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INSTRUCTION MANUAL

UniGear ZS3.2
Air-insulated medium voltage switchgear

Air-insulated medium voltage switchgear


UniGear ZS3.2

• Safety
• Reliability
• Flexibility
• Economy

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Table of contents

005 1 Summary

006 – 007 2 Technical data

008 – 016 3 Switchgear panel structure


and equipment installed

017 – 018 4 Dispatch and storage

019 – 031 5 Assembly of the switchgear


at site

032 – 038 6 Operation of the switchgear

039 – 043 7 Maintenance

044 8 Product quality and


environmental protection

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4 UniGear ZS3.2 I N S T R U C T I O N M A N U A L


For your safety!

• Make sure that the installation room (spaces,


divisions and ambient) is suitable for the
electrical apparatus

• Check that all the installation, putting into service


and maintenance operations are carried out by
qualified personnel

• with suitable knowledge of the apparatus Make


sure that the standard and legal prescriptions
are complied with during installation, putting
into service and maintenance, so that installations
according to the rules of good working practice
and safety in the work place are constructed

• Strictly follow the information given in this


instruction manual

Dangerous

Pay special attention to the danger notes


indicated in the manual by the following symbol.
• Check that the rated performance of the
apparatus is not exceeded during service

• Check that the personnel operating the apparatus


have this instruction manual to hand as well as
the necessary information for correct intervention

• Responsible behavior safeguards your own


and others’ safety

For any requests, please contact the ABB Assistance Service.

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SUMMARY 5


1 Summary

1.1 General • Humidity


The metal-enclosed, three-pole air-insulated - Highest average value measured
switchgear panels without disconnectors of over 24 hours
UniGear ZS3.2 series are factory-assembled, Relative humidity 95%
type-tested indoor panels for a rated voltage - Highest average value measured
of 36/40.5 kV. They are designed as withdrawable over 1 month
module type panels, and fitted with a single Relative humidity 90%
busbar system. The withdrawable parts are
fitted with vacuum circuit-breakers. Remark:
With indoor installation, it is assumed that the
Details of the technical design and configuration humidity within the enclosure can reach high
of individual switchgears, such as the technical values, but that there is normally no condensation
data, detailed equipment lists for the individual on the installed equipment. Condensation can
panels and comprehensive circuit documentation, be prevented by appropriate configuration of
etc., can be found in the relevant order documents. the station building or switchgear room.

1.2 Standards and specifications The maximum site altitude is 1000 m above
UniGear ZS3.2 switchgear panels comply with sea level.
the standards and specifications for factory-
assembled and type tested high voltage 1.3.2 Special service conditions
switchgears to IEC publications 62271-200 According to IEC 62271-100, the manufacturer
and 62271-100. In addition, in accordance with and user may agree on special service conditions
IEC 60529, the switchgear panels have degrees which deviate from the normal service conditions.
of protection. The manufacturer must be consulted in advance
about each special service conditions.
IP 4X for the enclosure and
IP 2X for the partitions. Examples are as follows:
• At site altitudes above 1000 m, the effects
The corresponding IEC publications, the national of the reduction in dielectric strength of the
or local safety at work regulations and the safety air on the insulation level are to be taken
regulations for production materials are to be into account
followed during erection and operation of these • Increased ambient temperatures must be
systems. Above and beyond this, the order-related compensated for in the design of the busbars
data from ABB Xiamen Switchgear Co., Ltd. are and tee-off conductors, or the current carrying
to be taken into account. capacity will be limited. Heat dissipation in
the switchgear panel can be assisted by fitting
1.3 Service conditions additional ventilation facilities
1.3.1 Normal service conditions
The switchgears are fundamentally designed
for the normal 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

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6 UniGear ZS3.2 I N S T R U C T I O N M A N U A L


2 Technical data

2.1 Electrical data

Standard: IEC/Chinese GB Russian GOST


Rated voltage kV 36/40.5 Unorm.: 35 Umax.: 40.5
Rated power frequency withstand voltage/1 min kV 70/95
Rated lightning impulse withstand voltage kV 170/185 190
Rated frequency Hz 50
Rated current of busbars A 1250, 1600, 2000, 2500, 3150
Rated current of tee-offs, circuit-breaker A 1250, 1600, 2000, 2500, 3150 3)
Rated peak withstand current 1)
kA 63, 80
Rated short-circuit breaking kA 25, 31.5
Current of circuit-breaker
Rated short-time current 4 s 1) kA 25, 31.5
Auxiliary voltage V DC 2) 110, 220, AC 110, 220

1) Take the short-circuit withstand capability of the instrument transformers into account separately.
2) Special DC voltages on request.
3) Up to 3150 A at 40°C and 2500 A at 55°C with forced ventilation.

2.2 Resistance to internal arc faults 2.3 Dimensions and weights


The switchgear units have been tested in (Figure 2/1 and 2/2)
according with IEC 62271-200 (Annex A, class Dimension according to Figures 2/1 and 2/2
A, criteria 1 to 5), the switchgear units are Weight: 1200 kg to 3000 kg, according to the
classified as IAC AFLR 31.5 kA for 1 s. equipment installed.

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TECHNICAL DATA 7


2/1 Dimensions,
without ventilation,
front view

2/2 Dimension,
UniGear ZS3.2,
…1600 A, section
view
2400

47

1200 55


2/1

R(L1)

C A B
Y(L2)

B(L3)
2400
2350

Service
D Position Test A Circuit-breaker compartment
Position B Low-voltage compartment
C Busbar compartment
D Cable connection compartment

450
30 2500 35


2/2

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8 UniGear ZS3.2 I N S T R U C T I O N M A N U A L


3 Switchgear panel structure and
equipment installed

3.1 Basic structure and variants side walls as result of embossing processing used.
(Figures 3/1 to 3/6) Thanks to that, it is possible to remove the middle
The basic structure of the switchgear panels panel of the switchgear without removing the
comprises the panel itself, which is fixed in adjacent panels. The separately fitted low-voltage
position, and the movable, withdrawable part compartment B is designed as a self-supporting
with vacuum circuit-breaker. Figures 3/1 to 3/6 shockproof and flameproof sheet steel enclosure,
show the structure of a panel and the electrical separate from the high-voltage area. Even with
equipment fitted. The whole panel is constructed the withdrawable part 50 removed (hinged
by bolting up the double folded components shutters 35.1/ 35.2 in the closed position), there
manufactured from high quality Al-Zn sheet steel, is protection against contact with live parts in
precisely folded and exactly fitted surface from busbar compartment C and cable connection
and extremely rigid construction. Illustration compartment D.
shows the structure of a panel and the electrical
equipment fitted. Together with the basic panel The necessary safety measures to counteract the
version for use as an incoming or outgoing effects of an internal arc fault must be ensured
feeder panel, variants, for example for busbar in connection with the ceiling height. This may in
sectionalizing (in conjunction with a bus riser individual cases possibly necessitate additional
panel) or metering, are available. Further details operator protection measures on the switchgear
on the structure and equipment configuration panels.
of the switchgears can be taken from the order
documents for the particular case. The front and rear doors of the switchgear panels
and the cover plates of the end panels are
The panel consists of the following components thoroughly cleaned, treated to prevent corrosion,
• Circuit-breaker compartment and then painted with a high-quality twocoat
• Busbar compartment stoved enamel system in colour RAL7035 (or
• Cable connection compartment special colours as agreed) which are notable
• Low voltage compartment after stoving for their particular insensitivity to
impacts and corrosion.
The compartments are seperated from each other
by earthed sheet steel partitions. 3.3 Compartments in the switchgear panels
Circuit-breaker compartment
3.2 Enclosure and partitions (Figures 3/6, 3/9 to 3/13)
(Figures 3/1 to 3/6) The circuit-breaker compartment A fitted with
The enclosure and internal partitions of the the necessary guide rails accommodates the
switchgear panels consist of high quality withdrawable part 50, which can be moved
aluminium zink coated sheet steel. The three between the service position and the test/
high-voltage compart-ments are fitted with disconnected position.
secured pressure relief plates located at the
top. These open upward if internal arc faults If the withdrawable part is moved from the
result in overpressure. The front and rear of the service position into the test/disconnected
panels is closed off by flameproof doors which position, the fixed contacts 25.1 located in the
open to an angle of almost 180°. Neighbouring connection block 20.1/20.2 in busbar compartment
switchgear panels are partitioned from one C and cable connection compartment D are
another by the side walls of each panel and the automatically covered by metal plates which will
air cushion which remains between these walls be interlocked mechanically or can be locked by
as a result of the design when the panels are a padlock when the withdrawable part is moved
joined together. This method of construction away. In the test/ disconnected position, the
prevents them from melting through if an arc withdrawable part is still completely inside the
fault should occur. All heads of the structure panel with the door closed.
bolts do not stick up the fitting surface on the

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SWITCHGEAR PANEL STRUCTURE AND EQUIPMENT INSTALLED 9

The switching operations (including manual Installation of surge arrestors is possible. Multiple
operation) are carried out with the doors closed. parallel power cables can also be entered without
difficulty. The cable sealing ends 16 can be fitted
Withdrawable part in particularly favourable conditions. A removeable
(Figures 3/1, 3/2, 3/14, 3/15, 3/16, 3/17, 6/1 to 6/7) plate for cable glands is located in the cable
The manually moved withdrawable part consists entry area.
of a robust sheet steel structure on which the
circuit-breaker poles are mounted and the breaker Installation of voltage transformers at cable
mechanism with anciallary components are side of the panel is in preparation and will have
installed. influence on the depth of the panel.

Contact arms 57.1/57.2 with spring-loaded contact The earthing switch is designed with a making
systems are fitted to the circuit-breaker poles. capacity of 80 kA.
These create the electrical connection to the
switchgear panel when the withdrawable part The detailed information on the earthing switch
is inserted into the service position. Detail can be found in the corresponding instruction
information on the vacuum circuit-breaker can manual.
be found in the corresponding instruction manual.
Low-voltage compartment
The signalling, protection and control wiring (Figures 3/6)
between the switchgear panel and the The low-voltage compartment, together with
withdrawable part is coupled by a multiple pin its front door, accommodates the secondary
control wiring plug connector 10. equipment of the switchgear panel required for
the particular application.
As soon as withdrawable part 50 has been slid
into the switchgear panel and its interlock yoke The control wiring in the switchgear panel area
51 has engaged in the test/disconnected position, is led through generously dimensioned and metal
it is positively connected to the switchgear panel. covered ducts. The lefthand duct is reserved for
At the same time, it is earthed by earthing the incoming and outgoing control wires, and
contacts 50.1 and earthing rail 19/19.1. The the internal wiring in the panel is located on the
position of the withdrawable part can be checked righthand side.
on the electrical position indicator or through
the sight glass in the door at any time. The stored- At the top of the left hand duct, an entry for
energy spring mechanism of the circuit-breaker control cables is reserved with the free-cut rubber
including controls and indicators is accessible at sealing which will keep the protection class IP4X
the front of the withdrawable part. Apart from the for the whole encloser of the switchgear panel.
version with a fitted circuit-breaker, withdrawable
parts with other equipment, e.g. for metering, 3.4 Interlocks/protection against maloperation
are available. (Figures 3/6, 3/10 to 3/12, 6/1 to 6/8)
A series of interlocks are provided to prevent
Busbar compartment fundamentally hazardous situations and
(Figures 3/6, 5/7 to 5/17) maloperation, thus protecting both personnel
Busbars 3 are laid in sections from panel to panel, and the switchgear itself. The interlocks which
and are held in place by the tee-off conductors are normally individually effective are as follows:
3.1 and by busbar bushings 29. The conductor • The withdrawable part can only be moved from
material used is tubing with a D-shaped the test/disconnected position into the service
cross-section, in either single or double position (and back) with the circuit-breaker
configuration depending on the current rating, open and the earthing switch open (between
or rectangle copper bar. The connection to the positions, the circuit-breaker is mechanically
flat tee-off conductors is made without any interlocked, and also electrically interlocked in
special connecting clamps. The busbars and the case of circuit-breakers with electrical
tee-off conductors are covered with shrink-on releases)
sleeves. The bolt connections in the busbar • The circuit-breaker can only be closed when the
system are normally covered by insulating covers withdrawable part is precisely in the defined
58. In conjunction with bushings 29, panel by panel test position or service position. Between these
partitioning is realised. positions, the circuit-breaker is mechanically
interlocked, and also electrically interlocked in
Cable connection compartment the case of circuit-breakers with electrical
(Figures 3/6, 5/5, 5/6, 6/10 to 6/12) releases
Current transformers and an earthing switch (with
manual operating mechanisms) are located here.

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10 UniGear ZS3.2 I N S T R U C T I O N M A N U A L


3/1 VD4 • The circuit-breaker can only be opened manually VD4 vacuum circuit breakers are suitable for
— in the service or test position when no control autoreclosing, and have exceptionally high
3/2 HD4/Z
voltage is applied, and cannot be closed operating reliability and long life.
(electro-mechanical interlock)
• Low-voltage plug 10.2 can only be inserted or The vacuum circuit breakers designed in column
removed when the withdrawable part is in the form, are supplied as withdrawable modules.
test/disconnected position
• Earthing switch 6 can only be closed when the SF6 circuit breaker HD4
withdrawable part is in the test/disconnected HD4 medium voltage circuit-breakers use sulphur
position or the removed position (mechanical hexafluoride gas (SF6) to extinguish the electric
interlock) arc and as the insulating medium.
• The withdrawable part cannot be moved from
the test/disconnected position into the service SF6 has smooth breaking characteristics, therefore
position when the earthing switch is closed breaking in SF6 gas takes place without any arc
(mechanical interlock) chopping and without generation of overvoltages.
• Details of any additional interlocks, e.g. in
connection with a blocking magnet on the These characteristics ensure long electrical life
withdrawable part and/or earthing switch of the circuit breaker and limited dynamic,
operating mechanism, can be found in the dielectric and thermal stresses on the installation.
order documents for each individual case (see
also section 7.4) The circuit-breaker poles, which make up the
• The hinged shutters can be secured with padlocks breaking part, are systems with lifelong sealed
in the closed position when the withdrawable pressure and are maintenance-free.
part has been removed (Figure 3/9)
The ESH type mechanical operating mechanism
3.5 Main apparatuses of HD4, with stored energy has free release and
3.5.1 Circuit breaker allows opening and closing operations
Vacuum circuit breaker VD4 independently of the operator’s actions.
The vacuum circuit breaker of type VD4 on
withdrawable parts for 36/40.5 kV rated voltage The operating mechanism and the poles are
are intended for indoor installation in air-insulated fixed to the metal structure which also acts as a
switchgear systems. Their switching capacity is support for the kinetics for operating the moving
sufficient to handle any conditions arising from contacts.
switching of equipment and system components
under normal operating and fault conditions, Circuit-breakers in the withdrawable version are
particularly short-circuits,within the parameters fitted with a truck to allow racking in and racking
of their technical data. out of the switchboard or enclosure.

Vacuum circuit breakers have particular The light and compact structure of the circuit-
ad-switching frequency in the working current breaker ensures great sturdiness and excellent
range and/or where a certain number of short- mechanical reliability.
circuit breaking operations are expected. Type

— —
3/1 3/2

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SWITCHGEAR PANEL STRUCTURE AND EQUIPMENT INSTALLED 11


3/3 MWK 3.5.2 Instrument transformers 3.5.3 Surge arrester
— Current transformers Protection of medium voltage AC networks
3/4 EK6-4008-280
The current transformers are of the type insulated against both, multiple atmospheric and switching
in resin and are used to supply the measurement overvoltages as well as Very Fast Transients
devices and protection instruments. These (VFT). Suitable for instance for the protection
transformers have a wound core with one or of transformers, cables, motors and other
more cores, with performances and accuracy medium voltage equipment.
classes suitable for the installation requirements.
3.5.4 Eearthing switch
Voltage transformers Earthing switches of Series EK6 are determined
The voltage transformers are of the type insulated for indoor installation and fitted with snap-action
in resin and are used to supply measurement operating mechanisms for positive high-speed
and protection devices. They are available for closing and sufficiently dimensioned to conduct
fixed assembly or for installation on removable the rated short-circuit making current when
and withdrawable trucks. closed under load. The speed of the snap-action
closing operation is independent controls. The
When they are installed on removable or earthing swithes are supplied as kits with a
withdrawable trucks they are fitted with medium pre-assembled active part and corresponding
voltage protection fuses. The withdrawable earthing contacts supplied lose. Correct
trucks also allow replacement of the fuses with installation of these parts in a switchgear panel
the switchgear in service. Truck racking-out with results in a functioning earthing earth.
the door closed automatically operates closure
of a metallic segregation shutter between the
live parts of the switchgear and the instrument
compartment.

Advantages
Low residual voltage
• Long protection distance
• High energy input capacity
• Stable U-I characteristics even after
multiple strokes
• Proof against ageing
• Explosion and shatter-resistant design
• Pollution resistant and UV-stable
• Housing resistant to rough handling
• Maintenance free
• Stable against shock and vibration
• High mechanical resistance

— —
3/3 3/4

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12 UniGear ZS3.2 I N S T R U C T I O N M A N U A L


3/5 UniGear ZS3.2,
front view


3/5

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SWITCHGEAR PANEL STRUCTURE AND EQUIPMENT INSTALLED 13


28
3/6 UniGear ZS3.2
35.1
section view, basic
3
structure of an
incoming or R(L1)
outgoing feeder 3.1
panel, …1600 A
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
3/6

A Circuit-breaker compartment 16 Cable sealing ends


B Low-voltage compartment 17 Floor cover plate
C Busbar compartment 17.2 Reducer ring
D Cable compartment 19 Main earthing bar
1 Enclosure 20.1 Spout, above
1.1 Pressure relief plate 20.2 Spout, below
1.2 Control wiring duct 21 Cable clamp
3 Busbar 23 Cable connection point
3.1 Tee-off conductor, busbar side 28 Bushing plate
3.2 Tee-off conductor, cable side 29 Busbar bushing
5 Insulated separating plate 30 Front door for circuit-breaker compartment
6 Earthing switch 30.1 Rear panel cover, above
9.1 Current transformer 30.2 Rear panel cover, below
10 Control wiring plug connector 35.1 Hinged shutter system, above
10.1 Control wiring socket 35.2 Hinged shutter system, below
10.2 Control wiring plug 50 Withdrawable part (with circuit-breaker, type VD4 or HD4)
10.3 Interlocking arm for wiring plug 50.2 Front partition plate
14 Earthing switch operation mechanism 51 Interlock yoke
14.1 Hexagonal shaft 52 Spindle

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14 UniGear ZS3.2 I N S T R U C T I O N M A N U A L


3/8 Panel of type
UniGear ZS3.2, rear
side

3/9 Circuit-breaker 30.1
compartment, door 35.3
open, withdrawable
part removed 35.1

3/10 Circuit-breaker
compartment, door 35.2
open, withdrawable
part in isolated/ 43.1
disconnected
position

44
30.2

19.1

— —
3/8 3/9
30.1 Rear cover, above 19.1 Earthing rail
30.2 Rear cover, below 35.1 Hinged shutter system, above
35.2 Hinged shutter system, below
35.3 Fishplate for inserting a padlock
43.1 Duct cover for control cables
44 Heater

50
50.2

14
14.1
14.2

51

10

Control wiring plug connection engaged.


10 Control wiring plug connector
14 Earthing switch, operation mechanism
14.1 Hexagonal shaft
14.2 Slide
50 Withdrawable part (with circuit-breaker, type VD4 or HD4)
50.2 Front partition plate
51 Interlock yoke


3/10

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SWITCHGEAR PANEL STRUCTURE AND EQUIPMENT INSTALLED 15


3/11 Circuit-breaker
compartment, door
open, withdrawable
part in service
position

3/12 Circuit-breaker
compartment
withdrawable part
in service position

3/13 View into
circuit-breaker 10.1
compartment
withdrawablepart
removed, hinged
shutters opened
— 10.2
3/14 Withdrawable
part with circuit
breaker, HD4
operation side

10.3

— —
3/11 3/12
Control wiring plug connection engaged.Interlocking arm not in
blocking position.
10.1 Control wiring socket
10.2 Control wiring plug
10.3 Interlocking, for control wiring plug, disengaged

20.1

25.1

20.2


3/13

20.1 Spout, above


20.2 Spout, below
25.1 Contact pin, ...1600 A


3/14

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16 UniGear ZS3.2 I N S T R U C T I O N M A N U A L


3/15 Withdrawable 50.2
part with circuit-
breaker, VD4,
operating
mechanism side
57.1
control wiring plug
pluged at front
partition of the 57.8
circuit-breaker
— 57.2
3/16 Withdrawable
part with circuit-
breaker, VD4,
operating side

3/17 Withdrawable
part with metering
unit, left and
operator‘s side view

50.1
50.8
— —
3/15 3/16

50.1 Earthing contact


50.2 Front partition plate
50.8 Wheel
57.1 Upper contact arm
57.2 Lower contact arm
57.3 Contact system
57.8 Embedded pole

50.2

9.2

50

50.3
50.4
9.2 Voltage transformer
50 Frame of the withdrawable part
50.2 Front partition plate
50.3 Pin (for opening the shutter)
50.4 Guide cam

3/17

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DISPATCH AND STORAGE 17


4 Dispatch and storage

4.1 Condition on delivery Transport switchgear panels upright.


The factory assembled switchgear panels are Only ever carry out loading operations
checked at the works for completeness in terms when it has been ensured that all
of the order and simultaneously subjected to precautionary measures to protect
routine testing (normally without AC voltage personnel and materials have been taken
testing of the busbars) to IEC publication and using a
62271-200, and thus tested for correct structure • Crane
and function. • Fork-lift truck and/or
• manual trolley jack
The busbars are not assembled at factory. The
circuit-breaker or metering truck, busbar material, The circuit-breaker or metering truck should be
fasteners and accessories are packed separately. transported separately ,the transportation of
panel not be allowed with circuit-breaker or
4.2 Packaging metering truck.
The switchgear panels are despatched in
appropriate packaging for the prevailing Loading by crane
conditions, e.g. “seaworthy packaging”, or also • Fit lifting ropes of appropriate load capacity
without packaging, as required in individual with shackles (opening width ≥30 mm, fastening
cases. Particularly for over-seas transport, even bore diameter 30 mm)
in containers, they are sealed in airtight plastic • Maintain an angle of ≥60° from the horizonta
sheeting with an appropriate quantity of drying for the ropes leading to the crane hook. The
agent to protect them from damage due to use of a crane cross beam is urgently
moisture, and in many cases fitted with a recommended
separate moisture indicator. When aluminium
composite sheeting is used, a window has to Transport circuit-breaker unit or metering truck
be fitted for observation of the moisture with appropriate care: Please refer to instruction
indicator. The drying agent is active as long as Manual BA 483/2E, section 4, transport.
the coloured indicator remains blue. When the • Only handle modules by crane with transport
colour changes to pink, the relative humidity crossbeam and a suitable harness with lifting
stated on the bag (e.g. 40%) has been exceeded ro-pes
inside the packaging (possibly as a result of • Lifting tackles must never catch on the breaker
damage). Suitable action including replacement poles or the part of the operating mechanism!
of the drying agent bags is then necessary if It is to be ensured that the breaker do not
the packaging condition is to be maintained. suffer impacts or other injurious physical
The instructions for use of the drying agent bags stresses during handling
to DIN 55 473 are to be followed carefully. • Only handle the modules by crane with bolted
on transport brackets (see BA 483/02E),
4.3 Transport suitable lifting ropes and crane har ness
(Figure 3/17,5/4,6/1 to 6/1) • Take care not to allow the modules to tip, as
The transport units are individual panels. The the centre of gravity is high
switchgear panels are each fitted with four • When transporting modules by forklift, they
lifting lugs. must be fastened to pallets and secured to
the lift truck column
• When moving the withdrawable part only use
the sliding handles 51.2 (e.g. for racking in/out
the withdrawable part into/out of the switchgear
panel or for the transport of the truck in the
switchgear room). Do not bring any force on
the front partition plate 50.2 of the truck

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18 UniGear ZS3.2 I N S T R U C T I O N M A N U A L

• Take care that the catch pins 51.1 on the inter- • Room temperature which does not fall below
lock yoke 51 are engaged with the guiding -15°C
rails 51.3 in the switchgear when moving-in • No other detrimental environmental influences
with-draw able part into the panel • Store switchgear panels standing upright
• Do not stack switchgear panels
4.4 Delivery and intermediate storage • Do not remove or damage the packaging
The responsibilities of the consignee when • Loosely cover unpackaged switchgear panels
the switchgear arrives at site include, but are with plastic film to prevent dirt ingress.
not limited to, the following: Sufficient air circulation must be maintained
• Checking the consignment for completeness to prevent corrosion
and freedom from damage (e.g. also for • Carry out regular checks for any condensation
moistu-re and its detrimental effects). In cases until erectionstarts
of doubt, the packaging must be opened and
then pro-perly resealed, fitting new drying Switchgear panels with seaworthy or similar
agent bags, when in termediate storage is pak-kaging and internal protective film
necessary • Store the transport units in a dry place,
• Precisely documenting any short quantities, protected from the weather and from damage
de-fects or transport damage on the • Check the packaging for undamaged condition
consignment note and notifying the shipper • Check the indicator for correct function of
or carrier imme-diately and reporting these the drying agent on arrival of the consignment
to the relevant authorities within two weeks and at appropriate intervals, see also the
• Always take photographs to document any details in section 4.2
mayor damage • When the maximum storage life after the date
of packaging is exceeded, the protective
Optimum intermediate storage – as far as this function of the packaging including its anti-
would be necessary at all – without detrimental corrosion effects will cease to be effective
consequences depends on compliance with a sooner or later, depending on local conditions.
number of minimum conditions for the If intermediate storage has to be prolonged,
switchgear panels and assembly materials. suitable action must be taken

Switchgear panels with simple packaging or Note:


no packaging Do not walk on the roof of the panels (rupture
• A dry and well-ventilated storeroom, points in pressure relief devices)!
atmosphere in accordance with IEC 62271-200

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ASSEMBLY OF THE SWITCHGEAR AT SITE 19


5 Assembly of the switchgear at site

In the interests of an optimum installation Installation of the foundation frame


sequence and the assurance of a high quality • If the foundation frame consists of several
standard, site installation of the switchgear part, bolt these together at the prepared
should only be carried out by specially trained joint locations using links in the specified
skilled personnel, or at least supervised and sequence and so as to achieve a level surface
monitored by responsible persons. • Place the foundation frame precisely in the
specified position on the concrete floor in
5.1 General site requirements accordance with the installation drawing
On commencement of installation at site, the • Enter jacking screws and place steel strips
below them
switch room must be completely finished,
• Carefully align the foundation frame along
provided with lighting and site electricity supply,
the entire surface and to the correct height
lockable, dry and with facilities for ventilation.
by screwing the jacking screws down by an
All the necessary preparations such as wall
appro-priate amount and using a levelling
openings, ducts, etc., for laying of the power
instrument
and control cables up to the switchgear must
already be completed. The top edge of the foundation frame should
be 5-12 mm above the finished floor surface.
Compliance with the conditions for indoor This facilitates erection and alignment of the
switch-gear to IEC 62271-200, including the switchgear panels.
conditions for the “minus 15 indoor” temperature
class must be ensured. e.g. evenness tolerance:
±1 mm within a measuring length of 1 m.
5.2 Foundation frame on a concrete floor
(Figures 5/1 to 5/2) e.g. straightness tolerance:
The switchgear is preferably to be erected on maximum 1 mm per m, but not more than 2
a foundation frame set into the switch room mm over the entire length of the frame.
floor.
• Slide brackets against the frame at two points
The guideline structural data listed below for each 3 m of frame length, secure them to
facilitate a rough calculation of the space the concrete floor with plugs and bolts, and
required and preliminary planning of the room weld them to the frame. The set position of
design for a switchgear project. When the final the frame on the concrete floor must not be
altered during this operation
construction documents are compiled, the
• Weld the foundation frame parts together.
binding data supplied by ABB Xiamen Switchgear
Grind projecting parts and weld seams on the
Co., Ltd. must always be taken into account!
top of the frame flat
• Make the necessary preparations for perfect
The stipulations of DIN 43 661 are also to be
earthing of the foundation frame with 30x4
complied with when the foundation is laid.
mm galvanized steel strip. Two connections
This particularly applies to the evenness and are necessary for long switchgears
straightness tolerances as a precondition for • When the floor topping is applied, carefully
perfect installation of the switchgear. back fill the foundation frame, leaving no gaps
• The foundation frame must not be subjected
The foundation frame, consisting of one or more to any injurious impacts or pressures,
parts depending on the size of the switchgear, particularly during the installation phase
can be supplied with the switchgear by ABB
Xiamen Switchgear Co., Ltd.; it is usually laid If these conditions are not fulfilled, problems
by site personnel and should if possible be during assembly of the switchgear and possibly
aligned and inspected under the supervision with movement of the withdrawable parts and
of a ABB specialist. opening and closing of the doors cannot be
ruled out.

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20 UniGear ZS3.2 I N S T R U C T I O N M A N U A L


Structural data
Table for figure 5/1 and 5/2:

Rated voltage kV 36/40.5


Panel type UniGear ZS3.2
Panel equipment Withdrawable
Panel width mm 1200
Aisle width (front side of panel) 1) mm 2000
Aisle width (rear side of panel) 1) mm 1500
Assembly openings
in ceilings
Width mm 1400
Length mm 2800
in doors
Width mm 1400
Height 2) mm 2600
Panel weight kg 1200 to 3000
Ceiling load kg/m2 1000

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
Use DIN screws of tensile class 8.8. The tightening prepared installation point in the sequence
torques for the busbar screw connections with shown on the switchgear plan
dished washers are as follows: • Dismantle lifting lugs 1.5
• Remove withdrawable parts 50 from the
Recommended tightening torque 1) 2) (Nm)
switchgear panels and store them with suitable
Lubricant 3) protection
Thread Without Oil or grease • Release and remove floor cover 17
M5 2.5 • Remove cover 43.1 from the vertical control
M6 10 wiring ducts at the front right and left of
Copper to copper M8 25 the panel
and copper to M 10 50 • Align the switchgear panels on the foundation
spout M 12 86 one after another for correct position and
M 16 170 vertical alignment (deviations of the panel
M 20 200 edges from the vertical must not exceed 2
M8 15 mm, particularly at the front) and bolt the
Copper or sheet to M 10 50 panels together. It is advisable to start from
epoxy materials M 12 70 the centre when assembling switchgears
M 16 110 90 with more than ten panels
M 20 120 • Install and screw bushing plates 28 externally
M 10 20 to the right or left hand panel wall
Copper or power
• When the switchgear has been properly
cable to voltage
assembled, fasten the panels to the foundation
transfomer
frame by welding or by using adequate bolts
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.

Consult the detailed technical documentation


for any tightening torques which deviate from
the general table (e.g. for contact systems or
switch terminals).

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ASSEMBLY OF THE SWITCHGEAR AT SITE 21

5.4 Installation of the busbars and bushings • Prepare and secure cable sealing ends 16 in
(Figures 3/6, 5/7 to 5/17) accordance with the manufacturer’s
• Install bushings 29 instructions
• Connect the cable cores to the prepared
Note: connection points 23 with strain relief
• (Upper) busbar system: • Fit the insulating separating plates to each
Insert bushing 29 (phase B/L3) for the lower phase
busbar into bushing plate 28 from the right • Connect the cable earth
in contrast to the procedure for the other • Cut the required holes in floor cover 17 – if
two bushings not already prepared–insert the cover and
• (Lower) tie bus system for bus section: fasten it
Insert bushing 29 (phase B/L3) for the rear, • Slide reducer ring 17.2 into the floor plates 17
lower tie bus into bushing plate 28.1 from so as to seal the cable entry
the right in contrast to the procedure for the • Insert the control cables into the left-hand
other two bush-ings side control wiring ducts 1.2
• Always check that there is proper contact be • Strip and fasten the control cables on the
tween the metal tube in the bushing and the cable clamps at the side wall in the cable
busbar via the contact spring 29.3. Ensure duct and in sert the cores via reducer ring
that the contact spring is in the correct into the low-voltage compartment B
position • Connect the control cables to the terminal
• Clean the insulation on the busbar sections strip as shown in the circuit diagram
with a dry, soft cloth, and check for insulation • Make the control wiring connections to the
damage adja-cent panel using bushing 1.11
• Busbar connections:
- The silver plated surfaces of the connections 5.6 Earthing the switchgear
must be cleaned with a metal-free non-woven (Figures 3/6 and 5/4)
cleaning cloth and thinly and evenly coated • Connect the main earthing bar 19 of the
with lsoflex Topas NB 52 grease switchgear with the prepared connection
- The non-silver plated surfaces of the links 1.3 panel by panel
connections are either brushed with a wire • Make the protection conductor connection
brush, preserving the grease film, or cleaned to the foundation frame
with a metal-free non-woven cleaning cloth • Connect the earthing conductor coming from
and evenly greased with a thin coat of lsoflex the ground electrode – preferably via a metering
Topas NB 52 point–to the main earthing bar 19 of the
• Remove greasy or adhesive dirt as described switchgear
in section 7.2
• Clean and grease the contact surfaces after 5.7 Concluding installation work
any dismantling of busbars • Check the paintwork of the switchgear for
• Prepare insulating covers 58 and lids 58.5 to any damage, and touch up where necessary
suit the relevant busbar connections and (see also section 7.3.1)
thread them onto the busbar • Check bolted connections, especially all those
• Install the busbars panel by panel. Screw on made during on-site assembly in the busbar
the individual busbar elements one above and earthing system, and tighten where
the other (depending on the system layout) necessary
and in line with the flat tee-off conductor. • Carefully clean the switchgear
Use the socket head bolt 163 as provided. • Remove all foreign bodies from the switchgear
For tightening torque see the table above. panels
Use two dished washers for each screw • Properly refit all covers etc. removed during
• Bolt one holder 58.1 to each end of the in stallation and connection
busbars to support the insulating cover 58. • Close off any openings remaining in the
The screws for holder 58.1 are to be tightened enclosure as a result of the particular design,
with a lower torque but which are no longer required
• Position insulating covers 58 and lids 58.5 • Insert the withdrawable parts into the
over the relevant bolted joint, and slide the switchgear panels
lid onto the cover until it clicks into place • Check the isolating contacts and interlock
mecha nisms for smooth function, and
5.5 Connection of the power and control cables relubricate with Isoflex Topas NB52 (section
(Figures 3/6, 5/5 and 5/6) 7.6.2) where necessary
• Insert, cut to length and strip the power cable
• Release floor cover and open the control cable
duct on the left hand side

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22 UniGear ZS3.2 I N S T R U C T I O N M A N U A L


5/1 Guideline
structural data for
foundation frame
on concrete floor
(for information
only)
1500

940 940

(280)(280) (280)(280)

30

430 220 200


Only for transformer

260
panel
C1 C1
2565

(360) (360)
50

50

50

1685
(130)
50 300 105 480
1000

C1
1340 C2 C2
665

M12(4X)

30
33 60 33 60 33 60
35

300 1000 300 600 300 600


E
(1600) 1600 1200 1200 (1600)
2000


5/1

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

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ASSEMBLY OF THE SWITCHGEAR AT SITE 23


5/2 Section view
for figure 5/1
Ceiling

1500 >4000 2565 2000

Circuit breaker
7

2400
(820) 1000 35

(130) (130)

(78)
1
2

50
200
9
3 14
10 5 8
300 2085

12
11
1732 650


5/2

1) Minimum dimensions
1 Operator aisle
2 Inspection aisle
3 Opening for control cables (instead of individual openings,
continuous openings or drilled holes are possible)
5 Openings for power cables
7 Panel type UniGear ZS3.2 ...31.5 kA
8 Power cables
9 Projecting of floor frame: 5-12 mm above finished floor level
10 Conductor to main earthing bar
11 Screen 50 mm to 60 mm
12 Hight of the cable cellar, to be determined by the client
14 Guiding ramp, optional (recommended for circuit-breaker insertion)

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24 UniGear ZS3.2 I N S T R U C T I O N M A N U A L


5/4 For bolting the 1.5
UniGear ZS3.2
panels together,
threaded brushings
are provided at the
1.11
right side near to 28
the front and rear
edges of the side
walls. Adequate
bors are located at (1.9)
the left hand side
of the panel

5/5 View into cable
1.10
connection
compartment max.
4 parallel cables
possible

5/6 Partial view 1.3
into the cable
connection
compartment
prepared for
connection of two
parallel cables — —
— 5/4 5/5
5/7 View into the
busbar compartment 1.3 Aperture for main earthing bar
1.5 Lifting lug
(1.9) Threaded bushing, for switchgear assembly
1.10 Bores (bushings), for switchgear assembly
1.11 Cut-out for control wiring bushing
28 Bushing plate

3.11

3.1

20.1

— —
5/6 5/7

3.1 Tee-off conductor, busbar side


3.11 Busbar section
20.1 Spout, above

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ASSEMBLY OF THE SWITCHGEAR AT SITE 25


5/8 Bushings with
busbar mountings
for busbar system
with double
D-profile, tee-off
...1600 A

5/9 Bushings with
busbar mountings
for busbar system
with double
D-profile, tee-off
...2000 A to 3150 A


5/8

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

5/9

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26 UniGear ZS3.2 I N S T R U C T I O N M A N U A L


5/10 Single
rectangular copper
busbar with single
branch bar system
(...1600 A)

8.3 8.4, 8.5, 8.6 8.7

8.3

8.7

5/10

8.3 Contact spring (for rectangle busbar)


8.4 Socket head bolt M6x16
8.5 Dished washer DIN 6796
8.6 Nut M6
8.7 Busbar mounting for single conductor

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ASSEMBLY OF THE SWITCHGEAR AT SITE 27


5/13 Contact spring
installation

29.3 3

29.3 3

a) Check the contact spring 29.3 surface without any crease and b) Pull open the contact spring 29.3, insert it into the hole of busbar 3.
deformation before installation. 3 Busbar
3 Busbar 29.3 Contact spring
29.3 Contact spring

29.3 3 29.3 3

29.3 3

5/13

c) Turn the contact spring 29.3 out from hole of busbar 3. d) Press the contact spring 29.3, turn it down and make sure that the
3 Busbar bottom plane is parallel to the busbar 3.
29.3 Contact spring 3 Busbar
29.3 Contact spring

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28 UniGear ZS3.2 I N S T R U C T I O N M A N U A L

29.3 3

e) Spring resilience checking: press the contact spring 29.3 down for
around 10 mm, the contact spring 29.3 should be rebounded freely
after loosen. Please repeat above process for 3 times.
3 Busbar
29.3 Contact spring

29.3 29.4 29 3

f) Finally using multimeter to check the contact resistance between


busbar 3 and metal tube 29.4 of busbar bushing 29. The contact
resistance must be less than 5 ohm. Please recheck the installation
correctness from step a) to step e) if thecontact resistance greater
than 5 ohm until it meet the test requirement.
3 Busbar
29 Busbar bushing
29.3 Contact spring
29.4 Metal tube

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ASSEMBLY OF THE SWITCHGEAR AT SITE 29


5/14 Busbar barriers

29.2 29.4 29.3 3.12

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

The shrink-on sleeves must be


cut-out above the bores in the
busbars. The bores are required
for the inset of the contact spring 29.3.

5/14

b) Installation position of the phase barriers, viewed from top.


28 Bushing plates
29 Busbar bushing

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.

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30 UniGear ZS3.2 I N S T R U C T I O N M A N U A L


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

5/16 Arrangement of
the busbar and
tee-off conductor at
the busbar end

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.


5/15

During assembly, cut out the insulation cover and lid to fit
cross-section of the feeder 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.

5/16

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ASSEMBLY OF THE SWITCHGEAR AT SITE 31


5/17 Insulating covers
for busbars

5/18 Guiding ramp Cut place for abzweig-
for circuit-breaker schienen-system 2x100x10
insertion, optional.
The rail on the
guiding ramp must
be in line with the
guiding rail in the
UniGear ZS3.2 panel.

Cut place for sammel-


schienen-system D 100

58.5 Lid for cover



5/17


5/18

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32 UniGear ZS3.2 I N S T R U C T I O N M A N U A L


6 Operation of the switchgear

Note on safety at work • Set the protective devices in the switchgear


The relevant work and operating procedures are to the required values and check their function
to be carried out carefully by trained specialists with test equipment
familiar with the installation, taking into account • Instruct the local operators in the fundamental
all the relevant safety regulations to DIN VDE/IEC details of regular handling of the switchgear
and the other relevant professional bodies, • Check the readiness for operation and switching
and other local and works regulations and status of electrical systems upstream and
instructions. down stream from the switchgear
• Display the instruction manual in a position
Note: accessible to the operator at any time
Do not walk on the top surfaces of the
switchgear panels (rupture points for Depending on the allocation of responsibilities,
pressure relief). it may also be necessary to check the following
equipment in areas adjacent to the switchgear.
6.1 Commissioning • Power cables
6.1.1 Preparatory work • Auxiliary cables
(Figures 3/2, 3/15, 6/1 to 6/7) • Auxiliary power source and its polarity
In preparation for commissioning, the following • Remote control system
work should be carried out prior to connection • Complete earthing system
with the high-voltage power supply. • Switch room equipment
• Check the general condition of the switchgear • Switch room condition
for detrimental circumstances of all kinds
• Perform a visual examination of the switching 6.1.2 Start-up
devices, withdrawable parts, isolating contacts, • Comply with all relevant safety regulations
insulating parts, etc • Ensure that the circuit-breakers in the system
• Check the connection of the main earthing are in the OFF position
bar to the station earthing conductor • Remove any existing earthing and
• Check the paintwork for damage and touch short-circuiting connections in the critical
up as described in section 7.3 where necessary switching area
• Remove all material residues, foreign bodies • Energize the feeder cables
and tools from the switchgear • Connect the switchgear step by step, observing
• Clean the switchgear, rubbing down insulating the signals and indicators
parts with a clean, soft, non-fraying and dry • Check that the relevant conductors are in
cloth. Remove greasy or adhesive dirt as phase, as far as necessary when several
described in section 7.2 incoming feeder cables and switchgear
• Properly refit all covers etc. removed during sections are concerned (see also section 6.3.2)
as sembly and testing processes • Carry out all measurements and check all
• Perform on site power frequency voltage functions dependent on the high-voltage
testing of the main circuits to IEC 62271-200 power supply being connected
as far as necessary. Pay special attention during • Watch out for irregularities of any kind
this procedure to voltage trans formers and
cables, etc 6.2 Switching operations
• Switch on the auxiliary and control voltage Carry out switching operations with the
• Carry out test operations of switching devices panel doors closed.
manually or by electrical control, and
simultaneously observe the relevant position
indicators
• Check mechanical and electrical interlocks
for effectiveness, without using force

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OPERATION OF THE SWITCHGEAR 33

6.2.1 Withdrawable circuit-breaker part 6.2.2 Circuit breaker


(Figures 3/2, 6/1 to 6/7) (Figures 6/1 to 6/5)
Manual insertion from the test/disconnected For operation refer to Manual BA 483/02E,
position to the service position: VD4, vacuum circuit breaker on withdrawable
• Connect control wiring plug 10.2 part or 1YHA000046-en, HD4 SF6 circuit breaker.
• Close the front door
• Ensure that the circuit-breaker is in the OFF 6.2.3 Earthing switch
position (Figures 3/2, 6/7 to 6/12)
• Fit hand crank 146 on square spigot 52.1 of For operation refer also to instruction manual
the spindle mechanism 52 1YHA000063-en, EK6 earthing switch.
• Turn the crank clockwise through approx. 45
turns until the stop is reached and the The earthing switch type EK6 has a snap-action
withdrawable part is in the service position closing mechanism which is independent of
• Observe the position indicator the rotation of the drive shaft. The earthing
• Remove hand crank 146 switch type EK6 is only enabled for switching
when the withdrawable part 50 is in the test/
Note: disconnected position or removed from the
The withdrawable part must not be stopped switchgear panel. Only switch earthing
at any position in the travel range between the switches on when the doors are closed. Only
service position and test/disconnected open the rear doors of the panel when the
position! earthing switch is closed.

Manual withdrawal from the service position Opening and closing


into the test/disconnected position • Press slide 14.2 on the operating lever recess
• Ensure that the circuit-breaker is in the OFF socket down (When the switch is closed, it is
position already in this position!)
• Reverse the procedure described above for • Fit operating lever 122 to hexagonal shaft
in sertion into the service position 14.1, which is now released for operation

Note: Note:
Do not use force to move withdrawable parts Fit operating lever 122 to the hexagon shaft
with blocking magnet Y0 in the event of a poin-ting either upwards or downwards for
voltage drop. If this occurs they are blocked each swit-ching operation in such a way that it
along the whole travel range between the is not obstructed at the sides, even in limited
service position and test position. To remove space.
the interlock, consult section 7.4.2.
• Turn the lever clockwise through approx.
Withdrawal from the test/disconnection 180° until the stop is reached to close the
position into the removed position earthing switch, or anti-clockwise until the
• Open the door of the circuit-breaker stop is reached to open the earthing switch
compartment • Observe the mechanical/electrical switch
• Release control wiring plug 10.2 and engage position indicator
it in the storage position on the withdrawable • Remove operating lever 122. Slide 14.2 remains
part open if the earthing switch is in the closed
• Deblock the interlock yoke by moving the sliding position
handle 51.2 inwards against the springs to
release the withdrawable part 50 Make sure that the operating lever is turned
• Move the withdrawable part out of the panel right up to the stop in the opening process, to
• Close the panel door ensure that the earthing switch is in its defined
limit position.
Insertion from the removed position into the
test/ disconnected position The operating mechanism can also be fitted
• Carry out the procedure as described above with a blocking magnet.
for withdrawal, changing the order accordingly
• When the switchgear is in operation, observe 6.3 Test procedures
all the operating data and condition indications 6.3.1 Testing the off-circuit condition
in the secondary area and watch for any The panels can be fitted with a capacitive voltage
irregulatities indication system including the corresponding
(hand-held) plug-in indicator for testing of the
off-circuit condition.

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34 UniGear ZS3.2 I N S T R U C T I O N M A N U A L

A distinction must be made between the low on all coupling components, e.g. with interface
impedance system and the high impedance tester KSP
system. For further details, see draft standard • The interface test is a repeat test as specified
IEC 61243 Part 5. in IEC 61243 Part 5

The two systems differ in several respects, Always follow the details given in the instructions
including different voltage levels which constitute for the particular indicator for your switchgear
the display thresholds. The capacitive voltage system.
dividers installed in the panels are correspondingly
of different ratings, and the measuring point 6.3.2 Testing of in-phase condition
sockets and indicator units are of different Testing of the in-phase condition, e.g. when
types. there is more than one incoming feeder, can be
carried out with a suitable phase comparator
Note: coupled to the measuring point sockets of the
The only permissible indicators are those capacitive voltage indication system (if fitted).
which satisfy the requirements of the IEC
standards and correspond to the technical Test procedure
design of the indication system in the • Only use phase comparators which
relevant switchgear! comply with the DIN VDE standards
and are of suitable design for the
Note: switchgear system
The measuring point sockets must on no account • Check the function of the unit immediately
be short-circuited, except for voltage tests on prior to use
the installation (e.g. at power frequency voltage • Ensure that the maximum permissible length
and/or impulse voltage). of the measuring cables for each phase is
not exceeded
Testing for the off-circuit condition is effected • Connect the measuring cables to precisely
using a plugin indicator at the corresponding the corresponding main conductor sections
socket pairs located among the controls on • Follow the directions for the phase comparator
the panels. in detail

Use of the indicator: After commissioning of the system, check all


• Carry out a functional test on the unit posi-tion indicators and displays for irregularities.
immediately before use, e.g. with interface
tester KSP. The display must be clearly Note:
perceptible For voltage testing at power frequency and/or
• The presence of operating voltage is displayed impulse voltage:
by a signal • Only short-circuit the sockets for the
capacitive voltage indicator on the relevant
Always follow the details given in the instructions panel for the duration of the test
for the particular indicator for your switchgear
system. Caution:
Operate truck slowly, be careful overturning
Interface testing: Caused by inertia of fast movement!
• Perform an interface test as a functional test

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OPERATION OF THE SWITCHGEAR 35


51.1 51.2 51 52 54.1
6/1 Withdrawable
part with
circuit-breaker,
VD4, operating
mechanism side

6/2 Charging the
55.8
spring energy
storage mechanism
manually by moving
55.6
the inserted lever
up and down 128

6/3 Fitting the hand
cranck (against
spring-loaded
intermediate plate)
to move the truck
inside the panel
clockwise towards
the service position,
and anti-clockwise
from the service
50.4 50.7 55.7 55.4 55.5 50.6
position towards — —
the test/disconnected 6/1 6/2
position.

6/4 Manual 50.4 Guide cam 52 Spindle 55.6 Socket for charging lever
operation of the 50.6 Front cover plate, right hand side 54.1 Link rod 55.8 Charging condition indicator
circuit-breaker, by 50.7 Front coverplate, left hand side 55.4 Switch position indicator 128 Charging lever
turning the double 51 nterlock yoke 55.5 Operating cycle counter
bit key approx. 15° 51.1 Catch pin spring loaded 55.6 Socket for charging lever
clockwise (ON), or 51.2 Sliding handle 55.7 Rating plate
approx. 15°
anti-clockwise (OFF)

146 52.1 52 54 145

— —
6/3 6/4

52 Spindle 54 ON-OFF operating shaft


52.1 Square spigot 145 Three bit key (ON-OFF operation)
146 Hand cranck

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36 UniGear ZS3.2 I N S T R U C T I O N M A N U A L


6/5 Interlock yoke
with sliding handles 51.3 10.4 10.5
which will be moved
inwards to release 54
the circuit-breaker
part for withdraw 51
from the panel.

6/6 Withdrawable 51 10
part in service 10.1
position, interlock 10.2
yoke engaged,
control wiring
pluged-in and 51.2
engaged.
51.4

6/7 Operating 51.1
accessories


6/6


6/5

51 Interlock yoke 10 Control wiring plug connector, closed


51.1 Catch pin, spring loaded 10.1 Control wiring socket
51.2 Sliding handle 10.2 Control wiring plug
51.4 Blocking shaft (interlocking circuit-breaker and earthing switch) 10.4 S8 /Limit switch for test position indicator
10.5 S9 /Limit switch for service position indicator
51 Interlock yoke
51.3 Guide rail (panel)
54 ON-OFF operating shaft

128 145 146 122



6/7

122 Operating lever (for earthing switch)


128 Charging lever (for circuit-breaker)
145 Three bit key (ON-OFF) operation
146 Hand 128 145 146 122 cranck (for moving the withdrawable part)

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OPERATION OF THE SWITCHGEAR 37


6/8 Earthing switch
operation mechanism.
14.3
Duct cover 43.1
removed (seen
from inside panel)

6/9 Earthing switch
operation mechanism
(panel front side)

6/10 Active part of
the earthing switch, 14.1
EK6 mounted in the 14.4
cable connection
compartment 14.2
shown in open
position 14.5

— —
6/8 6/9

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

14.1

6.10


6/10
5 Insulated separating plate
6.1 Bearing bracket
6.3 Short circuit bridge
6.4 Pair of earthing blades
6.6 Bevel gear mechanism (not belonging to the earthing switch)
6.7 Operating shaft
6.10 Fixed earthing contact
14.1 Hexagonal shaft

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38 UniGear ZS3.2 I N S T R U C T I O N M A N U A L


6/11 Earthing 6.1
switch, EK6
mounted in the 6.5
cable connection
58 6.7
compartment 6.6
shown in closed 6.10
position
— 6.4
6.8
6/12 Bevel gear
14.1 14.1
mechanism and
earthing switch, 6.2
EK6 in open 6.5
position

— —
6/11 6/12

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MAINTENANCE 39


7 Maintenance

7.1 General If necessary, further details can be taken from


Maintenance serves to preserve trouble-free the technical documentation for the switchgear
operation and achieve the longest possible instal-lation (including, for example, any agreed
working life of the switchgear. In accordance special service conditions).
with DIN 31 051, it comprises the following
closely related activities. 7.2 Inspection and servicing
Inspection
Inspection: Determination of the actual condition Inspection of the switchgear should be carried
Servicing: Measures to preserve the specified out approximately every two to four years,
condition depending on the service conditions and local
Repair: Measures to restore the specified condition environment, in accordance with VBG4 standard.

Note: Isolate the area where work is to be performed


When carrying out all maintenance work, the in accordance with the relevant safety regulations
regulations in the country of installation must to DIN VDE/IEC, and secure it against
be strictly complied with. reconnection.

Maintenance work may only be performed in a The inspection may become necessary at shorter
careful manner by trained personnel familiar intervals under unusual service conditions
with the characteristics of the individual (including advers climatic conditions) and/or
switchgear, in accordance with all relevant safety particularly injurious environmental influences
regulations to VDE/IEC and of other technical (e.g. heavy pollution and aggressive atmosphere).
authorities, and with other overriding
instructions. It is recommended that ABB service The inspection should include but not be
personnel be called in to perform servicing and limited to the following:
repair work, and this is necessary for some of • Check the installation for abnormalities of
the work detailed below. any kind, dirt and the effects of other
environmental influences
The inspection and servicing intervals for some • Check the function of the switching devices
of the equipment/components (e.g. parts subject and the controls, interlocks, protection,
to wear) are determined by fixed criteria such annunciation and other devices
as switching frequency, length of service and • Check the surface condition of the isolating
number of short-circuit breaking operations. contact system (for visual examination of
For other parts, on the other hand, the length the contact pins with the withdrawable part
of the intervals may depend, for example, on removed). When the galvanic silver coating
the different modes of operation in individual on the contact parts is worn to such an extent
cases, the degree of loading, and also that the copper conductor material below
environmental influences (including pollution becomes visible, or when their surfaces are
and aggressive air). heavily corroded or show signs of other
damage or overheating (discoloured surface),
The following service instructions must also replace the contact parts. See also section 7.3
be observed together with this instruction • Check all switchgear accessories and the
manual in the individual cases concerned. auxiliary equipment (e.g. storage batteries
etc.)
Vacuum circuit breaker • No external discharge may occur on the
VD4 BA 483/02E surfaces of equipment at operating voltage.
SF6 circuit breaker This can, for example, be detected by
HD4 1YHA000046-en characteristic noises, a clearly perceptible
Earthing switch smell of ozone, or visible glowing in the dark
EK6 9AKK1074920025

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40 UniGear ZS3.2 I N S T R U C T I O N M A N U A L

Servicing • Completely remove all rust from damaged


Basic servicing activities, and those which paintwork areas on steel sheet and other
may be found necessary during inspections, steel parts by mechanical means, e.g. with a
include the following: wire brush
• Carefully clean the unit, and in particular the
insulating material surfaces, when they are Lightly grind the surrounding paint coat and
found to be dirty (contamination may also be carefully degrease the entire area. Then
caused by salt, mould formations, insects or immediately apply an anti-rust primer and,
conductive materials in conjunction with after an appropriate hardening time, apply
frequent conden-sation when the switchgear the top coat. The total dry film thickness
is operated in a tropical climate). Remove dry should be approx. 60 μm. Only use suitable
dust deposits which do not adhere strongly and compatible paint products.
using a soft dry cloth. Re move more strongly
adhering, e.g. sticky/ greasy dirt, with a cloth Top coat in standard colour RAL 7035 or the
soaked in a slightly alka-line household cleaner. relevant special colour.
Wipe off with clear water and dry carefully
• Carefully remove any white rust from Al-Zn
Use halogen-free cleaners such as Rivolta sheet steel surfaces with a wire brush or
BWR 210 or cold cleanser 716 (for components Scotch Sprite, and remove loosely adhering
in insulating material and for major particles with a dry, non-fraying cloth. Then
contamination). Observe the manufacturer’s treat the cleaned areas with zinc spray or zinc
instructions and the special ABB instruction dust paint, and then with aluminium spray to
manuals BA 1002E and BA 1006E respectively match up the colour
on safety at work. Never use 1.1.1-trichloroethane,
trichloroethy-lene or car-bon tetrachloride! • Carefully remove any white rust on chromium
plated functional parts and rust on phosphatized
• Should external discharges occur as a result parts with a wire brush or Scotch Sprite, and
of condensation, application of a thin silicone clean with a dry cloth. Then evenly grease the
film on the surface concerned is often effective parts (with Isoflex Topas NB52)
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 Replacement of the isolating contact systems:
unusual problems (Figures 7/1 to 7/4)
• Slide the two inner annular tension springs
• Check that the bolt connections at the contact 57.6 facing the breaker pole to a position
points in the busbar system and the earth beside the two outer annular tension springs,
connections are tight, and that the isolating thus releasing contact system 57.7, and
contact system functions correctly remove the contact sys tem from isolating
contact arm 57.1/57.2
• Regrease the contact points and mechanism • Fit a new contact system back to front on
of the withdrawable part insertion system as the thin end of arbor 127, and slide it forwards
necessary, or, when lubrication is inadequate or onto the thicker part of the shank
missing, thoroughly clean the areas concerned • Fit arbor 127 onto the relevant contact arm
and regrease with Isoflex Topas NB52 lubricant 57.1/ 57.2, slide the contact system 57.3 over
onto the isolating contact arm, and withdraw
• Top up the grease on sliding and bearing the arbor
surfaces in the panels - for example on the • Check all contact fingers and annular tension
separating plates, the interlock and guide springs for perfect fit
systems, the spindle mechanism and the
travel rollers of the withdrawable part - or Note:
thoroughly clean and regrease with Isoflex The set installation position of isolating contact
Topas NB52 lubricant where necessary arms 57.1/57.2 must not be changed by the
improper use of force.
• Observe the maintenance instructions in the
manuals for the individual switch types Replacement of the contact pins
(Figure 3/13, 3/17 and 3/18)
7.3 Repair After any required replacement of contact
7.3.1 Switchgear surface pins 25.1/25.2, these are to be retightened
• Carry out repair work immediately after a using socket head screws:
defect has been discovered • Thread M10, non-greased, at 50 Nm
• Thread M12, non-greased, at 86 Nm

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MAINTENANCE 41

• Thread M20, non-greased, at 200 Nm 7.4.2 Testing of interlock conditions


(Figures 6/1 to 6/9)
7.4 Tests on withdrawable parts with 1. The withdrawable part must only be movable
circuit-breakers of VD4 or HD4 from the test/disconnected position into the
(Figures 3/12, 3/14, 3/15, 6/1 to 6/7) ser vice position when the circuit-breaker is
When functional tests are carried out on open and the earthing switch is open.
withdrawable parts, compliance with the
conditions listed below should also be checked. Check the following conditions individually:
• With the circuit-breaker closed, insertion of
7.4.1 Checking the auxiliary switch settings the withdrawable part towards the service
on withdrawable parts position must be blocked after only half a
(Figures 6/3 to 6/6) turn of the crank in the clockwise direction
Refer to manual BA 483/02E; VD4, vacuum • With the earthing switch closed, insertion of
circuit-breaker on withdrawable part or HD4 the withdrawable part towards the service
SF6 circuit breaker 1YHA000046-en. position must be blocked after only two
clockwise turns of the crank
Compliance with the interlock conditions in the
areas of the test/disconnected position and the 2. The withdrawable part must only be movable
service position is ensured by position signalling from the ser vice position into the test/
switches 10.4 (S8) and 10.5 (S9) located on the disconnected position with the circuit-breaker
withdrawable part and set at the works. open.

In the inspection and test operation, the Check this condition as follows:
withdrawable part is to be moved with the • With the circuit-breaker closed, withdrawal
crank fitted. movement of the withdrawable part must be
blocked after only half a turn of the crank in
1. Settings in the area of the test/disconnected the anti-clockwise direction
position
• Move the withdrawable part out of the test/ 3. Closing of the circuit-breaker must only be
disconnected position towards the service possible when the withdrawable part is in
position with a few turns of the crank the defined test/disconnected position or
• Slowly move the withdrawable part back to service position.
the stop Auxiliary switch 10.4 (S8) must then
operate when the hand crank still has ≥60° The control wiring plug 10.2 must previously
of turn to reach the stop have been inserted.
• Slowly insert the withdrawable part from
the test/disconnected position towards the Check this condition as follows:
service position until auxiliary switch 10.4 • It must not be possible to close the
(S8) just operates circuitbreaker with the withdrawable part in
any position between the test/disconnected
In this position, it must still just be possible position and the service position
to move the ONOFF operating shaft 54. For
this test, the function of the blocking magnet Enabling of switching when the withdrawable
must be deactivated manually. part moves into the service position is effected
electrically by operation of auxiliary switch
This condition ensures that the electrical 10.5 (S9), and mechanically slightly earlier; the
interlock becomes active before the mechanical latter corresponds to a position approximately
interlock in the motion sequence involved. half a turn of the crank before the stop.

2. Settings in the area of the service position: • The enable conditions for the movement
• Move the withdrawable part out of the limit into the test/disconnected position apply
position towards the test/disconnected accor-dingly, in this case established by
position with a few turns of the crank auxiliary switch 10.4 (S8)
• Slowly move the withdrawable part forwards
again up to the stop 4. It must only be possible to open the
circuit-breaker (manually) when the
Auxiliary switch 10.5 (S9) must then operate withdrawable part is in the service position
when the hand crank has a remaining angle of or test/ disconnected position and the
≥60° to turn up to the stop. control voltage has failed.

Check this condition.

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42 UniGear ZS3.2 I N S T R U C T I O N M A N U A L

5. The withdrawable part with blocking magnet 2. Limit position auxiliary switch Q8S2 for
Y0 (if ordered) may not be moved if the control earthing switch ON must be operated
voltage fails or is not avail able. Do not use immediately after the dead centre position
force to move the blocked withdrawable part! of the toggle spring mechanism is reached
in the closing process and the automatic
Removing the block: quick-closing process has started.
• Remove front plate 50.6 and 50.7 3. Limit position auxiliary switch Q8S1 for earthing
• Release the blocking magnet Y0 by pressing switch OFF must be operated on earthing
the armature continuously when moving the switches with manual mech anisms during
withdrawable part by using the hand crank the opening motion of the slide 14.2 before
146 for 1/2 right or left half of the hexagon shaft has become visible,
• The blocking magnet is effective only in the or 1 mm before the tongue of the slide makes
service and test/disconnected position and contact with the armature of the unexcited
is not effective in the intermediate position blocking magnet.

6. Removal of control wiring plug 10.2 and reinser 7.6 Spare parts, auxiliary materials and lubricants
tion of the plug must be blocked with the 7.6.1 Spare parts
with drawable part in the service position. A spare parts list is available on request for
procure-ment of spare parts. It fundamentally
Check this condition. comprises moving parts and parts subject to
wear. When parts are required, the serial
7. Operation of the earthing switch must only numbers of the relevant switchgear panel and
be possible when withdrawable part 50 is in circuit-breaker should always be quoted.
the test/disconnected position or the removed
position (subject to any additional 7.6.2 Auxiliary materials and lubricants Part no.
electromagnetic inter locks in individual Lubricant: (order ref.)
cases!). • Isoflex Topas NB52 GCE0007249P0100
Halogen-free cleansers:
Check these conditions as follows: • Rivolta BWR 210 GCE0007707P0100
• With the withdrawable part in the test/ (for general cleaning)
disconnected position, it must be possible ABB directions for use
to press slide 14.2 in front of the earthing BA 1002/E GCEA901002P0102
switch drive shaft 14.1 downwards to the • Cold cleanser 716 GCE0007706P0100
opening position. The earthing switch can (use for conductive
then be operated components, compon-ents
• When the withdrawable part is moved inwards in insulating material
towards the service position, pressing down and for heavy soiling)
of the slide 14.2 must be blocked after only ABB directions for use
one and a half clockwise turns on the crank BA 1006/E GCEA901006P0102

7.5 Tests on the switchgear panel Touch-up paint


7.5.1 Auxiliary switch setting on the earthing • Standard colour
switch RAL 7035
(Figures 6/8 and 6/9) - 1-kg-box GCE9014060R0103
1. There must be a run-on of 0.5 mm in the fully - 1 Spray tin GCE0007895P0100
operated position before the plunger reaches
the stop (for safety reasons).

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MAINTENANCE 43


7/1 Contact system
sample for 2000 A to
3150 A

7/2 Sliding the
contact system onto
the auxiliary arbour
with the rear end
first, schematic
representation here
for 1600 A

7/3 Contact shift
on auxiliary arbour
for 2000 A to 3150 A

7/4 Sliding of the
contact system from
the auxiliary arbour
onto the contact arm 127.1 127 57.3
1 2
and engaging it here
127.1 127 57.3
1 2
— —
7/1 7/2

1> Left: front view 57.3 Contact system, ...1600 A


2> Right: rear view 127 Auxiliary arbour, ...1600 A
127.1 Plug, ...1600 A

130.1 130130 57.13 57.6 57.7


57.13 57.6 57.7
130.1

— —
7/3 7/4

57.13 Contact system, 2000 A to 3150 A


57.6 Internal annular tension springs
57.7 External annular tension springs
130 Auxiliar arbour, 2000 A to 3150 A
130.1 Plug, 2000 A to 3150 A

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44 UniGear ZS3.2 I N S T R U C T I O N M A N U A L


8 Product quality and environmental
protection

The UniGear type panels are in compliance The duty of company is to facilitate subsequent
with the requirements of internationl recycling or disposal at the end of product life.
standards for the quality management system
and environmental management system. In During disposal of the product, it is always
these fields, the excellent level is proved by necessary to act in accordance with local legal
quality certificates according to ISO 9001 and requirements in force.
by the EMS according to ISO 14001.
The following methods of disposal:
End of life of product Disposal can either be carried out thermally in
The ABB company is committed to complying an incineration plant or by storing on a waste
with the relevant legal and other requirements site.
for environment protection according to the
ISO 14001 standard.

Raw material Recommended method 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

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ABB Xiamen Switchgear Co., Ltd.
No.885, FangShanXiEr Road, Xiang'an District,
Xiamen, Fujian, 361101
Tel: 0592 602 6033
Fax: 0592 603 0505

ABB China Customer Service Hot Line


TEL: 800-820-9696 / 400-820-9696
mail: cn-ep-hotline@abb.com

www.abb.com

1YHA000025_EN REV G 2019.02

© Copyright 2019 ABB. All rights reserved.


Specifications subject to change without notice.

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