the apparatus is in the open position.

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4.6.2.1 Handling by means of crane Circuit-breakers

Hook the lifting bolts to the relevant supports (figure 34). While handling, pay the utmost attention not to put any stress on the insulating parts and on the circuit-breaker terminals (figure 35).

Before putting into service, remove all the lifting eyebolts.

Contactor

• Insert the lifting bar (1) centring it with the contactor; • Hook the bracket (2) to the lifting bar (1);

• Hook the bracket (2) by means of a spring catch and lift the contactor; To remove the lifting equipment proceed in reverse order.

Figure 34: Correct handling Figure 35: Wrong handling

Figure 36: Mounting the lifting equipment

4.6.2.2 Handling by means of fork lift trucks

Do not insert the truck forks straight underneath the apparatus but put the apparatus on a sturdy support.

Handling by means of fork-lift trucks can be carried out only after the apparatus has been positioned on a sturdy support.

While handling, pay the utmost attention not to put any stress on the insulating parts and on the circuit-breaker terminals.

2

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(*) (**) 3 4 3 4 1

Figure 37: Handling by means of fork lift trucks

4.6.2.3 Handling by means of ABB truck

For handling and inserting the apparatus into the switchgear, use the truck 1 supplied by ABB (Figure 38). • Do not use the racking in/out truck for any purpose other than handling our apparatus. • Fix the circuit-breaker to the truck before moving it.

In order to handle the circuit-breaker by means of the relevant truck, follow the instructions below (figure 38):

• hook the lifting bolts to the circuit-breaker supports and align it above the truck (1):

• press the handles (2) towards the circuit-breaker centre (*) to make the horizontal check pins go in (3); • put the circuit-breaker on the truck;

• push the circuit-breaker towards the circuit-breaker compartment and insert the truck into the guides until the handles (2) are released (**) outwards and the horizontal locking pins go into the slots (4), locking the circuit-breaker.

Figure 38

(*) Handling direction for horizontal locking pin entry. (**) Handling direction for exit of the horizontal locking pins.

2 2

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5. Assembly of the switchgear on site

In order to obtain an optimum installation sequence and ensure high quality standards, site installation of the switchgear should only be carried out by specially trained and skilled personnel, or at least by personnel supervised and monitored by responsible persons.

5.1 General site requirements

On commencement of installation on site, the switchgear room must be completely finished, provided with lighting and the electricity supply, lockable, dry and with facilities for ventilation. All the necessary preparations, such as wall openings, ducts, etc., for laying the power and control cables up to the switchgear must already be completed. Where switchgear panels have top-mounted structures for earthing switches or instrument transformers, it must be ensured that the ceiling height is sufficient for the opening travel of the pressure relief plates.

The ceiling must be high enough for assembly of pressure relief duct and/or top-mounted VT box and earthing switch box.

Compliance with the conditions for indoor switchgear according to IEC 60694, including the conditions for the “minus 5 indoor” temperature class must be ensured.

5.2 Foundations

The following 3 basic installation methods of switchgear in the switchroom are distinguished:

Method A – installation on the base irons of “C” profile shape

As standard it is recommended to install the switchgear on the base irons of “C” profile shape set into the concrete floor of switchroom. In this case the units are fastened using the special bolt blocks (ABB delivers by request).

Method B – installation on the levelled concrete floor

Installation directly on the levelled concrete floor makes much higher demands on the floor levelling, which must, in this case, fulfill the same tolerances as the base irons during installation method A. The fastening is carried out by means of anchoring bolts in the concrete floor.

Method C – installation on the raised false floor

In this case fastening of units is carried out by welding of outside panels to the steel floor frame in the place where the frame exceeds the switchgear bottom, this means on the outside lateral walls of unit row.

This method of installation is not recommended if seismic resistance is required.

Generally it is possible to recommend the following procedure of switchgear anchoring and namely for any of the cited methods of installation:

1. The switchgear panels are bolted together in the front and rear part into one unit;

2. If seismic resistance is not required, it is not necessary to attach each switchgear panel to the floor or frame, but it suffices to only fix outside panels in each row of switchgear;

3. If seismic resistance is required, it is necessary to attach each switchgear panel to the floor or frame. To achieve seismic resistance the special fixing system is used. This system preferably makes use of a steel floor frame with “C” profile shape but moreover with an additional special fixing element – please contact the manufacturer for details.

Further given structural data guidelines given makes a rough calculation of the space required and planning of the room design for a switchgear project.

When the final construction documents are compiled for execution of building, the binding data supplied by ABB for a particular case must always be taken into account!

1) _{Pay attention to appropriate national standards.} 2) _{Applies to low voltage compartments of standard height.} 3) _{Approximate numbers depending on the type of panels.}

Dimension chart of structural data

Rated voltage kV 12/17.5 kV 24 kV

Panel width FT mm 550 650 800 1000 800 1000

Aisle width 1)_G _mm ₁₃₅₀ ₁₄₅₀ ₁₆₀₀ ₁₈₀₀ ₁₅₀₀ ₁₇₀₀

Door width mm 750 850 1000 1200 1000 1200

Door height 2) _mm ₂₄₀₀ ₂₄₀₀ ₂₄₀₀ ₂₄₀₀ ₂₅₂₅ ₂₅₂₅

Assembly opening in ceiling:

Width mm 1000 1000 1000 1200 1000 1200

Length mm 1500 1500 1500 1500 1800 1800

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5.2.1 Method of installation A – Installation of the base irons:

The general foundation drawing is given in figures 39, 40 according to parameters of units. • The base irons of “C” profile shape can be supplied by ABB manufacturer together with the

switchgear. Their installation is usually carried out by site personnel and should, if possible, be performed under supervision of an ABB specialist. The base irons must be installed in the slab before finishing the floor;

• Rest the irons in the specified position on the concrete floor as shown in the relevant foundation drawing and mark out holes for drilling in the place of prepared holes. Then drill the holes for anchoring bolts i.e. for plugs 14 for fixing the base irons in the floor. Then put the plugs in the holes and attach the base irons to the floor slightly with the bolts 13 without end tightening to make the required levelling possible.

• Carefully level base irons both longitudinally and transversally over the entire length and to the correct height by putting them under strips of suitable thickness and using a levelling instrument.

Tolerances for laying the floor frame are:

Evenness tolerance: ± 1mm within a measuring length of 1m

Straightness tolerance: 1mm per 1m, but not more than 3mm over entire length of frame. • After levelling of the base irons tighten the bolts 13. The adjusted position of the base irons on the

concrete floor must not be changed during this operation! Check again and if necessary correct deviations;

• Weld Individual parts of the base irons inside “C” profile in the seams together so that the conductive connection is mutually reached. In the version of intermittent base irons intended for the switch disconnector panel with rated voltage 12/17.5kV (for 24 kV there is no intermittent base irons) figure 40 the individual base irons must be conductively connected by welding galvanized steel strips of min. dimensions 30x4mm in the shape of loop. The connection strips must avoid the opening for power cables so that they do not obstruct the cables;

• Take necessary measures for perfect earthing of the base irons with galvanized steel strips of dimensions min. 30x4mm. Two earthing connections are recommended for the panel row longer than approx. 5 panels;

• When the floor top covering is applied, carefully backfill the floor frame, leaving no gaps. The top edge of floor frame should be 2mm above the finished floor surface; the tolerance of this value is within the limits of 0 to 5mm. This facilitates erection and alignment of the switchgear panels. In some cases, this means that the material thickness of an additional floor covering to be fitted later must be taken into account separately;

• The base irons must not be subjected to any harmful impact or pressures, particularly during the installation phase. If these conditions are not respected, problems during assembly of the switchgear and possibly with movement of the withdrawable parts, as well as opening and closing of the doors cannot be ruled out.

Attachment of units to the base irons of “C” shape (Figure 56)

The switchgear is attached to the base irons by means of special bolt blocks, which can be supplied on request.

• Put individual units of switchgear in successive steps onto correctly levelled and installed base irons and level them according to the relevant foundation drawings;

• Level the units and then bolt them together in the front and rear part;

• To attach to base irons, insert specially prepared bolt blocks into the fixing holes in the bottom of units and tighten.

5.2.2 Method of installation B – Fixing with anchoring bolts to concrete floor (Figure 55). The general foundation drawing is given in figure 41 according to parameters of units.

• Clean the installation area of the switchgear carefully;

• On the slab, visibly trace the perimeter of all the units making up the switchgear according to the relevant drawing, taking the minimum wall and obstacle clearances into account;

• Level the floor both longitudinally and transversally; evenness tolerance is ± 1mm within a measuring length of 1m;

• Drill the floor at the foreseen fixing points, referring to the slab drilling drawings. To make the holes, use a hammer drill with the bit according to the steel plugs used;

• Insert the plugs in the holes and put the individual panels on the traced perimeters of the units creating the switchgear;

• Level the units and then bolt them together in the front and rear part;

• Fix the units with bolts with special washers (the coupling material is supplied by request); • In the case of a metal floor, use the attachment according to the figure (Figure 57 or 58) To make

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Figure 39: UniGear ZS1 12÷24 kV (i.e. the above section is related to 12 kV, 2500A nominal current) Guideline structural data for foundation frame on concrete floor

It is not valid for the panel with switch-disconnector C Panel depth

G Width of operating aisle (panel width + 800mm) FT Panel width

TB Door width = FT + 200mm

TH Door height = panel height + 200mm 1) Min. dimensions

2) The dimension must be verified in the documentation of the relevant order 10 Door

11 Rear cover 12 Side end cover 13 Screw

14 Steel dowel

Top view

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Figure 40: UniGear 12÷24 kV with NAL switch-disconnector (i.e. the above section is related to 12 kV) Guideline structural data for foundation frame on concrete floor

C Panel depth is C=1340 mm or 1300 mm according to the depth of the other cubicles – however always consider note 2)

G Width of operating aisle FT Panel width

TB Door width = FT + 200 mm

TH Door height = panel height + 200 mm 1) Min. dimensions

2) The dimension must be verified in the documentation of the relevant order 10 Door

11 Rear cover 12 Side end cover 13 Screw

14 Steel dowel

Top view

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Figure 41: Example of 12/17.5 kV switchgear on foundation frame on concrete floor. Panel with pressure relief to the outside.

A Panel depth

1) Minimum dimensions

2) The dimension must be verified according to the documentation of the relevant order 1 Operator aisle

6 Control cabinet (optional) 8 Opening for ventilation

9 Height of cable base - as required 10 Concrete - see also fig. 5/8 12 Opening for power cables 14 Door

16 Wall opening for pressure relief 17 Pressure relief duct

16 17 6 8 9 10 14 1 12

5.2.3 Method of installation C – Fixing to a raised false (Figure 42)

The general foundation drawing is given in figure 42 according to parameters of units. In most cases the floating floor is created by steel structure in which the welded steel frame is installed. The frame produced from suitable steel profiles is used. ABB does not supply this frame.

• Clean the installation area.

• After installation of the frame, take any necessary measures for perfect earthing of the frame with galvanized steel strips of min. dimensions 30x4mm. Two earthing connections are recommended for the panel row longer than approx. 5 panels.

• Put the units on the frame according to the relevant foundation drawings, taking the minimum wall and obstacle clearances into account.

• Level the units and then bolt them together in the front and rear part.

• Carry out attachment by welding the outside panels to the steel floor frame in the place where the frame exceeds the switchgear bottom, this means on the outside lateral walls of the unit row. This method of installation is not recommended if seismic resistance is required.

• In the case of a metal floor use the attachment according to the figure (Figure 57 or 58) To make the holes, use a drill with a suitable bit for the type of fixing to be made (through or threaded hole).

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Figure 42: Guideline structural data for a raised false floor – 12, 17.5 and 24 kV UniGear ZS1 A Panel depth

G Width of operating aisle FT Panel width

TB Door width = FT + 200 mm

TH Door height = panel height + 200 mm 1) Min. dimensions

x) Max. dimensions

2) The dimension must be verified in the documentation of the relevant order

View B

Example of profiles for foundation frame for a raised false floor

Top view

Section A-A Section A-A Rated Panel B C 1) voltage depth A 2) kV m m m 12/17.5 bis 2500 A 1340/1300 1235 135 12/17.5 bei 3150/4000 A 1390/1350 185 24 1560/1520 1450 140

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Figure 44: 12/17.5 kV – 650/800/1000mm wide units – base iron fixing system

Figure 43: 12/17.5 kV – 650/800/1000mm wide units – anchoring bolt fixing system

Figure 45: 12/17.5kV – 550mm wide units – anchoring bolt fixing system

Figure 46: 12/17.5kV – 550mm wide units – base iron fixing system

70 105 550 340 105 50 200 300 0 6 37 70 430 60 50 200 311 843 1231 72 340 1231 843 72 31 1 60 70 105 340 200 50 70 105 340 550 300 430 60 200 50 37 FT A B (width of cubicle) mm mm mm 650 440 450 800 590 600 1000 790 800

Unigear Manual

UniGear ZS1

Installation, service and maintenance

Your safety first – at all times!

This is why our instruction manual begins with the following recommendations:

• Only install switchgear and/or switchboards in closed rooms suitable for electrical

equip-ment.

• Ensure that installation, operation and maintenance are only carried out by specialist

electricians only.

• Fully comply with the legally recognized standards (IEC or local), the connection conditions

of the local electrical utility and the applicable safety at work regulations.

• Observe the relevant information in the instruction manual for all actions involving

switchgear and switchboards.

• Danger!

Pay special attention to the hazard notes in the instruction manual marked with this warning

symbol.

• Make sure that the specified data are not exceeded under switchgear or switchboard

operating conditions.

• Keep the instruction manual accessible to all personnel involved in installation, operation

and maintenance.

• The user’s personnel must act responsibly in all matters affecting safety at work and correct

handling of the switchgear.

WARNING

Always follow the instruction manual and respect the rules

of good engineering practice !

Hazardous voltage

can cause electrical shocks and burns.

Disconnect power, then earth and short-circuit before proceeding

with any work on this equipment.

If you have any further questions about this instruction manual, the members of our field

organization will be pleased to provide the required information.

We reserve all rights to this publication. Misuse, and including in particular, duplication and

making this manual - or extracts thereof available to third parties is prohibited. We do not

accept any responsibility for the information provided, which is subject to alternation.

Contents

1. Summary

1.1 General

1.2 Standards and specifications

1.3 Operating conditions

2. Technical data

2.1 Electrical data

2.2

Resistance to internal arc faults

2.3

Dimensions and weights

3. Panel design and equipment

3.1 Basic structure and variants

3.2 Enclosure and partitioning (Figure 2)

A

B

D

C

3.3 Compartments in the panels

3.4 Interlock/protection against erroneous operation

A

A

B

B

C

C1

C2

D

D

3.5 Circuit-breaker and contactor plug connector coding

3.6 Fast recovery device

3.7 Ith Limiters

4. Dispatch and storage

4.1 Condition on delivery

4.2 Packing

4.3 Transport

4.4 Delivery

4.5 Intermediate storage

4.6 Handling

5. Assembly of the switchgear on site

5.1 General site requirements

5.2 Foundations

Top view

Top view

Top view