Compact Secondary Substations (CSS)

For secure, reliable power distribution and space saving solutions

ABB a global leader

ABB is a global leader in Power and Automation

technologies that enable utility and industry
customers to improve performance while lowering
environmental impact. The ABB Group of companies
operates in around 100 countries.

services for power generation, transmission and

distribution. ABBs turnkey solution capabilities in the
sector range from bulk power transmission,
substations and complete electrification to utility
automation and distribution systems.

In India, ABB serves customers with the complete

range of power and automation technologies. The
company has a vast installed base, extensive
manufacturing and a countrywide marketing and
service presence.

The product offering covers a wide spectrum of

technologies across the entire voltage range including
indoor and outdoor circuit breakers, air and gas
insulated switchgear, disconnectors, capacitor banks,
reactive power compensators, power distribution and
instrument transformers and a range of power
distribution products like Compact Substations
(CSS), Ring Main Units (RMU).

The Power Technologies division offers electric, gas

and water utilities as well as industrial and commercial
customers a wide range of products, systems and

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Compact Secondary Substations (CSS)

Designed in accordance with IEC 61330 standards,

the CSS is a prefabricated secondary substation
with type-tested equipment and includes a
distribution transformer, medium voltage switchgear,
low-voltage switchboard, connections and
associated equipment in a compact unit. The CSS is
designed keeping in mind high levels of personal
safety and aesthetics as they are often located in
high density, urban centres.
All components are housed in an enclosure, which
protects the equipment against environmental
hazards and unauthorised access. The enclosure is
typically divided into three sections or
compartments medium voltage switchgear, low
voltage switchboard and distribution transformer.
The substation can be operated from the inside
(Walk-in type) or from the outside (Non Walk-in type).
The electrical equipment is cooled by natural
ventilation through openings in the substation.

Applications
Secondary
Substation

Application

Distribution

Public distribution

Operation

At medium-voltage level

Supply

To satellite stations and major

electricity customers

Feeding

Connection of decentralised
power plant to the public
network

Satellite

Substations for the end of

radial connections

Pylon feeder
station

Smaller stations
connected to overhead lines

Type designations (example)

The standard degree of protection for CSS is IP23D

in accordance with IEC 60529 standards. If required,
CSS can be supplied with doors that comply with
IP54 standards, by including gaskets and excluding
the door ventilation openings.

Product type
CSS = Compact Secondary
Substation
Materials
S = Steel C = Concrete
Layout
W = Walk-in N = Non Walk-in
C = Compact

Key features

Wide modular product range

Enhanced safety

Several options and extensive flexibility

Appealing aesthetics

Reduced overall plant and operating costs

Width
Number of modules wide
Length
Number of modules long
CSS-S C - X - Y

Quality

ABB

The entire CSS range is manufactured in accordance with

ABBs stringent quality and environmental (ISO 9001 and
ISO 14001) standards.

parts. The galvanised steel foundation is bolted to the

structure. The result is a fully earthed enclosure,
providing a high level of personal safety.

Personal safety

Protection

All live parts in the CSS range are protected against

unintentional contact by means of lockable doors.
Cable connections and fuses in the medium voltage
room are also protected against unintentional contact.
Anti-contact protection is tested in accordance with
IEC 61330. Clinched or screwed connections form
electrical connections with all of the stations metal

The substation is subjected to moisture, condensation

and dirt. In coastal locations sea salt on the surface of
open, insulated surfaces can cause leaking current,
which can result in a flashover. Accordingly, the CSS is
designed and fabricated using material and equipment
capable of withstanding harsh climatic and operational
conditions.

Product overview

The CSS consists of modular components which makes it possible to custom design the equipment based
on customers requirements. The solutions shown below are a few examples of the many options.

Model CSS-SW
Walk-in station. Surface mounted and operated from the inside.

Model CSS-SN
Non-walk-in station. Surface mounted and operated from the outside.

Model CSS-SC
Compact station. Installed partially below the ground and operated from the outside.

Legend

Low voltage
switchboards
4

Medium voltage
switchgear

Distribution
transformer
ABB

Design
Modular structure
The enclosures of CSS consist of 300mm wide
modules (M) and plus corner sections measuring
115x115 mm. The walls are supplied in four different
heights and the roofs with two angles of pitch, 6o
and 18o. The doors are 2, 3 or 4 m wide and can be
fitted as either single or double doors. The ventilation
doors are 2 or 3 m wide.

Standard building sizes

Foundation or base frame

W = Width

4M

5M

6M

7M

External width, steel (mm)

1430

1730

2030

2330

L = Length

5M

6M

7M

8M

External length, steel (mm) 1730

2030

2330

2630

L = Length

9M

10 M

11 M

12 M

External length, steel (mm) 2930

3230

3530

3830

H = Wall height (mm)

1664

1914

2114

1266

R = Roof height (mm)

Clinching technology for maximum strength is

used to assemble the walls and the roof. Lifting
fittings, corner sections, bearing sections, base
plates and cable covers are assembled using bolts.
The low voltage switchboard and the medium
voltage switchgear are bolted to the structure. The
roof, the walls and doors are constructed from 1.5
mm galvanised sheet steel and the CSS is painted
with two coats of polyurethane paint.

Width of building
4M

5M

6M

6 roof pitch

203

219

235

251

18 roof pitch

365

414

463

512

The CSS models designed for installation at ground

level have a 130mm high base frame. The models for
installation partially below ground level are supplied
with foundations at three different heights: 528mm,
778mm or 978mm, depending on the size of the
transformer. The foundation and base frame are
produced using 2mm G.I. Sheet.

7M

The CSS comes in standard sizes and other

customised sizes can be supplied on request.

The Enclosure
The enclosure is typically divided into three
compartments for the medium voltage switchgear,
low voltage switchboard and distribution
transformer. All standard modules of walls, doors
and ceilings are produced using roller formed
sections. The detachable roof with ventilation
openings is supported by a beam and secured to
the corner sections with bolts.
Standard doors are fitted with handles and bolts for
padlocks. The doors are closed by means of a twopoint device, which secures the door to the top
frame and the base frame. The doors are fitted with
stainless steel hinges and with door stoppers. The
wall and roof modules are assembled by means of a
self-locking mechanism.
ABB

Oil collection pit

Ventilation

When the CSS is installed partly below the ground,

an integrated oil collection pit made from 1.5 mm
galvanised steel is a standard feature. A separate oil
collection pit for stations installed at ground level can
be supplied. The distribution transformer is fitted in
the oil collection pit, which has a volume of at least
20% of the transformers oil volume. The oil
collection pit provides protection against oil pollution
in case of a leak in the transformer. The oil pit is
normally supplied as per IE regulations where the
transformer oil capacity is >2000 litres.

Ventilation is achieved by means of natural air

circulation of air from the top of the roof to the lower
part of the doors that contain ventilation openings.
Sufficient cooling of the distribution transformers is
achieved by means of ventilation openings in the
transformer room that are designed considering
transformer rating, losses and climatic conditions.
A standard CSS is classified and type tested in
accordance with temperature class K20.
Temperature class K10 can be achieved for all
ground level substations by means of additional
ventilation that can be achieved by increasing the
ventilation area of the transformer room.

The oil collection pit

Partitioned roof
The standard roof of up to 3.8 m in length can be
detached in one piece. A partitioned roof can be
supplied for stations over 3 m.

Ventilation openings in the doors

Other options available

Functionality

CSS CSS CSS

SW
SN
SC

Doors
Standard doors are designed for padlocks and can
also be fitted with a cylinder lock.

Concrete slab as base

Doors with IP54 protection

Temperature class K10

Earthing system up to 20 kA

Partitioned roof (longer than 3 m)

Cylinder lock in doors

Protection
To provide protection against dust in the mediumvoltage and low-voltage compartments, the doors
can be fitted with gaskets that increase the degree of
protection to IP54.

Aluminium foundation plates

Snow panel below doors

ABB

Electrical equipment in the CSS

Medium voltage switchgear

Distribution transformer

The CSS range has been designed and type tested

with ABBs medium voltage switchgear and can
house the following:

CSS stations are designed to house distribution

transformers up to 1250 kVA / 24 kV:

Oil-insulated model, hermetically sealed

Ring Main Unit SafeRing 12-24kV

Oil-insulated with oil conservator

Fuse-switch disconnectors

The CSS can be supplied

with a pre-installed
distribution transformer.
The possibility of lifting the
substation with the
transformer depends on
the type of station, the
relevant solution and the
transformer size.

The range of medium

voltage switchgear
includes both
pre-configured and fully
configurable gasinsulated solutions. A
high level of personal
safety is ensured using
type tested equipment.

Cables and cable accessories

CSS is supplied with internal cables / terminations:

Low-voltage switchboard
CSS is designed to house various low voltage
solutions in accordance with standard norms and
regulations, as well as individual requirements. The
product range includes various types of fuse-switch
disconnectors, including DIN solutions and moulded
case circuit
breakers. Other
equipment can be
supplied as per
customer
specifications.

Medium-voltage cables from medium-voltage

switchgear to the distribution transformer

Low-voltage cables / busbars from low-voltage

switchboards to the distribution transformer

SF6 gas-insulated medium-voltage switchgear is

connected using elbow connections. The cable
termination to the transformer is through regular
cable adapters or, if required,
elbow connections. The lowvoltage cable / busbars
between the distribution
transformer and the lowvoltage switchboard are fitted
with the necessary
terminations.

Type test
The CSS range is designed and type tested in
accordance with IEC 61330, which covers the following
test programmes:
Control of insulation level
Control of temperature rise in the main components in
the substation
Control of earthing system
Control of internal protection class
Control the building resistance to mechanical effects
Function tests on mechanical parts
Additional type tests in accordance with IEC 61330:
Rated short-time current test
Noise test
EMC test

ABB

The main components are type tested in accordance with

their individual standards:
Medium-voltage switchgear

IEC 60265: High-voltage switches

IEC 60298: Metal-enclosed high-voltage switchgear

IEC 60694: High-voltage switchgear

Low-voltage switchboard

IEC 60439: Low-voltage switchgear and control gear

Distribution transformer

IEC 60076: Power transformers

ABB Limited
Medium Voltage
Power Technologies
Plot No. 79, Street No. 17
MIDC Area, Satpur
Nashik 422 007, India
Tel: +91 253 2351095-98,
2351260-68
Fax: +91 253 2351260

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