ABB UniGear ZS1 Installation, Operation And Maintenance Instructions Manual
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ABB UniGear ZS1 Installation, Operation And Maintenance Instructions Manual

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D I S T R I B U T I O N S O LU T I O N S
UniGear ZS1
Installation, operation and
maintenance instruction manual

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Summary of Contents for ABB UniGear ZS1

  • Page 1 — D I S T R I B U T I O N S O LU T I O N S UniGear ZS1 Installation, operation and maintenance instruction manual...

  • Page 2: Table Of Contents

    — Table of contents 1. Your safety first – at all times! 2. Summary 2.1 Introduction 2.2 General 2.3 Standards and specifications 2.4 Operating conditions 3. Technical data 3.1 Electrical data 3.2 Resistance to internal arc faults 3.3 Dimensions and weights 4.
  • Page 3 6.4 Procedure for setting-up the doors 6.5 Installation of the bushing 6.6 Fixing of the panels 6.7 Installation of the busbars 6.8 Installation of the top-mounted boxes 6.9 Pressure relief ducts 6.10 Cable connection 6.11 Earthing the switchgear 6.12 Installation of interconnecting bundles 6.13 Final erection work 6.14 Note on M&D 7.

  • Page 4: Your Safety First - At All Times

    Pay special attention to the hazard notes in the instruction manual marked with this warning If you have any further questions about this symbol. instruction manual, ABB’s field service team will • Make sure that the specified criteria are not be pleased to provide the required information.

  • Page 5: Summary

    Maximum 24 h average of relative humidity Maximum 24 h average of water vapour [kPa] pressure * UniGear ZS1 panel variants have the most common Maximum monthly average of relative classification LSC2B, PM. Check other panel variants and humidity their LSC classification in catalogue 1VCP000138.
  • Page 6 (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 resulting corrosion or other adverse effects. Figure 1: Curve for determining the altitude factor k in...

  • Page 7: Technical Data

    3 150 3 150 3 150 Feeders rated current with forced 4 000 4 000 4 000 ventilation UniGear ZS1 panel with VD4G circuit-breaker can be coupled with standard UniGear ZS1 panel with VD4/P circuit-breaker * Contact ABB for higher values...

  • Page 8: Resistance To Internal Arc Faults

    (3) The internal arc withstand values are guaranteed in the compartment on the supply side of the fuses (busbars) by the structure of the switchgear and on the load side (cables) by the limiting properties of the fuses Main parameters for UniGear ZS1 panels with vacuum contactor Rated voltage...

  • Page 9: Dimensions And Weights

    — 3. Technical data 3.3 Dimensions and weights Dimensions of UniGear ZS1 12 / 17.5 kV panels [mm] 2 200 / 2 595 A Height B Width - Feeder panels up to 1 250 A ( ≤ 40 kA) [mm] - Feeder panels up to 1 250 A ( ≥...
  • Page 10 1 400 ABB wishes to highlight that values of dimensions and weights provided herein are preliminary and may change after final design preparation, based on final scope of supply and installation details of the switchgear. As a consequence, provided values of dimensions and weights are NOT to be considered as final but only for standard reference purposes.

  • Page 11: Panel Design And Equipment

    — 4. Panel design and equipment The enclosure is completed on the roof by top- 4.1 Basic structure and variants mounted pressure relief flaps which, according to the rated current, are made of sheet steel or The basis for the UniGear panel is the incoming / expanded metal and at the base by means of outgoing feeder panel with vacuum or SF6 circuit- floor-covering made of Al sheet.
  • Page 12 (central handle). Instruction for switching of cooling fans: Incoming Feeder, UniGear ZS1 12 / 17.5 kV, 3 600 A Current Current Current Current...
  • Page 13 — 4. Panel design and equipment Figure 3: UniGear ZS1 17.5 kV, 1 250 A, 31.5 kA Spindle mechanism Current transformer Earthing switch operating mechanism Earthing switch Branch conductor Voltage transformer...
  • Page 14 — 4. Panel design and equipment Figure 4: UniGear ZS1 Digital 17.5 kV, 1 250 A, 31.5 kA with one set of sensors Spindle mechanism Current sensor Earthing switch operating mechanism Earthing switch Branch conductor Voltage sensor...
  • Page 15 — 4. Panel design and equipment Figure 5: UniGear ZS1 Digital 17.5 kV, 1 250 A, 31.5 kA with two sets of sensors Spindle mechanism Current sensor Earthing switch operating mechanism Earthing switch Branch conductor Voltage sensor...
  • Page 16 — 4. Panel design and equipment Figure 6: UniGear ZS1 17.5 kV with switch-disconnector with fuses and earthing switch Switch-disconnector operating mechanism Switch-disconnector Earthing switch operating mechanism Earthing switch Branch conductor...

  • Page 17: Compartments In The Panels

    For higher rated currents (3 150, 3 600 and There are six types of current and voltage sensors 4 000 A), the busbars have a open D-shaped for UniGear ZS1 Digital: cross-section. According to the current rating, • KEVA 17.5B20 either single or double configuration is used.
  • Page 18 — 4. Panel design and equipment Circuit-breaker compartment wiring required for test purposes needs not be The circuit-breaker compartment contains all the interrupted when in the test / disconnected necessary equipment for reciprocal operation of position. In the test / disconnected position the the withdrawable part and the panel.
  • Page 19 Figure 12: View of the push rod extension swung out by Figure 13: Current sensors KECA 80C165 mounted in the the knob at the front, with the withdrawable circuit- circuit breaker compartment in UniGear ZS1 Digital breaker part in service position and the door open Swivelling push rod Figure 14: Current sensors KECA 80C104 mounted in the Figure 15: Voltage sensors KEVA 17.5B20 mounted in the...
  • Page 20 — 4. Panel design and equipment Withdrawable parts Withdrawable parts of the same design and 1. Withdrawable circuit-breakers electrical parameters are interchangeable. In the The withdrawable circuit-breaker forms a case where the withdrawable parts have the same complete module consisting of the vacuum dimensions, but different electrical parameters, circuit-breakers type VD4 or VM1, SF6 circuit- the control wiring plug coding prevents any...
  • Page 21 Each switchgear panel must have its own Cable connection of UniGear ZS1 12 / 17.5 kV earthing switch or earthing truck. This panels: requirement also applies to busbars, where...
  • Page 22 In the case of any non standard cable connections can be also mounted for the motor operation of an agreement must be reached between the the switch-disconnector. The switchdisconnector customer and ABB during the technical can therefore be operated both locally and preparation stage of the order. remotely.

  • Page 23: Interlock/Protection Against Incorrect Operation

    — 4. Panel design and equipment • In the service or test positions, the circuit- 4.4 Interlock/protection breaker can only be switched off manually against incorrect operation when no control voltage is applied and it cannot be closed (electromechanical Important note: interlock).
  • Page 24 — 4. Panel design and equipment Door interlocking • When the busbar earthing switch is closed, The panels are equipped with the following the withdrawable parts in the earthed busbar interlocks: section cannot be moved from the test / • The apparatus (circuit-breaker or contactor) disconnected position to the service position can not be racked-in if the apparatus...
  • Page 25 — 4. Panel design and equipment Internal interlocking of panel with switch- • In panels with digital control techniques the disconnector protection against incorrect operation is To prevent hazardous situations and incorrect basically carried out by the panel software. operation, there is a series of interlocks to But the earthing switch is operated locally by protect both personnel and equipment: the operating lever 1 (Figure 20).
  • Page 26 — 4. Panel design and equipment Standard safety interlocks (mandatory) Type Description Condition to be met Apparatus racking-in/out Apparatus in OFF position Apparatus closing Defined truck position Apparatus racking-in Apparatus multi-contact plug plugged Apparatus multi-contact plug unplugging Truck in test position Earthing switch closing Truck in test position Apparatus racking-in...
  • Page 27 — 4. Panel design and equipment Figure 21: Circuit-breaker compartment door enabling device (A) and door locking pin (B) Figure 22: Circuit-breaker truck enabling slot (A) Figure 23: Circuit-breaker compartment door locking device (B)
  • Page 28 — 4. Panel design and equipment Figure 24: Cable compartment door enabling device (C) Figure 25: Cable compartment door enabling slot and earthing switch enabling pin Figure 26: Cables compartment door locking pin (D)

  • Page 29: Plug Connector Coding

    In case of instalation of the arc protection fibers or sensors please follow aditional manual 1VLD100104 or contact ABB. Figure 27: Control wiring plug connector coding, shown for a 58-pole connector Bore for actuating pin of the control wiring plug for...

  • Page 30: Ith Limiters

    — 4. Panel design and equipment 4.7 Ith Limiters Additional safety feature on the top of each panel. Install the Ith limiters on the top of the panel It consists of miniature microswitch embedded in frame. Install the lever on overpressure relieve the steel housing, generates an immediate trip flap and turn the limiter on.

  • Page 31: Monitoring And Diagnostics

    PDCOM processing unit communicates with SWICOM data concentrator via CAN bus. For more information refer to document 9AKK108468A6476 - Monitoring and diagnostics Figure 36: Envrionmental sensor for low-voltage guideline for UniGear ZS1 switchgear. compartment door Figure 33: Temperature sensor Figure 37: PDCOM...

  • Page 32: Dispatch And Storage

    — 5. Dispatch and storage 5.1 Condition on delivery 5.3 Transport At the time of dispatch, the UniGear panels are The transport units normally comprise individual factory assembled, the withdrawable parts are in panels and, in exceptional cases, small groups of the test position and the doors are closed.

  • Page 33: Intermediate Storage

    — 5. Dispatch and storage 5.5 Intermediate storage 5.6 Handling Optimum intermediate storage, where this is Switchgear necessary, without any negative consequences The switchgear sections are usually fixed to depends on compliance with a number of wooden pallets. Handling should be carried out minimum conditions for the panels and assembly by overhead or mobile cranes.
  • Page 34 — 5. Dispatch and storage Handling by rollers Lift the switchgear section by overhead or mobile crane or using jacks; remove the wooden pallet WARNING loosening the screws fixing it to the switchgear Only use rollers on a level floor. Move the section base.
  • Page 35 Handling by crane The apparatus can be handled by cranes, fork lift Circuit-breaker trucks or using the truck provided by ABB. For Hook the lifting bolts to the relevant supports. each piece of apparatus follow the instructions While handling, pay the utmost attention not to below.
  • Page 36 (4), locking the circuit-breaker. WARNING • Do not use the service truck for any purpose other than handling ABB’s apparatus. Figure 46: Handling by fork-lift trucks • Fix the circuit-breaker to the truck before moving it.
  • Page 37 — 5. Dispatch and storage Further warnings Do not try to open the cable or the circuit-breaker When moving the switchgear on cylinders always compartment doors, close the earthing switch or put the cylinders collinear (in parallel) with the withdraw the circuit breaker if an auxiliary front side of the switchgear and always keep the voltage is not connected to the switchgear! Do switchgear in the vertical position!

  • Page 38: Assembly Of The Switchgear At Site

    Method A – installation on C profile for concrete When the final building construction documents floor are drawn up, the binding data supplied by ABB As standard, it is recommended to install the for a particular case must always be taken into switchgear on “C”...
  • Page 39 — 6. Assembly of the switchgear at site Dimension chart of structural data - panels 12 / 17.5 kV Panel width FT [mm] 1 000 Aisle width G [mm] 1 150 1 300 1 500 Switchgear room door width [mm] 1 000 1 200 Switchgear room door height...
  • Page 40 • The “C" shaped base irons can be supplied by approx. 5 panels. ABB together with the switchgear. Their • When the floor top covering is applied, installation is usually carried out by...
  • Page 41 A frame produced using suitable steel • Clean the switchgear installation area profiles is used. ABB does not supply this frame. carefully • On the slab, visibly trace the perimeter of all - Evenness tolerance ± 1 mm over a measuring the units making up the switchgear length of 1 m.
  • Page 42 — 6. Assembly of the switchgear at site Figure 49: Fixing to the floor - Method A - Installation on C profile for conrete floor Figure 50: Fixing to the floor - Method B - Installation on anchoring bolts Figure 51: Fixing to the floor - Method C - Installation on bolts for raised floor...
  • Page 43 — 6. Assembly of the switchgear at site Figure 52: UniGear ZS1 12 / 17.5 kV up to 2 500 A. Guideline structural data for foundation frame on concrete floor. It is not valid for the panel with switch-disconnector. Typical panel depth C = 1 340 mm – however always...
  • Page 44 — 6. Assembly of the switchgear at site Figure 53: UniGear ZS1 12 / 17.5 kV up to 4 000 A. Guideline structural data for foundation frame on concrete floor. It is not valid for the panel with switch-disconnector. Typical panel depth C = 1 390 mm – however always...
  • Page 45 — 6. Assembly of the switchgear at site Figure 54: UniGear ZS1 24 kV. Guideline structural data for foundation frame on concrete floor It is not valid for the panel with switch-disconnector. Typical panel depth C = 1 700 mm (For short-time...
  • Page 46 — 6. Assembly of the switchgear at site Figure 55: UniGear ZS1 12 / 17.5 kV with switch-disconnector. Guideline structural data for foundation frame on concrete floor. Typical panel depth C = 1 340 mm – however always Door consider annotation 2) Side end cover Width of operating aisle ("6.2 Foundations")
  • Page 47 — 6. Assembly of the switchgear at site Figure 56: UniGear ZS1 24 kV with switch-disconnector. Guideline structural data for foundation frame on concrete floor. Typical panel depth C = 1 700 mm – however always Door consider annotation 2) Side end cover Width of operating aisle ("6.2 Foundations")
  • Page 48 Dimension must be verified according to documentation of the relevant order Figure 58: Example of UniGear ZS1 12 / 17.5 kV for 3 150 / 4 000 A on foundation frame on concrete floor. Panel with examples of gas duct including chimneys or pressure relief to the outside.
  • Page 49 6. Assembly of the switchgear at site Figure 59: Example of UniGear ZS1 12 / 17.5 kV, 40 / 50 kA on foundation frame on concrete floor. Panel with examples of gas duct including chimneys or pressure relief to the outside.
  • Page 50 — 6. Assembly of the switchgear at site Figure 61: Example of UniGear ZS1 24 kV, 31.5 kA on foundation frame on concrete floor. Panel with examples of gas duct includ- ing chimneys or pressure relief to the outside. Typical panel depth E = 1700 mm (For short-time current up to 25 kA a 1560 mm depth version is available) –...
  • Page 51 — 6. Assembly of the switchgear at site Figure 62: Guideline structural data for a raised false floor Larger dimension is valid for the cubicle with Door height = panel height + 200 mm circuit breaker HD4 including combination with them, Min.
  • Page 52 [mm] 1 000 Figure 63: UniGear ZS1 12 / 17.5 kV up to 40 kA – 650 (up to 31.5 kA) / 800 / 1 000 mm wide panels A) Anchoring bolts B) C profile for concrete floor Figure 64: UniGear ZS1 12 / 17.5 kV 40 kA – 650 mm wide panels...
  • Page 53 Figure 65: UniGear ZS1 12 / 17.5 kV, 50 kA, 1 250-2 000 A, 800 mm wide panels A) Anchoring bolts B) C profile for concrete floor Figure 66: UniGear ZS1 12 / 17.5 kV, 50 kA, 2 500-3 600 A, 1 000 mm wide panels A) Anchoring bolts B) C profile for concrete floor...
  • Page 54 — 6. Assembly of the switchgear at site Figure 67: UniGear ZS1 12 / 17.5 kV, 50 kA, 4 000 A, 1 000 mm wide panels A) Anchoring bolts B) C profile for concrete floor Anchoring bolts fixing system FT width [mm] A [mm] B [mm]...
  • Page 55 Figure 69: UniGear ZS1 24 kV, 25 kA, 800 mm wide panels A) Anchoring bolts B) C profile for concrete floor Figure 70: UniGear ZS1 24 kV, 25 kA, 1 000 mm wide panels A) Anchoring bolts B) C profile for concrete floor...
  • Page 56 Figure 71: UniGear ZS1 24 kV, 31.5 kA – 800 mm wide panels A) Anchoring bolts B) C profile for concrete floor Figure 72: UniGear ZS1 24 kV, 31.5 kA – 1 000 mm wide panels A) Anchoring bolts B) C profile for concrete floor...
  • Page 57 — 6. Assembly of the switchgear at site Figure 73: UniGear ZS1 12 / 17.5 kV panels with switch-disconnector A) Anchoring bolts B) C profile for concrete floor Figure 74: UniGear ZS1 24 kV – panels with switch-disconnector A) Anchoring bolts B) C profile for concrete floor...
  • Page 58 — 6. Assembly of the switchgear at site Figure 75: Anchoring bolts Figure 76: C profile for concrete floor Figure 77: Through hole on metal structure Figure 78: Threaded hole on metal structure...

  • Page 59: Assembly Of The Switchgear Panels

    (2) The tightening torques are recommended for screws ISO tables: 4014-4018 and ISO 4762 (tensile class 8.8). If using other types of screws please contact ABB for clarification. (3) Applicable only for fixing of subsidiary covers or terminal connections. Tightening torques for copper bars or combined busbar Tight.
  • Page 60 — 6. Assembly of the switchgear at site Any tightening torques that deviate from those in the general tables (e.g. for contact systems or device terminals) must be taken into account as stated in the detailed technical documentation. It is recommended that the threads and head contact surfaces of bolts should be lightly oiled or greased to achieve the precise tightening torque (column Oil or grease in table).

  • Page 61: Procedure For Setting-Up The Doors

    — 6. Assembly of the switchgear at site • Set up the blocking stop so that its lower 6.4 Procedure for setting-up edge is in the range of 29.8-30.3 mm above the doors the level of the lower edge of the slot in the door draw bar when the door handle is in the Instructions from the standpoint of the safety at closed position (Figure 85) (Figure 86).
  • Page 62 — 6. Assembly of the switchgear at site • Set up the blocking stop so that its lower • Close the door and verify the door blocking edge is in the range of 29.8-30.3 mm above function by operation with the earthing the level of the lower edge of the slot in the switch.
  • Page 63 — 6. Assembly of the switchgear at site Figure 85: Setting up right position Figure 84: Correct position of CB compartment door Figure 86: Setting up right position Figure 87: Lateral cover of control cables in cable com- partment Figure 89: Correct position of cable compartment door Figure 88: Cable compartment without lateral cover...
  • Page 64 — 6. Assembly of the switchgear at site Figure 90: Door is open - the blocking spike is in touch Figure 91: Door is closed but door handle is not in its with hexagonal control shaft of earthing switch final closed position - the blocking spike is in touch with hexagonal control shaft of earthing switch Figure 92: Self-locking nut M3...

  • Page 65: Installation Of The Bushing

    — 6. Assembly of the switchgear at site 6.5 Installation of the bushing Bushing of 12 / 17.5 kV panels Lower bus-tie system: Before fixing the panels side by side (according to Insert bushing 1 for the lower rear bus-tie into the general drawings) bushings (12 - 24 kV) must bushing plate 5 from the right side in contrast to be fixed (for switchgear with busbar partitioning...
  • Page 66 Figure 97: Correct position of the rubber partition Figure 98: Correct position of the rubber partition (busbar support) in UniGear ZS1 12 / 17.5 kV panels (busbar support) in UniGear ZS1 12 / 17.5 kV panels Figure 99: Correct position of the rubber partition...

  • Page 67: Fixing Of The Panels

    — 6. Assembly of the switchgear at site 6.6 Fixing of the panels The junction points where the panels should be fix are as follows: • Nr.6 in the front side • Nr.4 in the middle part WARNING • Nr.5 in the rear side Before fixing the panels side by side be sure that the bushings are fixed according to "6.5 The nuts are already fixed on the right side of the...

  • Page 68: Installation Of The Busbars

    — 6. Assembly of the switchgear at site 6.7 Installation of the busbars – The non silver-plated surfaces of the connections are either brushed with a wire Preparation of the material brush, preserving the grease film, or • Clean the insulation on the busbar sections cleaned with a metal-free non-woven with a soft, dry cloth, and check for any cleaning cloth and evenly greased with a...
  • Page 69 — 6. Assembly of the switchgear at site Figure 103: 24 kV panels - Arrangement of the busbar and branch conductors at the busbar ends. In continuous busbars, the connections are similar, but without the lid holder and without the spacer plate. During assembly, cut out the insulating cover and lid to fit the cross-section of the feeder bar of busbar.
  • Page 70 — 6. Assembly of the switchgear at site Busbar compartment access Access to the busbar compartment is possible either from the top of the panel after dismounting the pressure relief plate before the mounting of the gas duct, or from the front of the circuit-breaker compartment.
  • Page 71 "6.3 We recommend only checking tightness of busbar Assembly of the switchgear panels". Use connections during inspections. tightening material supplied by ABB. • Bolt one holder to each end of the busbars to Note: support insulating cover.
  • Page 72 — 6. Assembly of the switchgear at site Busbars for 12 / 17.5 kV panels the panel. Bushings are held in bushing plates. Busbars are made of copper and have a flat cross- For 12 kV, the busbars are bare (without section for rated current up to 2 500 A.
  • Page 73 — 6. Assembly of the switchgear at site Figure 110: 12 / 17.5 kV panels - T-off 630 -1 250 A, busbars 1 600, 2 000, 2 500 A nr. 4 10x60 screws nr. 4 M10 nuts nr. 8 M10 washers nr.
  • Page 74 — 6. Assembly of the switchgear at site Figure 112: 12 / 17.5 kV panels - T-off 630, 1 250 A, busbars 3 150, 3 600, 4 000 A nr. 4 10x60 screws nr. 4 M10 nuts nr. 8 M10 washers nr.
  • Page 75 — 6. Assembly of the switchgear at site Figure 114: 12 / 17.5 kV panels - T-off 1 600 - 4 000 A, busbars 3 150, 3 600, 4 000 A nr. 4 10x60 screws nr. 1 spacer (5 mm) nr.
  • Page 76 — 6. Assembly of the switchgear at site Busbars for 24 kV panels Busbars and branches are made of copper and both have a flat cross-section. The bushings are Important note: different from the 12 / 17.5 kV versions. They are Always check that there is good contact single for each phase and have an electrode between the metal tube in the bushing and the...
  • Page 77 — 6. Assembly of the switchgear at site Figure 118: 24 kV panels - T-off 1 250 A, busbars 2 500 A nr.4 10x60 screws nr.8 M10 washers nr.4 M10 nuts Figure 119: 24 kV panels - T-off 2 500 A, busbars 2 500 A nr.4 10x60 screws nr.8 M10 washers nr.4 M10 nuts...
  • Page 78 — 6. Assembly of the switchgear at site Figure 120: 24 kV panels - T-off 3 150 A, busbars 3 150 A nr.4 10x60 screws nr.8 M10 washers nr.4 M10 nuts...

  • Page 79: Installation Of The Top-Mounted Boxes

    — 6. Assembly of the switchgear at site 6.8 Installation of the top- • Connecting bars 1 with branch conductors 5 at the junction point must be screwed mounted boxes together according to (Figure 122) (Figure 124). However, if necessary, the additional For ease of transportation top mounted boxes spacer plate 2 (Figure 122) and threaded plate are delivered separate from the panel in pre-...
  • Page 80 — 6. Assembly of the switchgear at site Figure 122: Panels 12 / 17.5 kV - Bar connection to the top-mounting box. The figure shows the arrangement in panels the busbar ends. Connection bar Spacer plate, 5 mm thick Spacer plate, 8 mm thick Branch conductor Tapped plate Figure 123:...
  • Page 81 — 6. Assembly of the switchgear at site Figure 124: Panels 24 kV - Bolted busbar joint for top-mounted box, shown for left-hand busbar end. In continuous busbars the connection is similar, but without the lid holder and without the spacer plate. Connection bar Cylinder screw Branch conductor...
  • Page 82 — 6. Assembly of the switchgear at site Figure 126: Panels 12 / 17.5 kV - Top-mounted box with voltage transformers for busbar metering. The figure shows the arrangement in panels without the busbar bushings plate. Top mounted box with voltage transformer Intermediate box Hexagonal shaft Partitioning...
  • Page 83 — 6. Assembly of the switchgear at site Earthing switch for busbar earthing Note: • Top-mounted box 1 (Figure 128) with screw The auxiliary switches for the earthing switch are fixing material from the “top-mounted box adjusted at the factory. Correct operation is only for earthing”...
  • Page 84 — 6. Assembly of the switchgear at site Figure 129: Panels 12 / 17.5 kV - Top-mounted box with earthing switch for busbar earthing Auxiliary switch OFF Slide Auxiliary switch ON Locking magnet Figure 130: Panels 24 kV - Top-mounted box with earthing switch for busbar earthing.
  • Page 85 — 6. Assembly of the switchgear at site Ultra fast earthing switch UFES For more information see document 1VLG100128 Manual for installation of UFES into UniGear ZS1. Figure 131: Top-mounted box with UFES UFES Reducer ring Top-mounted box Intermediate box...
  • Page 86 — 6. Assembly of the switchgear at site Anti-ferroresonant resistor for voltage transformers open delta connection When using a ferroresonance resistor for VTs open delta connection is necesary to adjust the position of this resistor during site installation. The ferroresonance resistor is placed on the top of switchgear on the CB relief flap for the transportation (Figure 132).

  • Page 87: Pressure Relief Ducts

    — 6. Assembly of the switchgear at site 6.9 Pressure relief ducts The pressure relief duct is supplied assembled. The rear and front wall correspond, as far as length is concerned, with the appropriate panel width. The screw fixing material is contained in the “pressure relief duct”...
  • Page 88 Gas duct with top chimneys Note: In order to mount the gas duct with top chimneys For UniGear ZS1 24 kV; 31,5 kA with gas duct with please follow the appropriate instructions. The top chimneys for a duct height of 500 mm it is difference between the two solutions is that in necessary to use a deflector.

  • Page 89: Cable Connection

    — 6. Assembly of the switchgear at site These bars have different versions, which differ in 6.10 Cable connection their number of parallel cables and the values of rated and short-circuit currents. Power cables The bars are equipped with holes for M16 screws. The standard method for entry of power cables in Cable screens wires are connected with cable the switchgear is shown in Figure 144.
  • Page 90 (e.g. three-core cables, cables with paper mounting rail or special insulation etc.), an agreement must be - cutting of the loose ends not reached between the customer and ABB. recommended 2. Cable clamps Mounting procedure for power cables: - the maximum tightening torque •...
  • Page 91 — 6. Assembly of the switchgear at site UniGear ZS1 12 / 17.5 kV - Standard depth bottom entry Standard depth bottom entry UniGear ZS1 12 / 17.5 kV - 31.5 kA 40 kA 50 kA Height Max. available Max.
  • Page 92 — 6. Assembly of the switchgear at site UniGear ZS1 12 / 17.5 kV, 63 kA - Bottom entry UniGear ZS1 12/17.5 kV, 63 kA Bottom entry 63 kA Height (from Max. Height (from Rated Max. the top of Panel...
  • Page 93 — 6. Assembly of the switchgear at site UniGear ZS1 12 / 17.5 kV - Switch disconnector panel bottom entry UniGear ZS1 12 / 17.5 kV Switch disconnector panel bottom entry 25 kA Max. Panel Rated Max. Height cable width...
  • Page 94 — 6. Assembly of the switchgear at site UniGear ZS1 24 kV - Standard depth bottom entry Standard depth bottom entry UniGear ZS1 24 kV - 25 kA 31.5 kA Max. Max. Rated Max. Height Rated Max. Height Panel cable...
  • Page 95 ABB cable bushing. • It‘s recommended not to strip the armour • Pull control cables through ABB bushing and and the shield (if applicable) from the cable strap the ABB bushing with cable tie. untill the LV compartment entry •...

  • Page 96: Earthing The Switchgear

    — 6. Assembly of the switchgear at site 6.11 Earthing the switchgear 6.13 Final erection work Connect main earthing bar with connections • Check painted areas of the switchgear for provided in every panel. possible damage, touching up where Ensure protection for the wiring connection of required the floor frame or the erected raised false floor.

  • Page 97: Operation Of The Switchgear

    — 7. Operation of the switchgear Note on safety at work • Fit hand crank (Figure 160) on square spigot All relative work and operating procedures must of the spindle mechanism after opening the be carefully carried out by trained specialists aperture for them by turning slide (Figure familiar with the installation, taking into account 159)
  • Page 98 — 7. Operation of the switchgear • Remove the disk with the yellow sticker (Figure 162) by unscrewing the screw Important note: • For older switchgear version without the disk Insertion and withdrawal of circuit-breakers with the yellow sticker (Figure 162) switch off (and other withdrawable parts) must be gradual, the auxiliary power (m.c.b.), since the motor in order to avoid any shocks which could deform...
  • Page 99 — 7. Operation of the switchgear Withdrawal from the test / disconnected position • Press release lever 1 (Figure 163) (at the front onto the service truck: underneath the bench top) and release the • Open the door of the circuit-breaker service truck from the switchgear panel.
  • Page 100 — 7. Operation of the switchgear Circuit-breaker - type VD4 and VD4G Opening and closing the circuit-breaker: Charging the stored energy spring system: • Opening and closing operations with the • Charging of the circuit-breaker is carried out withdrawable part in the service position automatically by the charging motor.
  • Page 101 — 7. Operation of the switchgear Figure 164: Figure 163: Withdrawable part standing on Positioning the service truck with service truck and secured in the catches the guide pins on the adjustable height bench top at the correct height for approach to the Release lever for catch pin switchgear panel, and engaging the catch Catch (connected to sliding handle)
  • Page 102 — 7. Operation of the switchgear Circuit-breaker - type VM1 insert emergency manual operating lever 1 The maintenance-free VM1 circuit-breaker applies (Figure 168) onto the spigot of the a combination of moulded-in vacuum emergency shaft 3 (Figure 167) in the front interrupters, a magnetic actuator and an plate and turn it anticlockwise to open the electronic controller without auxiliary switches...
  • Page 103 — 7. Operation of the switchgear Circuit-breaker - type HD4 closing press pushbutton 4 (Figure 170). When Manual operation for spring charging: there is a shunt closing release, the operation can To manually charge the closing springs, fully also be carried out by means of a control circuit. insert charging lever into seat and turn it until the The indicator 2 shows that closing has been yellow indicator appears.
  • Page 104 — 7. Operation of the switchgear Withdrawable metering parts ConVac vacuum contactor Handling of the withdrawable metering part in The medium voltage ConVac contactor operates the metering panel is as described in "7.1 in alternating current and is normally used to Switching operations", without, however, the control devices requiring a high number of hourly switching operations and interlocking functions.
  • Page 105 — 7. Operation of the switchgear Earthing switch Opening and closing with motor operator: The The earthing switch has a snap closing earthing switch can also be fitted with a motor mechanism which is independent of the rotation operator. Briefly operate the electrical control for of the drive shaft.
  • Page 106 — 7. Operation of the switchgear Figure 174: Preparation for operation of branch Figure 175: Preparation for operation of branch earthing earthing switch - press the slide downwards switch - operating lever prepared for switching on/off Operating lever Hexagonal shaft of ES operating mechanism Slide Figure 176: Shutter lifting truck in...
  • Page 107 — 7. Operation of the switchgear Shutter lifting truck Shutter lifting truck (optional accessories) can be used for access to spouts after removing the circuit-breaker from the circuit-breaker compartment: • Place the shutter lifitng truck 1 (Figure 176) into the rails for the circuit-breaker truck in circuit-breaker compartment •...
  • Page 108 — 7. Operation of the switchgear NALF switch-disconnectors To secure the protection of connected MV The NALF switch-disconnectors, combining a equipment the UniGear switchgear with switch- switch-disconnector with fuses and earthing disconnector uses CEF medium voltage fuses. switches are intended for indoor use in The UniGear switchgear with NALF switch- switchboards.
  • Page 109 — 7. Operation of the switchgear Closing and opening of NALF switch- Closing and opening of NALF switch- disconnector: disconnector with the motor operating • The switch-disconnector can only be mechanism. switched on if the earthing switch is open. The switch-disconnector can also be equipped •...

  • Page 110: Test Procedure

    — 7. Operation of the switchgear 7.2 Test procedure Current and voltage tests The testing and earthing module is available for Testing the off-circuit condition carrying out current and voltage tests. It is also In switchgear panels which are not equipped with suitable for supplying primary current to any capacitive voltage indication, checking the off- current transformers which may be fitted during...
  • Page 111 — 7. Operation of the switchgear Power cable test Note: The power cable test can be carried out by AC Pictures show the shutters lifting truck for panel voltage, DC voltage or AC voltage applicable for 12 kV 650 mm. Shutters lifting truck for other very low frequency (VLF) testing at 0,1Hz.
  • Page 112 — 7. Operation of the switchgear Power cable test - Maximum applied voltage Rated voltage of the switchgear Ur [kV] 17.5 Rated power-frequency cable test voltage, max. [kV] 22.4 30.4 duration 1 min Uct (AC) Rated DC cable test voltage, max. Duration 15 min Uct [kV] (DC) Rated AC cable test voltage applicable for VLF testing...

  • Page 113: Service Trucks

    — 7. Operation of the switchgear During the racking-in phase, the main busbar 7.3 Service trucks earthing truck only lifts the top shutter and earths the contacts connected to the top Instead of earthing, short-circuiting and testing branches (and therefore to the main busbar with Testing and Earthing truck (Figure 187) it is system) by the switchgear structure.
  • Page 114 — 7. Operation of the switchgear Isolation truck • Further screw on the Testing and Earthing The isolation truck allows the switchgear top and truck insulating plate 1 with three removable bottom contacts to be connected directly. bushings as follows: Connection is made extremely safe by using the - Contact arms 3 in the bottom position poles of the HD4 circuit-breakers to insulate the...
  • Page 115 — 7. Operation of the switchgear Testing and Earthing truck Figure 187: Insulating plate with alternative mounting positions for cable or busbar earthing (turn through 180° for busbar earthing) Contact systems, replaceable for different contact pin diameters on the switchgear Contact arms (3 pcs.), removable - bottom position for cable compartment - top position for busbar compartment...

  • Page 116: Commissioning

    • Correctly remount all covers etc. removed manufacturer’s recommendation of test scope during assembly and testing procedures. and method please contact ABB’s Service • Transport caps on heavy duty vacuum circuit- Department. After performing the tests, make breakers if applicable - must be removed.

  • Page 117: Maintenance

    Please refer to next chapters technical authorities, and with other over-riding for details of preventive and risk-based instructions. It is recommended that ABB service maintenance programs. personnel be called in to perform the servicing and repair work detailed below. The inspection...

  • Page 118: Inspection

    — 9. Maintenance Intervals for inspection, servicing and repairs Checking readiness for operation can be carried Time intervals for maintenance work to be carried out as follows: out always depend on the operating conditions of • Load-dependent functional test with the switchgear, and mainly on the mode of controllable primary current supply of the operation, the number of rated and short-circuit...
  • Page 119 — 9. Maintenance • After removal of the bulkhead from the Use no force! Also see the note in "7.1 Switching circuit-breaker compartment, the main operations"! busbars are visible. • Visually check that the top monoblocks 4 The withdrawable part must only be movable (Figure 192), where the tulip isolating contact from the service position into the test / is housed, are fully intact and do not show...
  • Page 120 — 9. Maintenance Withdrawable parts with order-related locking For switchgear equipped with Monitoring and magnet may not be moved in case of control Diagnostics time interval for Inspection and power failure, or when there is no control power. Servicing is 5 years. Do not forcibly move locked withdrawable parts! The locking magnet is only present on manually For panels with Monitoring and Diagnostics...
  • Page 121 — 9. Maintenance Figure 190: Testing interlock conditions Figure 189: Auxiliary connections Key locks Circuit breaker Terminals Figure 191: Testing interlock conditions Door interlocks Fail safe...

  • Page 122: Servicing

    • Using a dynamometric spanner, check problem, contact the ABB service tightness of all the screws. Refer to the "6.3 department. Assembly of the switchgear panels" for the tightening values.
  • Page 123 — 9. Maintenance Earthing switches Voltage transformers in removable version: Cleaning the kinematics to prevent faults on the • Open the cable compartment door. signalling contacts • Manually withdraw the VT truck. • Carry out a visual inspection of the •...
  • Page 124 — 9. Maintenance Manual earthing switch operating mechanism Figure 194: Figure 195: Changeover of the earthing switch signalling contacts Drive shaft Auxiliary contact Figure 197: Anti-ferroresonance resistor Removable circuit-breaker plate Figure 196: Figure 198: Withdrawable part with measurement panel Figure 199: Shutter lifting truck in circuit-breaker compartment Resin tube (with fuse)

  • Page 125: Repairs

    UniGear ZS1 switchgear) • Remove faulty sensor • Treat the surface beneath the sensor if necessary (remove dust, dirt, corrosion) • Install new sensor following the procedure in document 9AKK108468A6476 - Monitoring and diagnostics guideline for UniGear ZS1 switchgear.

  • Page 126: Risk-Based Maintenance

    Repairs on withdrawable parts When functional tests are carried out on withdrawable parts, compliance with the ABB supports UniGear users with optimized and conditions listed below should also be checked. cost effective strategies to ensure that the The following operating instructions must also be...
  • Page 127 — 9. Maintenance Figure 201: Manual earthing switch operating mechanism Figure 200: View of inside circuit-breaker compartment, with auxiliary contacts, side protection removed withdrawable part removed, shutters open Isolating tulip Q8S1 auxiliary contact – earthing switch OFF Isolating contact Sliding closure Lower shutter Cam plate, adjustable Q8S2 auxiliary contact –...

  • Page 128: Operating Accessories

    — 9. Maintenance 9.8 Operating accessories Figure 203: Charging lever (for Figure 204: Double bit key (to Figure 205: Manual HD4 type cir cuit -breaker) use the central locking devic e emergency operating lever and the screw type door lock) (to remove voltage to VM1 type circuit -breaker) Figure 206:...

  • Page 129: Product Quality And Environmental Protection

    The following methods of disposal are possible: End of life of product Disposal can either be carried out thermally in an ABB is committed to complying with the relevant incineration plant or by storing on a waste site. legal and other requirements for environmental protection according to the ISO 14 001 standard.
  • Page 130 With regard to purchase orders, the agreed particulars shall prevail. ABB does not accept any responsibility whatsoever for potential errors or possible lack of infor- mation in this document.
  • Page 131 — ABB Ltd. Distribution Solutions Electrification P.O. Box 8131 CH-8050 Zurich Switzerland abb.com/mediumvoltage abb.com/contactcenters © Copyright 2024 ABB. All rights reserved. Specifications subject to change without notice.

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