Beruflich Dokumente
Kultur Dokumente
UniGear ZS3.2
Air-insulated medium voltage switchgear
1 Summary 3
1.1 General 3
1.2 Standards and specifications 3
1.3 Service conditions 3
1.3.1 Normal service conditions 3
1.3.2 Special service conditions 3
2 Technical data 4
2.1 Electrical data 4
2.2 Resistance to internal arc faults 4
2.3 Dimensions and weights 4
Dangerous
1.1 General
The metal-enclosed, three-pole air-insulated switchgear
Humidity
panels without disconnectors of UniGear ZS3.2 series are fac-
Highest average value measured
tory-assembled, type-tested indoor panels for a rated voltage over 24 hours
of 36/40.5 kV. They are designed as withdrawable module Relative humidity 95 %
type panels, and fitted with a single busbar system. The with-
Highest average value measured
drawable parts are fitted with vacuum circuit-breakers. over 1 month
Relative humidity 90 %
Details of the technical design and configuration of individual
switchgears, such as the technical data, detailed equipment Remark:
lists for the individual panels and comprehensive circuit doc- With indoor installation, it is assumed that the humidity within
umentation, etc., can be found in the relevant order docu- the enclosure can reach high values, but that there is normally
ments. no condensation on the installed equipment. Condensation
can be prevented by appropriate configuration of the station
1.2 Standards and specifications building or switchgear room.
UniGear ZS3.2 switchgear panels comply with the standards
and specifications for factory-assembled and type tested The maximum site altitude is 1000 m above sea level.
high voltage switchgears to IEC publications 62271-200 and
62271-100. In addition, in accordance with IEC 60529, the 1.3.2 Special service conditions
switchgear panels have degrees of protection According to IEC 62271-100, the manufacturer and user may
agree on special service conditions which deviate from the
IP 4X for the enclosure and normal service conditions. The manufacturer must be consult-
IP 2X for the partitions. ed in advance about each special service conditions.
The corresponding IEC publications, the national or local safe- Examples are as follows:
ty at work regulations and the safety regulations for produc-
At site altitudes above 1000 m, the effects of the reduction
tion materials are to be followed during erection and operation in dielectric strength of the air on the insulation level are to
of these systems. Above and beyond this, the order-related be taken into account
data from ABB Xiamen Switchgear Co., Ltd. are to be taken
into account.
Increased ambient temperatures must be compensated for
in the design of the busbars and tee-off conductors, or the
1.3 Service conditions current carrying capacity will be limited. Heat dissipation in
1.3.1 Normal service conditions the switchgear panel can be assisted by fitting additional
The switchgears are fundamentally designed for the normal ventilation facilities
service conditions for indoor switchgears IEC publication
62271-1. The following limit values, among others, apply:
Ambient temperature:
Maximum +40 C
Maximum 24 h average +35 C
Minimum (according to
minus 15 indoor class) -15 C
47
1200 55
Figure 2/2
R(L1)
C A B
Y(L2)
B(L3)
2350
2400
Service
D Position Test
Position
A Circuit-breaker compartment
450 B Low-voltage compartment
30 2500 35 C Busbar compartment
D Cable connection compartment
3.1 Basic structure and variants tate additional operator protection measures on the switch-
(Figures 3/1 to 3/6) gear panels.
The basic structure of the switchgear panels comprises
the panel itself, which is fixed in position, and the movable, The front and rear doors of the switchgear panels and the
withdrawable part with vacuum circuit-breaker. Figures 3/1 to cover plates of the end panels are thoroughly cleaned, treated
3/6 show the structure of a panel and the electrical equip- to prevent corrosion, and then painted with a high-quality two-
ment fitted. The whole panel is constructed by bolting up the coat stoved enamel system in colour RAL7035 (or special
double folded components manufactured from high quality colours as agreed) which are notable after stoving for their
Al-Zn sheet steel, precisely folded and exactly fitted surface particular insensitivity to impacts and corrosion.
from and extremely rigid construction. Illustration shows the
structure of a panel and the electrical equipment fitted. To- 3.3 Compartments in the switchgear panels
gether with the basic panel version for use as an incoming or Circuit-breaker compartment
outgoing feeder panel, variants, for example for busbar sec- (Figures 3/6, 3/9 to 3/13)
tionalizing (in conjunction with a bus riser panel) or metering, The circuit-breaker compartment A fitted with the necessary
are available. Further details on the structure and equipment guide rails accommodates the withdrawable part 50, which
configuration of the switchgears can be taken from the order can be moved between the service position and the test/dis-
documents for the particular case. connected position.
The panel consists of the following components If the withdrawable part is moved from the service position
Circuit-breaker compartment into the test/disconnected position, the fixed contacts 25.1
Cable connection compartment ment C and cable connection compartment D are automatical-
Low voltage compartment ly covered by metal plates which will be interlocked mechan-
ically or can be locked by a padlock when the withdrawable
The compartments are seperated from each other by earthed part is moved away. In the test/ disconnected position, the
sheet steel partitions. withdrawable part is still completely inside the panel with the
door closed.
3.2 Enclosure and partitions
(Figures 3/1 to 3/6) The switching operations (including manual operation) are
The enclosure and internal partitions of the switchgear panels carried out with the doors closed.
consist of high quality aluminium zink coated sheet steel. The
three high-voltage compart-ments are fitted with secured Withdrawable part
pressure relief plates located at the top. These open upward (Figures 3/1, 3/2, 3/14, 3/15, 3/16, 3/17, 6/1 to 6/7)
if internal arc faults result in overpressure. The front and rear The manually moved withdrawable part consists of a robust
of the panels is closed off by flameproof doors which open to sheet steel structure on which the circuit-breaker poles are
an angle of almost 180. Neighbouring switchgear panels are mounted and the breaker mechanism with anciallary compo-
partitioned from one another by the side walls of each panel nents are installed.
and the air cushion which remains between these walls as a
result of the design when the panels are joined together. This Contact arms 57.1/57.2 with spring-loaded contact systems
method of construction prevents them from melting through if are fitted to the circuit-breaker poles. These create the electri-
an arc fault should occur. All heads of the structure bolts do cal connection to the switchgear panel when the withdrawable
not stick up the fitting surface on the side walls as result of part is inserted into the service position. Detail information on
embossing processing used. Thanks to that, it is possible to the vacuum circuit-breaker can be found in the corresponding
remove the middle panel of the switchgear without removing instruction manual.
the adjacent panels. The separately fitted low-voltage com-
partment B is designed as a self-supporting shockproof and The signalling, protection and control wiring between the
flameproof sheet steel enclosure, separate from the high-volt- switchgear panel and the withdrawable part is coupled by a
age area. Even with the withdrawable part 50 removed (hinged multiple pin control wiring plug connector 10.
shutters 35.1/ 35.2 in the closed position), there is protection
against contact with live parts in busbar compartment C and As soon as withdrawable part 50 has been slid into the
cable connection compartment D. switchgear panel and its interlock yoke 51 has engaged in the
test/disconnected position, it is positively connected to the
The necessary safety measures to counteract the effects of switchgear panel. At the same time, it is earthed by earthing
an internal arc fault must be ensured in connection with the contacts 50.1 and earthing rail 19/19.1. The position of the
ceiling height. This may in individual cases possibly necessi- withdrawable part can be checked on the electrical position
06 Switchgear panel structure and equipment installed | UniGear ZS3.2 air-insulated medium voltage switchgear
indicator or through the sight glass in the door at any time. At the top of the left hand duct, an entry for control cables is
The stored-energy spring mechanism of the circuit-breaker reserved with the free-cut rubber sealing which will keep the pro-
including controls and indicators is accessible at the front of tection class IP4X for the whole encloser of the switchgear panel.
the withdrawable part. Apart from the version with a fitted
circuit-breaker, withdrawable parts with other equipment, e.g. 3.4 Interlocks/protection against maloperation
for metering, are available. (Figures 3/6, 3/10 to 3/12, 6/1 to 6/8)
A series of interlocks are provided to prevent fundamentally
Busbar compartment hazardous situations and maloperation, thus protecting both
(Figures 3/6, 5/7 to 5/17) personnel and the switchgear itself. The interlocks which are
Busbars 3 are laid in sections from panel to panel, and are normally individually effective are as follows:
held in place by the tee-off conductors 3.1 and by busbar
bushings 29. The conductor material used is tubing with a
The withdrawable part can only be moved from the test/
D-shaped cross-section, in either single or double configura- disconnected position into the service position (and back)
tion depending on the current rating, or rectangle copper bar. with the circuit-breaker open and the earthing switch open
The connection to the flat tee-off conductors is made without (between positions, the circuit-breaker is mechanically
any special connecting clamps. The busbars and tee-off con- interlocked, and also electrically interlocked in the case of
ductors are covered with shrink-on sleeves. The bolt connec- circuit-breakers with electrical releases)
tions in the busbar system are normally covered by insulating
covers 58. In conjunction with bushings 29, panel by panel
The circuit-breaker can only be closed when the with-
partitioning is realised. drawable part is precisely in the defined test position or ser-
vice position. Between these positions, the circuit-breaker is
Cable connection compartment mechanically interlocked, and also electrically interlocked in
(Figures 3/6, 5/5, 5/6, 6/10 to 6/12) the case of circuit-breakers with electrical releases
Current transformers and an earthing switch (with manual
operating mechanisms) are located here. Installation of surge
The circuit-breaker can only be opened manually in the ser-
arrestors is possible. Multiple parallel power cables can also vice or test position when no control voltage is applied, and
be entered without difficulty. The cable sealing ends 16 can cannot be closed (electro-mechanical interlock)
be fitted in particularly favourable conditions. A removeable
plate for cable glands is located in the cable entry area.
Low-voltage plug 10.2 can only be inserted or removed
when the withdrawable part is in the test/disconnected po-
Installation of voltage transformers at cable side of the panel is in sition
preparation and will have influence on the depth of the panel.
Earthing switch 6 can only be closed when the withdrawable
The earthing switch is designed with a making capacity of 80 kA. part is in the test/disconnected position or the removed
position (mechanical interlock)
The detailed information on the earthing switch can be found
in the corresponding instruction manual.
The withdrawable part cannot be moved from the test/
disconnected position into the service position when the
Low-voltage compartment earthing switch is closed (mechanical interlock)
(Figures 3/6)
The low-voltage compartment, together with its front door,
Details of any additional interlocks, e.g. in connection with
accommodates the secondary equipment of the switchgear a blocking magnet on the withdrawable part and/or earth-
panel required for the particular application. ing switch operating mechanism, can be found in the order
documents for each individual case (see also section 7.4)
The control wiring in the switchgear panel area is led through
generously dimensioned and metal covered ducts. The left-
The hinged shutters can be secured with padlocks in the
hand duct is reserved for the incoming and outgoing control closed position when the withdrawable part has been re-
wires, and the internal wiring in the panel is located on the moved (Figure 3/9)
righthand side.
UniGear ZS3.2 air-insulated medium voltage switchgear | Switchgear panel structure and equipment installed 07
3 Switchgear panel structure and equipment installed
3.5 Main apparatuses These characteristics ensure long electrical life of the circuit
3.5.1 Circuit breaker breaker and limited dynamic, dielectric and thermal stresses
Vacuum circuit breaker VD4 on the installation.
The vacuum circuit breaker of type VD4 on withdrawable parts
for 36/40.5 kV rated voltage are intended for indoor installation The circuit-breaker poles, which make up the breaking part,
in air-insulated switchgear systems. Their switching capacity are systems with lifelong sealed pressure and are mainte-
is sufficient to handle any conditions arising from switching of nance-free.
equipment and system components under normal operating
and fault conditions, particularly short-circuits,within the The ESH type mechanical operating mechanism of HD4, with
parameters of their technical data. stored energy has free release and allows opening and closing
operations independently of the operators actions.
Vacuum circuit breakers have particular ad-switching frequen-
cy in the working current range and/or where a certain number The operating mechanism and the poles are fixed to the metal
of short-circuit breaking operations are expected. Type VD4 structure which also acts as a support for the kinetics for op-
vacuum circuit breakers are suitable for autoreclosing, and erating the moving contacts.
have exceptionally high operating reliability and long life.
Circuit-breakers in the withdrawable version are fitted with a
The vacuum circuit breakers designed in column form, are truck to allow racking in and racking out of the switchboard or
supplied as withdrawable modules. enclosure.
SF 6 circuit breaker HD4 The light and compact structure of the circuit-breaker ensures
HD4 medium voltage circuit-breakers use sulphur hexafluoride gas great sturdiness and excellent mechanical reliability.
(SF6) to extinguish the electric arc and as the insulating medium.
08 Switchgear panel structure and equipment installed | UniGear ZS3.2 air-insulated medium voltage switchgear
3.5.2 Instrument transformers 3.5.3 Surge arrester
Current transformers Protection of medium voltage AC networks against both, mul-
The current transformers are of the type insulated in resin and tiple atmospheric and switching overvoltages as well as Very
are used to supply the measurement devices and protection Fast Transients (VFT). Suitable for instance for the protection
instruments. These transformers have a wound core with one of transformers, cables, motors and other medium voltage
or more cores, with performances and accuracy classes suit- equipment.
able for the installation requirements.
3.5.4 Eearthing switch
Voltage transformers
Earthing switches of Series EK6 are determined for indoor
The voltage transformers are of the type insulated in resin and
installation and fitted with snap-action operating mechanisms
are used to supply measurement and protection devices. They
for positive high-speed closing and sufficiently dimensioned
are available for fixed assembly or for installation on remov-
to conduct the rated short-circuit making current when closed
able and withdrawable trucks.
under load. The speed of the snap-action closing operation
is independent controls. The earthing swithes are supplied as
When they are installed on removable or withdrawable trucks
they are fitted with medium voltage protection fuses. The kits with a pre-assembled active part and corresponding earth-
withdrawable trucks also allow replacement of the fuses with ing contacts supplied lose. Correct installation of these parts
the switchgear in service. Truck racking-out with the door in a switchgear panel results in a functioning earthing earth.
closed automatically operates closure of a metallic segrega-
tion shutter between the live parts of the switchgear and the
instrument compartment.
Advantages
Low residual voltage
Long protection distance
Maintenance free
UniGear ZS3.2 air-insulated medium voltage switchgear | Switchgear panel structure and equipment installed 09
3 Switchgear panel structure and equipment installed
10 Switchgear panel structure and equipment installed | UniGear ZS3.2 air-insulated medium voltage switchgear
Figure 3/6: UniGear ZS3.2 section view, basic structure of an incoming or
outgoing feeder panel, 1600 A.
28
35.1
3
R(L1)
3.1
29
C A B 1
Y(L2)
30.1 1.2
29.1
30
5
50.2
6 14, 14.1
B(L3)
20.2
3.2 50
52
30.2 HEATING PLATE
23
16 51
9.1
35.2
21
17.2 D
10, 10.1, 10.2
19
10.3
17
UniGear ZS3.2 air-insulated medium voltage switchgear | Switchgear panel structure and equipment installed 11
3 Switchgear panel structure and equipment installed
Figure 3/8: Panel of type UniGear ZS3.2, rear side | Figure 3/9: Circuit-breaker
compartment, door open, withdrawable part removed
Figure 3/10: Circuit-breaker compartment, door open, withdrawable part in
isolated/disconnected position.
30.1
35.3
35.1
35.2
43.1
44
30.2
19.1
Figure 3/10
19.1 Earthing rail 35.3 Fishplate for inserting a padlock
50 35.1 Hinged shutter system, above 43.1 Duct cover for control cables
50.2 35.2 Hinged shutter system, below 44 Heater
14
14.1
14.2
51
12 Switchgear panel structure and equipment installed | UniGear ZS3.2 air-insulated medium voltage switchgear
Figure 3/11: Circuit-breaker compartment, door open, withdrawable part in
service position
Figure 3/12: Circuit-breaker compartment withdrawable part in service position
Figure 3/13: View into circuit-breaker compartment withdrawablepart removed,
hinged shutters opened
Figure 3/14: Withdrawable part with circuit breaker, HD4 operation side
Figure 3/11 Figure 3/12
10.1
10.2
10.3
20.1
25.1
20.2
UniGear ZS3.2 air-insulated medium voltage switchgear | Switchgear panel structure and equipment installed 13
3 Switchgear panel structure and equipment installed
50.2
57.1
57.8
57.2
Figure 3/17
50.2
9.2
50
50.3
50.4
14 Switchgear panel structure and equipment installed | UniGear ZS3.2 air-insulated medium voltage switchgear
4 Dispatch and storage
4.1 Condition on delivery care: Please refer to instruction Manual BA 483/2E, section 4,
The factory assembled switchgear panels are checked at the transport
works for completeness in terms of the order and simultaneously
Only handle modules by crane with transport crossbeam and a
subjected to routine testing (normally without AC voltage testing suitable harness with lifting ro-pes
of the busbars) to IEC publication 62271-200, and thus tested for
correct structure and function.
Lifting tackles must never catch on the breaker poles or the part
of the operating mechanism! It is to be ensured that the breaker
The busbars are not assembled at factory. The busbar material, do not suffer impacts or other injurious physical stresses during
fasteners and accessories are packed separately. handling
4.2 Packaging
Only handle the modules by crane with bolted on transport
The switchgear panels are despatched in appropriate packaging brackets (see BA 483/02E), suitable lifting ropes and crane har ness
for the prevailing conditions, e.g. seaworthy packaging, or also
without packaging, as required in individual cases. Particularly for
Take care not to allow the modules to tip, as the centre of
over-seas transport, even in containers, they are sealed in airtight gravity is high
plastic sheeting with an appropriate quantity of drying agent to
protect them from damage due to moisture, and in many cases
When transporting modules by forklift, they must be fastened to
fitted with a separate moisture indicator. When aluminium com- pallets and secured to the lift truck column
posite sheeting is used, a window has to be fitted for observation
of the moisture indicator. The drying agent is active as long as
When moving the withdrawable part only use the sliding handles
the coloured indicator remains blue. When the colour changes to 51.2 (e.g. for racking in/out the withdrawable part into/out of the
pink, the relative humidity stated on the bag (e.g. 40%) has been switchgear panel or for the transport of the truck in the switch-
exceeded inside the packaging (possibly as a result of damage). gear room). Do not bring any force on the front partition plate
Suitable action including replacement of the drying agent bags is 50.2 of the truck
then necessary if the packaging condition is to be maintained. The
instructions for use of the drying agent bags to DIN 55 473 are to
Take care that the catch pins 51.1 on the inter-lock yoke 51 are
be followed carefully. engaged with the guiding rails 51.3 in the switchgear when mov-
ing-in with-draw able part into the panel
4.3 Transport
(Figure 3/175/46/1 to 6/1) 4.4 Delivery and intermediate storage
The transport units are individual panels. The switchgear panels The responsibilities of the consignee when the switchgear arrives
are each fitted with four lifting lugs. at site include, but are not limited to, the following:
Checking the consignment for completeness and freedom from
Transport switchgear panels upright. Only ever carry out damage (e.g. also for moistu-re and its detrimental effects).
loading operations when it has been ensured that all pre- In cases of doubt, the packaging must be opened and then
cautionary measures to protect personnel and materials pro-perly resealed, fitting new drying agent bags, when in terme-
have been taken and using a diate storage is necessary
crane
fork-lift truck and/or
Precisely documenting any short quantities, de-fects or transport
manual trolley jack damage on the consignment note and notifying the shipper or
carrier imme-diately and reporting these to the relevant autho-
Loading by crane: rities within two weeks
Maintain an angle of 60 from the horizonta for the ropes lead- Optimum intermediate storage as far as this would be necessary
ing to the crane hook. The use of a crane cross beam is urgently at all without detrimental consequences depends on compliance
recommended with a number of minimum conditions for the switchgear panels
and assembly materials.
Transport circuit-breaker unit or metering truck with appropriate
A dry and well-ventilated storeroom, atmosphere in accordance weather and from damage
with IEC 62271-200
Check the packaging for undamaged condition
No other detrimental environmental influences arrival of the consignment and at appropriate intervals, see also
Do not remove or damage the packaging exceeded, the protective function of the packaging including its
Loosely cover unpackaged switchgear panels with plastic film to anti-corrosion effects will cease to be effective sooner or later,
prevent dirt ingress. Sufficient air circulation must be maintained depending on local conditions. If intermediate storage has to be
to prevent corrosion prolonged, suitable action must be taken
If the foundation frame consists of several part, bolt these drawable parts and opening and closing of the doors cannot
together at the prepared joint locations using links in the be ruled out.
specified sequence and so as to achieve a level surface.
UniGear ZS3.2 air-insulated medium voltage switchgear | Assembly of the switchgear at site 17
5 Assembly of the switchgear at site
Structural data
Table for figure 5/1 and 5/2:
1) Determined by VDE 0101 and the data for maximum panel width.
2) Applies to low voltage compartments of standard height. Add 200 mm for top mounted low voltage compartments and customized low voltage compartments.
5.3 Assembly of the switchgear panels The individual installation stages are as follows:
(Figures 3/5 to 3/6, 3/9,5/4 to 5/17)
Transport the switchgear panels to the prepared installation
Use DIN screws of tensile class 8.8. The tightening torques point in the sequence shown on the switchgear plan
for the busbar screw connections with dished washers are as
Dismantle lifting lugs 1.5
follows:
Remove withdrawable parts 50 from the switchgear panels
and store them with suitable protection
1)2)
Recommended tightening torque (Nm)
Release and remove floor cover 17
3)
Lubricant
Remove cover 43.1 from the vertical control wiring ducts at
Thread Without Oil or grease the front right and left of the panel
M5 2.5
Align the switchgear panels on the foundation one after
M6 10 another for correct position and vertical alignment (deviations
M8 25 of the panel edges from the vertical must not exceed 2 mm,
Copper to copper and
M 10 50 particularly at the front) and bolt the panels together. It is
copper to spout
M 12 86 advis0able to start from the centre when assembling switch-
M 16 170 gears with more than ten panels
M 20 200
Install and screw bushing plates 28 externally to the right or
M8 15 left hand panel wall
Copper or sheet to M 10 50
When the switchgear has been properly assembled, fasten
epoxy materials M 12 70 the panels to the foundation frame by welding or by using
M 16 110 90 adequate bolts
M 20 120
Copper or power cable
M 10 20
to voltage transfomer
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, partly not inconsiderable, spread).
2) Rated tightening torques for fasteners with lubrication in accordance with DIN 43 673.
3) Thread and head contact surface lubricated.
18 Assembly of the switchgear at site | UniGear ZS3.2 air-insulated medium voltage switchgear
5.4 Installation of the busbars and bushings
Position insulating covers 58 and lids 58.5 over the relevant
(Figures 3/6, 5/7 to 5/17) bolted joint, and slide the lid onto the cover until it clicks
(Lower) tie bus system for bus section: with the manufacturers instructions
Insert bushing 29 (phase B/L3) for the rear, lower tie bus
Connect the cable cores to the prepared connection points
into bushing plate 28.1 from the right in contrast to the pro- 23 with strain relief
cedure for the other two bush-ings
Fit the insulating separating plates to each phase
Connect the cable earth
Clean the insulation on the busbar sections with a dry, soft ducts 1.2
cloth, and check for insulation damage
Strip and fasten the control cables on the cable clamps
at the side wall in the cable duct and in sert the cores via
Install the busbars panel by panel. Screw on the individual touch up where necessary (see also section 7.3.1)
busbar elements one above the other (depending on the
Check bolted connections, especially all those made during
system layout) and in line with the flat tee-off conductor. on-site assembly in the busbar and earthing system, and
Use the socket head bolt 163 as provided. For tightening tighten where necessary
torque see the table above. Use two dished washers for
Carefully clean the switchgear
each screw
Remove all foreign bodies from the switchgear panels
Properly refit all covers etc. removed during in stallation and
Bolt one holder 58.1 to each end of the busbars to support connection
the insulating cover 58
Close off any openings remaining in the enclosure as a result
of the particular design, but which are no longer required
The screws for holder 58.1 are to be tightened with a lower
Insert the withdrawable parts into the switchgear panels
torque
Check the isolating contacts and interlock mecha nisms for
smooth function, and relubricate with Isoflex Topas NB52
(section 7.6.2) where necessary
UniGear ZS3.2 air-insulated medium voltage switchgear | Assembly of the switchgear at site 19
5 Assembly of the switchgear at site
B
1500
940 940
30
200
220
Only for transformer
260
430
panel C1 C1
2565
(360) (360)
50
50
50
1685
(130)
480
C1
1000
C2 C2
105
1340
665
M12(4X)
50 300
30
33 60 33 60 33 60
35
A
2000
A Operator aisle
B Inspection aisle
C1 Opening for power cables
C2 Opening for control cables(instead of individual openings, continuous openings or drilled holes are possible)
E Points for fixing the switchgear panel on the floor frame
20 Assembly of the switchgear at site | UniGear ZS3.2 air-insulated medium voltage switchgear
Ceiling
>4000
7
Circuit breaker
2400
(820) 1000 35
(130) (130)
(78)
1
2
50
200
9
3 14
5 8
10
300 2085
11
12
1732 650
1)
Minimum dimensions 8 Power cables
1 Operator aisle 9 Projecting of floor frame: 5-12 mm above finished floor level
2 Inspection aisle 10 Conductor to main earthing bar
3 Opening for control cables (instead of individual openings, continuous 11 Screen 50 mm to 60 mm
openings or drilled holes are possible) 12 Hight of the cable cellar, to be determined by the client
5 Openings for power cables 14 Guiding ramp, optional (recommended for circuit-breaker insertion)
7 Panel type UniGear ZS3.2 ...31.5 kA
UniGear ZS3.2 air-insulated medium voltage switchgear | Assembly of the switchgear at site 21
5 Assembly of the switchgear at site
Figure 5/4: For bolting the UniGear ZS3.2 panels together, threaded brushings are
provided at the right side near to the front and rear edges of the side
walls. Adequate bors are located at the left hand side of the panel
Figure 5/5: View into cable connection compartment max. 4 parallel cables possible
Figure 5/6: Partial view into the cable connection compartment prepared for connection
of two parallel cables
Figure 5/7: View into the busbar compartment
Figure 5/4 Figure 5/5
1.5
1.11
28
(1.9)
1.10
1.3
3.11
3.1
20.1
22 Assembly of the switchgear at site | UniGear ZS3.2 air-insulated medium voltage switchgear
Figure 5/8: Bushings with busbar mountings for busbar system with double
D-profile, tee-off ...1600 A.
Figure 5/9: Bushings with busbar mountings for busbar system with double
D-profile, tee-off ...2000 A to 3150 A.
3 Busbar
3.1 Tee-off conductor, busbar side
25.5 Sealing ring
28 Bushing plate
29 Busbar bushing
29.2 Busbar mounting for double conductor
84 Partitioning
UniGear ZS3.2 air-insulated medium voltage switchgear | Assembly of the switchgear at site 23
5 Assembly of the switchgear at site
Figure 5/10: Single rectangular copper busbar with single branch bar system
(...1600 A)
8.3
8.7
24 Assembly of the switchgear at site | UniGear ZS3.2 air-insulated medium voltage switchgear
Figure 5/14: Busbar barriers
a) Detail of a busbar bushing, sectional view. Always check that there is proper contact
between the metal tube in the bushing and the busbar via the contact spring.
3.12 Busbar section (length)
29.1 Busbar mounting for single conductor
29.2 Busbar mounting for double conductor
29.3 Contact spring
29.4 Metal tube
Caution:
The contact arm springs 29.3 or 8.3 must be
inserted during the installation of the busbars.
These contact springs prevent damages by glow
discharges inside the bushings on Live busbars.
UniGear ZS3.2 air-insulated medium voltage switchgear | Assembly of the switchgear at site 25
5 Assembly of the switchgear at site
Figure 5/15: Arrangement and bolting of single and double conductor busbars with
single and double tee-off bars. Ensure that screws and accessories
of the specified quality are used! Use 2 dished washers per screw
Figure 5/16: Arrangement of the busbar and tee-off conductor at the busbar end
Figure 5/15
3 Busbar
3.1 Tee-off conductor
3.5 Spacer plate, 15 mm
3.6 Spacer plate, 10 mm
29 Busbar bushing
58 Insulation cover
58.5 Lid of cover
163 M10 socket head bolt
164 M10 nut
165 10 mm dished washer
a) Arrangement for tee-off current up to 1600 A and 1600 A or 3150 A busbar current.
Figure 5/16
During assembly, cut out the insulation cover and lid to fit cross-section of the feed-
er or busbar.
3 Busbar
3.1 Tee-off conductor
3.5 Spacer plate, 15 mm
3.6 Spacer plate, 10 mm
58 Insulation cover
58.5 Lid of cover
163 M10 socket head bolt
164 M10 nut
165 10 mm dished washer
a) Arrangement for 1600 A tee-off current and 1600 A busbar current.
b) Arrangement for 1600 A tee-off current and 2000 A or 3150 A busbar current.
26 Assembly of the switchgear at site | UniGear ZS3.2 air-insulated medium voltage switchgear
Figure 5/17: Insulating covers for busbars | Figure 5/18: Guiding ramp for
circuit-breaker insertion, optional. The rail on the guiding ramp
must be in line with the guiding rail in the UniGear ZS3.2 panel
Figure 5/17
Figure 5/18
UniGear ZS3.2 air-insulated medium voltage switchgear | Assembly of the switchgear at site 27
6 Operation of the switchgear
Check the connection of the main earthing bar to the station necessary when several incoming feeder cables and switch-
earthing conductor gear sections are concerned (see also section 6.3.2)
Clean the switchgear, rubbing down insulating parts with 6.2 Switching operations
a clean, soft, non-fraying and dry cloth. Remove greasy or
adhesive dirt as described in section 7.2 Carry out switching operations with the panel doors
Properly refit all covers etc. removed during as sembly and closed.
testing processes
Perform on site power frequency voltage testing of the main 6.2.1 Withdrawable circuit-breaker part
circuits to IEC 62271-200 as far as necessary. Pay special (Figures 3/2, 6/1 to 6/7)
attention during this procedure to voltage trans formers and
cables, etc Manual insertion from the test/disconnected position to the
Display the instruction manual in a position accessible to the The withdrawable part must not be stopped at any position in
operator at any time the travel range between the service position and test/discon-
nected position!
Reverse the procedure described above for in sertion into Fit operating lever 122 to the hexagon shaft poin-ting either
the service position upwards or downwards for each swit-ching operation in such a
way that it is not obstructed at the sides, even in limited space.
Note:
Do not use force to move withdrawable parts with blocking
Turn the lever clockwise through approx. 180 until the stop
magnet Y0 in the event of a voltage drop. If this occurs they is reached to close the earthing switch, or anti-clockwise
are blocked along the whole travel range between the service until the stop is reached to open the earthing switch
position and test position. To remove the interlock, consult
Observe the mechanical/electrical switch position indicator
section 7.4.2.
Remove operating lever 122. Slide 14.2 remains open if the
earthing switch is in the closed position
Withdrawal from the test/disconnection position into the re-
moved position: Make sure that the operating lever is turned right up to the
Open the door of the circuit-breaker compartment stop in the opening process, to ensure that the earthing
Release control wiring plug 10.2 and engage it in the storage switch is in its defined limit position.
position on the withdrawable part
Deblock the interlock yoke by moving the sliding handle 51.2 The operating mechanism can also be fitted with a blocking
inwards against the springs to release the withdrawable part 50 magnet.
Carry out the procedure as described above for withdrawal, tor for testing of the off-circuit condition.
changing the order accordingly
When the switchgear is in operation, observe all the operat- A distinction must be made between the low impedance sys-
ing data and condition indications in the secondary area and tem and the high impedance system. For further details, see
watch for any irregulatities draft standard IEC 61243 Part 5.
6.2.2 Circuit breaker The two systems differ in several respects, including different
(Figures 6/1 to 6/5) voltage levels which constitute the display thresholds. The
For operation refer to Manual BA 483/02E, VD4, vacuum capacitive voltage dividers installed in the panels are corre-
circuit breaker on withdrawable part or 1YHA000046-en, HD4 spondingly of different ratings, and the measuring point sock-
SF 6 circuit breaker. ets and indicator units are of different types.
Carry out a functional test on the unit immediately before Only use phase comparators which comply with the
use, e.g. with interface tester KSP. The display must be DIN VDE standards and are of suitable design for
clearly perceptible the switchgear system
The interface test is a repeat test as specified in IEC 61243 tors and displays for irregularities.
Part 5
Note:
Always follow the details given in the instructions for the par- For voltage testing at power frequency and/or impulse volt-
ticular indicator for your switchgear system. age:
Only short-circuit the sockets for the capacitive voltage indi-
6.3.2 Testing of in-phase condition cator on the relevant panel for the duration of the test
Testing of the in-phase condition, e.g. when there is more
than one incoming feeder, can be carried out with a suitable Caution:
phase comparator coupled to the measuring point sockets of Operate truck slowly, be careful overturning Caused
the capacitive voltage indication system (if fitted). by inertia of fast movement!
Test procedure:
Figure 6/1: Withdrawable part with circuit-breaker, VD4, operating mechanism side
Figure 6/2: Charging the spring energy storage mechanism manually by moving the inserted lever up and down
55.8
55.6
128
54
51 51
10
10.1
51.2 10.2
51.4
51.1
14.3
14.1
14.4
14.2
14.5
14.3 Auxiliary switch Q8S1, earthing switch OFF 14.1 Hexagonal shaft
14.4 Auxiliary switch Q8S2, earthing switch ON 14.2 Slide
14.5 Interlocking rod (Earthing switch - withdrawable circuit-breaker unit)
6.1
6.3
6.4
6.7
6.6
Figure 6/11
58
6.10
6.4
14.1
6.2 6.4 Pair of earthing blades
6.5 6.5 Earthing conductor
6.2 Toggle spring
6.10 Fixed earthing contact
14.1 Hexagonal shaft
58 Insulation cover
Figure 6/12
6.1
6.5
6.7
6.6
6.8
14.1
6.1 Bearing bracket
6.5 Earthing conductor
6.6 Bevel gear mechanism (not belonging to the earthing switch)
6.7 Operating shaft
6.8 Driver lever
14.1 Hexagonal shaft
7.1 General with the relevant safety regulations to DIN VDE/IEC, and se-
Maintenance serves to preserve trouble-free operation and cure it against reconnection.
achieve the longest possible working life of the switchgear. In
accordance with DIN 31 051, it comprises the following close- The inspection may become necessary at shorter intervals
ly related activities: under unusual service conditions (including advers climatic
conditions) and/or particularly injurious environmental influenc-
Inspection: Determination of the actual condition es (e.g. heavy pollution and aggressive atmosphere).
Servicing: Measures to preserve the specified condition The inspection should include but not be limited to the follow-
Repair: Measures to restore the specified condition ing:
Note:
Check the installation for abnormalities of any kind, dirt and
When carrying out all maintenance work, the regulations in the the effects of other environmental influences
country of installation must be strictly complied with.
Check the function of the switching devices and the con-
Maintenance work may only be performed in a careful manner trols, interlocks, protection, annunciation and other devices
by trained personnel familiar with the characteristics of the
individual switchgear, in accordance with all relevant safety
Check the surface condition of the isolating contact system
regulations to VDE/IEC and of other technical authorities, and (for visual examination of the contact pins with the with-
with other overriding instructions. It is recommended that ABB drawable part removed). When the galvanic silver coating
service personnel be called in to perform servicing and repair on the contact parts is worn to such an extent that the
work, and this is necessary for some of the work detailed be- copper conductor material below becomes visible, or when
low. their surfaces are heavily corroded or show signs of other
damage or overheating (discoloured surface), replace the
The inspection and servicing intervals for some of the equip- contact parts. See also section 7.3
ment/components (e.g. parts subject to wear) are determined
by fixed criteria such as switching frequency, length of service
Check all switchgear accessories and the auxiliary equip-
and number of short-circuit breaking operations. For oth- ment (e.g. storage batteries etc.)
er parts, on the other hand, the length of the intervals may
depend, for example, on the different modes of operation in
No external discharge may occur on the surfaces of equip-
individual cases, the degree of loading, and also environmen- ment at operating voltage. This can, for example, be detect-
tal influences (including pollution and aggressive air). ed by characteristic noises, a clearly perceptible smell of
ozone, or visible glowing in the dark
The following service instructions must also be observed
together with this instruction manual in the individual cases Servicing
concerned: Basic servicing activities, and those which may be found nec-
essary during inspections, include the following:
Vacuum circuit breaker
VD4 BA 483/02E
Carefully clean the unit, and in particular the insulating
SF6 circuit breaker material surfaces, when they are found to be dirty (con-
HD4 1YHA000046-en tamination may also be caused by salt, mould formations,
Earthing switch insects or conductive materials in conjunction with frequent
EK6 1YHA000063-en conden-sation when the switchgear is operated in a tropical
climate). Remove dry dust deposits which do not adhere
If necessary, further details can be taken from the technical strongly using a soft dry cloth. Re move more strongly
documentation for the switchgear instal-lation (including, for adhering, e.g. sticky/ greasy dirt, with a cloth soaked in a
example, any agreed special service conditions). slightly alka-line household cleaner. Wipe off with clear wa-
ter and dry carefully
7.2 Inspection and servicing
Inspection Use halogen-free cleaners such as Rivolta BWR 210 or cold
Inspection of the switchgear should be carried out approx- cleanser 716 (for components in insulating material and for
imately every two to four years, depending on the service major contamination). Observe the manufacturers instruc-
conditions and local environment, in accordance with VBG4 tions and the special ABB instruction manuals BA 1002E
standard. and BA 1006E respectively on safety at work.
Never use 1.1.1-trichloroethane, trichloroethy-lene or car-
Isolate the area where work is to be performed in accordance
Should external discharges occur as a result of conden- brush or Scotch Sprite, and clean with a dry cloth. Then
sation, application of a thin silicone film on the surface evenly grease the parts (with Isoflex Topas NB52)
concerned is often effective as a temporary remedy. It is
advisable to request advice from the ABB after-sales service 7.3.2 Replacement of components
department on permanent solutions to such unusual prob- Replacement of the isolating contact systems: (Figures 7/1 to
lems 7/4)
Slide the two inner annular tension springs 57.6 facing the
Check that the bolt connections at the contact points in the breaker pole to a position beside the two outer annular
busbar system and the earth connections are tight, and that tension springs, thus releasing contact system 57.7, and
the isolating contact system functions correctly remove the contact sys tem from isolating contact arm
57.1/57.2
Top up the grease on sliding and bearing surfaces in the the contact system 57.3 over onto the isolating contact arm,
panels - for example on the separating plates, the interlock and withdraw the arbor
and guide systems, the spindle mechanism and the travel
Check all contact fingers and annular tension springs for
rollers of the withdrawable part - or thoroughly clean and perfect fit
regrease with Isoflex Topas NB52 lubricant where necessary
Note:
Observe the maintenance instructions in the manuals for the The set installation position of isolating contact arms
individual switch types 57.1/57.2 must not be changed by the improper use of force.
Carry out repair work immediately after a defect has been After any required replacement of contact pins 25.1/25.2,
discovered these are to be retightened using socket head screws:
Thread M10, non-greased, at 50 Nm
Top coat in standard colour RAL 7035 or the relevant spe- 7.4.1 Checking the auxiliary switch settings on withdrawable
cial colour parts
(Figures 6/3 to 6/6)
Carefully remove any white rust from Al-Zn sheet steel Refer to manual BA 483/02E; VD4, vacuum circuit-breaker on
surfaces with a wire brush or Scotch Sprite, and remove withdrawable part or HD4 SF6 circuit breaker 1YHA000046-en.
loosely adhering particles with a dry, non-fraying cloth. Then
treat the cleaned areas with zinc spray or zinc dust paint, Compliance with the interlock conditions in the areas of the
and then with aluminium spray to match up the colour test/disconnected position and the service position is ensured
by position signalling switches 10.4 (S8) and 10.5 (S9) located
on the withdrawable part and set at the works.
In the inspection and test operation, the withdrawable part is 3. Closing of the circuit-breaker must only be possible when
to be moved with the crank fitted. the withdrawable part is in the defined test/disconnected
position or service position.
1. Settings in the area of the test/disconnected position
Move the withdrawable part out of the test/disconnected The control wiring plug 10.2 must previously have been insert-
position towards the service position with a few turns of the ed.
crank
Slowly move the withdrawable part back to the stop Check this condition as follows:
It must not be possible to close the circuitbreaker with the
Auxiliary switch 10.4 (S8) must then operate when the hand withdrawable part in any position between the test/discon-
crank still has 60 of turn to reach the stop. nected position and the service position
Slowly insert the withdrawable part from the test/discon- Enabling of switching when the withdrawable part moves into
nected position towards the service position until auxiliary the service position is effected electrically by operation of
switch 10.4 (S8) just operates auxiliary switch 10.5 (S9), and mechanically slightly earlier; the
latter corresponds to a position approximately half a turn of
In this position, it must still just be possible to move the ON- the crank before the stop.
OFF operating shaft 54. For this test, the function of the
blocking magnet must be deactivated manually.
The enable conditions for the movement into the test/dis-
connected position apply accor-dingly, in this case estab-
This condition ensures that the electrical interlock becomes lished by auxiliary switch 10.4 (S8)
active before the mechanical interlock in the motion sequence
involved. 4. It must only be possible to open the circuit-breaker (manually)
when the withdrawable part is in the service position or test/
2. Settings in the area of the service position disconnected position and the control voltage has failed.
Slowly move the withdrawable part forwards again up to the 5. The withdrawable part with blocking magnet Y0 (if ordered)
stop may not be moved if the control voltage fails or is not avail
able. Do not use force to move the blocked withdrawable
Auxiliary switch 10.5 (S9) must then operate when the hand part!
crank has a remaining angle of 60 to turn up to the stop.
Removing the block:
7.4.2 Testing of interlock conditions
Remove front plate 50.6 and 50.7
(Figures 6/1 to 6/9)
1. The withdrawable part must only be movable from the test/
Release the blocking magnet Y0 by pressing the armature
disconnected position into the ser vice position when the continuously when moving the withdrawable part by using
circuit-breaker is open and the earthing switch is open. the hand crank 146 for 1/2 right or left
With the circuit-breaker closed, insertion of the withdrawable disconnected position and is not effective in the intermedi-
part towards the service position must be blocked after only ate position
half a turn of the crank in the clockwise direction
6. Removal of control wiring plug 10.2 and reinser tion of the
With the earthing switch closed, insertion of the with- plug must be blocked with the with drawable part in the
drawable part towards the service position must be blocked service position.
after only two clockwise turns of the crank
Check this condition.
2. The withdrawable part must only be movable from the ser
vice position into the test/disconnected position with the 7. Operation of the earthing switch must only be possible when
circuit-breaker open. withdrawable part 50 is in the test/ disconnected position or
the removed position (subject to any additional electromag-
Check this condition as follows: netic inter locks in individual cases!).
With the withdrawable part in the test/ disconnected posi- 7.6.1 Spare parts
tion, it must be possible to press slide 14.2 in front of the A spare parts list is available on request for procure-ment of
earthing switch drive shaft 14.1 downwards to the opening spare parts. It fundamentally comprises moving parts and
position. The earthing switch can then be operated parts subject to wear. When parts are required, the serial
numbers of the relevant switchgear panel and circuit-breaker
When the withdrawable part is moved inwards towards the should always be quoted.
service position, pressing down of the slide 14.2 must be
blocked after only one and a half clockwise turns on the 7.6.2 Auxiliary materials and Part no.
crank lubricants (order ref.)
Lubricant:
7.5 Tests on the switchgear panel
Isoflex Topas NB52 GCE0007249P0100
7.5.1 Auxiliary switch setting on the earthing switch Halogen-free cleansers:
(Figures 6/8 and 6/9)
Rivolta BWR 210 GCE0007707P0100
1. There must be a run-on of 0.5 mm in the fully operated position (for general cleaning)
before the plunger reaches the stop (for safety reasons). ABB directions for use
BA 1002/E GCEA901002P0102
2. Limit position auxiliary switch Q8S2 for earthing switch ON
Cold cleanser 716 GCE0007706P0100
must be operated immediately after the dead centre posi- (use for conductive
tion of the toggle spring mechanism is reached in the closing components, compon-ents
process and the automatic quick-closing process has started. in insulating material
and for heavy soiling)
3. Limit position auxiliary switch Q8S1 for earthing switch OFF ABB directions for use
must be operated on earthing switches with manual mech BA 1006/E GCEA901006P0102
anisms during the opening motion of the slide 14.2 before Touch-up paint:
half of the hexagon shaft has become visible, or 1 mm be-
Standard colour
fore the tongue of the slide makes contact with the arma- RAL 7035
ture of the unexcited blocking magnet.
1-kg-box GCE9014060R0103
1 Spray tin GCE0007895P0100
7 Maintenance
Figure 7/1: Contact system sample for 2000 A to 3150 A | Figure 7/2: Sliding
the contact system onto the auxiliary arbour with the rear end first,
schematic representation here for 1600 A | Figure 7/3: Contact shift
on auxiliary arbour for 2000 A to 3150 A
Figure 7/4: Sliding of the contact system from the auxiliary arbour onto the
contact arm and engaging it here
Figure 7/1 Figure 7/2
UniGear ZS3.2 air-insulated medium voltage switchgear | Product quality and environmental protection 39
Contact us
ABB Xiamen Switchgear Co., Ltd. We reserve the right to make changes in the course of
technical development.
G.
ABB Industrial Park, Torch High-Tech Zone, No. 319,
Xiamen, Fujian, P.R.China
Tel: +86 592 602 6033
Fax: +86 592 603 0505
Zip code: 361006
Service hotline: 800-820-9696 400-820-9696
www.abb.com.cn/mv