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Me diu m v olt ag e prod uct
UniGear 500R
Installation, operation and maintenance instruction manual
1. Your safety first - at all tim es! .................................... 1
2. Sum m ary ................................ ................................. 2
2.1 Introduction ................................ ........................ 2
2.2 General ................................ .............................. 2
2.3 Standards and specifications ................................ 2
2.4 Operating conditi o n ................................ ............. 3
3. T echnical data ................................ .......................... 4
3.1 Electrical data ................................ ..................... 4
3.2 Resistance to internal arc faults ............................ 4
3.3. Dim ensions and w eights ...................................... 5
4. Panel design and equipm ent .................................... 1 3
4.1 Sw itchgear construction features ........................ 1 3
4.2 Internal arc clasification ..................................... 1 3
4.3 Sw itchgear typical com partm ents ........................ 1 4
4.4 Main com ponents ................................ .............. 1 6
4.5 Interlock s/lock s ................................ ................. 2 0
4.6 Optional applications ................................ ......... 2 1
5. Dispatch and storage ................................ .............. 2 2
5.1 Pack ing and transport ................................ ........ 2 2
5.2 Control on receipt ................................ .............. 2 2
5.3 Storage ................................ ............................ 2 3
5.4 Handling ................................ ........................... 2 4
6. Assem bly of the sw itchgear at site ............................ 2 6
6.1 General ................................ ............................ 2 6
6.2 Foundations ................................ ...................... 2 6
6.3 Assem bly of the sw itchgear panels ...................... 3 8
6.4 Installation of the busbars .................................. 4 1
6.5 Releasing the gas ov erpressure .......................... 4 2
6.6 Cable connection ................................ .............. 4 4
6.7 Earthing circuit ................................ ................. 4 6
6.8 Final erection work ................................ ............ 4 6
7. Operation of the sw itchgea r ..................................... 4 7
7.1 Circuit -break er operation ................................... 4 7
7.2 Three -position disconnector operation ................. 4 8
7.3 Front panel of incom ing/feeder unit ..................... 4 9
7.4 Front pan el of Bus -section unit ........................... 5 9
7.5 Access to v oltage transform ers, fuses or link s ...... 6 1
8. Com m issioning ................................ ....................... 6 3
8.1 Prelim inary operations ................................ ....... 6 3
8.2 Measurem ents and tests ................................ ..... 6 3
9. Maintenance ........................................................... 6 4
9.1 General ................................ ............................ 6 4
9.2 Inspection ................................ ......................... 6 4
9.3 Serv icing .......................................................... 6 5
9.4 Repairs ................................ ............................ 6 8
9.5 Accessories and spare parts ............................... 6 8
10. Product quality and env ironm ental protection ........... 6 9
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Summary of Contents for ABB UniGear 500R
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Page 1: Table Of Contents
Me diu m v olt ag e prod uct UniGear 500R Installation, operation and maintenance instruction manual 1. Your safety first - at all tim es! ........1 2. Sum m ary ..............2 2.1 Introduction ............2 2.2 General ........ -
Page 3: Your Safety First - At All Times
That is w hy our instruction manual begins w ith the If you have any further questions about this instruction manual, ABB’s field service team will be pleased to follow ing recommendations: Only install switchgear in closed rooms suitable for provide the required information. - Page 4 Reference standards: ENATS 41 -36, IEC 62271- Thanks to the advanced design of ABB switchgear, 200, IEC 62271-102 and IEC 62271-100 UniGear 500R is suitable not only for a high number of Depth: 1140 mm (bottom entry) / 1471 mm (top...
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Page 5: Operating Condition
Preventive action (e.g. suitable ventilation and proper air conditioning of the building or housing, use of dehumidifying equipment, etc.) must be taken into consideration with ABB to avoid this condensation phenomenon and any resu lting corrosion or other adverse effects. -
Page 6: Technical Data
3. Technical data 3.1 Electrical data Versi o n [ - ] EN A I EC I EC Rat ed v olt age [ k V ] 17. 5 Rat ed ins ul at ed v olt age [ k V ] 17. -
Page 7: Dimensions And Weights
3.3. Dimensions and weights F i g u re 2: Sw i tch g ear d i men si o n s. Di men si o n s o f th e u n i ts - Versi o n I EC [mm] EN A [ mm/ i n ch ] wit h 585 mm LV co mpart ment... - Page 8 Typical units of UniGear 500R (ENA version) F i g u re 3: 630 / 1250 A, Bo tto m en tr y cab l e. F i g u re 4: 630 / 1250 A, T o p en try c ab l e.
- Page 9 F i g u re 6: 2000 A, T o p en try c ab l e. F i g u re 7: Uni t BS – Bu s secti o n 12 kV, 1250 A, 2 5 k A. F i g u re 8: Uni t M - M easu rem en t 12 kV, 25 k A.
- Page 10 F i g u re 9: Uni t M - M easu rem en t 12 kV, 25 k A. F i g u re 10: Un i t BS – Bu s secti o n 12 kV, 2000 A, 25 k A.
- Page 11 Typical units of UniGear 500R (IEC version) F i g u re 11: 12 / 17. 5kV, 630 / 1250 A R ea r cab l e. F i g u re 12: 12 / 17. 5 kV, 630 / 1250 A F ro n t cab l e.
- Page 12 F i g u re 14: 12 / 17. 5 kV, 2000 A F ro n t cab l e. F i g u re 1 5: 12 / 17. 5 kV, 1250 A, BT / R. F i g u re 16: Un i t BS – Bu s secti o n 12 kV, 2000 A, 31. 5 k A.
- Page 13 F i g u re 17: Un i t I F D - I n co ming / F eed er / Di rect, 12 / 17. 5 kV, 2000 A, 31. 5k A, Bo tto m en tr y cab l es. F i g u re 18: Un i t M - M easu remen t 12 / 17.
- Page 14 Typical units of UniGear 500R Digital F i g u re 20: Un i t I F - In co mi n g/ F eed er w i th 1 set o f cu rren t sen so rs an d 1 set o f vo l tag e sen so rs...
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Page 15: Panel Design And Equipment
4. Panel design and equipment 4.1 Switchgear construction features UniGear 500R is a medium voltage switchgear for indoor applications with metal enclosure. Each cubicle is divided into the following segregated compartments (Figure 23)(Figure 24): A: Low voltage compartment B: Busbar compartment... -
Page 16: Switchgear Typical Compartments
4.3 Switchgear typical compartments 4.3.1. Low voltage compartment The low voltage compartment (Figure 25), houses all the standard low voltage equipment: terminal boards and cables (in special ducts); measurement instruments, protect ion relays, signalling and operating devices on the low voltage compartment door;... - Page 17 4.3.4. Gas duct channel (IEC version only) UniGear 500R arc -proof version features metallic duct (Figure collecting conveying internal arc gases. UniGear 500R switchgear available with following solutions of gas ducts Gas duct w ith outlet The duct is installed on the roof of the switchgear and, normally, the ends of the duct have been extended so as to convey the gases externally to a safe area.
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Page 18: Main Components
4.4 Main components UniGear 500R switchgear is equipped with a Vmax 4.4.2. Three-position disconnector (Figure 33) manually operated “off -load” three-position removabl vacuum circuit -breaker. The circuit-breaker is connec ted in series with a disconnector is located in the busbar compartment three-position “off-load”... - Page 19 F i g u re 35: Th ree - p o si ti o n d i sco n n ecto r. 4.4.3. Instrument transformers a) Voltage transformers (Figure 36). The resin-insulated voltage transformers are used for supplying measurement instruments and protections. They comply with IEC 61869-1, IEC 61869-3 which have fully replaced previous standard IEC 60044 -2.
- Page 20 They KECA 250 B1 comply with IEC 61869 -1, IEC 61869-2 which have dynamic current measurement (protection fully replaced previous standard IEC 60044 -1. Their purposes) the ABB sensors KECA 250 B1, fulfill dimensions accordance with 42600 requirements protection class...
- Page 21 Indoor voltage sensors Voltage measurement in the KEVA sensor is based on the resistive divider principle. KEVA 17.5 B20 KEVA B sensor can be used in all applications up to the voltage level 17.5 kV. The sensor fulfills requirements of accuracy class 0.5 for measurement purposes and accuracy class 3P for protection purposes.
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Page 22: Interlock S/Lock
4.5 Interlocks/locks 3 – Padlocks: Using of padlocks is optional for the following: a) Circuit-breaker opening W ARNING b) Circuit-breaker closing The operations must be carried out by applying c) Operation with three -position disconnector (from normal force (not more than 450 N), only using the ON to OFF and vice versa;... -
Page 23: Optional Applications
4.6 Optional applications 4.6.1. Earthing sw itch for busbar earthing (Figure 4.6.3. Ith Limiters 43). The sensors consist of micro -switches positioned on Earthing the busbar can also be carried out using an the top of the switchgear near the gas exhaust flaps of earthing switch (mounted in a box), fitted on the top of the two power compartments (busbars and circuit - the switchgear. -
Page 24: Dispatch And Storage
Should any damage or imperfection in the supply be This equipment must be carefully checked on receipt, noticed, report this immediately to ABB (directly or packed again properly stored until... -
Page 25: Storage
If this is not possible, store the switchgear in a well - ventilated room, cover the apparatus with tarpaulins or waterproof sheets (e.g . polyethylene) and provide anti-condensation heaters. package contains dehydrating bags that must be replaced every six months. Please do not hesitate to contact ABB for any further information. -
Page 26: Handling
5.4 Handling 5.4.1. Sw itchgear 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. The weights and dimensions of each section are listed in the shipping documents and in the plant drawings. - Page 27 5.4.2 Handling by means of rollers (Figure 51). 5.4.3 Handling by transpallets or fork -lift trucks Lift the switchgear section by means of a bridge or (Figure 52). mobile crane or by using jacks. To guarantee stability, the switchgear must not be Remove the wooden pallet, loosening the screws lifted too high.
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Page 28: Assembly Of The Switchgear At Site
W hen the final building construction documents are 6.2 Foundations drawn up, the binding data supplied by ABB for a particular case must always be taken into account! The following three basic installation methods of switchgear in the switchroom are distinguished: 6.2.1. - Page 29 5 panels; profiles is used. ABB does not supply this frame. W hen the floor top covering is applied, carefully backfill the floor frame, leaving no gaps. The top Clean the installation area.
- Page 30 F i g u re 53: Un iG ear 500R (I E C) - 12 kV u n i t u p to th e n o min al cu rren t o f T -o ffs 2000 A, f rame “C” p ro fi l e. G u id el i n e stru ctu ral d ata fo r fo u n d atio n frame o n co n crete fl o o r.
- Page 31 F i g u re 54: Un iG ear 500R (EN A) - 12 kV u n i t u p to th e n o min al cu rren t o f T -o ffs 2000 A, f rame “C” p ro fi l e. G u id el i n e stru ctu ral d ata fo r fo u n d atio n frame o n co n crete fl o o r.
- Page 32 F i g u re 55: Stru ctu ral d ata gui d el i n e fo r a rai sed fal se fl o or. (see table) Simple w eld ed f ou ndat i on f ra me in para grap h 6.
- Page 33 F i g u re 56: Examp l e o f 12 kV sw i tchg ear o n a fou n d atio n frame o n co n crete fl o o r, w ith pressu r e rel i ef to th e o u tsid e (I EC versi o n o n l y).
- Page 34 F i g u re 57: Examp l e o f 12 kV sw i tchg ear o n a fou n d atio n frame o n co n crete fl o o r (EN A v ersi o n o n l y). Panel d ept h Panel h ei ght W idt h of operat ing ais le = 100 0 mm...
- Page 35 6.2.4 IEC version F i g u re 58: IF un i t, 630 / 1250 A. A) RE AR c ab l e en tr y, B) F RO NT cab l e en try. F i g u re 59: IF un i t, 2000 A, R E AR / F RO NT cab l e en try. F i g u re 60: M u n i t.
- Page 36 F i g u re 61: Bu s - secti o n un i t. 6.2.5 ENA version F i g u re 62: IF un i t, 630 / 1250 A. A) BO T T OM and B) TO P cab l e en try.
- Page 37 F i g u re 63: IF un i t 2000 A. A) ANG L E an d B) BO T T OM cab l e en try. F i g u re 64: IF un i t, 630 / 1250 A, ANG L E cab l e en tr y. F i g u re 65: Bu s - secti o n un i t.
- Page 38 F i g u re 66: M u n i t.
- Page 39 F i g u re 67: An ch o ri n g b o l ts F i g u re 68: C p ro fi l e fo r con crete fl o o r F i g u re 69: Th ro u gh ho l e on metal stru ctu re. F i g u re 70: Th read ed h o l e o n metal stru ctu re.
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Page 40: Assembly Of The Switchgear Panels
Use screws of tensile class 8.8. The tightening torques for the busbar screw connections with dished W ARNING washer are as follows: Installation must be carried ABB either by our personnel or by suitably qualified skilled customer personnel w ith in-depth know ledge sw itchgear instalation. - Page 41 Department. Note: in order to find the precise points, see where the screws are positioned in the cubicles already 6.3.3. Positioning the cubicles coupled in ABB factory. In case of need, please do not Follow these steps: hesitate contact Customer Service ...
- Page 42 6.3.4. Auxiliary circuit connection (Figure 72) After fixing coupling switchgear cubicle An example of connection groups, connect the auxilia ry interconnections. Code 2/1 (terminal 1-terminal box XC of cubicle 3) The auxiliary connection wires, fitted with female shows that terminal 1 must be connected to terminal faston terminals and detached from the terminal box box XC of cubicle 2 terminal 1.
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Page 43: Installation Of The Busbars
6.4 Installation of the busbars Busbar connections Preparation of the material. Clean the insulation on the busbar sections with a soft, dry cloth, and check for any insulation damage. Remove greasy or adhesive dirt. Busbar connections: The silver-plated surfaces of the connections must be cleaned with a metal -free non-woven cleaning cloth and thinly and evenly coated with SYN-setral- EK 339 grease. -
Page 44: Releasing The Gas Overpressure
Do not install any apparatus in the gas exhaust area w hich has not been provided by ABB. Do not w alk on the switchgear. 6.5.2. ENA version Evacuation of the gases in the switchgear... - Page 45 F i g u re 77: EN A ver si o n .
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Page 46: Cable Connection
6.6 Cable connection Access power cables, version switchgears, is only made from the rear, while in IEC version switchgears it is either from the front or the rear, (if the switchgear is not wallmounted). The feeder cubicle terminals provided cable terminal connection. - Page 47 F i g u re 81: Ap p l i cati o n o f i sol ati n g sh rou d s. F i g u re 82: Secti o n vi ew o f fin al arran g emen t. Rated Rated Pan el...
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Page 48: Earthing Circuit
6.7 Earthing circuit 6.7.1 Primary earthing busbar 6.7.3 Secondary earthing busbar (ENA version only) (Figure 87). All the switchgear cubicles are equipped with a copper base earthing busbar 1 with a 240 mm -section. The ENA version switchgear is equipped with an additional earthing busbar joints must be connected to the secondary earthing busbar which runs along the coupling... -
Page 49: Operation Of The Sw Itchgea
7. Operation of the switchgear operation can be carried out remotely by means of a special control circuit. Final closing is signalled by the relative indicator W ARNING (Figure 88). A padlock can be fitted onto the closing For ENA version: do not access the area behind or button to prevent unintentional operation (Figure 89). -
Page 50: Three-Position Disconnector Operation
7.2 Three-position disconnector operation The “off -load” three-position disconnector is ma nually operated by means of a manual mechanism. A firm action is required to overcome the resistance as the blades make contact. If excessive resistance is experienced, stop and make sure that the operation is correct. -
Page 51: Front Panel Of Incoming/Feeder Unit
7.3 Front panel of incoming/feeder unit F i g u re 92: I EC versi o n . - Page 52 F i g u re 93: Th ree - p o si ti o n d i sco n n ecto r an d ci rcu i t - b reaker sel ecto r i n d i cato rs.
- Page 53 7.3.1. Three-position disconnector operation from OFF to ON position Now it is possible to close the circuit -breaker. The indicator of the three -position disconnector Ensure that the circuit -breaker is open (Figure 94) position will indicate the ON position (Figure 94) - A).
- Page 54 7.3.2. Three-position disconnector operation from Pull the three-position disconnector handle fully down to the end of movement (“O” position) the ON to OFF position (Figure 95) - C). Ensure that the circuit -breaker is open (Figure 95) Remove the handle and release the selector which - A).
- Page 55 7.3.3. Three-position disconnector operation from Remove the handle and release the selector which OFF to EARTH position will return to the central position (Figure 96) - D). Now it is possible to close the circuit -breaker indicator three -position disconnector position will show EARTH (Figure 96) - E).
- Page 56 7.3.4. Three-position disconnector/ operation from Lift the handle fully u p to the end of its movement (“O” position) the EARTH to OFF position (Figure 97) - C). Remove the handle and release the selector which Ensure that the circuit -breaker is open (Figure 97) will return to the central position (Figure 97)
- Page 57 7.3.5 Cable test equipment (ENA version only) Interlocked cable test equipment (Figure provided on the front of each incoming/feeder unit. Access to this equipment is obtained by earthing the cable and opening the cable test access cover (Figure 99), thus removing the earth star point. The cover i s mechanically interlocked with the circuit -breaker and the three-position disconnector in order to prevent dangerous contacts with live parts.
- Page 58 To access cable test points Remove the padlock from the cable test access cover lever (Figure 100)A) Pull down the lever (Figure 100)B) to FREE position of the cable test access cover – see position indicator on the front cover. Before opening the cable test access cover fit a W ARNING padlock on the cable test access cover lever in...
- Page 59 because dimensions, tes t equipment connectors cannot be inserted in the earth connection, then use an earth contact extension blade (provided as an accessory) (Figure 101). W ARNING Ensure that test points dead before connecting the test equipment. F i g u re 102: Cab l e test acce s s l o cki n g - L O CKED p o si ti o n F i g u re 103: Cab l e test acce s s l o cki n g - F REE po si ti on F i g u re 101: Earth co n tact exten si o n bl ad e.
- Page 60 To restore normal operating conditions W ARNING Cables are only earthed if both the cable test access cover and the circuit -breaker are closed W ARNING (the three-position disconnector must be in the After testing, the test connections may retain a EARTH position).
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Page 61: Front Panel Of Bus-Section Unit
7.4 Front panel of Bus-section unit bus-section unit consists indiv isible interlocked together and with the circuit-breaker in modules with following main elements: order to prevent their operation when the circuit - breaker is closed and to prevent the circuit-breaker left module: one three -position disconnector (Ds) being operated when either selector is in use. - Page 62 7.4.1. To operate the three -position disconnector Electrical tripping of the breaker is disabled when of the bus-section unit (Figure 106). the three-position disconnector is in the EARTH The two busbar systems can be isolated from each position. other by opening either three -position disconnector Close the circuit-breaker (E) to apply the earth (Ds and Dd) (chapter...
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Page 63: Access To V Oltage Transform Ers, Fuses Or Link
All the operations describeb must only be carried out by qualified and skilled personnel with in - depth know ledge of the apparatus. Only use fuses indicated by ABB. In order to have access to voltage transformers MV removable fuses or links (if instal led), make reference... - Page 64 F i g u re 111: Remo vi n g o f screw s an d secu ri t y co ver s. IEC version (front fused VTs) Apply earth to the circuit by moving the three - position disconnector to the EARTH position (see par.
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Page 65: Commissioning
All operations for putting into service must be conditions are restored. carried out either by ABB personnel or by ABB trained personnel. Should the operations be prevented, do not force the mechanical interlocks but make sure that the operating sequence is correct. -
Page 66: Maintenance
9. Maintenance recommended that ABB service personnel be called in to perform the servicing and repair work detailed below. The inspection and servicing intervals for some W ARNING of the equipment/components (e.g. parts subjects to For ENA version: do not access the area behind or... -
Page 67: Servicing
For a permanent remedy to this F i g u re 113: I EC versi o n . type of unusual problem, contact the ABB after - sales assistance department. 9.3.1 Maintenance in busbar and cable comp. - Page 68 2000 opening/closing operations. After operation counter reached this number, inform ABB who will verify directly that mechanical life limit earthing switch has been reached. Lubrication of fixed and movable contacts of three position disconnector by applying a thin layer of...
- Page 69 9.3.2 Maintenance in the low voltage compartment 9.3.2.1 Checking correct operation protection release Make the plant you want to work on safe (follow the plant safety regulations). Move the three-position disconnector to EARTH position and close the circuit breaker. ...
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Page 70: Repairs
For any enquiry about spare part availability and Apply the top coat in standard RAL 7035 col our, or ordering, contact the ABB Service Department. the relevant special colour. Carefully remove any white rust on high qualit y galvanized steel surfaces with a wire brush or 9.5.1. -
Page 71: Product Quality And Environmental Protection
ABB is committed to complying with the relevant legal Disposal can either be carried out thermally in an and other requirements for environmental protection incineration plant or by storing on a waste site. Raw materi al... - Page 74 1 V CD6 0 0 7 6 8 - E, EN - In s t r u c ti on M a n u a l - 2 0 23 ( Un i G e a r ) ( gs ) Y o u r s a l e s c o n t a c t : w w w .a b b .