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UniGear ZS1

Installation, service and maintenance


instruction manual
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 users 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.

1
Contents
Page Page
1. Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5.6.2 Busbar compartment access . . . . . . . . . . . . . . . . . . . . . . . . 48
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5.6.3 Busbar installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.2 Standards and specifications . . . . . . . . . . . . . . . . . . . . . . . . . 7 5.7 Installation of the top-mounted boxes . . . . . . . . . . . . . . . . . . 53
1.3 Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5.7.1 Voltage transformers for busbar metering . . . . . . . . . . . . . . . 53
1.3.1 Normal operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5.7.2 Earthing switch for busbar earthing . . . . . . . . . . . . . . . . . . . 57
1.3.2 Special operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5.8 Pressure relief ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.8.1 Standard gas duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 5.8.2 Compact gas duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.1 Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 5.8.3 Compact gas duct with top chimneys . . . . . . . . . . . . . . . . . . 63
2.1.1 Main parameters for panels with circuit-breakers . . . . . . . . . . . 8 5.9 Cable connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.1.2 Main parameters for panels with NALF switch-disconnector . . 8 5.9.1 Power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.2 Resistance to internal arc faults . . . . . . . . . . . . . . . . . . . . . . . 8 5.9.2 Control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.3 Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 5.10 Earthing the switchgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.3.1 Dimensions and weights of 12/17,5 kV units . . . . . . . . . . . . . . 9 5.11 Laying the ring circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.3.2 Dimensions and weights of 24 kV units . . . . . . . . . . . . . . . . . 10 5.12 Final erection work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.3.3 Dimensions and weights of panels with the
NALF 12/17,5 kV switch-disconnectors . . . . . . . . . . . . . . . . 10 6. Operation of the switchgear . . . . . . . . . . . . . . . . . . . . . . . 71
2.3.4 Dimensions and weights of panels with the NALF 24 kV 6.1 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
switch-disconnectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 6.1.1 Preparatory work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.1.2 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3. Panel design and equipment . . . . . . . . . . . . . . . . . . . . . . . 11
6.2 Switching operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.1 Basic structure and variants . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.2.1 Withdrawable apparatus . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.2 Enclosure and partitioning . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.2.2 Circuit-breaker type VD4 and Vmax . . . . . . . . . . . . . . . . . . 75
3.2.1 Ventilation of the panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.2.3 Circuit-breaker type VM1 . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.3 Compartments in the panels . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.2.4 Circuit-breaker type HD4 . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.3.1 Busbar compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.2.5 Vacuum contactor type V-contact . . . . . . . . . . . . . . . . . . . 79
3.3.2 Circuit-breaker compartment . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.2.6 Withdrawable metering parts . . . . . . . . . . . . . . . . . . . . . . . . 80
3.3.3 Withdrawable parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.2.7 Earthing switch type EK6 and ST-VG-01 . . . . . . . . . . . . . . 80
3.3.4 Cable connection compartment . . . . . . . . . . . . . . . . . . . . . . . 16
6.2.8 Busbar earthing switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.3.5 Control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.2.9 Earthing and short-circuiting with earthing module . . . . . . . . 81
3.3.6 Switch-disconnector and cable compartment
6.2.10 NALF type switch-disconnector . . . . . . . . . . . . . . . . . . . . . . 82
in the panel with switch-disconnector . . . . . . . . . . . . . . . . . . 17
6.3 Test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.4 Interlock/protection against erroneous operation . . . . . . . . . . 18
6.3.1 Testing the off-circuit condition . . . . . . . . . . . . . . . . . . . . . . . 84
3.4.1 Panel internal interlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.3.2 Current and voltage tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.4.2 Door interlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.4 Service trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.4.3 Interlocks between panels . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.4.1 Earthing truck without making capacity . . . . . . . . . . . . . . . . 85
3.4.4 Locking devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.4.2 Earthing truck with making capacity . . . . . . . . . . . . . . . . . . . 85
3.4.5 Internal interlocking of panel with
6.4.3 Power cable test truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
switch-disconnector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.4.4 Isolation truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3.5 Circuit breaker and contactor plug connector
coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.6 Fast recovery device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.7 Ith Limiters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.1.1 Intervals for inspection, servicing and repairs . . . . . . . . . . . . 87
7.2 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4. Dispatch and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.3 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.1 Condition on delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.3.1 Maintenance in busbar compartment . . . . . . . . . . . . . . . . . . 89
4.2 Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.3.2 Maintenance in cable compartment . . . . . . . . . . . . . . . . . . . 90
4.3 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.3.3 Maintenance in circuit breaker compartment . . . . . . . . . . . . 94
4.4 Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.3.4 Maintenance in the low voltage compartment . . . . . . . . . . . . 95
4.5 Intermediate storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.4 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.6 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.4.1 Switchgear in general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.6.1 Switchgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.4.2 Replacement of complex functional groups . . . . . . . . . . . . . 98
4.6.2 Apparatus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.5 Testing withdrawable parts . . . . . . . . . . . . . . . . . . . . . . . . . . 99
7.5.1 Motor-driven withdrawable parts . . . . . . . . . . . . . . . . . . . . . . 99
5. Assembly of the switchgear on site . . . . . . . . . . . . . . . . . 31
7.5.2 Checking correctness of dimensional settings . . . . . . . . . . . 99
5.1 General site requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.5.3 Checking auxiliary switch setting on withdrawable parts . . 100
5.2 Foundations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.5.4 Checking the direction of rotation of the travel motors
5.2.1 Method of installation A Installation of the base irons . . . . . 32 on motor-driven withdrawable parts . . . . . . . . . . . . . . . . . . 100
5.2.2 Method of installation B Fixing with anchoring bolts to 7.5.5 Testing interlock condition . . . . . . . . . . . . . . . . . . . . . . . . . . 101
concrete floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.6 Tests on the panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.2.3 Method of installation C Fixing to a raised false . . . . . . . . . 32
7.6.1 Auxiliary switch settings on the earthing switch . . . . . . . . . 102
5.3 Assembly of the switchgear panels . . . . . . . . . . . . . . . . . . . . 40
7.7 Spare parts, auxiliary materials and lubricants . . . . . . . . . . 102
5.4 Installation of the bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.7.1 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.4.1 Bushing of 12/17,5 kV panels . . . . . . . . . . . . . . . . . . . . . . . . 43
7.7.2 Auxiliary materials, lubrificants . . . . . . . . . . . . . . . . . . . . . . 102
5.4.2 Bushing of 24 kV panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.8 Operating accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5.5 Fixing of the panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.6 Installation of the busbars . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8. Product quality and environmental protection . . . . . . . . 104
5.6.1 Preparation of the material . . . . . . . . . . . . . . . . . . . . . . . . . . 46

2
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.

Figure 1: Curve for determination of the altitude factor k in relation to the altitude H.

3
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.

2.1.2 Main parameters for panels with NALF switch-disconnectors

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.

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

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.

4
2.3 Dimensions and weights

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

Dimension mm

Height A 2200/2595 1)

Width B
- Feeder panels up to 1250 A (31.5 kA) 5) 550
4)
- Feeder panels up to 1250 A (up to 31.5 kA) 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.

Weights of 12/17,5 kV panels (including withdrawable circuit-breaker parts)

Rated current Weight


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

5
2.3.2 Dimensions and weights of 24 kV units
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.

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


Rated current Mass
A Kg
...1250 1000-1050
1600 1200
2000 1200
2500 1200

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

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

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

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


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

6
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 ) 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-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.
) 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.

7
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.

1.7
1.1

A D
1 12.1

2
15.1

3
10

84
1.2

12.2
12 B
5 13
18
18.1
6 18
18.2

7
20.2 20.2
14 20
14.1
14.2 14

8 1.2
C 16

21

17
19

A Busbar compartment 5 Isolating bushing 14.2 Slide


B Circuit-breaker compartment 6 Earthing switch 15.1 Terminal rack
C Cable compartment 7 Current transformer 16 Cable sealing end
D Low voltage compartment 8 Voltage transformer 17 Floor cover split
9 Partition removable 18 Spindle mechanism
1Enclosure 10 Control wiring plug connector 18.1 Spigot on spindle
1.1Pressure relief flap 12 Mounting plate 18.2 Hole in spindle for insertion lever
1.2Control wiring duct 12.1 Top shutter 19 Main earthing bar
1.7Pressure relief flap made of expanded 12.2 Lower shutter 20 Horizontal partition, removable
metal 13 Withdrawable part 20.2 Ventilation grid
2 Branch conductor 14 Earthing switch operating mechanism 21 Cable clamp
3 Busbar 14.1 Operating shaft for earthing switch 84 Partition

Figure 2: Example of UniGear ZS1

8
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 voltageRated short-time withstand currentPartitions


1)
25 kA No
2)
12/17,5 kV 31,5 kA Every third panel
3)
40 kA, 50 kA Every panel
1)
24 kV 25 kA, 31,5 kA No
3)
Marine version All ratings Every panel
1)
In these panels, busbar bushing and bushing plates dont 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 dont 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.

58.5
58

Figure 3: Example of insulating covers

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.

9
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.

10.1

10.2

12.1

43.3

13.1
12.2

42

18.1

14/14.1
14

Figure 4: View into the circuit breaker compartment Figure 5: Circuit breaker compartment open
10.1 Control wiring socket Withdrawable part in disconnected position,
12.1 Top shutter control wiring plug connector open
12.2 Lower shutter 10.2 Control wiring plug
14 Earthing switch operating mechanism 13.1 Withdrawable part
14.1 Drive shaft 14 Earthing switch operating mechanism
42 Right-hand travel rail 18.1 Square spigot
43.1 Duct cover, top left
43.3 Duct cover, top right

13.16

Figure 6: Withdrawable part of VD4 circuit breaker pole side


13.16 Actuating bars

10
45.2

45.3

45.1

Figure 7: Push button for mechanical ON/OFF breaker Figure 8: View of the push rod extension swung out by
operation with the door closed (on request). the knob at the front, with the withdrawable
If the withdrawable part is in the service circuit-breaker part in service position and the
position, operation is carried out using the door open
knob which swings a push rod extension out. 45.3 Swivelling push rod
45.1 Mechanical pushbutton
45.2 Turning knob

3.3.3 Withdrawable parts (Figure 2)


1. Withdrawable circuit-breaker parts
The withdrawable circuit-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.

11
13.15 18.2 18.1 S9 S8 10.3

Figure 9: Withdrawable part with circuit-breaker, type Figure 10: Withdrawable assembly for circuit-breaker,
VD4, operating mechanism side with auxiliary switches
13.15 Withdrawable assembly 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

91.15

91.13

91.14

Figure 11: V-Contact VSC type vacuum contactor front Figure 12: V-Contact type vacuum contactor pole side
view 91.15 MV fuses
91.13 Signalling device ON/OFF 91.13 Signalling device ON/OFF
91.14 Operating cycle counter 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.

12
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 630mm.
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 630mm.
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 mm.
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 mm.
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 240mm 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.

13
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 );
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). );
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 );
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 ).

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.

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.

14
A

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

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

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

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

15
C

Figure 17: Cable compartment door enabling device (C)

C1

C2 Pin ON Pin OFF

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

Figure 19: Cable compartment door locking device (D)

Figure 20: Cable compartment door locking pin (D)

16
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.

200.1

200

215

205.1

205

Figure 21: Switch-disconnector compartment open Figure 22: Preparation for the operation of earthing
position. Insulating plate in the isolating switch in panel with the switch-disconnector.
distance of switch-disconnector 200 Switch- Operating lever prepared for the operation
disconnector OFF.
200.1 Position indicator of switch- 215 Operating lever
disconnector
205 Insulation partition wall
205.1 Movable insulation plate

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.
The plug connector coding is order-related, and is noted in the relevant wiring documentation.

17
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
24.12.25
1250 A
1600 A
2000 A 24.25.25
2500 A

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

18
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.

Resetting the auxiliary contacts

Figure 24: Pressure sensor Figure 25: Shunt opening release

Compressed air system

1 Pressure reducer
2 Lever for opening the air valve
3 Manometer

Figure 26: Fast recovery system Figure 27: Testing equipment

19
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.

A) Valid for crouzet type microswitch

11.5

49.2
49.5

49.4

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
flaps 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)
49.5 Socket screw

20
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.

1.5

Figure 29: Handling by crane


1.5 lifting eyebolt

21
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.
Weight and lifting opening angle must be taken into account when choosing the circular slings.

22
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.

23
Metal sheet
Sliding rollers

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.

Figure 32: Lifting switchgear packed in a wooden crate Figure 33: Switchgear handling

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.

24
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.

Figure 34: Correct handling Figure 35: Wrong handling

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.

2 2

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.

25
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.

3 3

4 4

2 2

1
(*)

(**)

(*) Handling direction for horizontal locking pin entry.


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

Figure 38

26
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!

Dimension chart of structural data

Rated voltage kV 12/17.5 kV 24 kV

Panel width FT mm 550 650 800 1000 800 1000


1)
Aisle width 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


3) 2
Ceiling load kg/m 1200 1200 1400 1400 900 850

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.

27
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
the holes, use a drill with a suitable bit for the type of fixing to be made (through orthreaded hole).

28
Top view

Section A-A

Figure 39: UniGear ZS1 1224 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

29
Top view

Section A-A

Figure 40: UniGear 1224 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

30
16 17 6 8

14

10

12 9

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

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).

31
Top view

Section A-A

Example of profiles for foundation


frame for a raised false floor

Section A-A

View B

Rated Panel B C 1)
2)
voltage depth A
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

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

32
Figure 43: 12/17.5 kV 650/800/1000mm wide units Figure 44: 12/17.5 kV 650/800/1000mm wide units
anchoring bolt fixing system base iron fixing system

FT A B
(width of cubicle)
mm mm mm
650 440 450
800 590 600
1000 790 800

37
37

843
843

60 430 60 60 430 60
1231
1231

300
300

50 200
50 200

340
340

200
200

311
311

50
50

70 70 70 70
72
72

105 340 105 105 340 105


550 550

Figure 45: 12/17.5kV 550mm wide units Figure 46: 12/17.5kV 550mm wide units
anchoring bolt fixing system base iron fixing system

33
Figure 47: 24 kV 800 mm wide units Figure 48: 24 kV 800 mm wide units
anchoring bolt fixing system base iron fixing system

Figure 49: 24 kV 1000 mm wide units Figure 50: 24 kV 1000 mm wide units
anchoring bolt fixing system base iron fixing system

34
Figure 51: 12/17.5 kV cubicle with switch-disconnector Figure 52: 12/17.5 kV cubicle with switch-disconnector
anchoring bolt fixing system base iron fixing system

Figure 53: 24 kV cubicle with switch-disconnector Figure 54: 24 kV cubicle with switch-disconnector
anchoring bolt fixing system base iron fixing system

35
80

80
16

16

Figure 55: Anchoring bolts on concrete floor Figure 56: Base irons on concrete floor

M 12
M 12

Figure 57: Through hole on metal structure Figure 58: Threaded hole on metal structure

5.3 Assembly of the switchgear panels


Use screws of tensile class 8.8. The tightening torques for the busbar screw connections with dished
washer are as follows:

Recommended tightening torque 1) 2) Nm


Lubricant 3)
Thread Without Oil or grease
M6 10.5 4.5
M8 26 10
M10 44.1 20
M12 74.6 40
M16 165 80
1)
The rated tightening torques for fasteners without lubrication are based on a coefficient of friction for the thread of 0.14 (the actual
values are subject to an unavoidable range, in part not inconsiderable).
2)
Rated tightening torques for fasteners with lubrication in accordance with DIN 43 673 Standard .
3)
Thread and head contact surface lubricated.

Any tightening torques which deviate from those in the general table (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, so as to achieve a precise rated tightening torque.

36
The individual installation stages are as follows:
Remove withdrawable parts 13 (figure 2) from the switchgear panels and store them with suitable
protection;
Dismantle lifting eyebolts 1.5 (figure 29);
Transport the switchgear panels to the prepared installation point following the sequence shown on
the switchgear plan;
Remove vertical partitions 9 in front of the busbar compartments by releasing the fixing screws;
Release the fixing screws and draw out horizontal partition 20 below the withdrawable part travel
rails;
Release and remove floor cover 17;
Remove covers 43.2 and 43.3 (figure 59) from the vertical control wiring ducts at the front right and
left of the panel.

43.1

1.8

20

43.2

Figure 59: View into the high voltage area at the front
1.8 Central catch
1.11 Bore, for control wiring bushing 24
20 Horizontal partition, removable
43.1 Duct cover for external control cables in LV comp.
43.2 Duct cover for external control cables in cable comp.
43.3 Duct cover for external control cables in circuit breaker comp.

If any top-mounted enclosures with busbar earthing switches or instrument transformers have been
removed for transport, bolt these in place in the specified position where the rear and middle pressure
relief plates would otherwise be located on the switchgear panels, and make the internal connections
again.
Fit and screw the separate mechanism enclosures for any top-mounted earthing switches in the
specified position on the low voltage compartment with the front edge flush.

Note the correct positions of the parts fitted on the hexagonal drive shaft supplied loose, and then
remove the parts from the shaft, discarding the rubber ring at the front.
Insert the drive shaft step by step at the front of the mechanism enclosure until it is completely fitted,
threading on the individual parts in the correct positions for the open position of the earthing switch.

Secure the setting rings. Adjust the mounting positions and operating moments of the auxiliary
switches:
1. Adjust the positions of the auxiliary limit position switches in their slots in such a way that there is
a run-on of 0.5 mm in the fully operated position before the plunger reaches the stop (for safety
reasons);
2. The auxiliary limit position switch 78.4 (Figure 60) or earthing switch ON must operate immediately
after the dead centre position of the toggle spring mechanism is reached in the closing process and
the automatic quick-closing process has started;
3. The auxiliary limit position switch 78.5 for earthing switch OFF must be operated during the opening
movement of the slide (78.2) 1 mm before the tab of the slide makes contact with the armature of
the de-energised locking magnet 78.6 (Figure 60).

37
77 78

78.1

Figure 60: Panels - 12/17.5 kV - Top-mounted box with earthing switch for busbar earthing

77 Top-mounted box for top-mounted earthing switch


78 Operating mechanism box
78.1 Operating shaft
78.2 Slide
78.4 Auxiliary switch ON
78.5 Auxiliary switch OFF
78.6 Locking magnet

38
5.4. Installation of the bushing
Before fixing the panels side by side (according the general drawings) bushings 29 (1224 kV) must
be fixed (for switchgear with busbar barriers only; refer to the table on page 13).

5.4.1 Bushing of 12/17,5 kV panels


29

30

31

32

Figure 61: 12/17.5kV panels - fixing bushings

29 nr. 1 bushing 31 nr. 8 M8 washer


30 nr. 8 8x25 screws 32 nr. 3 Rubber partition (busbar support)

5.4.2 Bushing of 24 kV panels


Assembly procedure for bushings main (upper) busbar system:
Insert bushing 29 for the lower busbar into bushing plate 28 from the right side, and the middle and
upper one from the left side (figure ).

Lower bus-tie system:


Insert bushing 29 for the lower rear bus-tie into bushing plate 28.2 from the right side in contrast to
the procedure for the other two bushings (see Figure 8).

28

37

36

29
35

Figure 62: 24 kV panels - fixing bushings


28 nr. 1 bushing plate 35 nr. 12 8x25 screws
29 nr. 3 bushing 36 nr. 12 M8 washer
37 nr. 12 M8 die

39
5.5 Fixing of the panels
Fit and screw down the lids.
Align the switchgear panels on the floor frame for correct positioning and vertical alignment
(deviations of the panel edges from the vertical must not exceed 2 mm, especially at the front) and
bolt the panels together (figure 63). It is advisable to start from the centre when assembling
switchgear with more than ten panels.
The junction points where you have to fix the panels are the followings:
- Nr.6 in the front side (A-B-C-D-E-F).
- Nr.4 in the middle part (L-M-N-O).
- Nr.5 in the rear side (G-H-I-J-K).
The nuts on the carpentry are already fixed on the right side of the panel (except in the middle part);
on the left side there is the empty space where the screws are to be fixed.
The screws needed are the followings:
- 10x30 screws (complete with M10 washer) for front and rear side.
- 10x35 screws (complete with washer and M10 nuts) for middle part.

Figure 63: View of the fixing points

40
When the switchgear has been properly assembled, fix the panels to the floor using plugs, or weld
or adequately bolt them to the foundation frame.

Figure 64: Fixing to the floor - method of installation A with base irons

Figure 65: Fixing to the floor - method of installation B with anchoring bolts to concrete floor

Figure 66: Fixing to the floor - method of installation C to raised false floor

41
5.6 Installation of the busbars

5.6.1 Preparation of the material

Before to fix the panels side by side be sure that the bushings are fixed according to the
chapter 3.3.1 at page 11.

Clean the insulation on the busbar sections with a soft, dry cloth, and check for insulation damage.
Remove greasy or adhesive dirt as described in section 7.3;
Busbar connections:
- The silver plated surfaces of the connections must be cleaned with a metal-free non-woven
cleaning cloth and thinly and by appling a thin layer of mechanical grease;
- The non-silver plated surfaces of the connections are either brushed with a wire brush, preserving
the grease film, or cleaned with a metal-free non-woven cleaning cloth and evenly greased with a
thin layer of mechanical grease;
Prepare insulating covers 58 and lids 58.5 (figure 3, 67, 68) to suit the relevant busbar connections
and thread them onto the busbar. (For insulated busbars only).

Figure 67: 12/17.5kV panels, installation of the busbars. The lower picture shows the installation at the busbar ends.

29 busbar bushing
58 insulating cover
58.1 support for cover (at end panels only)
58.5 lid
58.6 washer, ISO 7089
58.7 washer, 25mm diameter

42
58.5 58.1 165 165 58 2 58.5 3

(10)

During assembly, cut out the insulating cover and lid to fit the cross-
section of the feeder bar or busbar.

(58.6) 163 164 58.7

a) Arrangement for 1250 A branch current and 1600 or 2500 A busbar


current.

58.5 3.5 165 2 165 58 2 58.5 3


(10)

b) Arrangement for 2500 A branch and busbar current.

58.1 58.7 163 164(58.6) 165 3

Figure 68: 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 58.1 and without the spacer plate 3.5.

2 Branch conductor
3 Busbar section
3.5 Spacer plate
58 Insulating cover
58.1 Lid holder
58.5 Lid for insulating cover
(58.6) Washer ISO 7089
58.7 Washer 25 mm diameter
163 M10 hexagon socket head screw
164 M10 nut
165 10mm spring washer

43
5.6.2 Busbar compartment access
Access to the busbar compartment is possible
either from the top of the panel after dismounting
the pressure relief plate 1.1 (figure 2) before the
mounting of the gas duct, or from the front of the
circuit-breaker compartment.
After circuit-breaker 13 (figure 2) has been with-
drawn from the panel, it is possible to dismount
horizontal partition 20 by unscrewing nr.4 screws
holding the partition from the inside.
After that, the partition 9 can be dismantled (by
unscrewing nr.7 screws) and taken out of the
panel, which makes access to busbars from the
circuit-breaker compartment possible.

20 9

Figure 69: accessing busbar compartment

5.6.3 Busbars installation


Install the busbars panel by panel according to the ratings of the switchgear (figures 7077). Screw
on the individual busbar elements one above the other (depending on the system layout) and in line
with the flat branch conductor.
For the tightening torque please make reference to the table at page 40. Use two dished washers
for each screw. Use screws of tensile class 8.8.

Bolt one holder 58.1 (figure 67, 68) to each end of the busbars to support insulating cover 58. The
screws for holder 58.1 must be tightened with a lower torque. (For insulated busbars only).
Position insulating covers 58 and lids 58.5 over the relevant bolted joint, and slide the lid onto the
cover until it clicks into place. (For insulated busbars only).

Note:
Busbar connection is carried out with so-called stabilized connections.
This means that quality of the copper busbar connections does not change according to the operating
time and therefore it is not necessary to inspect tightness of busbar connections regularly. But this is
on condition that correct assembly is carried out as described above and especially that all connections
are tightened with the prescribed torque according to the above table.
We recommend only inspecting tightness of busbar connections during inspections (see chapter 7).

44
5.6.3.1 Busbars for 12/17.5kV units
Busbars are made of copper and have a flat cross-section for rated current up to 2500A. For 3150, 3600
and 4000A, the busbars have a double D-shaped cross-section. Branch conductors always have a flat
cross-section.
12/17.5kV bushings are made of epoxy resin castings and are arranged as a single casting for all three
phases (figure 61). For bus-tie units the bushings are single and are arranged in the lower part of the
unit. Bushings are held in bushing plates.
For 12 kV, the busbars are bare (without insulation) and without insulating covers up to 2500A.
3150, 3600 and 4000A D-shaped busbars are insulated by means of shrink sheaths and are fitted with
insulating covers.
For 17.5 kV, the busbars are insulated and fitted with covers over the whole current range.

40

42

43

Figure 70: 12/17,5 kV panels Tee-off 630-1250A, busbars 1250A


40 nr. 4 10x35 screws
42 nr. 8 M10 washers
43 nr. 4 M10 nuts

41

42

43

44

Figure 71: 12/17,5 kV panels Tee-off 630-1250A, busbars 1600A-2000A-2500A


41 nr. 4 10x60 screws
42 nr. 8 M10 washers
43 nr. 4 M10 nuts
44 nr. 1 spacer (15mm)

45
41

42

45

43

Figure 72: 12/17,5 kV panels Tee-off 1600-2000A-2500A, busbars 1600A-2000A-2500A

41 nr. 4 10x60 screws


42 nr. 8 M10 washers
43 nr. 4 M10 nuts
45 nr. 1 spacer (5mm)

41

42

43

44

Figure 73: 12-17,5 kV panels Tee-off 630-1250A, busbars 3150A-3600A-4000A

4 nr. 4 10x60 screws


42 nr. 8 M10 washers
43 nr. 4 M10 nuts
44 nr. 1 spacer (15mm)

46
41

42

45

43

Figure 74: 12-17,5 kV panels Tee-off 16004000A, busbars 3150A-3600A-4000A

41 nr. 4 10x60 screws


42 nr. 8 M10 washers
43 nr. 4 M10 nuts
45 nr. 1 spacer (5mm)

5.6.3.2 Busbars for 24 kV units


Busbars and branches are made of copper and both have a flat cross-section. Bushings are different
from the 12/17.5kV ones. They are single for each phase and have an electrode inside, which must
be connected to the busbar.
Busbars for 24 kV units are insulated by means of shrink sheaths and the connection points are covered
by insulating covers.

- 1250 A
41

42

43
- 1250 A

Figure 75: 24 kV panels Tee-off 1250A, busbars 1250A

41 nr. 4 10x35 screws


42 nr. 8 M10 washers
43 nr. 4 M10 nuts

47
41
- 2500 A
42

43

- 1250 A

Figure 76: 24 kV panels Tee-off 1250A, busbars 2500A

41 nr.4 10x60 screws


42 nr.8 M10 washers
43 nr.4 M10 nuts

41

42
- 2500 A

43
- 2500 A

Figure 77: 24 kV panels Tee-off 2500A, busbars 2500A

41 nr.4 10x60 screws


42 nr.8 M10 washers
43 nr.4 M10 nuts

48
Important note:
Always check that there is good contact between the metal tube in the bushing and the busbar
via contact spring 29.3. Ensure that the contact spring is in the correct position! (figure 78).

Important note:
The contact springs 29.3 must be inserted
during the installation of busbars. These contact springs make the connection between the busbar 3 and the metal tube
29.4 and prevent damage caused by partial discharges inside the bushing on live busbars.

Always check that there is good contact between the metal tube 29.4 in the bushing and the busbars via the contact spring.

Figure 78: 24 kV panels - detail of the busbar bushing, sectional view

3 Busbar
29 Busbar bushing
29.2 Busbar support for double conductor
29.3 Contact spring
29.4 Metal tube

5.7 Installation of the top-mounted boxes


For transport reasons, attachments to the panels are not completed at our works. However, they are
pre-mounted as far as possible.

5.7.1 Voltage transformer for busbar metering


Top-mounted box 79 (figure 81) with screw fixing material in the set of bags Top-mounted box for
metering must be mounted on the busbar compartment.
Notes
- In panels without busbar bushing plate 28, the partition between the busbar compartment and the
top-mounted box is necessary. They are installed at the works in the top-mounted box;
- As far as equipment with busbar partitioning is concerned (i.e. with bushing plate 28), the space
between the busbar compartment and the top-mounted box must remain open for purposes of
pressure relief;
Connecting bars 2.2 with branch conductors 2 at the junction point must be screwed together
according to figures 79 and 80. However, if necessary, the additional spacer plate 3.2 or 3.3 and
threaded plate 3.4 or 3.8, as well as the screw fixing material from the top-mounted box for metering
set of bags must be used;
Insulating cover 58 must be brought into position as is described in section 5.4;
Intermediate box 79.1, with the screw fixing material from the top-mounted box for metering set
of bags must be mounted on the control cabinet. Conduction tube 79.2 must be positioned and
inserted in reducer rings 79.3;
Secondary circuits from the voltage transformers must be led to the terminal strips and connected
according to the cable core markings and circuit diagram.

49
2.2

3.8

3.2

3.2

Figure 79: 12/17.5kV panels - Bar connection to the top-mounted box. The figure shows the arrangement in panels the
busbar ends

2 Branch conductor
2.2 Connection bar
3.2 Spacer plate, 5 mm thick
3.8 Tapped plate
3.10 Spacer plate, 8 mm thick

50
58.5 3.5 (58.6) 3.4 58 162 2.2 58.5 3

(35)
58.1 58.7 163 165 2 3

3.3 3,4 162 2.2


(10)

58.1 58.7 163 (58.6) 165 2 3

3.3 3.4 3.5


35 25
M10 35 15

24
24

50
80

80
32
32

32

70

Figure 80: 24 kV panels - Bolted busbar joint for top-mounted box, shown for left-hand busbar end. In continuous
busbars is the connection is similar, but without the lid holder 58.1 and without the spacer plate 3.5.

2 Branch conductor
2.2 Branch conductor to the top-mounted box
3 Busbar section
3.3 Spacer plate, 10 mm thick
3.4 Threaded plate
3.5 Spacer plate
58 Insulating cover
58.1 Lid holder
58.5 Lid for insulating cover
(58.6) Washer 2 mm
58.7 Washer 3 mm
162 Cylinder screw
163 M10 hexagon socket head screw
165 10 mm spring washer

51
79
79.2 79.3 79.1

28.3

Figure 81: 12/17.5kV panels - Top-mounted box with voltage transformers for busbar metering. The figure shows the
arrangement in panels without the busbar bushing plate 28 (see the notes in section 5.7.1)

28.3 Partitioning
79 Top-mounted box with voltage transformer
79.1 Intermediate box
79.2 Conductor tube
79.3 Reducer ring

79.4

79
79.2 79.3 79.1

2.3

28

Figure 82: 24 kV panels - Top-mounted box with high voltage transformers for busbar metering. The figure shows the
arrangement in panels with busbar bushing plate 28 and bushings 29

2.3 Flat branch conductor for voltage transformers


28 Bushing plate
79 Top-mounted box for busbar voltage transformers
79.1 Intermediate box
79.2 Conductor tube
79.3 Reducer ring
79.4 Pressure relief

5.7.2 Earthing switch for busbar earthing


Top-mounted box 77 (figure 83) with screw fixing material from the top-mounted box for earthing
set of bags must be mounted on the busbar compartment;
Operating mechanism box 78 with screw fixing material from the top-mounted box for earthing set
of bags must be mounted on the control cabinet;
Pre-mounted single parts of hexagonal shaft 78.1 must be removed. Pay attention to the sequence
and angling of the parts!,

52
Hexagonal shaft from the operating mechanism box must be pushed through into the bevel gear of
the earthing switch. Sequence and angles of the part must be restored!
Connecting bars 2.2 with the branch conductors 2 at the junction point must be screwed together
according to figure 5/26 and 5/34. However, if necessary, additional spacer plate 3.3 or 3.2 and
threaded plate 3.4 or 3.8, as well as the screw fixing material from the top-mounted box for earthing
set of bags must be used;
Insulating cover 58 must be brought into position as described in section 5.4.

Note
The auxiliary switches for the earthing switch are adjusted at the works. Problem-free operation is only
guaranteed if the working elements on the hexagonal shaft are correctly mounted.
Because of final installation of the earthing switch and operating mechanism on site, it may be
necessary to make precise adjustment of the auxiliary switches.
In that case, the following is important:
The auxiliary switch OFF 78.5 must be operated:
- before slide 78.2 has uncovered half of the opening in front of the hexagonal shaft and;
- before the lower edge of the slide has touched the anchor of locking magnet 78.6;
The auxiliary switch ON 78.4 must be operated:
- before the toggle spring of the earthing switch has reached its dead centre point;
The push-rod of the auxiliary switch must still have about 0.5 mm to go to the end position in the
operated position.

77 78

78.1

Figure 83: 12/17.5kV panels - Top-mounted box with earthing switch for busbar earthing

77 Top-mounted box for top-mounted 78.4 Auxiliary switch ON


earthing switch 78.5 Auxiliary switch OFF
78 Operating mechanism box 78.6 Locking magnet
78.1 Operating shaft
78.2 Slide

53
77
78.1 78

2.2

Figure 84: 24 kV panels - Top-mounted box with earthing switch for busbar earthing. The arrangement is the same as
the figure above
2.2 Flat branch conductor for earthing switch
77 Top-mounted box for earthing switch
78 Operating mechanism box
78.1 Hexagonal shaft

5.8 Pressure relief ducts


The standard solution provided for the arc-proof version of the UniGear ZS1 consists of a metal sheet
duct for collecting and exhausting the hot gases; this duct is mounted on the upper side of the
switchgear and normally it is extended on both the right and left extremities
This solution is capable to guarantee the safety for the persons that are standing in front of the
switchgear, according to the IEC 62271-200 Standard (criteria 1 to 5).
The recommended solution in order to avoid the exhausting of the gases and the overpressures inside
of the switchgear installation room is to prolong the exhaust duct outside of the substation (from left
and right sides or front and rear sides). In this case, take care of the accessibility of the persons in the
gas-exhausting zone and protect the gas exhaust channel extremity in order to avoid the entrance of
water, dust, small animals and any foreign object.

UniGear ZS1 switchgear is available with the following solution of gad duct:
Standard duct;
Compact duct;
Compact duct with top chimneys.

The pressure relief duct is supplied dismantled in single parts. The rear and front wall correspond, as
far as length is concerned, with the appropriate panel width. They are joined together by means of the
attachment strips.
The screw fixing material is contained in the pressure relief duct set of bags. Rivet nuts are already
provided in the metal sheets.

Note
The rear pressure relief flap must be mounted according to figure 85.
Details regarding connection to the wall and a discharge grating for pressure relief outside the
switchroom will be agreed on with the customer.

54
50

1)

Figure 85: Schematic diagram of the pressure relief duct. The components are assembled panel by panel and bolted
together with overlaps at the panel joints.

50 pressure relief duct


1) If the switchgear is equipped with a pressure relief duct, the pressure relief flap for the cable connection
compartment is fixed to the rear side of the panel and will open to the front (into the duct) in case of an
arc fault.

5.8.1 Standard gas duct


Once that the panels are fixed between them and to the floor, it is possible to start to fix the gas duct
on the top of the switchgear. Every panel have three fixing points in the front part (figure 86) and three
fixing points on the rear part (figure 87).

Figure 86: Fixing points on the front. Figure 87: Fixing points on the rear.

With nr. 6 screws 8x20 and nr. 6 washer M8, fix the front and rear part of the gas duct sheets
(figures 88, 89).

Figure 88: Front sheet. Figure 89: Rear sheet.

55
Once that the two sheets are fixed to the panel, it is possible to fix the two sheets between them (figure
90) using nr.6 screws.

Figure 90: Junction of the front and rear sheet.


Nr. 6 screws 10x30
Nr. 6 M10 nuts
Nr. 12 M10 washer

Repeat the above described operations for the adjacent panel.


At this point it is possible to fix the front connection plate between the two gas duct panels (figures 91).

Figure 91: Front connection plates.


Nr. 8 screws 8x30
Nr. 8 M8 washer

Fix the central connection plate between the two gas duct panels (figures 92).

Figure 92: Central connection plates.


Nr. 10 screws 8x30
Nr. 10 M8 washer

56
Fix the rear connection plate between the two gas duct panels (figures 93).

Figure 92: Rear connection plates.


Nr. 8 screws 8x30
Nr. 8 M8 washer

Repeat the above described operations for all the panels.


The next operation is the fixing of the left and right end side (figures 93).

Figure 93: Side plates.


Nr. 13 screws 8x30
Nr. 13 M8 washer

The last operation in order to complete the gas duct is the fixing of the gas duct extension on both sides
(figure 94).

Figure 94: Side plates.


Nr. 10 screws 8x30
Nr. 10 M8 nuts
Nr. 10 M8 washer

57
Figure 95: Overview of the standard gas duct.

5.8.2 Compact gas duct


In order to mount the compact gas duct must be followed the operations described for the standard
gas duct.

Figure 96: Overview of the compact gas duct.

58
5.8.3 Compact gas duct with top chimneys
In order to mount the compact gas duct with top chimneys must be followed the operations described
for the compact gas duct.
The difference between the two solutions is that in this case there are no side exits, but the gas
generated from an internal arc goes out from the duct through the top chimneys located on the top part
of the gas duct on each panel.
On the top of the gas duct there are two openings (figure 97); for each opening it must be fix the net
and the nr.6 spacers (figure 98).

At this point it is possible to fix the top cover with nr.12 M8 screws.

Figure 97: Openings on top of the gas duct. Figure 98: Net and spacers of top chimneys.

Figure 99: Top cover of top chimneys.

59
5.9 Cable connection

5.9.1 Power cables


The standard method for entry of power cables in the switchgear is shown in Figures 100, 101.
The cables are conveyed from below through floor covering 17, which is divided at the cable entry point.
The cables go through rubber reducer rings 17.2, which can be adapted to the required cable diameter
in a range from 27 to 62mm. Cables are fastened in the panel by means of cable clamps mounted on
cable strips, which are part of the panel floor covering. The clamps make it possible to fasten cables
with diameters between 35 and 54mm.

39

6.1

23

19.1 21 17 17.2 19 19.2


17.2

17

Figure 100: View into the cable connection compartment, Figure 101: Partial view of the cable compartment,
max. six parallel cables are possible prepared here for connection of
triple cables.
6.1 Earthing switch position indicator
17 Floor cover, split 17 Floor cover, split
17.2 Reducer ring 17.2 Reducer ring
23 Cable connection bar 19 Main earthing bar
19.1 Connecting link
19.2 Earthing connection pin
21 Cable clamp
39 Mounting rail, connected to earth
potential

Cable sealing ends are mounted on the cable cores according to the manufacturers instructions. It
is possible to use cable sealing ends of different manufactures (e.g. Pirelli, Raychem etc.), but it is
necessary to keep the length of the cable ends, including cable sealing ends, which is given by the
distance of cable connecting bars 23 from the panel floor covering.
These bars have different versions, hich differ in their number of parallel cables and the values of rated
and short-circuit currents. See ig. Figure 102106.
The bars are equipped with holes for M16 screws. If M12 screws are used for cable connections, special
washers with the diameter for M12 screws must be used. In all cases, the earthing of cable screens
is carried out on the strip-holding cable clamps. The cable strip is connected to the earth potential.
It is also possible to place the removable arrangement of voltage transformers in the cable
compartment. These can be fitted with HV fuses similar to those in the measuring panel. Three fixed
mounted surge arresters can also be installed here. But in both these cases the number of parallel
cables must be reduced see the table.

The cable connections bars are equipped with holes for M16 screws, but they are supplied
without screws, washer and nuts.
The supply of this material, according to the cable termination, is at Customer charge.

60
Connection of cables in typical panels:

Range Panel Max. number Max. cross- Range of Range of


voltage width of parallel cables section of cables cable clamp reducer ring
(kV) (mm) in phase (mm2) (mm) (mm)
12 550 3 600
1)
650 3
12/17.5 800 6 2) 630
1000 35 - 54 27 - 62
24 800 3 1) 500
2)
1000 6

1) In the case where there are removable voltage transformers on the truck, or surge arresters are used, the number of parallel cables
is reduced to a max. of 2 per phase.
2) In the case where there are removable voltage transformers on the truck, or surge arresters are used, the number of parallel cables
is reduced to a max. of 4 per phase.

Cable connection in the panel with switch-disconnector

Range Panel Max. number Max. cross- Range of Range of


voltage width of parallel cables section of cables cable clamp reducer ring
(kV) (mm) in phase (mm2) (mm) (mm)
12/17.5 800 1 240 35 - 54 27 - 62
24 1000

Important note
Connection with single-core plastic insulated cables is presumed in the typical panels. In the case of
any atypical cable connections or of special cables (e.g. three-core cables, cables with paper or special
insulation etc.), an agreement must be reached between the customer and manufacturer.

Mounting procedure for power cables:


Power cables must be inserted, cut to length and stripped;
Reducer rings 17.2 (figure 100) must be adapted to the cable diameter and fitted onto the cable;
Cable sealing ends must be prepared and mounted on cable cores according to manufacturers
instructions;
Cable eyes must be connected to the prepared connections bars 23 with strain relief;
Earthing of cables must be connected;
Individual parts of the floor covering must be mounted;
Reducer rings 17.2 must be moved down so that nuts in the rings fit into the corresponding recesses
in the floor coverings. In this way, the cable passages are sealed;
Cables must be fastened in the prepared cable clamps 21 (the maximum tightening torque applicable
to the clamp screws is 9 +2 Nm).

5.9.2 Control cables


The control cables are conveyed into the panel through the control wiring duct 1.2 on the left-hand panel
side.

Mounting procedure:
Insert the cables into the control wiring duct 1.2 (figure 2) on the left-hand side. The duct is covered
by covers 43.1, 43.2 (figure 59);
Fasten the control cables at the top end of the duct, strip the insulation and convey cable control cores
into the low voltage compartment D, after the terminal strip frame has been swung up (figure 107);
Connect control cables to the terminal strip according to the circuit diagram;
Make the control wiring connections to adjacent panels using bushing 24 (figure 59).

61
Dimension of power cable connection of UniGear ZS1 12/17.5 kV classic panels

23

A
C C C C C B

D1)

17.2 21

In width Ith max. number A B C


of cables
A mm kA in one phase mm mm mm
630 1 840
1000 650 31.5 535
1250 3 480 180
1250 40 465
1600 800
2000
1600 31.5/40 440
2000 6 460 100
2500 1000
3150
40 455
4000

Figure 102: Dimension of power cable connection of UniGear ZS1 12/17.5 kV classic panels.

D Panel depth with HD4 circuit-breakers is 1340 mm,


in other cases 1300 mm - however always consider note 1)
Panel depth for rated current 3150 to 4000 A with HD4 circuit breakers is 1390 mm,
in other cases 1350 mm - however always consider note 1)

1) The dimension must be verified according to the documentation of the relevant order
17.2 Reducer ring
21 Cable clamp
23 Cable connection bar

62
Dimension of power cable connection of UniGear ZS1 12/17.5 kV 550 panels

In width Ith max. number A


of cables
A mm kA in one phase mm
630
550 25 2 105
1250

Figure 103: Dimension of power cable connection of UniGear ZS1 12/17.5 kV 550 panels.

63
Dimension of power cable connection of UniGear ZS1 24 kV classic panels

23

21

(1)

With Ith N of phases


mm kA (cables) A B C

IF 800 31,5 3 (6) 465 700 100


IFM 800 31,5 2 (2) 460 740 118
IF 1000 31,5 3 (5) 425 770 120
IFM 1000 31,5 3 (6) 415 690 100

Figure 104: Dimension of power cable connection of UniGear ZS1 24 kV classic panels.

(1) The dimension must be verified according to the documentation of the relevant order
21 Cable clamp
23 Cable connection bar

64
Dimension of power cable connection of UniGear ZS1 12/17.5 kV switch disconnector

Figure 105: Dimension of power cable connection of UniGear ZS1 12/17.5 kV switch disconnector.

D The depth of the panel with switch disconnector in combination with HD4 circuit-breaker panel
is 1340 mm, in other cases 1300 mm - however always consider note 1)

1) The dimension must be verified according to the documentation of the relevant order
17.2 Reducer ring
21 Cable clamp
23 Cable connection bar

Dimension of power cable connection of UniGear ZS1 24 kV switch disconnector

Figure 106: Dimension of power cable connection of UniGear ZS1 24 kV switch disconnector.

D The depth of the panel with switch disconnector in combination with HD4 circuit-breaker panel
is 1560 mm, in other cases 1520 mm - however always consider note 1)

1) The dimension must be verified according to the documentation of the relevant order
17.2 Reducer ring
21 Cable clamp
23 Cable connection bar

65
Figure 107: Terminal frame swung up for connection works

5.10 Earthing the switchgear


Connect main earthing bar 19 (figure 101) with connections 19.1 provided in every panel.
Protection wiring connection of the floor frame or the erected raised false floor respectively, should
be made.
Connect the earthing conductor coming from the earth electrode, preferably via a removable bolted
connection for testing purposes, to the main earthing bar 19 of the switchgear.

5.11 Laying the ring circuits


The ring circuits are supplied rolled up in a bundle in the control cabinet or in the accessories. They
are marked and fitted with ferrules or connectors at both ends. Openings are provided in the side walls
of the control cabinet for these lines to be looped through from panel to panel.

5.12 Final erection work


Check painted areas of the switchgear for possible damage, touching up where required (also see
section 7.4.1);
Check bolt connections and tighten where required, in particular all those carried out during on-site
erection of the busbars and earthing system;
After the lifting eyebolts have been removed, the Ith limiter auxiliary switch (if delivered) must be
mounted and adjusted:
- The auxiliary switch holder is fixed by means of screws 49.5 in the panel (figure 28);
- The auxiliary switch holder must be positioned horizontally (figure 28);
- The control pin of the auxiliary switch must be moved to the centre of the hole in the pressure relief
flap;
- Adjust the auxiliary switch according to figure 28;
- If the auxiliary switch is mounted and adjusted according to the above instructions, checking during
regular inspections is not necessary;
Clean the switchgear thoroughly;
Remove all foreign bodies from the panels;
Correctly replace all coverings, etc. removed during erection and connection;
In the enclosure, any remaining openings must be closed if they are no longer needed;
Check the isolating contacts and interlocking mechanisms for smooth motion, and grease again with
mechanical grease where necessary (see section 7.4.1 and 7.7.2);
Withdrawable circuit-breaker parts must be inserted and the control wirings connected;
Panels doors must be properly closed.

66
6. Operation of the switchgear

Note on safety at work


The relative work and operating procedures must be carried out carefully by trained
specialists familiar with the installation, taking into account all the relative safety
regulations according to the IEC and other relevant professional bodies, as well as any
local and work regulations and instructions.

Warning
Do not walk on the top surfaces of the switchgear panels (rupture points for pressure
relief).
The pressure relief devices could be damaged!

6.1 Commissioning
6.1.1 Preparatory wok
In preparation for commissioning, the following work must be carried out prior to connection with the
high voltage power supply:
Check the general condition of the switchgear for any damage or defects;
Visually inspect the switching devices, withdrawable parts, isolating contacts, insulating parts, etc.;
Check connection of the main earthing bar to the installation earthing conductor (following the
appropriate safety regulations);
Check the paintwork for damage and, where necessary, touch up as described in section 7.4;
Remove all residues of materials, foreign bodies and tools from the switchgear;
Clean the switchgear, rubbing down insulating parts with a soft, dry, clean, non-fraying cloth.
Remove any greasy or sticky dirt as described in section 7.3;
Correctly remount all covers etc. removed during assembly and testing procedures;
Transport caps 13.9 (figure 108) on vacuum circuit-breakers - if still fitted - must be removed;
Pole tube lids 13.10 on vacuum circuit-breakers may be fitted in certain systems and on certain
circuit- breakers. Check that they are fitted correctly;
Lifting eyebolts 13.13 on high current vacuum circuit-breakers must be removed if still fitted;

13.9

13.13

Figure 108: Withdrawable part with VD4 type high current circuit- breaker - pole side

13.9 Transport caps (to be removed on commissioning)


13.13 Lifting eyebolt (to be removed on commissioning)

67
Preparatory works for SF6 circuit-breakers:
- Clean the insulating parts with clean dry cloth;
- Check that the upper and lower terminals are clean and free of any deformation caused by shocks
received during transport and storage;
- It is advisable to check the SF6 gas pressure;
Perform AC voltage testing of the main circuits according to IEC 62271-200 where necessary. Pay
special attention to voltage transformers and cables, etc. during this procedure. A testing and
earthing module 142 (figure 129) can be used to make the connections (see section 6.3.2);
Switch the auxiliary and control voltage on;
Carry out testing operations on switching devices manually or by electrical control, and simultane-
ously observe the relative position indicators;
Check mechanical and electrical interlocks for effectiveness, without using force;
Set the protection devices in the switchgear to the required values and check their function with test
equipment;
In switchgear panels with an additional ventilation system for high current circuit-breakers (required
for ambient temperature higher than > 40 C and/or higher frequency - 60Hz -according to section
1.3 and figures 109 and 110), flap 20.3 hanging in partition 20 must rest loosely against leaf spring
20.4 (with the centrifugal fan at a standstill, if fitted ). This is not standard.
To check:
- Insert a suitable screwdriver through opening 20.5 in horizontal partition 20 and into bracket 20.6
on flap 20.3;
- Swing flap 20.3 upwards and allow it to rest loosely again on leaf spring 20.4;
- If the flap is in the locked position, use the screwdriver to press leaf spring 20.4 downwards by
approx. 5 mm to release the lock before swinging the flap;
- If any centrifugal fans controlled in relation to primary current are fitted, also check that these
function correctly;

Figure 109: Fitting of horizontal partition 20 with addi-


tional ventilation ventilation for high current
circuit-breakers, required due to increased
ambient temperature (>40C) and/or in-
creased frequency (60 Hz) according to
section 1.3. The internal flap is shown in the
service position (open). Side view, but without
the wind vane with micro-switch required with
a fan. Not standard.

20 Horizontal partition, here fitted with the


additional ventilation facilities for the
circuit-breaker
20.3 Flap Figure 110: Horizontal partition with additional ventilation
20.4 Leaf spring facilities. Checking unimpeded movement of
20.5 Inspection aperture the internal flap 20.3
20.6 Bracket
20.7 Centrifugal fan 20.5 Inspection opening

68
On motorized withdrawable parts, check the direction of rotation of the travel motor in accordance
with section 7.5.4;
For any other matters regarding operation of the withdrawable circuit-breaker part and testing
facilities for the withdrawable part, see section 7.5;
Instruct local operators regarding the basic details of regular handling of the switchgear;
Check readiness for operation and switching status of electrical systems upstream and downstream
of the switchgear.

Depending on allocation of responsibilities, it may also be necessary to check the following equipment
in areas adjacent to the switchgear:
power cables;
auxiliary cables;
auxiliary power source;
remote control system;
complete earthing system;
switchroom equipment;
switchroom conditions.

6.1.2 Start-up
Comply with all relevant safety regulations;
Ensure that the circuit-breakers in the system are in the OFF position;
Remove any existing earthing and short-circuiting connections in the critical switching area;
Energize the feeder cables;
Connect the switchgear step by step, observing the signals and indicators;
Check that relative conductors are in phase, where necessary, when there are several incoming
feeder cables and switchgear sections (also see section 6.3.2);
Carry out all measurements and check all functions which depend on high voltage power supply
being connected;
Watch out for irregularities of any kind.

6.2 Switching operations

Carry out switching operations with the front doors closed!

6.2.1 Withdrawable apparatus


Manual insertion from the test/disconnected position to the service position:
Connect control wiring plug 10.2 (figure 111);
Close the front door;
Ensure that the apparatus is in the OFF position;
Before inserting the hand crank, it is necessary to open the hole for it - turn the slide 121.1 (figure
112) by means of the key 145;
Fit hand crank 121 (figure 113) on square spigot 18.1 (figure 10) of the spindle mechanism 18, after
opening the hole for them by turning slide 121.1;
Turn the crank clockwise (approx. 20 turns at 12/17.5kV and 30 at 24 kV) until the stop is reached
and the withdrawable part is in the service position;
Observe the position indicator;
Remove hand crank 121.
It must be considered that the spring loaded pin head 18.2 (figure 10) will lie completely on the rear
side of the panel door when the hand crank is moved from square spigot 18.1 of spindle mechanism
18. This ensures that the rear part of the pin head has been shifted onto the hexagonal cap of the spindle
and prevents unintentional wrenching of the spindle during panel service. Wrenching may lead to the
circuit-breaker blocking.

69
145

32

10.2

10.1

121.1

Figure 111: Control wiring plug connector blocked to it is Figure 112: Before inserting the hand crank, necessary to
prevent disconnection with the withdrawable open the hole for it - turn the slide by means
part in the service position. of the key.

10.1 Control wiring socket 121.1 Slide


10.2 Control wiring plug 145 Double bit key
32 Interlock

121

Figure 113: Movement of the withdrawable part between. The test/disconnected position and the service position, clock-
wise up to the stop to the to the service position and anti-clockwise for the test/disconnected position

121 Hand

70
Note
The withdrawable part must not be stopped in any intermediate position in the travel range between
the service and test/disconnected position!

Manual withdrawal from the service position into the test/disconnected position
Ensure that the apparatus is in the OFF position;
Reverse the procedure described above for insertion into the service position.

Important note
Insertion and withdrawal of circuit-breakers (and other withdrawable parts) must be gradual, in order
to avoid any shocks which could deform the mechanical interlock. If the operations are prevented, do
not force the interlocks and check that the operating sequence is correct.
The force normally applicable to the insertion/withdrawing lever is 260 N. In any case, the maximum
applicable force must never exceed 400 N.
Please also refer to the technical documentation of the circuit-breakers for installation operations.

Caution: the insertion and withdrawal must always be carried out with the apparatus open!
Do not use force to move withdrawable parts with locking magnet Y0 or RL2 in the event of an auxiliary
voltage drop. If this occurs, they are locked along the whole travel range between the service and test
positions.
To remove the interlock, consult the technical documentation of the circuit-breakers.

Motorized movement of the withdrawable part


Briefly operate the electrical control for insertion or withdrawal (the withdrawable part then
automatically moves into the opposite position);
Observe the position indicator.

Note
When the drive motor is faulty, the withdrawable part can be moved using the emergency manual
operation.
If the drive motor fails during movement of the withdrawable part, the withdrawable part must be moved
into a limit position using emergency manual operation.
Emergency manual operation is carried out with hand crank 121 (figure 113) on spindle mechanism
18, in a similar way to operation of a withdrawable circuit-breaker part with manual systems. To
disengage the motorized withdrawable part, consult section 7.5.1.
Switch off the auxiliary power (m.c.b.), since the motor would otherwise be braked electrically;
Turn hand crank 121 in the required direction.
When the withdrawable part moves, the motor turns. In this case, the motor functions like a generator,
i.e. it can lead to reserve voltages in the terminals.
The motor fuse must not be changed from the specified type and rated value, otherwise the behaviour
of the permanent magnet motor could be irreversibly impaired!

Caution
In emergency manual operation of a motorized withdrawable circuit-breaker part, the interlock with the
earthing switch is not effective!

Withdrawal from the test/disconnected position onto the service truck


Open the door of the circuit-breaker compartment;
Release control wiring plug 10.2 (figure 111) and place it in the storage position on the withdrawable
part;
Position service truck 124 (figure 114) with guide pins 124.2 (figure 116) of the adjustable bench top
at the correct height facing the panel front, and allow catch 124.3 to engage;
Move sliding handles 13.11 (figure 114) inwards against the springs to release withdrawable part
13, draw the withdrawable part out onto the service truck and secure it in the catches on the truck;
Press release lever 124.4 (at the front underneath the bench top) and release the service truck from
the switchgear panel;
Secure the position of the shutters with padlock 130 (figure 117).

Insertion from the service truck into the test/disconnected position


Carry out the procedure described above for withdrawal in reverse order.

71
13

13.11

124.4

124 13.12 124.1 124


Figure 114: Service truck engaged with the switchgear Figure 115: Withdrawable part standing on service truck
truck and panel. Withdrawable part released and secured in the catches
for withdrawal with the handles slid inwards
13 Withdrawable part
13 Withdrawable part 13.11 Sliding handle
13.11 Sliding handle 13.12 Catch (connected to sliding handle
124 Service truck 13.11)
124 Service truck
124.1 Height adjuster
124.4 Release lever for catch pin (124.3)

130 38

124.2

124.3

124.1

Figure 116: Positioning the service truck with the guide 38 130
Pins on the adjustable height bench top at
the correct height for approach to the
switchgear panel, and engaging the catch. Figure 117: Lower shutter secured with padlock to prevent
unauthorized operation.
124.1 Height adjuster
124.2 Guide pin 38 Lever for shutter operation
124.3 Catch pin 130 Padlock (customer component)

72
6.2.2 Circuit-breaker - type VD4 and V-max
Charging the stored energy spring system:
On the circuit-breaker with charging motors, charging is carried out automatically. If the charging
motor should fail, the charging procedure can be carried out or completed manually;
On breakers with manual charging systems, either open the door with the withdrawable part in the
disconnected position, insert charging lever 128 (figure 118) into the recess and pump for approx.
25 strokes until the charged condition is indicated;
On breakers where the charging lever is integrated, take the lever and pump 10 times;
When the charged condition is reached, the charging mechanism is automatically disengaged, and
any further strokes of the lever have no effect. Pumping is effective if the lever is moved in angle 90
(figure 119).

Opening and closing the circuit-breaker:


Opening and closing operations with the withdrawable part in the service position should only be
performed with the door closed;
Operate the local or remote electrical control;
Observe the switch position indicator.
The switching operation counter 13.5 for the circuit-breaker automatically increases by one unit with
each operating cycle. An additional control mechanism fitted in the door of the circuit-breaker
compartment enables mechanical operation of the circuit-breaker with the door closed and with the
withdrawable part in either position.
Press the relative mechanical pushbutton, having previously turned knob 45.2 (figure 7) anti-
clockwise to the stop if the withdrawable part is in the service position;
Observe the switch position indicator.
For further details regarding operations and maintenance of VD4 and V-max circuit-breakers, see the
relative instruction manuals.

13.12 13.2 13.1

13.4
13.2

90 13.8

13.4 128
13.5
128a 13.8

13.5

13.11
13.11

Figure 118: Manual operation of withdrawable part with Figure 119: Manual operation of withdrawable part with
VD4 circuit-breaker (old design). Vmax circuit-breaker.

13.1 Mechanical ON push-button


13.2 Mechanical OFF push-button
13.4 Mechanical switch position indicator
13.5 Mechanical operating cycle counter
13.8 Charging condition indicator
13.11 Sliding handle, connected with the
catch on the withdrawable assembly
13.12 Locking OFF position
128 Charging lever

73
6.2.3 Circuit-breaker - type VM1
The maintenance-free VM1 circuit-breaker applies a combination of moulded-in vacuum interrupters,
a magnetic actuator and an electronic controller without auxiliary switches and with sensors.
Before connecting the primary voltage:
Connect the auxiliary voltage. OFF command (closed circuit release) and the closing lock-out must
be energized before the circuit-breaker can be closed;
The auxiliary voltage has been established when the (Ready) LED 31.2 lights up (figure 120).
Carry out the closing and opening test of the circuit-breaker by pressing pushbuttons 31.3 and 31.4;
Closing:
- by remote control via closing contacts or locally by pressing ON pushbutton 31.3;
Opening:
- by remote control via closing contacts or locally by pressing OFF pushbutton 31.4;
Opening on failure of the auxiliary power supply:
- Electrical opening is still possible within the first 200s;
- After a period of 200s, emergency manual opening is necessary;
- Insert emergency manual operating lever 28 onto the spigot of the emergency shaft 8 in the front
plate and turn it anticlockwise to open the circuit-breaker. Just before the final stop is reached, a
slight resistance on the emergency shaft has to be overcome.
Closing on failure of the auxiliary power supply:
- Closing is not appropriate and not possible;
After each operating cycle (ON-OFF), the operating cycle counter 31.5 increases by one full digit.
On termination of a switching operation, the position indicator 31.6 in the window of the front plate
displays the relative switch position.
Anti-pumping system:
- The circuit-breaker controller ensures that circuit-breaker closing is locked when an opening
command is active;
- When closing on a subsequent opening command, further closing with the closing command still
active is locked. The closing command must be given again for the next closing operation.
For details, refer to the users manual.

31.9

31.16

31.2 28
31.3
31.4

31.5 31.6

Figure 120: Withdrawable part with VM1 type circuit-breaker - operating mechanism side

8 Recess for emergency manual opening lever


28 Emergency manual opening lever
31.2 Ready display
31.3 ON pushbutton
31.4 OFF pushbutton
31.5 Mechanical operating cycle counter
31.6 Mechanical switch position indicator
31.9 Catch for emergency manual operating lever
31.16 Front cover plate

74
6.2.4 Circuit-breaker - type HD4
Manual operation for spring charging:
To manually charge the closing springs, fully insert charging lever 90.8 (figure 122) into seat 90.6 and
turn it until the yellow indicator 90.7 appears.
Electrical operation for spring charging:
On request, the circuit-breaker can be fitted with the following accessories for electrical operation:
geared motor for automatic charging of the closing springs;
shunt closing release;
shunt opening release.
The geared motor automatically recharges the springs after each closing operation until the yellow
indicator 90.7 appears. Should there be no voltage during charging, the geared motor stops and then
starts recharging the springs automatically when the voltage is on again. In any case, it is always
possible to complete the charging operation manually.
Circuit-breaker closing:
This operation can only be carried out with the closing springs completely charged. For manual closing
press pushbutton 90.3. When there is a shunt closing release, the operation can also be carried out
by means of a control circuit. The indicator 90.4 shows that closing has been accomplished.
Circuit-breaker opening:
For manual opening, press pushbutton 90.2. When there is a shunt opening release, the operation can
also be carried out with remote control by means of a control circuit. The indicator 90.4 shows that
opening has been accomplished.
An additional control mechanism fitted in the door of the circuit-breaker compartment enables
mechanical operation of the circuit-breaker with the door closed and with the withdrawable part in
either position (figures 7, 8);
Press the relative mechanical pushbutton, having previously turned knob 45.2 anti-clockwise to the
stop, if the withdrawable part is in the service position;
Observe the switch position indicator.
Detailed information about installation and maintenance can be found in instruction manual.

10.2 90.4 90.5

90.1

90.2

90.3
90.7

90.6

13.15

Figure 121: HD4 type circuit-breaker - side view Figure 122: Operating and signalling parts of HD4 circuit-
breaker
10.2 Control wiring plug 90.1 Signalling device for state of SF6
13.15 Withdrawable assembly pressure (on request)
90.2 Opening pushbutton
90.3 Closing pushbutton
90.4 Operation counter
90.5 Circuit-breaker open/closed indicator
90.6 Shaft for manual closing spring
charging
90.7 Signalling device for closing springs
charged/discharged

75
6.2.5 Vacuum contactor - type V-Contact
The V-Contact type vacuum contactor is ideal for controlling users in a.c. requiring a high number of
operations. The contactors basically consist of a moulded resin monobloc, where the vacuum
interrupters, moving apparatus, control electromagnet, multivoltage control feeder and auxiliary
accessories are housed.
The monobloc is also the support for assembly of the fuse-holder frame.
Closing of the main contacts is carried out by means of the control electromagnet. Opening is carried
out by means of a special opposing spring. The contactor can be equipped with electrical or mechanical
latching.
The fuses are positioned in special supports to be connected in series between the contactor and the
user. The supports can house fuses in compliance with DIN or BS standards.
For details, please refer to installation manual.

91.15

91.13

91.14

Figure 123: V-Contact type vacuum contactor - front view Figure 124: V-Contact type vacuum contactor - pole side
91.13 Signalling device ON/OFF
91.14 Operating cycle counter 91.15 MV fuses

95.2

95.1

95.3

Figure 125: Withdrawable part with metering unit Figure 126: 95.3 Mini circuit-breakers of transformers
secondary circuits (mounted in the
95.1 Voltage transformer cabinet of auxiliary circuits as
95.2 Cast resin tube (with fuse cartridge) standard)

76
6.2.6 Withdrawable metering parts
Handling of the withdrawable metering part in the metering panel is as described in section 6.2.1,
without, however, the switching operations and interlocking functions.
Withdrawable metering parts in incoming and outgoing feeder panels are put into the cable
compartment using a ramp. They reach their service position immediately and engage in the panel
earthing by means of the two locking pins at the sides. The voltage transformers used correspond
to the type used in the metering panel, and therefore HRC fuses can also be used along with the
voltage transformers.

6.2.7 Earthing switch - type EK6 and ST-VG-01


The earthing switch - has a snap closing mechanism which is independent of the rotation of the drive
shaft. An earthing switch 6 (figure 2) allocated to a circuit-breaker is only enabled for switching when
withdrawable part 13 is in the test/disconnected position or removed from the switchgear panel. Only
turn earthing switches on when the doors are closed.

Manual opening and closing:


Press slide 14.2 (picture 127) onto the operating lever recess socket downwards. (When the switch
is closed, it is already in this position!)

Caution
If the operation is prevented, do not force the interlock and check that the operation sequence is
correct.
Fit operating lever 122 onto hexagonal shaft 14.1,(figures 127, 128) which is now released for
operation.

Note
Put operating lever 122 in pointed upwards or downwards on the hexagonal shaft so that there is
sufficient room for movement of the operating lever even if space is limited at the sides.
Turn the lever clockwise through approx. 180 until the stop is reached to close the earthing switch,
or anticlockwise until the stop is reached to open the earthing switch;
Observe the mechanical/electrical switch position indicator;
Remove operating lever 122. Slide 14.2 remains open if the earthing switch is in the closed
position.
Make sure that the operating lever is turned right up to the stop in the opening process, to ensure
that the earthing switch is in its defined limit position. The manual operating mechanism can also
be fitted with a locking magnet.

Opening and closing with motor operator (EK6 only)


The earthing switch can also be fitted with a motor operator.
Briefly operate the electrical control for opening or closing. The earthing switch is then switched
automatically into the opposite position.

Emergency manual operation


If a fault should occur in the motor operator, the earthing switch can be switched to emergency
manual operation with lever 122, in a similar way to manually operated earthing switches.

Caution
During emergency manual operation of a motor-operated earthing switch, the interlock is not
functional!
On emergency manual operation, coupling with the motor operator is automatically released. To
disengage the coupling to the motor operator, first turn the lever 122 further in the pre-selected
direction up to the relative stop (small angle of turning). On the next operation with the motor operator
after its function has been restored, the coupling automatically engages again.

Note
The lever may only be fitted temporarily to carry out an emergency manual switching operation.
The power to the motor operator must be switched off for the duration of any breakdown.

77
14.1

122

14.2

Fig. 127: Preparation for operation of branch earthing Fig. 128: Preparation for operation of branch earthing
switch - press the slide downwards. switch - operating lever prepared for switch-
ing on/off
14.1 Hexagonal shaft of earthing switch
operating mechanism 122 Operating lever
14.2 Slide

6.2.8 Busbar earthing switch


To earth the busbars, earthing switches are used, also of type EK6. Their operating mechanism is
identical to that of the branch earthing switches (see section 6.2.7). The conditions for panel to panel
interlocking of the busbar earthing switches are described in section 3.4.2.

6.2.9 Earthing and short-circuiting with earthing module


Isolate the area to be earthed and secure it against reconnection;
Carefully follow all safety regulations;
Remove the withdrawable circuit-breaker part from the relative switchgear panel;
Secure the shutter in front of the live contact pins by means of the padlock. Screw on the earthing
module 142 actuating bars 142.1 (figure 129) as follows:
- To the top position for opening of bottom shutter;
- To the bottom position for opening of top shutter;
Further screw on the earthing module 142 insulating plate 142.5 with 3 removable bushings as
follows:
- Contact arms 142.2 in the bottom position for earthing of cable output feeder;
- Contact arms 142.2 in the top position for earthing of busbars;
Insert the earthing module 142 into the test/disconnected position and then move it into the service
position with the hand crank 121 (for procedure - see sect. 6.2.1);
Using a high voltage tester, check that contact pins 142.7 of the earthing module are definitely
offcircuit;
Withdraw the earthing module back into the test/disconnected position (see sect. 6.2.1);
Mount a complete short circuit link 142.8 on the earthing module 142. Connect one end of earthing
cable 133.1 under one of three screws M12, with which short circuit link 142.8 is connected to contact
pins 142.7. Connect the second end of this cable to the earthing terminal 19.3 in the panel;

78
Insert the earthing module 142 with short-circuit link 142.8 mounted and earthing cable 133.1
returned from the test/disconnected position into the service position in the panel with hand crank
121. For safety reasons, insert the module only with the circuit- breaker compartment door closed
and with door catches 1.8 locked (see Fig. 5/20);
Display earthing warning label on the switchgear panel door;
Secure neighbouring areas to prevent inadvertent contact with live parts (e.g. feeder cables);
The procedure for removing earthing is the same, only in reverse order.

Figure 129: Testing and earthing module with:


- Actuating bars, removable - top position for bottom shutter;
- bottom position for top shutter;
- Contact arms, removable - bottom position for cable area;
- top position for busbar area;
- 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;
- Ball handles, removable, for voltage tests;
- Short-circuiting connection - can be replaced with ball handles.

133.1 Earthing cable


142 Testing and earthing module with manual mechanism
142.1 Actuating bars (1 pair)
142.2 Contact arms (3 pcs.)
142.3 Contact systems
142.4 Ball handles (3 pcs.)
142.5 Insulating plate with 3 removable bushings
142.6 Bushings
142.7 Contact pin
142.8 Short-circuiting connection, complete

79
6.2.10 NALF type switch-disconnector
The NALF type switch-disconnectors, a combination of switch-disconnector with fuses and type E
earthing switches are intended for indoor use in switchgear. The switch-disconnectors are capable of
to opening and closing loaded and unloaded inductive and capacitive circuits. In the open position the
device has a visible isolating distance.
The switch-disconnectors are used in combination with power fuses for short-circuit protection . This
combination excludes two-phase power supply, because interruption of any fuse link causes the
opening of switch-disconnector by means of its tripping system.
The type E earthing switches are constructed with a snap closing mechanism. They are capable of
closing and carrying short-circuit currents.

Operating mechanism of switch-disconnector for use in UniGear switchgear

Operating mechanism A with two springs.


The opening spring is always charged before switch-disconnector closing. This means that the closed
switch-disconnector always has opening spring stored energy and opening follows immediately with
the manual lever, shunt opening release or tripping mechanism of fuses.
This mechanism makes remote opening possible and, in the combination with motor operator, makes
complete remote control possible.
The type E earthing switch is always operated locally by means of operating lever 215 (figure 131).To
secure the protection of connected HV equipment the UniGear ZS1 switchgear with switch-disconnector
uses CEF type high voltage fuses. The UniGear ZS1 switchgear with NALF switch-disconnector can
be equipped with fuses in the range indicated in the following table:

Urated [kV] Irated min. [A] Irated max. [A]


3.6 / 7.2 6 200
12 6 125
17.5 6 160
24 6 125

In the case where the switch-disconnector without HV fuses will be required, the current-carrying bars
will be inserted in holders instead of HV fuses to maintain the same location of the earthing switch.

Note
The switch-disconnector and earthing switch can only be operated with the switchgear panel door
closed.
The switch-disconnector and earthing switch are mutually mechanically interlocked.

209
210

207.1

208.1

215

Fig. 130: Preparation for the operation of earthing switch in Fig. 131: Preparation for the operation of earthing
panel with the switch-disconnector switch in panel with the switch-
Operating lever prepared for the operation ON disconnector
207.1 Position indicator of earthing switch Operating lever prepared for the opera-
208.1 Operating shaft for the earthing switch tion OFF
209 Lockable operating handle Chubb lock
210 Lockable operating handle padlock 215 Operating lever

80
Closing and opening of NALF switch-disconnector
The switch-disconnector can only be switched on if the earthing switch is open;
Put operating lever 215 (figure 131) in pointed upwards or downwards on the grooved shaft of the
switch-disconnector so that there is sufficient room for movement of the operating lever even if space
is limited at the sides;
Turn the lever clockwise through approx. 180 to charge the opening spring;
Turn the lever anticlockwise to charge the closing spring and to close the switch-disconnector;
Turn the lever clockwise through approx. 20 to open the switch-disconnector;
Observe switch positioning indicator 200.1 (figure 21).

Caution
Until the latch of opening or closing spring snaps, the lever is returned back into the
starting position through the action of spring. Proceed with caution during the
manipulation to prevent the lever from slippingfrom your hand RISK OF INJURY

Closing and opening of integrated E type earthing switch


The earthing switch can only be switched on if the switch-disconnector is open;
Put operating lever 215 in pointed leftwards or upwards on the grooved shaft of the earthing switch
so that there is sufficient room for movement of the operating lever even if space is limited at the
sides;
Turn the lever clockwise through approx. 90 until the stop is reached to close the earthing switch;
Turn the lever anticlockwise through approx. 90 until the stop is reached to open the earthing switch;
Observe switch positioning indicator 207.1.

Closing and opening of NALF switch-disconnector with the motor operator


The switch-disconnector can also be equipped with the motor operator mechanism type UEMC 40 K3
Briefly operate the control buttons for closing or opening. The switch-disconnector is then switched
automatically or the springs of the switch-disconnector are charged.

Note: We recommend using a protection circuit-breaker in the supply circuit of motor operator. The
opening time of mechanism A operated with the motor operator is approx. 1s. If faster opening is
required, it is necessary to equip mechanism A with an opening coil

Emergency manual operation


If a fault should occur in the motor operator, the switch-disconnector can be switched manually with
the operating lever 215 directly on the shaft of switch-disconnector.

Note: After the manual operation the motor operator will not be synchronous with the switch-
disconnector, which means that it must be manipulated twice to reach synchronization, e.g. opening
- closing.

Caution
The operating lever may only be fitted temporarily to carry out an emergency manual
switching operation - RISK OF INJURY

81
6.3 Test procedure
6.3.1 Testing the off-circuit condition
In switchgear panels which are not equipped with capacitive voltage indication, checking the off-circuit
condition is carried out with a HV tester on the isolating contacts 4.1 (figure 133) in the isolating tulips
5 (figure 132), after the corresponding upper shutter 12.1 or lower shutter 12.2 has been opened.
Shutter opening can be carried out by means of module 129 (figure 134).
If the panels are equipped with capacitive voltage indication, checking the off-circuit condition can be
carried out by means of this device. In this case, proceed according to the manufacturer's instructions
or the indicators. (Optionally, switchgear can be equipped with various types of indicators coming from
various manufacturers).
In case of any doubt about correct operation of capacitive voltage indication, the off-circuit condition
must be checked using a HV tester.
Checking the off-circuit condition must always be carried out in compliance with the relevant safety
regulations and local operating conditions!

12.1

4.3 5

4.2

4.1
5

12.2

12.2

Figure 132: Withdrawable part during insertion into the Figure 133: View inside the circuit-breaker compartment,
service position, shutters not yet fully open withdrawable part removed, shutters open
4.2 Contact arm, with insulating sleeve
4.3 Contact system 4.1 Isolating contact
5 Isolation tulip 5 Isolating tulip
12.1 Top shutter 12.2 Lower shutter
12.2 Lower shutter

6.3.2 Current and voltage tests


The testing and earthing module 142 (figure 129) is available for carrying out current and voltage tests.
It is also suitable for supplying primary current to any current transformers which may be fitted during
measurements in the protection circuit and, for example, for application of a test voltage during
insulating tests.
Isolate and secure the working area in accordance with the IEC safety regulations;
For primary current supply, fix the connecting cable of the test transformer to the contact pins 142.7;
For AC voltage tests, ball 142.4 is required on the contact pin. The bore in the ball is used for
connection of the voltage supply;
For current tests, for example of small connected generators, the short-circuit bridge 142.8 must be
fixed onto the contact pins.

Note
With voltage tests at power frequency withstand voltage and/or impulse voltage, carry out the following
procedure:
Disconnect any voltage transformers and capacitive dividers and cover them with an insulating plate.

82
6.4 Service trucks
The service trucks are divided into four different types:

6.4.1 Earthing truck without making capacity


These trucks carry out the same function as the earthing switches without making capacity. Therefore
they do not have any capacity to earth the live circuits under fault conditions. They are used to ensure
fixed additional earthing, as required by the plant service and maintenance procedures, as a further
guarantee for personnel. The use of these trucks foresees removal of the switching device from the
switchgear (circuit-breaker or contactor) and its replacement with the truck. The units preset for use
of earthing trucks are fitted with a key lock which, if activated, prevents their racking-in.
This truck is available in two versions:
main busbar system earthing;
power cable earthing.
During the racking-in phase, the main busbar earthing truck only lifts the top shutter and earths the
contacts connected to the top branches (and therefore to the main busbar system) by means of the
switchgear structure.
During the racking-in phase, the power cable earthing truck only lifts the bottom shutter and earths the
contacts connected to the bottom branches (and therefore to the power cables) by means of the
switchgear structure.
These trucks can also be used in the bus-tie units. In this case, they earth the two sides of the main
busbar system.

6.4.2 Earthing truck with making capacity


These trucks carry out the same function as the earthing switches with making capacity. They consist
of circuit-breakers only fitted with top (main busbar earthing) or bottom (power cable earthing)
terminals. The contacts without terminals are short-circuited by means of a copper bar and connected
to earth by means of the apparatus truck. They keep all the characteristics of the circuit-breakers, such
as full making capacity and opening of the live circuits under fault conditions.
They are used to ensure extremely efficacious earthing on circuits stressed by a fault. They allow
opening and closing moperations to be carried out rapidly with remote electric control.
The use of these trucks foresees removal of the switching device from the switchgear (circuit-breaker
or contactor) and its replacement with the truck. The units preset for use of earthing trucks are fitted
with a key lock which, if activated, prevents their racking-in.
This truck is available in two versions:
main busbar system earthing;
power cable earthing.
During the racking-in phase, the main busbar earthing truck only lifts the top shutter and presets the
contacts connected to the top branches (and therefore the main busbar system) for closing to earth
by means of a control.
During the racking-in phase, the power cable earthing truck only lifts the bottom shutter and presets
the contact connected to the bottom branches (and therefore to the power cables) for closing to earth
by means of the control.
These trucks can also be used in bus-tie units. In this case, they earth the two sides of the main busbar
system.

6.4.3 Power cable test truck


These trucks allow the insulation tests to be carried out on the power cables without accessing the
feeder unit or disconnecting the cables from the switchgear.
The use of this trucks foresees removal of the switching device from the switchgear (circuit-breaker
or contactor) and its replacement with the truck.
During the racking-in phase, the truck only lifts the bottom shutter and, by means of the connectors
it is fitted with, allows connection of the test apparatus cables. This truck can only be used in the
incoming/outgoing units.

6.4.4 Isolation truck


The isolation truck allows the switchgear top and bottom contacts to be connected directly. Connection
is made extremely safe by using the poles of the HD4 circuit-breakers to insulate the connection bars
from the external environment.
In the incoming/outgoing units, it connects the main busbar system to the power cables, whereas in
the bus-tie units, to the two sides of the busbar system. This truck is used in the UniGear switchgear
to make incoming/outgoing units without circuit-breakers in radial networks, to make cable connec-
tions between two piece of switchgear placed in front of each other, and for constructing interconnec-
tion units and creating bus-tie-riser units with double insulation (in this case, both the units are made
from bus-ties, the first fitted with a circuit-breaker and the other with an isolation truck).

83
7. Maintenance

7.1 General

Maintenance serves to preserve trouble-free operation and achieve the longest possible working life
of the switchgear. It comprises the following closely related activities:

Inspection: Determination of the actual condition

Servicing: Measures to preserve the specified condition

Repair: Measures to restore the specified condition

Note
When carrying out all maintenance work, the regulations in the country of installation must be strictly
complied with.
Maintenance work may only be performed in a careful manner by trained personnel familiar with the
characteristics of the individual switchgear, in accordance with all relevant IEC safety regulations and
those of other technical authorities, and with other overriding instructions. It is recommended that ABB
service personnel be called in to perform the servicing and repair work detailed below.
The inspection and servicing intervals for some of the equipment/components (e.g. parts subjects to
wear) are determined by fixed criteria, such as switching frequency, length of service and number of
short-circuit breaking operations. On the other hand, for other parts the length of the intervals may
depend, for example, on the different modes of operation in individual cases, the degree of loading,
and also environmental influences (including pollution and aggressive air).

The following operating instructions must also be followed, together with this instruction manual in the
individual cases concerned:
" Vacuum circuit-breaker: type VD4;
" Vacuum circuit-breaker: type VD4 - high current;
" Vacuum circuit-breaker with magnetic actuator: type VM1;
" Gas circuit-breaker: type V-max;
" Gas circuit-breaker: type HD4;
" Vacuum contactor: type V-contact;
" Switch-disconnector NAL - catalogue;
" Switch-disconnector - installation, service and maintenance instruction manual;
" Operating mechanisms of the circuit-breakers with high voltage - catalogue;
" Motor operator UEMC 40 K3 - installation, service and maintenance instruction manual (for units
with NALFE earthing switch).

If necessary, further details can be taken from the technical documentation for the switchgear
installation (including, for example, any special operating conditions agreed on).

7.1.1 Intervals for inspection, servicing and repairs


Time intervals for maintenance work to be carried out always depend on the operating conditions of
the switchgear, and mainly on the mode of operation, the number of rated and short-circuit current
switching operations, ambient temperature, pollution etc. We recommend carrying out the mainte-
nance work at the following intervals:

Activity performed According to section Time interval in years According to number


of switching operations
Inspection 7.2 4 1)
Servicing 7.3 4 2) 10 000 3)
Repair 7.4 As required As required

) In more demanding service conditions, we recommend reducing this interval suitably also see sections 1 and 2.
) According to the results of the inspection.
) See the instruction manuals of the circuit-breakers.
*) Earthing switch.

84
7.2 Inspection
Where necessary, the working area must be isolated and secured against reconnection in
accordance with the Safety Regulations specified by IEC and appropriate national standards before
inspection;
Correct condition of the switchgear should be monitored by regular inspections;
Under normal operating conditions, inspection should be carried out once every four years by
specially trained professional electricians;
Under abnormal operating conditions (including adverse climatic conditions) and/or special
environmental stresses (heavy pollution and aggressive atmosphere, among others), inspection
may be necessary at shorter intervals.
Inspection is primarily to carry out a visual check for grime, corrosion and moisture:
- Effects of high temperature on the main circuits;
- Traces of partial discharge on the insulating material parts;
- Traces of leakage current on the insulating material parts;
- Surfaces of the contact systems;
However, inspection must also include correct mechanical/electrical operation of the following parts:
switching devices, actuating, interlocking, protection and signalling devices.

Special conditions
On panels with additional ventilation devices due to increased ambient temperature (also see section
1.3):
1. Check flap 20.3 for correct operation. (Also see section 6.1.1 and figures 109, 110);
2. The centrifugal fan (if fitted) does not require any special maintenance. Its working life
depending on the service conditions, and one significant parameter being the room temperature
- is approx. between 20,000 and 30,000 operating hours.

Checking readiness for operation can be carried out as follows:


a)Load-dependent functional test with controllable primary current supply of the relative instrument
transformer. on current rise:
1. to approx. 70% of the rated instrument transformer current, the fan must start;
2. to 80 % of the rated instrument transformer current, the fan must have reached the required
minimum air flow. Corresponding monitoring/signalling by the wind vane with microswitch.
b) Basic checking with temporary operation of the centrifugal fan with an external power supply of
220 V AC;
c) In both cases, check for unimpeded normal running of the fan and listen for any unusual bearing
noise. Remove any dirt on the fan rotor.
d) Check unimpeded operation of the wind vane and microswitch by starting the fan several times.
e) The wiring to removable horizontal partition 20 can be disconnected behind the right-hand side
duct cover. Follow the circuit diagram and carefully reconnect the wiring again on completion.

Caution: instrument transformer circuit

With regard to the switching devices, their separate Instruction manual should be followed;
Check all switchgear accessories and auxiliary devices (e.g. storage batteries);
No partial discharge must occur on the surfaces of equipment at operating voltage. This can, for
example, be detected by characteristic noises, a clearly perceptible smell of ozone, or visible glowing
in the dark;
Visually checking the contact system. We recommend turning the contact system alternately in order
to clean the inner contact points of the contact system.
The contact points should be cleaned if signs of overheating (discoloured surface) are visible (see
section 7.4);
If any irregular conditions are detected, then relative repair measures must be taken.

7.3 Servicing
When, during an inspection as per paragraph 7.2, the need to carry out cleaning operations is noted,
proceed as follows:
Where necessary, the work area must be disconnected and locked against reconnection in
conformity with the safety standards specified in the IEC directive and in the relative national
regulations;

85
Clean the surfaces:
- Remove any dry dust deposits which are not very adherent using a soft dry cloth;
- Remove any more adhering dirt with a low alkaline detergent or with ETHANOL F 25 M;
Clean the insulating surfaces and the conductive components with ETHANOL F 25 M;
After cleaning, rinse with clean water and dry carefully;
Should any partial discharges occur as a consequence of the condensation phenomenon, a
temporary remedy which is often effective is application of a thin layer of silicone over the surface
involved. For a permanent remedy to this type of unusual problem, contact the ABB after-sales
assistance department.

7.3.1 Maintenance in busbar compartment


7.3.1.1 Checking of the tightening main busbars
Make the plant you want to work on safe (follow the plant safety regulations).
Remove the circuit-breaker from the panel where you want to work and close the earthing switch.
Close the earthing switch relative to the main busbars.
By accessing through the circuit-breaker compartment, remove the bulkhead 9 (Figure 2) unscrew-
ing no.7 screws M8.
After the removal of the bulkhead from the circuit-breaker compartment, the main busbars are
visible.
Using a dynamometric spanner, check tightness of all the screws. Refer to the table on page 40 for
the tightening values;

7.3.1.2 Visual inspection of the insulating materials


Make the plant you want to work on safe (follow the plant safety regulations);
Remove the circuit-breaker from panel where you want to work and close the earthing switch;
Close the earthing switch relative to the main busbars;
By gaining access from the circuit-breaker compartment, remove bulkhead 9, unscrewing no.7 M8
screws;
After removal of the bulkhead from the circuit-breaker compartment, the main busbars are visible;
Visually check that the top monoblocs 5, where the tulip isolating contact is housed, are integral and
do not show any breakages;
Visually check that the insulating covering of the main busbars and the insulating joining cover of
the busbars are integral and do not show any breakages;

Figure 134: View of the busbar compartment, shown without insulating covers

2 Branch conductor
3 Busbars
5 Tulip isolating contact
9 Bulkhead, removable

86
7.3.2 Maintenance in cable compartment

7.3.2.1 Checking tightening of the cable busbar connections


Make the plant you want to work on safe (follow the plant safety regulations);
Make sure that the circuit-breaker is in the open position;
Rack the circuit-breaker out from the service position to the test/isolated position;
Manually close the earthing switch;
Open the cable compartment door; the cable busbar connections are visible;
Using a dynamometric spanner, check tightness of all the screws. Refer to the table on page 40 for
the tightening values;

6.1

23

17.2

17

Figure 135: Internal view of the cable connection compartment, with a maximum number of six cables in parallel

6.1 Earthing switch position indicator


17 Slotted bottom plate
17.2 Fairlead
23 Cable busbar connection

Note
The cable compartment door cannot be opened if the earthing switch is open.

7.3.2.2 Visual inspection of the insulating materials


Make the plant you want to work on safe (follow the plant safety regulations);
Make sure that the circuit-breaker is in the open position;
Rack the circuit-breaker out from the service position to the test/isolated position;
Manually close the earthing switch;
Open the cable compartment door; the connections cable busbar are visible;
Visually check that the bottom monoblocs 5 where the tulip isolating contact is housed are integral
and do not show any breakages;
Visually check that the insulating covering of the cable busbar connections is integral and does not
show any breakages.

7.3.2.3 Earthing switch type EK6


7.3.2.3.1 Carrying out mechanical operations to check the kinematics
Make the plant you want to work on safe (follow the plant safety regulations);
Make sure that the circuit-breaker is in the open position;
Rack the circuit-breaker out from the service position to the test/isolated position;
Manually carry out 5 closing/opening operations of the earthing switch.

87
7.3.2.3.2 Cleaning the kinematics and the main contacts
Carry out a visual inspection of the mechanical connections and check for any presence of dirt,
humidity and signs of corrosion on the main operating shaft and on the contact parts of the blades;
Remove any deposits of dust using a dry cloth that does not leave any deposits on the treated
surfaces (do not use woollen cloths);
If necessary, grease the moving mechanical parts by applying a thin layer of mechanical grease for
moving parts.

7.3.2.3.3 Cleaning, greasing and checking the kinematics


Carry out a visual inspection of the kinematics and check for any presence of dirt, humidity and signs
of corrosion on the moving parts;
Remove any deposits of dust using a dry cloth that does not leave any deposits on the treated
surfaces (do not use woollen cloths);
If necessary, grease the mechanical moving parts by applying a thin layer of mechanical grease for
moving parts.

Figure 136: EK6 earthing switch

7.3.2.3.4 Reaching mechanical life limit


The mechanical life of the earthing switch is set at 2000 opening/closing operations. After the operation
counter has reached this number, inform ABB who will verify directly that the mechanical life limit of
the earthing switch has been reached.

Note
The operation counter is not provided with the switchgear. It is up to the engineering department to
connect the auxiliary closed/open contacts in order to measure the number of operations carried out.

7.3.2.4 Earthing switch operation mechanism


Carrying out mechanical operations to check the kinematics
Make the plant you want to work on safe (follow the plant safety regulations);
Make sure that the circuit-breaker is in the open position;
Rack the circuit-breaker out from the service position to the test/isolated position;
Manually carry out no.5 closing/opening operations of the earthing switch.

Cleaning the kinematics to prevent faults on the signalling contacts


Carry out a visual inspection of the kinematics and check for any presence of dirt, humidity and signs
of corrosion on the moving parts;
Manually check correct changeover of the earthing switch signalling contacts 18 (figure 137);
Remove any deposits of dust using a dry cloth that does not leave any deposits on the treated
surfaces (do not use woollen cloths);
If necessary, grease the mechanical moving parts by applying a thin layer of mechanical grease for
moving parts.

Cleaning, greasing and checking the kinematics


Carry out a visual inspection on the toothed wheel and pinion 20 (figure 138) and check any presence
of dirt, humidity and signs of corrosion on the moving parts;
Remove any deposits of dust using a dry cloth that does not leave any deposits on the treated
surfaces (do not use woollen cloths);
If necessary, grease the mechanical moving parts by applying a thin layer of mechanical grease for
moving parts.

88
19

18

18

Figure 137 Figure 138

Figure 139 Figure 140

Reaching mechanical life limit


The mechanical life of the earthing switch is set at 2000 opening/closing operations. After the operation
counter has reached this number, inform ABB who will verify directly that the mechanical life limit of
the earthing switch has been reached.

Note
The operation counter is not provided with the switchgear. It is up to the engineering department to
connect the auxiliary closed/open contacts in order to measure the number of operations carried out.

7.3.2.5 Instrument transformers

7.3.2.5.1 Cleaning and checking of the current transformers


Make the plant you want to work on safe (follow the plant safety regulations);
Make sure that the circuit-breaker is in the open position;
Rack the circuit-breaker out from the service position to the test/isolated position;
Remove the circuit-breaker from the panel;
Manually close the earthing switch;
Open the cable compartment door;
Remove the circuit-breaker plate 27 (figure 140) to get larger access;
Visually check the connections of the current transformers;
Using a dynamometric spanner, check the tightness of all the screws. Refer to the table on page 87
for the tightening values.

89
7.3.2.5.2 Cleaning and checking of the voltage transformers and anti-ferroresonance circuit

a) Fixed version voltage transformers


Make the plant you want to work on safe (follow the plant safety regulations);
Make sure that the circuit-breaker is in the open position;
Rack the circuit-breaker out from the service position to the test/isolated position;
Remove the circuit-breaker from the panel;
Manually close the earthing switch;
Open the cable compartment door;
Remove the circuit-breaker plate 27 to get larger access;
Visually check the voltage transformer connections.;
Using a dynamometric spanner check tightness of all the screws. Refer to the table on page 87 for
the tightening values;
Carry out a visual inspection of the transformers and check for any presence of dirt;
Remove any deposits of dust using a dry cloth that does not leave any deposits on the treated
surfaces (do not use woollen cloths).

b) Voltage transformers in removable version


Make the plant you want to work on safe (follow the plant safety regulations);
Make sure that the circuit-breaker is in the open position;
Rack the circuit-breaker out from the service position to the test/isolated position;
Manually close the earthing switch;
Open the cable compartment door;
Manually withdraw the VT truck (figure 17).
Carry out a visual inspection of the transformers and check for any presence of dirt.
Remove any deposits of dust using a dry cloth that does not leave any deposits on the treated
surfaces (do not use woollen cloths).

c) Voltage transformers in withdrawable version


Make the plant you want to work on safe (follow the plant safety regulations);
Make sure that the circuit-breaker is in the open position;
Rack the circuit-breaker out from the service position to the test/isolated position;
Open the cable compartment door;
Manually withdraw the VT truck (figure 141);
Carry out a visual inspection of the transformers and check for any presence of dirt;
Remove any deposits of dust using a dry cloth that does not leave any deposits on the treated
surfaces (do not use woollen cloths).

95.2

95.3

95.1

Figure 141 Withdrawable part with measurement unit

95.1 Voltage transformer


95.2 Resin tube (with fuse)
95.3 Fuse

90
d) Cleaning and checking the anti-ferroresonance circuit
Make the plant you want to work on safe (follow the plant safety regulations);
Make sure that the circuit-breaker is in the open position;
Rack the circuit-breaker out from the service position to the test/isolated position;
Manually close the earthing switch;
Open the miniature circuit-breakers 25 (figure 146) positioned inside the low voltage compartment
to remove the auxiliary power supply to the panel;
Carry out a visual inspection on the anti-ferroresonance resistance 27 (figure 142) and check for any
presence of dirt;
Manually check correct insertion of the cabling.

27

Figure 142

7.3.2.5.3 Cleaning and checking of the fuses


With the VT truck withdrawn, manually hook up the fuses contained in the resin tube of the voltage
transformers (figure 20);
Carry out a visual inspection on the fuses and check for any presence of dirt;
Remove any deposits of dust using a dry cloth that does not leave any deposits on the treated
surfaces (do not use woollen cloths).

7.3.3 Maintenance in circuit-breaker compartment

7.3.3.1 Visual inspection and lubrication of the isolating contacts


Make the plant you want to work on safe (follow the plant safety regulations);
Carry out a visual inspection on the top and bottom isolating contacts 21 (figure 143) in the circuit-
breaker compartment and check for any presence of dirt, humidity and signs of corrosion on the
moving parts;
Remove any deposits of dust using a dry cloth that does not leave any deposits on the treated
surfaces (do not use woollen cloths);
If necessary, grease the mechanical moving parts by applying a thin layer of mechanical grease for
moving parts.

27

Figure 143

91
7.3.3.2 Checking functionality of the interlocks
Carry out a visual inspection of the mechanical parts of the interlocks (key locks 22, door interlocks
23, fail safe 24) and check for any presence of humidity and signs of corrosion on the moving parts.
Remove any deposits of dust using a dry cloth that does not leave any deposits on the treated
surfaces (do not use woollen cloths).
Check that the moving parts can slide evenly. If necessary, grease the mechanical moving parts by
applying a thin layer of mechanical grease for moving parts.

23

24
22

Figure 144 Figure 145

7.3.4 Maintenance in the low voltage compartment

7.3.4.1 Checking of correct operation of the protection release


Make the plant you want to work on safe (follow the plant safety regulations);
Make sure that the circuit-breaker is in the open position;
Rack the circuit-breaker out from the service position to the test/isolated position;
Manually close the earthing switch;
Withdraw the protection release from the fixed part fixed onto the door of the low voltage
compartment;
Using current and volumetric test boxes, carry out injections to check perfect operation of the
protections themselves.

Note
To check operation of the protection releases, refer to the operating manual of the protection provided
by the manufacturer.

7.3.4.2 Cleaning and checking the auxiliary connections


Make the plant you want to work on safe (follow the plant safety regulations);
Make sure that the circuit-breaker is in the open position;
Rack the circuit-breaker out from the service position to the test/isolated position;
Manually close the earthing switch;
Open the miniature circuit-breakers 25 (figure 146) positioned inside the low voltage compartment
to remove the auxiliary power supply to the panel;
Carry out a visual inspection on all the cabling, terminal boxes 26 and check for any presence of dirt;
Manually check correct insertion of the cabling in the terminal box.

25

25

26

Figure 146

92
7.3.4.3 Measuring the insulation resistance of the auxiliary circuits
Make the plant you want to work on safe (follow the plant safety regulations);
Make sure that the circuit-breaker is in the open position;
Rack the circuit-breaker out from the service position to the test/isolated position;
Manually close the earthing switch;
Open the circuit-breakers 25 positioned inside the low voltage compartment to remove the auxiliary
power supply to the panel;
From one of the circuit-breakers 25 disconnect the wires on the internal side of the panel, short-circuit
the man apply 500 Vcc;
Using the Megger instrument, measure the resistance between the phase involved and the
conductive electric part (switchgear structure). The value must not be less than 2M and in any case
constant over time;
Repeat the operation for the number of circuits (circuit-breakers) inside of the panel (110Vdc,
220Vac, etc).
Replace the connections and put the panel into service.

7.4 Repairs
7.4.1 Switchgear in general
Repair of surface damage:
Carry out repair work immediately after a defect has been discovered;
Completely remove all rust from damaged paintwork areas on steel sheet and other steel parts by
mechanical means, e.g. with a wire brush;
Lightly grind the surrounding paint coat and carefully degrease the entire area. Then immediately
apply an anti-rust primer and, after an appropriate hardening time, apply the top coat. Only use
suitable and compatible paint products;
Apply the top coat in standard RAL 7035 colour, or the relevant special colour;
Carefully remove any white rust on aluminium/zinc surfaces with a wire brush or cleaning pad, e.g.
Scotch-Brite, and clean loosely adhering particles with a dry, non-fraying cloth. Next treat the
cleaned parts with zinc spray or zinc powder paint and, finally, treat with aluminium spray for colour
matching;
Carefully remove any white rust from passivated operating parts and rust formation on phosphatised
parts with a wire brush or metal-free cleaning pad, e.g. Scotch-Brite, and clean with a dry cloth. Then
grease evenly (with mechanical grease for moving parts).

Apparatus in general:
Follow the maintenance instructions in the manuals for individual equipment components;
Check that the bolt connections at the contact points in the busbar system and the earth connections
are tight, and that the contact system functions correctly;
Where necessary, grease slide plates and bearings in the panel again or thoroughly clean them.
Then grease them again with mechanical grease for moving parts lubricant;
Top up grease on contact areas in the contact system when corroded or otherwise as necessary,
or, when lubrication is inadequate or missing, thoroughly clean the areas concerned and grease
them again with mechanical grease for moving parts lubricant;
Remove the contact system for thorough cleaning as described below (Figures 7/1, 7/3):
- Slide in the two inner ring tension springs 4.4 facing the breaker pole to a position beside the other
two outer ring tension springs, thus releasing contact system 4.3, and remove the contact system;
- The contact pin of the contact system and the slot on the contact arm must be cleaned and greased.
Fit contact system back to front on the thin end of arbor 127 and slide it forwards onto the thicker
part of the shank;
- Fit arbor 127 onto the relative contact arm 4.2, slide the contact system 4.3 over onto the contact
arm, and withdraw the arbor;
- Check that all contact fingers and ring tension springs have a perfect fit.

Replacement of the contact pins when the surface is damaged

After any required replacement of contact pins 4.1 (figure 147), the latter should be retightened using
the socket head bolts.
Thread Rated tightening torque ungreased
M10 46 Nm
M20 250 Nm

93
5

4.1

12.2

Figure 147 View of inside circuit-breaker compartment, withdrawable part removed, circuit-breakers open.
4.1 Isolating contact
5 Isolating tulip
12.2 Bottom circuit-breaker

94
7.4.2 Replacement of complex functional groups
Precise matching of functions for control, interlocking and signalling only permits replacement of
individual components to a limited extent.
The following assemblies are prefabricated and tested at the works, maintaining high quality
standards. In the case of faults, they must therefore be completely replaced.

1. Withdrawable assembly:
Disconnect plug connector 10.3 (figure 148);
Remove interlock rod 13.91 with pin 13.27 from the withdrawable assembly;
For motor-operated withdrawable assemblies, remove the two socket head bolts (M4), which are
accessible from below the assembly;
Remove the circuit-breaker from the withdrawable assembly (4 x M12 bolts);
Mount the circuit-breaker on a new withdrawable assembly in the reverse order, using new circlips
and special pliers for pin 13.27;
Check the setting of interlocking rod 13.91;
- Turn spindle 18 anti-clockwise to the stop for the disconnected position:
- The distance between lever 13.26 and cam 13.25 must be 2w1 mm;
- The distance between roller 13.24 and angle lever 13.92 must be 0.5 mm;
- Turn spindle 18 clockwise to the stop for the service position:
- The distance between lever 13.26 and cam 13.25 must be 2w1 mm;
- The distance between roller 13.24 and angle lever 13.92 must be 0.5 mm;
- Loosen bolts 13.91.2 or 13.92.1 for any necessary adjustment.

3.25

3.26

13.91

13.90

13.91.1
13.91.2
3.24 13.92.1
max. 0.5

13.27
3.92

Figure 148 Detail of the withdrawable part of VD4 circuit-breaker with motor operator, seen from the left-hand side.
13.24 Roller
13.25 Plastic cam
13.26 Lever
13.27 Pin
13.90 Motor operator
13.91 Tie-rod
13.91.1 Bolt
13.91.2 Bolt
13.92 Angular lever
13.92.1 Bolt

95
2. Motor operator for the earthing switch
Disconnect the terminals;
Loosen the grub-screw in the set collars;
Withdraw operating shaft 14.1;
Observe the position of locking disc 14.6 relative to cam 14.7;
Replace the motor operator;
Slide the operating shaft through from the front;
Observe the position of locking disc 14.6 relative to cam 14.7;
Tighten the grub-screw in the set collars;
Connect the control wiring;
Set the operating mechanism manually to an intermediate position and only then perform a test run
to determine the direction of rotation;
Ensure that the motor shuts down correctly in the final positions!

Note
The auxiliary switches of the interchangeable groups are adjusted at the works.
When final installation of the earthing switch and operator takes place on site, it may be necessary to
carry out further precise adjustment of the auxiliary switch. In this case, the following should be taken
into account:
There must be a run-on of 0.5 mm in the fully operated position before the plunger reaches the stop
(for safety reasons);
Auxiliary limit switch 11.4 (figure 149) for earthing switch ON must be operated immediately after
the dead centre position of the toggle spring mechanism has been reached in the closing process
and the automatic quick-closing process has started;
Auxiliary limit switch 11.3 for earthing switch OFF must
a) be operated on earthing switches with manual mechanisms during the opening movement of slide
14.2 before half of the hexagonal shaft has become visible, or 1 mm before the tab of the slide
makes contact with the armature of the de-energised locking magnet;
b) be operated on earthing switches with motor operator (no slide 14.2 fitted) immediately after the
toggle spring mechanism has passed the dead centre position during rotation to the OFF position.

11.3

14.6

14.1 14.7

14.1
14.2

14.3

11.4

11.4 11.3
Figure 149 Manual earthing switch operating mechanism Figure 150 Earthing switch motor operator with auxiliary
with auxiliary contacts, side protection contacts installed, protections removed
removed 11.3 Q8S1 auxiliary contact earthing
11.3 Q8S1 auxiliary contact earthing switch OFF
switch OFF 11.4 Q8S2 auxiliary contact earthing
11.4 Q8S2 auxiliary contact earthing switch ON
switch ON 14.1 Drive shaft for earthing switch
14.1 Drive shaft (earthing switch) 14.6 Locking disk
14.2 Sliding closure 14.7 Cam
14.3 Cam plate, adjustable

96
7.5. Testing withdrawable parts
When functional tests are carried out on withdrawable parts, compliance with the conditions listed
below should also be checked.

7.5.1 Motor-driven withdrawable parts (not standard)


Carry out testing of motor-driven withdrawable parts in the same way as for manually operated
withdrawable parts:
Switch off the auxiliary power (m.c.b.), since the motor could otherwise be braked electrically;
Turn hand crank 121 in the required direction;
Ensure that the spindle nut is correctly lubricated.

Note
When the withdrawable part moves, the motor turns. The motor functions like a generator in these
cases, i.e. it can lead to reverse voltages in the terminals.

7.5.2 Checking correctness of dimensional settings


1. The distance between lever 13.26 operated by tie-rod 13.91 (figure 148) and plastic cam 13.25
should be 21mm.
If adjustment is required, loosen the two bolts 13.91.1 and 13.91.2. Deviations from the specified
value can have the following effects:
Dimensions too large, locking system for the drive spindle deactivated;
Dimensions too small, proper action of the electrical interlock no longer guaranteed;
2. The distance between roller 13.24 and angle lever 13.92 should be 0.5 mm when the circuitbreaker
is closed.
If adjustment is required, loosen the two bolts 13.91.2 and 13.92.1.

7.5.3 Checking auxiliary switch settings on withdrawable parts


Compliance with the interlock conditions in the test/disconnected and service position areas is ensured
by position signalling switches S8 and S9 (figure 151) located in the withdrawable assembly and
factory-set.
During testing operations, the withdrawable part must be moved by hand with the crank fitted and with
the motor power switched off.
1. Settings in the area of the test/disconnected position:
Move the withdrawable part out of the test/disconnected position towards the service position with
a few turns of the crank;
Slowly move the withdrawable part back to the stop.
Auxiliary switch S8 must then switch over just before the stop is reached.
Slowly insert the withdrawable part from the test/disconnected position towards the service
position until auxiliary switch S8 just operates.
In this position, it must still just be possible to move closing push-rod 13.2.1. For this test, the
function of the locking magnet Y0 must be deactivated manually.
This condition ensures that the electrical interlock takes effect before the mechanical interlock in
the motion sequence involved.
2. Settings in the area of the service position:
Move the withdrawable part out of the limit position towards the test/disconnected position with
a few turns of the crank;
Slowly move the withdrawable part forward again to the stop. Auxiliary switch S9 must then switch
over just before the stop is reached.

7.5.4 Checking the direction of rotation of the travel motors on motor-driven withdrawable
parts
Move the withdrawable part by hand into a central position between the test/disconnected position
and the service position;
Remove the hand crank;
Switch the auxiliary voltage for the travel motor on;
Use the local electrical controls to check that the withdrawable part moves in the correct direction.

Caution
Do not allow the withdrawable part to run up against a lock when the travel direction is incorrect! Switch
the motor power off immediately (the travel process functions electrically by a seal-in system with limit
position switch-off).
There may be a danger of injury when the door is open!

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18.2 18.1 S9 S8 10.3

Figure 151 Withdrawable assembly (truck) for circuit-breaker with auxiliary devices.
S8 Test position indicator
S9 Service position indicator
10.3 Control circuit plug connector for withdrawable assembly
18.1 Square rod
18.2 Hole for shaft insertion lever

7.5.5 Testing interlock conditions


1. The withdrawable part must only be movable from the test/disconnected position into the service
position when the circuit-breaker is open and the earthing switch is open.
Check the following conditions individually:
With the circuit-breaker closed, insertion of the withdrawable part towards the service position
must be locked after only half a turn of the crank in the clockwise direction, and it must not be
possible to switch on the travel motor on motor-operated withdrawable parts;
With the earthing switch closed, insertion of the withdrawable part towards the service position
must be locked after only two clockwise turns of the crank, and it must not be possible to switch
on the travel motor on motor-operated parts.
Use no force! Also see the note in chapter 6.2.1!

2. The withdrawable part must only be movable from the service position into the test/disconnected
position with the circuit-breaker open.
Check this condition as follows:
With the circuit-breaker closed, withdrawal movement of the withdrawable part must be locked
after only half a turn of the crank in anti-clockwise direction, and it must not be possible to switch
on the travel motor on motor-operated withdrawable parts.

3. Closing of the circuit-breaker must only be possible when the withdrawable part is in the defined test/
disconnected position or service position.
The control wiring plug 10.2 (figure 152) must previously have been inserted.
Check this condition as follows:
It must not be possible to close the circuit-breaker with the withdrawable part in any position
between the test/disconnected position and the service position.
Enabling of switching when the withdrawable part moves into the service position is carried out
electrically by operation of auxiliary switch S9 (figure 151) in the withdrawable assembly, and
slightly earlier mechanically - this corresponds to a position approximately half a turn of the crank
before the stop;
For movement into the test/disconnected position, the same enabling conditions apply in the
same way, in this case by means of auxiliary switch S8 in the withdrawable assembly.

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4. It must only be possible to open the circuit-breaker (manually) when the withdrawable part is in the
service position or test/disconnected position and the control voltage has failed.
Check this condition.

5. Withdrawable parts with order-related locking magnet Y0 may not be moved in case of control
power failure, or when there is no control power. Do not forcibly move locked withdrawable parts!
The locking magnet Y0 is only present on manually operated withdrawable parts.
Releasing the locking magnet Y0:
Remove front plate 13.17;
Disengage locking magnet Y0 by pulling the magnet armature;
While doing so, turn crank 121 about one half turn (either direction of rotation is permissible). The
locking magnet is only active in the test position and service position. In intermediate positions
it has no effect.

6. Disconnection of the control wiring plug 10.2 as well as later insertion must be locked in the
withdrawable part service position. Check this condition.

7. Operation of the earthing switch must only be possible when withdrawable part 13 is in the test/
disconnected position or the removed position (subject to any additional electro-magnetic interlocks
in individual cases).
Check this condition:
With the withdrawable part in the test/disconnected position, it must be possible to press slide
14.2, in front of the earthing switch operating shaft 14.1 (figure 127), downwards to the opening
position. The earthing switch can then be operated;
With the slide pressed down, it must also be impossible to start the travel motor on motor-driven
withdrawable parts;
If the slide is pressed down slightly when the travel motor is running, the motor must then
automatically switch off immediately.
The selected travel direction is continued by pressing the button.
It is only possible to press slide 14.2 down fully with a running travel motor when the latter is in
the start-up phase;
When the withdrawable part is moved inwards towards the service position, pressing down of
slide 14.2 must be locked after only one and a half clockwise turns on the crank.

10.2

13.1

18.1

14

Figure 152 Circuit-breaker compartment, open.Withdrawable part in isolated position, control circuit plug connector open
10.2 Control circuit plug connector
13.1 Withdrawable part
14 Earthing switch operating mechanism
18.1 Square rod

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7.6 Tests on the panel

7.6.1 Auxiliary switch settings on the earthing switch


1. There must be a run-on of 0.5 mm in the fully operated position before the plunger reaches the stop
(for safety reasons);
2. Auxiliary limit switch 11.4 (Q8S2) for earthing switch ON must be operated immediately after the
dead centre position of the toggle spring mechanism is reached in the closing process and the
automatic rapid closing process has started;
3. Auxiliary limit switch 11.3 (Q8S1) for earthing switch OFF must:
a) be operated on earthing switches with manual mechanisms during the opening movement of the
slide 14.2 before half of the hexagonal shaft has become visible, or 1 mm before the tab of the
slide makes contact with the armature of the de-energised locking magnet;
b) be operated on earthing switches with motor operators (no slide 14.2 fitted) immediately after the
toggle spring mechanism has passed the dead centre position during rotation to the OFF position.

Note
Check the direction of rotation of the motor after repair work.
Do not allow the motor to run up against a lock if the direction of rotation is incorrect (also see section
7.5.4).

7.7 Spare parts, auxiliary materials and lubricants

7.7.1 Spare parts


A spare parts list is available on request for procurement of spare parts. It basically includes moving
parts and parts subject to wear. When parts are required, the serial number of the relative switchgear
or switching device should always be quoted.

7.7.2 Auxiliary materials, lubricants


Lubricant
Vaselina as oxidation protection for busbars;
Mechanical grease for moving parts.

Halogen-free cleansers
ETHANOL F 25 M (for general cleaning);

Touch-up paint
Standard colour RAL 7035.

100
7.8 Operating accessories

145 31.29
147
128

31.28

122 121

90.8

Figure 153 Operation accessories


31.28 Manual emergency operating lever (to remove voltage to VM1 type circuit-breaker
31.29 Auxiliary spring to lock the opening capacity (for VM1 type circuit-breaker)
90.8 Charging lever (for HD4 type circuit-breaker)
121 Crank handle (to move the withdrawable part inside the panel)
122 Operating lever (for earthing switch)
128 Charging lever (for HD4 type circuit-breaker)
145 Double bit key (to use the central locking device and the screw type door lock)
147 Crank handle (to use the central locking device or the screw type door lock)

101
8. Product quality and environmental protection

The UniGear ZS1 type panels are produced in compliance with the requirements of international
standards for the quality management system and environmental management system. In these
fields, the excellent level is proved by quality certificates according to ISO 9001 and by the EMS
according to ISO 14 001.

End of life of product

The ABB company is committed to complying with the relevant legal and other requirements for
environment protection according to the ISO 14 001 standard.

The duty of company is to facilitate subsequent recycling or disposal at the end of product life.
During disposal of the product, it is always necessary to act in accordance with local legal requirements
in force.

We use the following methods of disposal:


Disposal can either be carried out thermally in an incineration plant or by storing on a waste site.

RAW MATERIAL RECOMMENDED METHOD OF DISPOSAL

Metal material (Fe, Cu, Al, Ag, Zn, W, others) Separation and recycling

Thermoplasts Recycling or disposal

Epoxy resin Separation of metal material and the disposal of rest

Rubber Disposal

Oil as dielectric (transformer oil) Draining from equipment and further recycling or disposal

SF6 gas Discharging from equipment and further recycling or disposal

Packing material wood Recycling or disposal

Packing material foil Recycling or disposal

102
The data and illustrations are not binding. We reserve the right to make
changes in the course of technical development of the product.
1VLM000363 - Rev. F, en - Instruction manual - 2008.10

ABB S.p.A. ABB s.r.o.


Power Products Division Org. unit EJF
Unit Operativa Sace-MV Vidensk 117. 619 00 Brno
Via Friuli, 4
Czech Repubblic
I-24044 Dalmine
Tel: +420 5 4715 2413, 1111
Tel: +39 035 395 111
Fax: +420 5 4715 2190
Fax: +39 035 395 874
E-mail: info.ejf@cz.abb.com
E-mail: sacetms.tipm@it.abb.com
Internet://www.abb.com
Internet://www.abb.it